01 Mm Bo105 (maintenance Manual) Aeronaves.pdf

.eurocopter

MAINTENANCE MANUAL (MM) BO 105 (not applicable for BO 105 LS)

EUROCOPTER DEUTSCHLAND GMBH 86607 Donauw6rth

Revision 25

MAINTENANCE MANUAL 80 105

RECORD OF INCORPORATED ALERT SERVICE BULLETINS AND SERVICE BULLETINS

ALERT SERVICE BULLETINS

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HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

A R R A N G·E M E N T Chapter

OF

C H A P TER S

Title 1 N T R O D U C T ION GE NERAL

01 02 03

04 05 06

D 1 M E N S ION S A N D R E F E R E N C E P L A N E S G E N E R A L 1 N S T R U e T ION S C O N S U M A B L E M A TER 1 A L S S E L F - MA N U F A C T U R A B L E S P E e 1 A L T OOL S H E L 1 C O P TER GRO U N D H A N D L 1 N G RE F UE L 1 NG AND DE F UE L 1 NG L 1 F T1 NG S YS TEM

11

12 13 14

M A 1 N T R A N S M 1 S S ION ROTOR BRAKE S YS T EM

MA 1 N R O T O R S Y S T E M MA 1 N R O T O R B L A D E F U S E LAG E

21 22

F

U

S E LAG E 1 NGS

e O WL

TAl L U N 1 T 31 32 33

34

TAl TAl TAl TAl

L L L L

B R R R

O O M A S S E MB L Y OTOR DR1 VE OTOR OT OR BL ADE

F L 1 GHT 41 42 43

e

O N T ROL

S YS T EM

M A 1 N R O T O R C O N T ROL S TAl L R O T O R C O N T ROL S HYDRAUL 1 C S y S T EM

BO 105 ARRANGEMENT OF CHAPTERS Page 1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Chapter

Title L AND1 NG GE AR

51

L AND1 NG GE AR P O WE R P L A N T

61 62 63 64 65

E F L F E

NG 1 NE UE L S YS T EM U B R 1 C A T ION S Y S T E M 1 R E WA L L S N G 1 N E O P E R A T ION A N D C O N T ROL

700

S T A N DAR D E Q U 1 P M E N T Refer to Table of Contents Chapter 700

800

O P T ION A L E Q U 1 P M E N T Refer to Table of Contents Chapter 800 1 N S T R U M E N T A N DEL E C TRI CAL S Y S T E MS

91 92

1 N S T R U ME N T S Y S T E MS E LEC TRI CAL S Y S T E M S 1 N S P E C T ION S A N D PRO C E D U R E S

101 102 103 104 105 106 107

1 N S P E C T ION S A N D A 1 R WO R T HIN E S S L 1 M 1 T A T ION S B A SIC R 1 G G 1 N G O F T H E M A 1 N R O T O R A N D TAl L R O T O R C O N T ROL S M E A S U R 1 N G T H E H E L 1 C O P TER W E 1 G HIN G T H E H E L 1 C O P TER GRO U N D R U N / F U N C T ION A L T E S T F L 1 GHT T R A C K 1 N G A N D B A L A N C 1 N G O F MA 1 N ROT OR S YS T EM B A L A N C 1 N G O F TAl L R O T O R S Y S T E M

BO 105 ARRANGEMENT OF CHAPTERS Page 2

EUROCOPTER

MAINTENANCE MANUAL 80105

INTRODUCTION 1. Effectivity 01 the Maintenance Manual This maintenance manual applies to all 80105 series helicopters, excluding 80 105 LS. Information concerning the particular variants of the series helicopters is also contained in separate appendixes.

2. Arrangement 01 the Maintenance Manual a.

Filed in front of the manual are: 1) Title page 2) Record of revisions 3) List of ef1ective pages 4) Record of incorporated Alert Service Bulletins and Service Bulletins 5) Arrangement of chapters 6) Introduction

b. The Maintenance Manual is arranged according to main assemblies and is divided in chapters and paragraphs.

3. Inspection schedule Chapter 101 contains instructions for inspections, overhauls and retirement life Iimitations. The specified inspections are minimum requirements and shall not be reduced in their extent. Local conditions may require more frequent and more thorough inspections.

4. Revisions The manual is updated by"Revisions". Every revision shall be incorporated in the manual as directed in the Change Instruction. Revised or supplemented passages are marked by marginal asterisks or black verticallines, respectively. Revised or supplemented figures are marked by black verticallines or pointing hands, respectively. Relocated passages, renumbered pages, or corrected misprints are not marked.

5. Identification 01 pages Pages marked with O in the Iist of ef1ective pages have no further identification. Revised pages are marked with the lettering "Revision" and the respective revision number.

Revision 24

INTRODUCTION Page 1

EUROCOPTER

MAINTENANCE MANUAL BO 105

6. Warning, Cautions, Notes In front of the respective instruction they have the following meanings:

WARNING

IS USED IF INCORRECT EXECUTION OR DISREGARD OF INSTRUCTIONS MAY LEAD TO INJURIES OR FATAL ACCIDENTS.

CAUTION

IS USED IF INCORRECT EXECUTION OR DISREGARD OF INSTRUCTIONS MAY CAUSE DAMAGE TO THE EQUIPMENT.

NOTE

is used if a feature of particular interest or importance is to be emphasized

7. Reference numerals Reference numerals in the text apply to the figure number last mentioned in the text above, provided they are not given in conjunction with a new figure number.

8. Abbreviations MM

Maintenance Manual

WDM

Wiring Diagram Manual

REM

Repair Manual

CM

Consumable Material

IPC

lIIustrated Parts Catalog

OPM

Operation Manual

FLM

Flight Manual

PCL

Pilot Checklist

Kt

Knot

LOAP

List of Applicable Publications

9. Expressions of time The expressions of time used in this maintenance manual: -

Operating time

-

Inspection interval

-

Retirement time

-

Time between overhauls

mean the time between takeoff and landing of the helicopter. This rule does not apply when the expression of time is stated in terms of calendar time or operating cycles. The expressions of time appearing in engine documentation and equipment specifications are subject to the rules contained therein.

INTRODUCTION Page 2

Revision 24

EUROCOPTER

MAINTENANCE MANUAL BO 105

10. Utilization of parts from helicopters ¡nvolved in accidents Incidents keep recurring whereby parts from helicopters involved in accidents are subsequently reused in other helicopters. However, such parts may have incurred initial damage ín the accident as a result of excessive stress, exposure to heat, etc. Parts thus weakened will fail prematurely when subjected to further stress during flight operations. Certain types of ínitial damage cannot be positively identified by means of the non-destructive tests outlined in the MM or REM. Therefore, there is always the danger that parts showing no evidence of damage during testing may still not be airworthy, thereby constituting a safety hazard. In consequence, the reuse of parts from helicopters involved in accidents is permissible only if there ís proof that the mechanical and thermal stresses at the time were within the allowable Iimits. Otherwise, the affected parts shall be considered damaged and on no account shall be reused. If you have any doubts as to the integrity of any parts, you are urgently recommended to consult the manufacturero

11. Use of rivets for structural repairs Rivets of original type must be used for structural repairs. You must get permission from ECO when you wantto use rivets which are not of original type. The usage of oversize rivets (ofthe original type) is allowed, if the mínimum specified distance to the edges is observed (see AIRCRAFT INSPECTION ANO REPAIR FAA AC 43.13-1 A (Standart Repair). Oocument is not made available by ECO). You will endanger the structural integrity of the helicopter if you use rivets which are not of original type or not approved by ECO.

Revision 24

INTROOUCTION Page3

EUROCOPTER

MAINTENANCE MANUAL SO 105

BLANK PAGE

INTRODUCTION Page4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 01

D I M E N S ION S A N D R E F E R E N C E P L A N E S

Table of Contents

Page

Paragraph

Title

01 - 1

DIMENSIONS

3

01 - 2

REFERENCE PLANES

6

BO 105 CHAPTER 01 Page 1/2

MAINTENANCE MANUAL 80105

EUROCOPTER

01 - 1, 1.

DIMENSrONS (see figure 01-1)

Overall diroensions Length Width (= roain rotor diaroeter) Width (without roain rotor blades) Height (tail rotor vertical) Height (tail rotor horizontal)

•

2.

8.56 ro 1.58 ro 0.35 ro

8.81 ro

&

* * *

0.72 ro 1.35 ro

2.53 ro 2.70 ro

Main rotor Diaroeter Blade chord length Main rotor disc area

5.

&

Landing gear Track (unloaded) Length of skids

4.

11. 84 ro

Fuselage Length including tailbooro (tail rotor vertical) Width Ground clearance (fuselage) Ground clearance (high landing gear) Ground clearance (tail skid)

3.

ro ro ro ro ro

11.86 9.84 2.24 3.80 3.02

9.84 ro 0.27 ro 76.00 ro2

9.80 ro & 0.30 ro (0.22& blade tili 3 75.39 ro2 3

* * * *

Tail rotor Diaroeter Blade chord length Tail rotor disc area

&.

1.90 thru 1. 915 ro 0.180 ro 2.83 thru 2.88 ro2

~ ~

The helicopter roodels BO 105 S

~ Depending on tail rotor blade version

&

* *

The helicopter roodels BO 105 CBS-5, DBS-5

Revision 10

*

BO 105 CHAPTER 01 Page 3

EUROCOPTER

* * EFFECTIVITY *

MAINTENANCE MANUAL 80105

Models BO 105 A,

e und D

E C')

Itl

Ñ

* * *

000003

Figure 01-1 80 105 CHAPTER 01 Page 4

Three-view drawing

(1 of 3)

Revision 10

EUROCOPTER

EFFECTIVITY

MAINTENANCE MANUAL 80 105

Models BO 105 CBS-S, DBS-S



•

E ~

• ~

~

000022

Figure 01-1

Revision 10

Three-view drawing

(2 of 3)

BO 105 CHAPTER 01 Page 4 A/B

EUROCOPTER

EFFECTIVITY

MAINTENANCE MANUAL 80105

Models BO 105 S

E

ID

...~

e

C")

___

~--

gE

---1~

ri 000021

Figure 01-1 Revision 10

Three-view drawing

(3 of 3) RO 105 CHAPTER 01 Page 5

* * *

MAINTENANCE MANUAL 80 105

EUROCOPTER

01 - 2

REFERENCE PLANES (figure 01-2)

Figure 01-2 shows the reference planes tor the BO 105 helicopter. These reference planes also apply to the BO 105 S version. 1.

Fuselage longitudinal stations (STA) Fuselage longitudinal stations are vertical planes which are at right angles to and are measured along, the helicopter longitudinal axis. Longitudinal station O (STA O) is the reference planeo It is an imaginary vertical plane in front of the helicopter.

2.

Lateral stations / Buttock Lines (BL) Lateral stations referred to as Buttock Lines (BL), are vertical planes which are at right angles to the lateral axis of the helicopter. Theyare measured to the right and left of the lateral axis. Lateral station O (BL O) is the reference plane and is the plane on the longitudinal axis of the helicopter.

3.

Height stations / Water Lines (WL) Height stations, referred to as Water Lines (WL), are horizontal planes at right angles to the vertical axis of the helicopter. They are measured along the axis. Height station O (WL O) is an imaginary horizontal plane underneath the helicopter.

i , , , ij , , , ij ¡ ¡ , , i ' " , ji

,"

i , , , , i , , , IJ , , , , i , , , , i , , , , ¡ , , , '1 , , , i i

Bl2000

E E Bl1000 I

w Z :::; ~

BLO

(J

e Bl1000 ~

::)

ID

Bl2000 WL5000

Wl4000 E E WL3000 I

W

Z

:::; ti: w le ¡¡:

Wl2000

Wl1000

WLO

STA O

STA 2000

STA4000 STA 6000 FUSELAQE STATiON -

STA 8000

mm

000007

Figure 01-2 BO 105 CHAPTER 01 Page 6

Reference planes

STA10000

STA12 000

-eurocopter •

MAINTENANCE MANUAL 80105

8ft EAOO ComplJny

02 GENERAL INSTRUCTIONS Table 01 Contents

Paragraph Title

Page

02 -1

REPLACEMENT OF BEARINGS

3

02 - 2

REPLACEMENT OF CAMLOC-FASTENERS

17

02 - 3

REPLACEMENT OF CAMLOC-FASTENERS WITH EJECTOR SPRING .. . . . . . . . .

17

02 - 4

REPAIR OF SURFACE PROTECTIVE COATING OF ALUMINIUM PARTS

19

02 - 5

REPAIR OF SURFACE PROTECTIVE COATING OF MAGNESIUM PARTS

20

02 - 6

REPAIR OF SURFACE PROTECTIVE COATING OF STEEL PARTS

20

02 -7

REPAIR OF FIBERGLASS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

02 - 8

TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

02 - 9

COLOR COOING OF PIPE ANO HOSE L1NES

24

02 -10

ANTI-CORROSION TREATMENT OF TRANSMISSION ASSEMBLlES

25

02 - 11

PRESERVATION OF TRANSMISSION ASSEMBLlES

26

02 -12

FREE

02 -13

FREE

02 - 14

TESTING MAGNETIC RETAINING FORCE OF MAGNETIC PLUGS ANO CHIPS OETECTORS

.

02 - 15

CLEANING - HELlCOPTER INTERIOR

.

02 -16

PROCEOURES FOR OE-ICING - HELEICOPTER

.

,,,,..-~

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

28 31 33

i''''-''''

Revision 25

CHAPTER 02 Page 1/2

I

MAINTENANCE MANUAL BO í05

EUROCOPTER

02 - 1

REPLACEMENT OF BEARINGS

EFFECTIVITY

1.

The bearings 1isted in the BO 105 IPC rnay be rep1aced in accordance with the following instructions. However, these instructions do not apply to bearings 105-13142.03 of rod ends 105-13143 and 105-13144 (see WARNING in step 2.).

Rernoval of spherical bearings Special tools:

refer to tables 02-1 and 02-1A

2----+-

1 Support 2 Cutter

100313.1

Figure 02-1

2.

Milling tool

a.

Place part with installed bearing on support of appropriate rnilling tool (1, figure 02-1).

b.

Mili off flanged portion of bearing with cutter (2), whilst taking care not to darnage the parto

c.

Press out bearing.

Installation of spherical bearings Special tools: NOTE

Revision 10

The following text describes spherical bearing installation using the adjustable tool (i.e. staking tool retainer 105-40001 W1 together with the appropriate staking tool). However, sorne bearing configurations, except those listed in the following WARNING, rnay be installed using earlier-type tools (105-1314J W1 and W2). The following description and the corresponding values in tables 02-1 and 02-1A also apply to these tools. BO 105 CHAPTER 02 Page 3

* * * * *

EUROCOPTER

WARNING

MAINTENANCE MANUAL 80 105

BEARINGS WITH THE FOLLOWING p/N: ATBY6V, ADBY6V, ABYT6V-2002 ANO KOSY6-14 MUST NOT BE INSTALLED USING TOOL 105-13141 W1 OR 105-13141 W2. THERE IS NO GUARANTEE THAT THE STAKING GROOVE OF THESE BEARINGS WILL CORRESPOND WI~H THE CUTTING EDGES OF THESE TOOLS. CONSEQUENTLY, THERE WILL BE DANGER OF THE BEARING BEING INSTALLED INCORRECTLY AND OF THE BEARING OR PART SUBSEQUENTLY FAILING. BEARINGS 105-13142.03 ARE NOT INTENDED FOR INSTALLATION BY THE CUSTOMER, BUT ARE SUPPLIED BY ECD ALREADY ASSEMBLED IN THE ROD END. BEARING REPLACEMENT IS BY EXCHANGE OF THE COMPLETE ROD END AND BEARING ASSEMBLY (105-13143 or 105-

*

* * * * * *

13144) .

IN VIEW OF THIS, THE FOLLOWING PROCEDURE AND ASSOCIATED TOOLS SHALL NOT BE USED FOR THESE BEARINGS. Staking tool retainer 105-40001 W1 For additional tools, refer to table 02-1. a.

Inspect accomodating part for signs of damage. The part must not exhibit damage in excess of the specified limits (refer to appropriate chapter). The bore chamfer must be undamaged and the chamfer edges free from wear.

b.

Unscrew and remove retainer ring (2, figure 02-2) from support (1) of staking tool retainer 105-40001 W1.

c.

Position appropriate pressing-in tool (4) on support (1) so that sliding pads (3) come to rest in the grooves. Insta1l püsitioning screw (5).

d.

Screw retainer ring (2) in place, handtight.

e.

Using caliper gauge, accurately measure diameter DG of bearing staking groove at the base of the groove. WARNING

BO 105 CHAP'J'F,I\ 02 Page 4

THE DIAMETER Oc OF THE STAKING TOOL CUTTING EDGES MUST NOT BE LESS THAN THE DIAMETER DG OF THE STAKING GROOVE AS THIS WOULD CAUSE PRESSURE ON THE BEARING INNER RACE. AS A RESULT THERE WILL BE NO GUARANTEE THAT THE BEARING WILL FUNCTION PROPERLY AND THE BEARING OR PART WILL BE IN DANGER OF FAILING DURING OPERATIQN.

Revision 10

EUROCOPTER

MAINTENANCE MANUAL BO 105

f.

Turn positioning screw (5) on staking tool until diameter De of the staking tool cutting edges corresponds to diameter of the staking groove.

g.

Deburr outer edges of bearing.

h.

Clean contact surfaces and brush-coat bore of the part with corros ion preventive paste (CM 510) .

i.

Insert bearing into bore without canting it.

Revision 10

BO 105 CHAPTER 02 Page 4 AlE

MAINTENANCE MANUAL BO 105

EUROCOPTER

..,/-,t--- 2

DETAlL

-----4

A

"'------ 5

-D c- '

1 2 3 4 5

41111

Figure 02-2 j.

Support Retainer ring Sliding pad Staking tool Positioning screw

Staking tool retainer and staking tool

Place part with installed bearing on lower part of pressing-in tool, and place upper part of tool on top of it. WARNING

DO NOT EXCEED THE STAKING FORCE OR THE MAXlMUM STAKING FORCE SPECIFIED IN TABLES 02-1 ANO 02-1A RESPECTIVELY, OTHERWISE THERE WILL BE NO GUARfu~TEE THAT THE SPHERICAL BEARING WILL FUNCTION PROPERLY ANO THE BEARING OR PART WILL BE IN DANGER OF FAILING DURING OPERATION.

k.

Apply a grad1lal1y increasing staking force up to the value specified for the particular part in TabIe 02-1 or 02-1A under the column headed "Staking force" or "Staking force-initia1 value " respectively (i.e., 30, 50, 55, 80 or 85 kN), and maintain this force fOL approx. 10 seconds.

l.

Remove excessive corres ion preventive paste.

m.

Measure circumferential breakaway torque of the following spherical bearings: BO lOS CHAPTER O¿ Page 5

EUROCOPTER

1)

MAINTENANCE MANUAL 80105

Spherical bearings installed in parts listed in Table 02-1.

WARNING

THE MAXIMUM BREAKAWAY TORQUE OF THE SPHERICAL BEARING MUST NOT BE EXCEEDED OTHERWISE THERE WILL BE NO GUARANTEE THAT THE BEARING WILL FUNCTION PROPERLY AND THE BEARING OR PART WILL BE IN DANGER OF FAILING DURING OPERATION.

If the existing breakaway torque is not within the tolerances specified in Table 02-1, the bearing rnust be replaced. 2)

Spherical bearings installed in parts listed in Table 02-1A.

WARNING

a)

The bearing is properly installed if its breakaway torque is within the tolerances specified in table 02-1A.

b)

If the existing breakaway torque exceeds the tolerance limit, replace the bearing.

c)

If the existing breakaway torque is less than the specified torque, keep restaking the bearing by increasing the initial staking force each time by the appropriate increment of force (see table 02-1A), until the breakaway torque is within the specified tolerance range. If the maximum staking force is reached (see table 02-1A) without the specified breakaway torque being obtained, replace bearing.

n.

Visually inspect staked groove. The edges of the bearing outer race must be flared uniformly against the chamfered edges of the bore, and must not be cracked. If either of these requirements is not met, replac..:e bearing.

o.

Check that bearing installation is syrnmetrical along the mating bore axis. If it is not, replace bearing.

p.

Inspect bearing for play and tight fit in the parto Replace bearing in the event of play or loose fit.

NOTE

* * *

THE INCREMENTS OF FORCE, MAXIMUM STAKING FORCE AND MAXIMUM BREAKAWAY TORQUE FOR THE RESPECTIVE BEARINGS MUST NOT BE EXCEEDED OTHERWISE THERE WILL BE NO GUARANTEE THAT THE BEABEARING WILL FUNCTION PROPERLY AND THE BEARING OR PART WILL PART WILL BE IN DANGER OF FAILING DURING OPERATION.

q.

Depending on the diarneter of the staking groove and, consequently, that of the tool cutter, ridges may be visible in the staking groove asa result of the gaps between the individual cutting segments. These ridges affect neither bearing nor part adv~rsely and can be evened out by turning the control rod through 45 0 and restaking the bearing using a force approx. 5 kN less then prepreviously applied force. Then measure breakaway torque again. Following the installation of a spheri~al bearing in a rod end of control rod 105-13121 or 1121-13126, inspect thread of rod end 105-13141 or 105-13142 for cracks using a magnifying glass.

BO 105 CHAPTER 02 Page 6

Revision 10

Part

Milling tool

Staking tool

Staking force

Breakaway torque

Bellcrank 105-31781

105-31781 W2

105-45361 W3

50 kN

0.1-0.5 Nm

Control rod 105-41069

105-41069 W2

105-41069 W3

80 kN

0.05-0.2 Nm

Control rod 105-41481 105-41480

105-41069 W2

105-41069 W3

80 kN

0.05-0.2 Nm.

~

H

z

1-'3

t"1

1-'3 l1J

tt ..... lt>

z

Support bracket 105-42123

105-31821 W4

105-31821 W5

55 kN

0.05-3.0 Nm

Support bracket 105-42322

105-42322 W2

105-42322 W3

85 kN

0.05-0.6 Nm

~~

t"1tJ:l

~~

o

F:8

.....

~~

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tJ:l~

I

tJ:l

o ..... o

111

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en

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\Q~

ro

1-'

00

-.J N

(JI

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEE - EO 105

3.

Removal of ball bearing with bushing Special tools:

refer to table 02-2

a.

Place part with installed bearing on support of appropriate milling tool (1, figure 02-1).

b.

Mili off flanged portion of bushing with cutter (2).

c.

Place part with installed bearing and bushing on support (2, fig. 02-3) and push out bearing and bushing with drift (1).

2

020001lS

1 2

Figure 02-3 EO 105 CHAP'l'ER

Page 8

02

Drift Support

Pushing out of ball bearing and bushing

- - - - - - ' - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

4.

Installation of ball bearing with bushing Special tools: Staking tool retainer for further special tools

105-40001 W1 refer to table 02-2

a.

Remove retainer ring (2, figure 02-2) from support (1) of staking tool retainer 105-40001 W1.

b.

Position pressing-in tool (4) on support (1) such that sliding pads (3) come to rest in grooves. Install positioning screw (5).

c.

Screw on retainer ring (2) handtight.

d.

Deburr edges of bearing and bushing.

e.

Clean contact surfaces and brush-coat bore of part with corrosion preventive paste (CM 510) .

f.

Chill bushing to -50 oC.

g.

Center bushing in bore. Use appropriate tool (table 02-2) as necessary. Position part on support (2, figure 02-4) and press in bushing with drift (1).

Drift 2 Support

1 020002LS

Figure 02-4

Pressing-in of bushing

BO 105 CHAPTER 02

Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 h.

Remove excess corros ion preventive paste. Check inner diarneter of bushing for dimensional accuracy (refer to table 02-2). Hone bushing, i f necessary.

i.

Brush inner diameter of bushing with corros ion preventive paste (CM 510) .

j.

Center bearing in bushing.

k.

Place part with installed bearing and bushing on lower part of pressing-in tool, and put upper part of tool on top of it.

l.

Slowly and evenly apply staking force to bushing (refer to table 02-2) and maintain for approx. 10 s.

m.

Remove excess corrosion preventive paste.

n.

Visually inspect staked groove. It must be uniformly flared, with the staked edges of the bushing seating on the charnfered edges of both the part bore and the bearing, and must not be cracked.

o.

Inspect bearing for roughness and play.

BO 105 CHAPTER 02 Page 10

Part

Control lever 105-42121

Milling tool

Staking tool

Staking force

Bushing diameter

105-42121 W3

105-42121 W6

80 kN

32

+ 0.003

Mounting tool

105-42121 W7

- 0.013 Bell crank 105-31781

105-31781 W2

105-42121 W6

80 kN

32

+ 0.010 - 0.006

~

H

z

~

t":l

z

105-31781 W2 ~

QI

O'

.......

ro o

IV I IV

105-31781 W6

60 kN

19

+ 0.008 - 0.005

~~

t":ltn

~~

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...... N

01

en

I

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 5.

Removal ef bearings with claw-bushings a.

b.

Breguet claw bushings 1)

Bend up claws using a screw driver.

2)

Press out bearing with suitable tool.

Transall claw bushings Special tool: Pushing-out tool

tool no. 20 (117-46300 W2)

refer to chapter 04 (2~

1)

Place part with installed bearing en support sleeve 02-5) .

2)

Position drift (1) as shown and press out bearing and clawbushing.

3)

Press out second claw-bushing by hand .

.

\

figure

_

.lJ"-"L.I.........-Ef/77 )'l _.' ...._7 .~ I

1

2

I

I I I I

020003LS

1 2

Figure 02-5

BO 105 CHAPTER 02 Page 12

Drift Support sleeve

Pushing-out tool, tool no. 20 (117-46300 W2) - Removal of bearing with Transall claw bushing

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

6.

Installation of bearings with Transall claw bushings Special tool: Assembly tool

117-46300 W1

a.

Clean faying surfaces and brush-coat bore of the part with corrosion preventive paste (CM 510) .

b.

Insert bearing (2, figure 02-6) and claw-bushings (1) into bore.

"---1f---- 2

~i

~. 1 2

"OO04LS - - - ,

Figure 02-6 c.

Claw bushing Bearing

Insertion of bearing and claw-bushings

Assemble assembly tool 117-46300 W1 as shown in figure 02-7. Position part with bearing on bolt (2) and place upper thrust piece on topo

1B-----2

111/'4---3

400627

Figure 02-7

1 2 3

Upper thrust piece Bolt Lower thrust piece

Assembly tool 117-46300 W1 - Meshing of claws BO 105 CHAPTER 02 Page 13

--"--------------MBB HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

To mesh claws, press tool halves together until they abut against the parto

e.

Assemble assembly tool 117-46300 W1 as shown in figure 02-8. Position part with installed bearing on bolt (2, figure 02-8) so that claws at lower side of the part fit in recesses provided in lower thrust piece (3). Place upper thrust piece (1) on topo

111-----2

~il---3

400627.1

Figure 02-8

1 2 3

Upper thrust piece Bolt Lower thrust piece

Assembly tool 117-46300 W1 - Bending of claws

f.

Press tool halves together until claws on upper side of part rest on the parto

g.

Detach upper thrust piece, reverse part and re-insert so that bent claws come to rest in recesses provided in lower thrust piece. Place upper thrust piece on top (refer to figure 02-8).

h.

Press tool halves together until claws on upper side of part rest on the parto

i.

Remove squeezed out corrosion paste.

j.

Check that bearing is centered and properly installed.

BO 105 CHAPTER 02 Page 14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 7.

Installation of bearing with Breguet claw bushing Special tools: Pressing-in tool

105-21832 W1 for spherical bearing LN9367GE12N1 and LN9367GE10N1

Pressing-in tool

105-40131 W1 for spherical bearing LN9193GE6D2

a.

Apply corrosion preventive paste (CM 510) to hole in component.

b.

Fit washer (2, figure 02-9) on claw bushing (1) and insert claw bushing from outboard in component (3).

~1~\----2

1---3

1 Claw bushing 2 Washer 3 Component (e.g. transrnission attach fitting) 4 Bearing

r
}----- 2 800255

Figure 02-9

Insértion of bearing, washers and claw bushing 7

6 ~_;_-

5 800256

1 Frame 2 End support insert 3 Shaping insert 4 Large drift 5 Drift 6 Connecting pin 7 Threaded bolt

-'C--oJ1---

4

" 3

Figure 02-10

2

Pressing-in tool BO 105 CHAPTER 02 Page 15

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - " ' - - MAINTENANCE MANUAL MEB - BO 105 c.

Insert bearing (4) in claw bushing (1) to full extent and fit washer (2) on claw bushing.

d.

To press bearing into component, place frame (1, figure 02-11) around same and guide connecting pin (5) through threaded bolt (4), end support insert (3), inserted bearing, and drift (2); now screw in threaded bolt all the way to upper stop.

~-----1

~-----2

4

Frame Drift End support insert 4 Threaded bolt 5 Connecting pin

1 2 3

5 02000SLS

Figure 02-11

Pressing-in of bearing

e.

To locate bearing and claw bushing in the bore, exchange drift (2, figure 02-11) for shaping insert (3, figure 02-10), then again screw in threaded bolt all the way to upper stop. This causes the protruding part of the claw bushing to be cut into at regular intervals by the shaping insert, whereby the lugs thus formed are alternately bent slightly inwards and outwards.

f.

To finalize press-in procedure, exchange shaping insert (3) for large drift and again screw threaded bolt (7) all the way to upper stop. This causes the slightly bent lugs to be bent fully against the component and the bearing.

g.

Remove pressing-in tool and wipe off any corrosion preventive paste that may have escaped.

h.

Check that bearing is centered and properly installed.

BO 105 CHAPTER 02 Page 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 02 - 2

REPLACEMENT OF CAMLOC-FASTENERS

Special tools:

Camloc pliers 4P3

1.

Remove cowling or fairing as applicable.

2.

Remove damaged stud (2, figure 02-12) from grornmet using Camloc pliers 4P3 (1).

3.

Insert new stud in grornmet (3) using Camloc pliers and secure with receptacle (5).

4.

Install cowling or fairing, as applicable .

./

___- - - 2

=~~~~;::¡ ~----5

02111

Figure 02-12

02 - 3

1 2 3 4

Camloc pliers Stud Grornmet Cowling, fairing or ejector spring 5 Receptacle

Removal and installation of Camloc-fasteners

REPLACEMENT OF CAMLOC-FASTENERS WITH EJECTOR SPRING

Special tools:

Camloc p1iers 4P3

1.

Remove cowling or fairing as applicable.

2.

Remove stud (2, figure 02-13) from ejector spring (1) using Camloc pliers 4P3 (3).

3.

Secure broken ejector spring stub with screw clamp.

4.

Drill out rivet heads and press out rivets with a drift. Remove ejector spring. BO 105 CHAPTER 02 Page 17

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

5 02/12

1 Ejector spring 2 Stud 3 Camloc pliers Figure 02-13

4 5

Receptacle Rivet

Camloc-fasteners with ejector spring

5.

Clean and degrease new ejector spring with acetone (CM 203) .

6.

Mix two-component washprimer (CM 423) with hardener (CM 419) and apply to ejector spring.

7.

Apply Aerodur finish to ejector spring to match with coating of adjacent cowling/fairing.

8.

Insert stud (2, figure 02-12) with Carnloc pliers (1) in grornmet (3) and secure with receptacle (5).

9.

Rivet ejector spring (1, figure 02-13) to cowling or fairing as applicable.

BO 105 CHAPTER 02 Page 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 02 - 4

CAUTION

1.

2.

REPAIR OF SURFACE PROTECTIVE COATING OF ALUMINIUM PARTS

STEEL WOOL, STEEL WIRE BRUSHES OR POLISHING CLOTH CONTAINING FERROUS OXIDE MUST NOT BE USED SINCE STEEL RESIDUES MAY BECOME EMBEDDED IN THE ALUMINIUM ANO CAUSE FURTHER CORROSION.

Removal of corrosion: a.

Remove damaged paint coating from repair area using paint remover (CM 213) in the case of more extensive damage. For locally limited damage use polishing cloth 400.

b.

Remove minor corrosion traces with an acid-free abrasive powder or an nylon abrasive pad. More serious corrosion shall be removed with aluminium wool or aluminium wire brush. Excessive corrosion shall be removed by filing, milling or polishing.

c.

Eliminate corrosion so that it is not visible with a magnifying glass (5 to 10 X magnification) . To ensure that any corrosion that may have penetrated deeper in the structure is removed, remove a further amount of material to a depth of approx. 0.05 mm.

d.

Polish reworked area with polishing cloth 400 to provide a smooth transition from blank to paint-finished surface.

e.

Clean repaired area with acetone (CM 203) and allow to dry.

Touch up of paint coating: a.

In the case of minor damage, touch up surface protection with two-component zinc chromate primer (CM 417) and coating lacquer (CM 402) or two-component PUR topcoat (CM 412) as applicable. CAUTION

b.

TAKE CARE THAT CHEMICAL CONVERSION MATERIAL (CM 316) DOES NOT ENTER INTO CRACKS ANO JOINTS FROM WHERE IT CANNOT BE REMOVED BECAUSE IT CAN CORRODE MATERIALS NON-RESISTANT TO ACIO.

In the case of major damage, renew surface protection by applying chemical conversion material (CM 316), two-component zinc chromate primer (CM 417) and either coating lacquer (CM 402) or two-component PUR topcoat (CM 412) as applicable. After applying the chemical conversion material, allow time for it to act on the surface, then rinse away with water and allow surface to dry.

BO 105 CHAPTER 02 Page 19

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 02 - 5

REPAIR OF SURFACE PROTECTIVE COATING OF MAGNESIUM PARTS

CAUTION

1.

2.

STEEL WOOL, STEEL WIRE BRUSHES OR POLISHING CLOTH CONTAINING FERROUS OXIDE MUST NOT BE USED SINCE STEEL RBSIDUES MAY BECOME EMBEDDED IN THE MAGNESIUM AND CAUSE FURTHER CORROSION.

Removal of corrosion and scratches: a.

Remove loase paint from damaged areas.

b.

Remove corrosion marks using a stiff, nonmetallic brush or ScotchBrite.

c.

Remove deep scratches and notcheswith a sharp steel scraper or a carbide tipped cutting tool.

d.

Sand reworked areas with polishing cloth 400 and finish with polishing cloth 600. Then clean with cleaning agent (CM 217).

Touch up of paint coating: a.

Using a brush, apply passivating solution (CM 701) and allow to act on surface for 1 minute. Then thoroughly rinse with clean water and al10w to dry.

b.

Apply PUR topcoat (CM 437) .

REPAIR OF' SURFACE PROTECTIVE COATING OF STEEL PARTS

02 - 6

1.

2.

Removal of mechanical damage and corrosion: a.

In the case of extensive damage, remove damaged paint coating from repair area using paint remover (CM 213). For minor damage, use polishing cloth 400.

b.

Remove corros ion traces, scratches, notches and scores with polishing cloth 280. Final-polish the surface with polishing cloth 400 to provide a smooth transition from bare to paint-finished surface.

c.

Clean reworked areas with acetone (CM 203) and allow to dry.

Touch up of paint coating: Touch up surface protection with zinc chromate primer (CM 401) and with either coating lacquer (CM 402) or two-component PUR topcoat (CM 412), as applicable.

BO 105 CHAPTER 02 Page 20

- - - - - - - - - - ' - - - - - M B B HELICOPTERS - - - - - - - - - - - - - - ' - - MAINTENANCE MANUAL MBB - BO 105 02 - 7

l.

REPAIR OF FIBERGLASS COMPONENTS

General The following repairs are applicable to fuselage parts made of fiberglass laminates and fiberglass-PVC foam sandwich structures. During repair work, the room temperature shall not be less than 18 oC and the relative hurnidity shall not exceed 60%. The tools used for repair shall be free of grease, silicone and oily substances. WARNING

2.

FOLLOW THE APPROPRIATE SAFETY REGULATIONS WHEN HANDLING SYNTHETIC RESIN.

Consumable Materials, Tools and Aids: a.

Consumable Materials - Fiberglass cloth (CM 727) - Epoxy resin (CM 616), hardener (CM 617) - C1eaning agent (CM 203)

b.

Too1s - Electric drill with grinding disc - Grinding block, mixing bowl, spatula, brush, scissors - Crow bar, knife

c.

Aids - Cloth, colored crayon, chalk - Grinding paper 180, 200, 250 and 300 grit - Protective gloves

3.

Repair surface protection as follows: a.

Deter.mine the extent of damage and outline repair area.

b.

Remove damaged material. Sand damaged are a and wipe surface clean with cleaning agent (CM 203) .

c.

Cut fiberglass cloth (CM 727) to size. The upper layer shall overlap by approximately 10 to 15 mm. Mix epoxy resin (CM 616) and hardener (CM 617) in compliance with manufacturer's instructions. Brush-coat repair area with the resin-hardener mixture. Position fiberglass cloth, then saturate, smooth and dab using a brush. Mix resin and glass fiber at a ratio of 1:1 by volume.

d.

Cure at room temperature for approximately 24 hours.

e.

Smoothen uneven spots and edges of the repaired area, using grinding paper 180.

BO 105 CHAPTER 02 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

02 - 8

1.

TORQUE VALUES

Table 02-3 lists standard terque values fer screws, belts and nuts. These values shall be ebserved unless ether values are explicitly specified in the illustratiens.

Terque value fer tensile stress ± 10 % (Nm)

Thread Dia.

Torque value fer shear stress ± 15 % (Nm)

M 4

1.8

1.8

M 5

3.6

3.6

M 6

6.4

6.4

M 8

16.0

8.0

M 10

32.0

11. O

M 12

57.0

19.0

M14

92.0

30.0

M 16

140

47

M 18

200

60

M 20

280

67

M 22

380

73

M 24

510

80

M 27

730

90

M 30

980

100

M 33

1350

110

M 36

1790

120

M 39

2360

130

Table 02-3

BO 105 CHAPTER

Page 22

02

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 2.

Table 02-4 lists torque values for steel and aluminum pipe unions. Torque values in Nm Outer Diameter

Steel tubes

NG NG NG NG NG NG NG

6.8 7.5 8.0 16.3 23.0 33.9 57.0

4 5 6 8 10 12 16

to te te te te te te

Aluminum tubes

10.8 12.0 13.5 29.4 40.7 61. O 79.0

5.4 6.8 8.1 13.6 16.3 24.4 54.2

te te te te te te te

10.8 12.2 13.6 24.4 40.7 61.0 78.6

Table 02-4

BO 105 CHAPTER 02 Page 23

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 COLOR CODING OF PIPE ANO HOSE LINES

02 - 9

The ID markings, sy.mbols and color codes indicated on the pipe and hose lines shown in fig. 02-4 serve to identify the fluid flowing in them. The ID markings (adhesive tape) are attached to the line unions and at particular intervals along the lengths of the lines. Arrows indicate the direction of flow. Pipes conveying a hazardous fluid are identified by adhesive tape displaying a warning symbol.

-

FF +

Kraftstoff IBn:!

:>nnBJpÁH

+

Krafts10ff

Hydraulik

+

IBn:!

:>nnBJpÁH

e

H

F

luf!

JIV IUawnJISUI

G

¡nstrumentenlurt J!V luaWnJISUI

f-

H

Instrumentenlutl JIV luawnJ1SUI

[.-

H

Schmiersl0tl üOlle~IJQn,

sChmierslofl

e

H

H

F

H

l

Code letter

l H

A B C D E F

G H

000032

Figure 02-14

BO 105 CHAP'I'ER 02 Page 24

H

H

-

all BJ 8

-

Pltot

--

Bremse

H

---_-o

aqnl

G H

H

H

H

Entlüftung Static

G H

E

e

A

H

H

E

H

;

Instrumenten-

E

§

Hydraulik

Color per RAL standard 840 HR

RAL

brilliant blue grass green lemon yellow copper brown vermillion purple red silver grey cream

5'007 6010 1012 8004 2002 3004 7001 9001

Color coding of pipe and hose lines

standard

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 02 - 10 1.

ANTI-CORROSION TREATMENT OF TRANSMISSION ASSEMBLIES

General This section contains measures for the prevention and elimination of corrosion on transmission housings. Take special care when performing these measures on helicopters which are operated in a corrosive environment (e.g. at sea or in industrial regions). Anti-corrosion measures for the other assemblies and parts are specified in the appropriate chapters of this manual.

2.

Touch up of protective coating of transmission housings, see paragraph 02-5.

3.

Protective coating and sealing of split lines of housings It is recornmended to seal split lines with Aerodur finish (CM 437) or sealing compound (CM 662). Seal the following split lines against moisture using Aerodur finish or sealing compound: a.

Main transmission -

b.

Upper housing/Center housing Center housing/Lower housing Free wheel unit/Lower housing Tail rotor drive cover/Center housing Lower housing/Angular flange Angular flange/Engine deck

Tail rotor transmission - Housing/covers (3 split lines)

c.

Intermediate gear - Housing/covers (3 split lines)

4.

Protective coating of bolt and screw heads and nuts Apply Aerodur finish (CM 437) to the following bolts and screws, nuts and washers: - All nuts and bolts of the above mentioned split lines, - Screw heads including flanges of nozzle pipes on the two main transmission inputs, - Heads of transmission attachment bolts and screws. The coating shall also cover the irnmediate area surrounding the contact surfaces of bolt or screw heads, nuts or washers. This will prevent moisture from permeating contact surfaces between housing and bolt and screw heads, nuts or washers.

BO 105 CHAPTER 02 Page 25

MAINTENANCE MANUAL

EUROCOPTER

02 - 11

1.

*

PRESERVATION OF TRANSMISSION ASSEMBLIES

Transmission assemblies affected Transmissions (main transmission, tail rotor gearbox, interrnediate gearbox) installed in helicopters which are out of operation for periods of more than three months and transmissions awaiting shipment, repair or overhaul.

* * * 2.

Preservation procedures a.

Two methods of preparing a preservation mixture are given below: 1)

If lubricating oil has not been drained from the transmission, add 15 mI corrosion preventive concentrate (CM 509) per liter lubricating oil.

2)

Transmissions not yet containing lubricating oil: Fill with lubricating oil (CM 103) and add 15 mI corros ion preventive concentrate (CM 509) per liter lubricating oil.

b.

Run the transmission at operating speed for 10 minutes (no load) to spread the mixture evenly. Take care that transmission oil temperature does not exceed 80 oC.

c.

Drain the preservation mixture.

CAUTION

* * * * *

* * * * *.

eo 105

d.

LUBRICATING OIL CONTAINING CORROS ION PREVENTIVE CONCENTRATE IS NOT PERMISSIBLE FOR OPERATION; TRANSMISSIONS WHICH HAVE UNDERGONE PRESERVATION TREATMENT CAN BE PUT INTO OPERATION WITHOUT FLUSHING. BEFORE PLACING THE HELICOPTER IN SERVICE REPLENISH TRANSMISSION ASSEMBLIES WITH LUBRICATING OIL (CM 103) TO THE REQUIRED LEVEL.

Enter details of the preservation treatment as follows: - On accompanying tag and in the Historical Record if the transmission is removed. - In the respective helicopter records if the transmission remains installed on the helicopter. In addition, a note shall be included which requires the transmission to be checked when it is operated again. This check is described in the section headed "Installation-" for the respective transmission.

BO 105 CHAPTER 02 Page 26

Revision 13

EUROCOPTER

02 - 12

MAINTENANCE MANUAL 80 105

* * *

F r e e

BO 105

Revision 12

CHAPTER 02

Page 27

EUROCOPTER

* 02 -13 * * * * * * * * * * * * * * * * * * * *

02 - 14

1.

F

MAINTENANCE MANUAL 80 105

r e e

TESTING MAGNETIC RETAINING FORCE OF MAGNETIC PLUGS ANO CHIP DETECTORS

General The functional efficiency of magnetic plugs and chip detectors is determined by the strength of their magnetic retaining force. The magnetic retaining force is tested by lifting a specific test mass straight up with the magnetic plug/chip detector to see if the force is sufficient to hold the test mass on the magnetic plug/chip detector. If a test mass is not specified, a steel ball to DIN 17230 (Material: 1.3505, Hardness: 100.CR6) or equivalent shall be used. Steel balls having the required minimum mass and the corresponding diameters, as listed in table 02-5, can be obtained from bearing manufacturers (e.g. SKF, FAG). Table 02-5 indicates which test mass is to be used for each type of magnetic plug/chip detector.

BO 105 CHAPTER 02 Page 28

Revision 12

MAINTENANCE MANUAL 80 105

EUROCOPTER

2. Assign of test mass (steel ball) to magnetic plug/chip detector Magnetic plug/chip detector Type/P/N

Test mass (steel ball, OIN 17230, material: 1.3505, hardness: 100.CR6) diameter in mm (in)

Test mass (g)

A 4509/6896482

10.319 mm (0.406 in)

4.43 9

6871534

----

B75A

12.70 mm (0.5 in)

8.40 9

K 402 AC

12.70 mm (0.5 in)

8.40 9

P 40214619208043

22.225 mm (0.875 in)

45.20 9

B 722A!0639490002

25.40 mm (1.0 in)

68.00 9

105 - 61901.06

22.225 mm (0.875 in)

45.20 9

B4704

Test mass (see tool No. 36, Chapo 04)

190.00 9

&, 2.8 - 3.1 9

&'Because the face of the magnetic plug magnet cannot be reached with a steel ball, measure the magnetic retaining force using a split pin LN 94-30055, or a screw LN 9439 AM 5 x 10. Table 02-5

3. Test

NOTE

Do not expose the magnetic pluglchip detector to any other magnetic field during the test. as this would falsify the test result.

a. Clean magnetic plug/chip detector with dry cleaning solvent (CM 202), then dry. b. Place magnet (2, fig. 02-15) of magnetic plug/chip detector (1) on appropriate test mass (3). c. Lift magnetic plug/chip detector straight up. The test mass must remain on the magnet. If the test mass drops, this indicates insufficient magnetic retaining force. Replace magnetic plug/chip detector.

Revision 17

CHAPTER 02 Page 29

I

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

1 Magnetic plug/ chip detector 2 Magnet 3 Test mass

3

Fig. 02-15

BO 105 CHAPTER

Page 30

Testing magnetic retaining force

02

Revision 3

EUROCOPTER

02 -15

MAINTENANCE MANUAL BO 105

CLEANING - HELlCOPTER INTERIOR Clean EMS optional equipment of the helicopter i.a.w. EMS vendor documentation.

NOTE 1.

Ensure that the helicopter is deenergized and the EPU is disconnected.

2.

Open all doors.

3.

Clean the interior helicopter windshield and windows (see chapter 21-21).

4.

If necessary, remove pilots and copilots seats (see chapter 701-03).

5.

Clean the helicopter interior with vacuum cleaner.

6. Clean the interior plastic panels with CM 228 plastics c1eaner. 7. C/ean the instrument panel and the center console with lint-free c10th or a small hand brush. 8. Clean the further interior and the f100r as follows: CAUTION

DO NOT LET CM 227 AIRCRAFT INTERIOR CLEANER TOUCH THE SEAT BELTS. IT WILL DAMAGE THEM IF IT COMES INTO CONTACT WITH THEM.

WARNING

IN THE CONCENTRATED FORM CM 227 AIRCRAFT INTERIOR CLEANER IS A DANGEROUS MATERIAL. IT CAN CAUSE DAMAGE TO YOUR SKIN AND EYES IF IT TOUCHES THEM. ONLY USE IT IN AN AREA THAT IS WELL VENTILATED WITH FRESH AIR. DO NOT BREATH THE FUMES. DO NOT LET IT TOUCH YOUR SKIN OR EYES. IF IT TOUCHES YOUR SKIN OR YOUR EYES FLUSH IMMEDIATELY WITH A LARGE QUANTITY OF CLEAN WATER. USE EQUIPMENT TO BREATHE, GOGGLES AND GLOVES WHEN YOU USE 11. KEEP IT AWAY FROM FLAMES AND SPARKS.

a. Mix 1 part of the interior cleaner CM 227 with 10 parts of water for use.

9.

b.

Clean the interior paneling and the f100r with a lint-free c10th and the premixed interior c1eaner.

c.

Clean the seat rails with CM 202 as necessary.

If prior removed, reinstall pilots and copilots seats (see chapter 701-04).

10. If necessary disinfect the interior as follows: WARNING

• OBEY THE MANUFACTURER INSTRUCTIONS FOR THE DISINFECTANT CM 2002. • PREVENT INSTRUMENTS FROM PENETRATION OF HUMIDITY.

a.

Prepare the disinfectant CM 2002 according to the Manufacturer Instructions.

b.

Disinfect the helicopter interior according to the Manufacturer Instructions and the local authority disinfection regulations. Ensure the reaction time of the disinfectant CM 2002.

11. Close all doors after finished cleaning and if the interior of the helicopter is dried.

Revision 25

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BLANK PAGE

-

CHAPTER 02 Page 32

EUROCOPTER

02 - 16

MAINTENANCE MANUAL BO 105

PROCEDURES FOR DE-ICING - HELlCOPTER

Special tools: Commercial

Heatable De-icing Equipment e.g. Portable and heatable compressed air spray WEYER HOTSRAY

Commercial

Refractormeter

WARNING

• THE FOLLOWING PROCEDURES FOR DE-ICING ARE TO BE USED ON THE HELlCOPTER ONLY WHEN IT IS ON THE GROUND AND PARKED. THEY PROVIDE NO DE-ICING PROTECTION FOR FLlGHT OPERATION. • IN FLlGHT, THE DE-ICING FLUID IS BLOWN OFF THE PREVIOUSLY PROTECTED SURFACES. THIS IS DUE TO ROTOR ROTATION AND DOWNWASH, TO ENGINE EXHAUST AND TO THE AIRBLAST DURING FLlGHT. THUS NO DE-ICING PROTECTION REMAINS ON THE SURFACES OF THE HELlCOPTER SKIN. OBEY THE OPERATIONAL L1MITS OF THE HELlCOPTER. • DURING HELlCOPTER OPERATION, FROST, ICE, SNOW OR SLUSH CAN CAUSE MALFUNCTIONING OF THE HELlCOPTER AND OF ITS SYSTEMS AND COMPONENTS AND CAN ALSO CAUSE DAMAGE OR PROBLEMS SUCH AS: -

REDUCTION OR EVEN BLOCKING OF THE CONTROLABILlTY OF THE HEL1COPTER,

-

SIGNIFICANT DETERIORATION OF THE AERODYNAMIC PERFORMANCE OF THE HELlCOPTER, ESPECIALLY OF THE ROTOR BLADES,

-

HELlCOPTER VIBRATION GENERATED BY UNBALANCE OF THE ROTOR BLADES CAUSED BY ICE BUILDUP,

-

REDUCTION OF L1FT PERFOMANCE,

-

INCREASED DRAG,

-

INCORRECT INDICATION OR NO INDICATION OF PITOT-STATIC PRESSURE,

-

PARTIAL OR TOTAL LOSS OF AIR SUPPLY (E.G.: TO THE ENGINES OR TO THE AIR CONDITIONING SYSTEM, ETC.),

-

DAMAGE DUE TO THE BREAKING OFF OF ICE OR FROZEN SNOW. THE HELlCOPTER MUST THEREFORE BE CLEAR AND FREE OF FROST, ICE, SNOW AND SLUSH BEFORE IT IS PUT INTO OPERATION.

WARNING

CAUTION

OPERATION OF THE HELlCOPTER UNDER KNOWN ICING CONDITIONS IS PROHIBITED, SO THE FOLLOWING PROCEDURE WILL NOT DEAL WITH ANTI-ICING. • DE-ICING PRODUCTS CAUSE MICROCRACKS IN ACRYLlC GLASS WINDOW PANES. ANY DE-ICING FLUIDS THAT MAY HAVE COME INTO CONTACT WITH THE WINDOWS MUST BE REMOVED IMMEDIATELY. WINDOWS MUST BE CLEANED ACC. CHAPTER 21-21. • WINDOW PANES MUST BE PROTECTED WITH SUITABLE COVERS BEFORE DE-ICING OF THE HELlCOPTER.

Revision 25

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EUROCOPTER

NOTE

MAINTENANCE MANUAL BO 10S

To ease de-icing of the windows, it is recommended to clean the windows and treat them with CM722 Rain Repellant befare parking the Helicopter outside in known icing canditions and to cover the windows with suitable covers.

1. General aspects for de-icing For de-icing, de-icing fluids are used for the following pracedures which can be sprayed by means of suitable equipment anta the surfaces to be treated. Use of heated fluids melts frast, ice, snow and slush. By use of a suitable pressure and amount of fluid, melt water and melting deposits are flushed away. 2.

Definition of terms used in this pracedure a.

De-icing: Pracedure by which frost, ice, snow or slush is removed fram the helicopter to pravide c1ear surfaces (free fram frast, ice, snow and slush).

b.

_.

De-icing procedures: Pracedures for de-icing of the helicopter. These pracedures can be conducted: 1) together in one work step (one-step-procedure), in which de-icing is performed at temperatures araund the freezing point. 2) as two separate work steps, one after the other (two-step-pracedure):

3.

-

first step: de-icing,

-

second step: de-icing at very low temperature.

De-icing agents a.

De-icing fluids:

CAUTION

• DE-ICING FLUIDS CAUSE MICROCRACKS IN ACRYLlC GLASS WINDOW PANES. ANY DE-ICING FLUIDS THAT MAY HAVE COME INTO CONTACT WITH THE WINDOWS MUST BE REMOVED IMMEDIATELV. WINDOWS MUST BE CLEANED I.A.W. Chapter 21-21. • PROTECT WINDOW PANES WITH SUITABLE COVERS BEFORE DE-ICING THE HELlCOPTER.

NOTE

• The glycol cantent in de-icing fluids prevents the fluids freezing and pravides a limited holdover time. • The relative praportions of glycol, water and additive in de-icing fluids, and thus the praperties of the various fluids, differ depending upon the manufacturer and the product.

1) CM 781 De-icing/anti-icing fluid type 1. Use and praperties of fluid type 1: -

fluid type I is used mainly for de-icing purposes.

-

use preferably in dry weather, Le. not while precipitation is falling.

-

heat fluid type I for de-icing to achieve the greatest melting effect.

-

fluid type I has a low viscosity and forms a thin fluid film which quickly runs off the treated surface.

-

its glycol praportion is higher than in fluid type 11. Thus, fluid type I has a lower freezing point and can be used at lower outside air temperatures than type 11.

-

for information on freezing point of fluid type I and on temperature limits for application, see safety data sheets issued by the manufacturers.

2) CM 797 De-Icing/anti-icing fluid type 11. CHAPTER 02 Page 34

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EUROCOPTER

MAINTENANCE MANUAL SO 105

Conditions for use and properties of fluid type 11: -

fluid type 11 is used for de-icing. It can also be used during precipitation, e.g. in rain or snow fa 11.

-

depending on the purpose, fluid type 11 can be used heated or not.

-

a lower temperature limit for application of -25°C (-13°F) is typical for use of fluid type 11. This lower temperature limit for application can vary however, depending upon the manufacturer. For this reason, attention must paid to the details in the safety data sheets issued by the manufacturers. The temperature limit for application may be lower, if the freezing point of the fluid is at least 7°C (13°F) lower than the outside air temperature.

-

if fluid type 11 can no longer be used, because the outside air temperature is too low, fluid type I can be used for de-icing, because of its lower freezing point.

-

fluid type 11 contains a thickening agent and thus forms a thicker fluid film which adheres better to the treated surface than fluid type 1.

-

for information on the freezing point of fluid type 11 and on temperature limits for application, see safety data sheets issued by the manufacturers.

3) Safety precautions WARNING

DE-ICING FLUIDS CONTAINING GLYCOL CAN CAUSE MINOR IRRITATION, IF THEY COME INTO PROLONGED CONTACT WITH MUCOUS MEMBRANES AND SKIN.

a) Protection of persons and health -

comply with the health and safety regulations of the national and local authorities and with the safety data sheets issued by the manufacturers.

b) Environmental protection -

Comply with the environmental regulations of the national and local authorities and with the safety data sheets issued by the manufacturers.

CAUTION

DUE TO THE DANGER OF FIRE, DE-ICING FLUIDS MUST NOT COME INTO CONTACT WITH HOT COMPONENTS. SEE WORK STEP 7. b. FOR INSTRUCTIONS.

c) Fire protection NOTE

The flash point of the approved undiluted de-icing fluids is not below 100°C (212°F).

While handling and working with de-icing fluids within their range of application: -

do not light or ignite any fire,

-

do not use open flames or fire,

-

do not smoke.

Comply with the fire protection regulations of the local and national authorities and with the safety data sheets issued by the manufacturers. Revision 25

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MAINTENANCE MANUAL 80 105

-

4) Mixtures of fluids type I or type 11 with water

CAUTION

MIXING OF THE FLUIDS CHANGES THEIR PROPERTIES. DIFFERENT PRODUCTS FROM VARIOUS MANUFACTURERS AND FLUIDS TYPE I AND TYPE 1I MUST NOT BE MIXED TOGETHER, BECAUSE THEIR CONSTITUENTS AND RELATIVE MIXTURE PROPORTIONS DIFFER.

NOTE

The mixture proportions of a fluid mixture and its glycol proportion can be determined by means of a refractometer.

a) Fluid type I Depending upon the outside air temperature and thus upon the associated freezing point of the fluid itself, this fluid can be mixed with water in any mixture proportion (percent by volume) as required. An increase in the proportion of type I in the fluid mixture lowers the freezing point of the fluid mixture. For ínformation on freezing points of the mixtures and on their temperature limits for application, see safety data sheets issued by the manufacturers. b) Fluid type 11 Depending upon the outside air temperature, upon the required freezing point of the fluid and upon the weather condítions, this fluid can be mixed and used in the following standard fluid type 11/ water mixture proportions (percent by volume) or undiluted: 50/50 or 75/25 or 100/0. For information on freezing points of the fluid mixtures and on their temperature limits for aplícation, see safety data sheets issued by the manufacturers. 5) Storage of fluids type I and type 11 a) Comply with storage conditions and storage periods specified in the safety data sheets issued by the manufacturers. 6) Stability of fluids type I and type 11 a) The properties of fluid type I mixtures with water will not be altered by mechanical effects from pumps of de-icing equipment.

-

b) The properties of fluid type 11 and its mixtures with water can deteriorate through mechanical effects from: -

unsuitable pumps of de-icing equipment,

-

sharp edges in tubes, valves and outlets,

-

unsuitable spray nozzles.

For this reason, use only the suitable pumps and spray nozzles which are recommended by the manufacturero c) Do not overheat de-icing fluids and avoid unnecessarily long or repeated heating, since this will impair the properties of the fluids. b.

Protective agent for door sealings: CM 525 protective agent. This protective agent provides protection against icing ofthe door sealings and is used before helicopter missions in winterly conditions or when icing conditions are to be expected.

CHAPTER 02 Page 36

Revision 25

-

EUROCOPTER 4.

MAINTENANCE MANUAL BO 105

Requirements and preliminary work for de-icing a.

De-icing should be peformed only by staff trained and qualified to do it.

b.

The area on which the helicopter is going to stand for de--icing should have a slight slope or a possibility for the fluid to flow away from the helicopter.

c.

To provide sufficient space for staff and equipment, remove all objects from around the helicopter, which are not needed for de-icing.

CAUTION

DE-ICING FLUrDS CAUSE MICROCRACKS IN ACRYLlC GLASS WINDOW PANES. ANY DE-ICING FLUIDS THAT MAY HAVE COME INTO CONTACT WITH THE WINDOWS MUST BE REMOVED IMMEDIATELV. WlNDOWS MUST BE CLEANED I.A.W CHAPTER 21-21.

d. Cover the following areas to protect them from fluid effects: -

gill openings in the LH and RH side panels,

WARNING

5.

MAKE SURE THAT PITOT HEATING IS SWITCHED OFF AND THE PITOT TUBE IS COOLED DOWN.

-

openings of pitot- and static pressure system,

-

air inlets and exhaust ejectors of engines,

-

gap around the EPU socket door,

-

bearing locations of the main rotor blades,

-

front and side window panes.

e.

Ensure that all doors and sliding windows of the helicopter are c1osed.

f.

If installed, cover items of optional equipment such as external hoist, search light, FLlR camera unit and external loudspeakers in such a way that de-icing fluids do not come into contact with them.

g.

Ensure that the de-icing equipment is operative and that the spray nozzle (see also safety data sheets issued by the manufacturers) is suitable for the fluid which is going to be used.

Preparation of de-icing fluids

a. For de-icing in the 2-step procedure, prepare and provide the f1uids for each step in an individual and separate containerlitem of equipment. b.

Mix fluid type I or type 11 with water in the required mixture proportions. 1) For de-icing in the 1-step procedure and for the second step in the 2-step procedure, the mixture proportion is dependent upon: -

the outside air temperature and thus upon the required freezing point of the fluid. For details of the freezing points of the fluids, see safety data sheets issued by the manufacturers.

-

the weather conditions (type and amount of precipitation).

2) For the first step of de-icing in the 2-step procedure, the mixture proportion is dependent upon the outside air temperature. For details of the freezing points of the fluids, see safety data sheets issued by the manufacturers. Revision 25

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EUROCOPTER

c.

MAINTENANCE MANUAL BO 105

-

Depending on the application procedure (see step 6.) heat de-icing fluids or use them unheated: -

for the 1-step de-icing procedure and for the first step of the of the 2-step procedure for de-icing: heat fluid to 60°C (140°F) (For details of application temperatures, see also safety data sheets issued by the manufacturers).

6. Application procedure for de-icing CAUTION a.

TO AVOID DAMAGE, NO SHARP-EDGED TOOLS MADE OF METAL (E.G. SPADES, SCRAPERS) ARE TO BE USED FOR REMOVING FROST, ICE, SNOW AND SLUSH.

Removal of snow In order to de-ice more effectively as well as to save de-icing fluid, remove loose snow before de-icing:

b.

-

by means of brooms or brushes made of soft, non-scratching material,

-

by blowing off with air,

-

by means of a scraper with a rubber lip.

-

Selection of the procedures for de-icing with fluid type I or type 11:

NOTE

The procedure (see steps c. thru e.) which is to be performed depends on the weather conditions, the outside air temeprature and the required holdover time.

De-icing can be performed in the: 1-step-procedure, when the degree of icing is lower, c.

2-step-procedure, when the degree of icing is higher.

Procedures for de-icing with fluid type I This procedures are preferably to be performed, if there is no precipitation and if the main aim is to de-ice. 1) De-icing in the 1-step-procedure: -

Use heated mixture made of fluid type I and water.

-

Freezing point of the mixture must be at least 10°C (18°F) below the outside air temperature.

-

2) De-icing in the 2-step-procedure: a) First step: -

Use heated water or heated mixture made of fluid type I and water.

-

Because of the danger of icing, use pure heated water only at an outside air temperature down to -3°C (27°F).

-

At outside air temperatures below -3°C (2JOF): Freezing point of the mixture must not exceed the outside air temperature by more than 3°C (5°F).

b) Second step: -

d.

Spray on not heated mixture made of fluid type I and water immediately after the first step and before the de-icing fluid, which was sprayed on in the first step, freezes (within 3 minutes after the first step).

Procedures for de-icing with fluid type 11

CHAPTER 02 Page 38

Revision 25

-

EUROCOPTER

MAINTENANCE MANUAL BO 105

These procedures can also be performed, in freezing precipitation (rain, snow, etc.). 1) De-icing in the 1-step-procedure: -

Use heated mixture made of fluid type 11 and water or use pure type 11.

2) De-icing in the 2-step-procedure: a) First step: -

Down to an outside air temperature of -3°C (27°F): use heated water or heated mixture made of fluid type I or type 11 and water.

-

Below an outside air temperature of -3°C (27°F): use heated mixture made of fluid type 1 or type 11 and water. The freezing point of the mixture must not exceed the outside air temperature by more than 3°C (27°F).

b) Second step: -

CAUTION

e.

Spray on unheated mixture made of fluid type 11 and water or pure type 11 immediately after the first step and before the de-icing fluid, which was sprayed on in the first step, freezes (within 3 minutes after the first step). BY REPEATED APPLlCATION OF THE PURE FLUID TYPE 11, RESIDUES MAY ACCUMULATE ON SURFACES, IN HOLLOW SPACES AND IN GAPS. THEREFORE, TYPE 1I MUST NOT BE SPRAYED ON TWO TIMES IN SUCCESSION, IF THE HELlCOPTER WAS NOT FLOWN AFTER THE FIRST TREATMENT. BEFORE REPEATED APPLlCATION OF THE PURE FLUID TYPE 11, THE HELlCOPTER MUST BE CLEANED.

Procedure for de-icing with fluid type 11 This procedure is not applicable for flight operations and is only performed as preventive anti-icing measure, if the helicopter is to be parked outside and freezing precipitation is forecasted by the meteorological service. If the de-icing fluid is sprayed on before the precipitation starts, a limited anti-icing is achieved when there is precipitation, furthermore, it decreases the freezing of ice and snow on theprotected surfaces and also eases later de-icing. -

If pure fluid type 1I is to be applied anew on an already existing layer of pure fluid type 11 (e.g. because of insufficient holdover time) prior to this, the helicopter must be thoroughly cleaned with heated water or with a heated mixture made of water and fluid type 1. Do not use heated fluid type 11. However, the requirement for this is a clean surface (free from frost, ice, snow, slush). Use pure fluid type 11 to achieve the longest possible holdover time.

7.

Procedural instructions for de-icing a.

If protection is to be provided against icing and an indication about the holdover time is desired, note the type of the de-icing fluid used and the point of time when the de-icing fluid has been applied.

CAUTION

b.

DE-ICING FLUIDS MUST NOT COME INTO CONTACT WITH HOT COMPONENTS DUE TO THE RISK OF FIRE.

Before spraying on of de-icing f1uids, wait until hot areas on the helicopter have cooled down, such as:

Revision 25

CHAPTER 02 Page 39

EUROCOPTER

c.

MAINTENANCE MANUAL SO 105

-

engine exhaust ejectors,

-

pitot tubes,

-

search lights.

-

Using a suitable device (e.g. heatable compressed air spray WEYER HOTSPRAY), spray fluid onto the surfaces to be treated: -

For de-icing on iced surfaces in the 1-step-procedure and de-icing at the first step of the 2-step-procedure: use narrow-coned, rough spray jet with a big (high) flow-through quantity at the spray nozzle.

Use sufficient amounts of the de-icing fluid to avoid re-icing, because melting frost, ice, snow and slush dilute de-icing f1uids. For de-icing of light icing (free from frost, ice, snow, slush): use wide-coned, fine spray jet with less impact pressure and with a smaller fluid flow quantity. In the second step of the 2-step-procedure, spray the fluid onto the surfaces until the fluid previously sprayed onto the surfaces during the first step, has been completely washed away and replaced. Apply an even film of fluid. d.

In order to prevent the de-icing fluid from dripping onto the window panes, spray de-icing fluid onto rotor blades only when they are in the backward position. While doing so, carefully turn rotor in the rotational direction and de-ice blades individually starting from the blade root over the leading edge.

e.

Start at the top of the helicopter and work down first one side and then down the other side in the same way.

f.

Perform de-icing briskly without stopping and as quickly as possible.

g.

If icing is severe, de-ice small areas one after the other.

h.

If the fluid freezes during de-icing, stop the de-icing work immediately and perform the work again with a mixture of de-icing fluid which has a lower freezing point.

i.

If such icing occurs in the second step of the 2-step-procedure, both steps of the 2-step-procedure must be perfomed again.

CAUTION

j.

-

DAMAGE AND MALFUNCTIONING CAN BE CAUSED, IF THE FLUID JET IS SPRAYED DIRECTLY AT THE FOLLOWING LlSTED PARTS.

Always direct the jet so that f1uids cannot penetrate or seep into the helicopter. Do not spray fluid jet directly onto the following parts or into openings, but to the area surrounding them and then allowing the fluid to f10w over these parts and openings: -

window panes, Specially heated fluids may cause cracking on cold acrylic-glass panes,

-

greased parts (such as e.g. swashplate), ensure that the grease is not washed out,

-

gaps at doors, covers and fairings or cowlings,

-

openings on the side and the top of both engine and the main transmission cowlings,

-

air inlets and exhaust ejectors of engines,

CHAPTER 02 Page 40

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EUROCOPTER

MAINTENANCE MANUAL BO 105

-

pitot tube opening, opening for static pressure system, gill openings and drain holes,

-

exposed controls of main and tail rotor,

-

bearing locations of main rotor blades,

-

sliding sleeve and gearbox of the tail rotor and tail rotor blades,

-

antennas,

-

servomotors, actuators and other electrical parts and interfaces.

-

housing openings of optional equipment such as external mounted hoist system, external loudspeakers, cargo hook, search light, FlIR camera, etc.

k.

To prevent heat loss of the fluid, loss of fluid due to wind drift and to achieve the maximum effect, hold spray or spray jet c10se to the surface to be treated.

1.

The angle between spray jet and surface should be smaller than 90° while spraying.

m. When it is windy, pay attention to the direction of the wind. Make sure not to spray against the wind. n.

8.

While spraying, make sure not to rinse snow, ice or melt water into openings and hollow spaces with the spray jet.

Application of CM 525 protective agent for door sealings

a. C/ean door sealings, b. 9.

Apply CM 525 protective agent onto door sealings.

Measures after de-icing a.

b.

Ensure that helicopter is completely de-iced and especially check the following areas: -

main and tail rotor blades including attachment areas,

-

control elements on main and tail rotor,

-

air inlets of engines, pitot tube openings, openings for static pressure system, drain and vent holes,

-

antennas,

-

outside air temperature sensors,

-

horizontal stabilizer including vertical fin with position Iights,

-

actuators and other electrical components and interfaces,

-

landing gear,

-

externally installed optional equipment such as external mounted hoist system, externaI loudspeakers, landing lights, cargo hook, search lights, FlIR camera, etc.

Ensure that there is no accumulation of f1uids and deposits of snow, slush and ice in the area of all moving parts, in hollow spaces and on cowlings/fairings, etc.

10. Measures before putting helicopter into operation:

WARNING

Revision 25

MAKE SURE THAT ALL PRIOR INSTALLED PROTECTION COVERS ANO TAPE ARE REMOVED. CHAPTER 02 Page 41

EUROCOPTER

CAUTION

a.

MAINTENANCE MANUAL 80105

WINDOW PANES MAY BE SCRATCHED, IF THEY ARE CLEANED WITH DIRTY OR ROUGH CLEANING CLOTHS.

Clean all cockpit and cabin window panes using hot water. To do so, use c1ean suede leather washing c1oth. If fluid type 11 was used, the window panes may be smeared. If this is the case, carefully c1ean window panes and wiper blades:

b.

-

if smears or impurities cannot be removed as described above, clean window panes i.a.w. Chapter 21-21.

-

Clean wiper blades using a mixture made of water and commercial washing up Iiquid.

If a helicopter, protected against icing, was not operated for a longer period of time and the de-icing fluid has dried up, aerodynamically critical parís, such as e.g. rotor blades must be c1eaned by removing old deposits of de-icing fluid before t1ight. To do so, depending on the respective outside air temperature, use heated water or a heated mixture made of water and fluid type 1.

c.

Do a check of the helicopter for icing before it is put into operation. See also step 10. a.. If necessary, de-ice helicopter.

d.

Examine the main rotor and tail rotor control for freedom of movement.

_

-

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MAINTENANCE MANUAL MBB B0105

03 CONSUMABLE MATERIALS Table 01 Contents

Pragraph

Title

03-1

EXPLANATORY NOTES

3

03-2

EQUIVALENT MATERIALS

3

03-3

ABBREVIATIONS

3

03-4

FORMULA

4

03-5

CONSUMABLE MATERIALS

5

03-6

ECD-APPROVED SUPPLlERS

Revision 24

Page

22

CHAPTER 03 Page 1

MAINTENANCE MANUAL MBB B0105

BLANK PAGE

CHAPTER 03

Page 2

Revision 24

MAINTENANCE MANUAL MBB B0105

03-1 EXPLANATORY NOTES The Iist of Consumable Materials contains materials required for maintenance. The consumable materials are grouped according to their purpose and are numbered as follows. Lubricants

CM 101-199, 1001-1999

Cleaning Agents

CM 201-299, 2001-2999

Protectants

CM 301-399, 3001-3999

Primers, Paints and Finish Coats

CM 401-499, 4001-4999

Corrosion Preventive Agents

CM 501-599, 5001-5999

Sealants and Adhesives

CM 601-699, 6001-6999

Miscellaneous

CM 701-799, 7001-7999

Al! products listed in the List of Consumable Materials can be obtained from: Interturbine Logistik GmbH Kisdorfer Weg 36-38 0-24568 Kaltenkirchen Germany Phone:

+49-4191-809300

Fax:

+49-4191-809-333

or wortdwide from the corresponding local service office (as published in Eurocopter Customer Service News No. 22-98).

03-2 EQUIVALENT MATERIALS Equivalent materials of other manufacturers may be used as alternate selections to those listed here. In determining wether or not an item is equivalent, the burden of proof rests with the holder/user.

03-3 ABBREVIATIONS MIL

=

US Military Specification

FEO

=

US Federal Specification

LAC

=

LOCKHEEO Specification

WL

=

Werkstoff-Leistungsblatt, Werkstoffhandbuch der Oeutschen Luftfahrt (Material Oata Sheet, German Aviation Materials Manual)

TL

=

Technische Lieferbedingungen des Bundesamtes für Wehrtechnik und Beschaffung (BWB) (Technical Specifications of the German Federal Office for Military Technology and Procurement)

Revision 24

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MAINTENANCE MANUAL MBB B0105

03·4 FORMULA Preparation of passivating liquid (CM 701) for treatment of magnesium alloy castings after polishing.

Composition: 180g sodium dichromate (Na2 Cr207 2H 20) 188 mi concentrated nitric acid (HN03 ) (densitiy 1.42 kg/dm

3

)

Dissolve in distilled water and add more destilled water to obtain 1 liter of solution. The passivating liquid has an unlimited shelf life if kept in a suitable glass container at room temperature (approx. 20°C). Carefully c10se tM container each time passivating Iiquid has been taken out.

CHAPTER03 Page4

Revision 24

MAINTENANCE MANUAL 80 105

03-5 CM

CONSUMEABLE MATERIALS MATERIAL

SPECIFICATION

PRODUCT/SOURCE

LUBRICANTS 101

Grease, aircraft general purpose

MIL-RPF-81322 G-395 (Nato) AIR 4222 CMS N49999X0108 DEF STAN 91-52/1 ECD CODE 757550

102

Grease, heavy duty general purpose

ECD CODE 69660 / 104541 / Molykote BR 2 Plus, 104541 Dow Corning GmbH

103

Lubricating oil, synthetic base

MIL-PRF-23699 Grade STD 0-156 (NATO) CMS N49999X0040 DERD 2499 ECD CODE 1443206

TurbonycoH 600, Nyco Corp. Aeroshell Turbine OH 500 MOBIL JET 11, Mobil BP TO 2380

104

Silicon compound

MIL-S-8660 S-736 (Nato) ECD CODE 1381738/79365

MS4 Dow Corning GmbH

105

Lubricating oil, petroleum base

TL 9150-005 0-180 (Nato)

INTERTURBINE LOGISTIK

106

Lubricating oíl, synthetic base

108

Talcum powder, white

FED U-T-30 MIL-C-5024 (invalid) ECD CODE 47236

INTERTURBINE LOGISTIK

110

Hydraulic fluid

MIL-PRF-5606F (*) TL 9150-0020 AIR 3520B H-515 (NATO) DEF STAN 91--451 Grade OM15 ECD CODE 97533/608738

Aeroshell Fluid 41 Hydraunycoil FH51, Nyco Corp (*) MIL-PRF-5606F und weitere, freigegebene Ausgaben der MIL-PRF-5606 ab Index F

111

Anti-seize and lubricating compound, corrosion preventive compound

ECD CODE 670701/23756

Never Seez Pure Nickel Special, Never Seez Compound Corp. / Bostik Findley

112

Grease

113

Lubricating oH, synthetic base

Revision 25

Aero Shell, Grease 22 Mobíl Grease 28 Nyco Grease GN 22 Elf Aviation Grease 22 Castrol, Braycote 662, Grease 22

BP Turbo Oil 25 (ersetzt EXXON T.O. 25)

Ore Lube Wadell AD-172 Wadell Equipment Co.lnc. MIL-L-7808 0-148 (Nato)

Turbonycoil 160, Nyco Corp Aeroshell Turbine OiJ 308

CHAPTER 03 Page 5

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MAINTENANCE MANUAL SO 105

an EAOS Oompeny

CM

MATERIAL

.-...... SPECIFICATION

PRODUCT/SOURCE

LUBRICANTS 115

Grease

MIL-PRF-23827 G-354 (NATO) AIR 4210B

Aeroshell Grease 7 (Type 11), Castrol Aeroplex (Type 11) Nyco Grease GN 10 (Type 1), Elf Aviation Grease 10 (Type

1) , KALOR Antares EP (Type 1) Lubrí Moly M6 (Type 1), BTGV (Type 1), IMPERATOR 1332 (Type 1) 117

Hydraulic fluid for preservation

MIL-PRF-6083 TL 9150-0051 C-635 (NATO)

Hydraunycoil FH6, Nyco Corp

120

Grease

ECD CODE 540023

Plastilube Moly Nr. 3, Warren Refining and Chemicals Co.

122

Lubricating oil, petroleum base

0-135 (NATO) AIR 3515/B

Aero Shell Turbine Oil3 Deutsche Shell AG

133

Lubricating oil, petroleum base

MIL-PRF-6081 Grad 1010 0-133 (NATO)

Turbonycoil3516, Nyco Corp.

137

Anti-seize compound

MI L- T-5544C (invalid) AIR 4247A S-720 (NATO)

Nyco Grease GN GA 47, Nyco Corp.

140

Grease, molybdenum disulphide

ECD CODE 46145 MIL-G-21164D G-353 (NATO) AIR 4217A CMS N49999X0024

Nyco Grease GN 17

142

Lubricant, solid film

TL 8010-026

Molykote 7409, Dow Corning GmbH

143

Thinner

146

Lubricant

ECD CODE 710810

Molykote TP42, Dow Corning GmbH

147

Anti-fretting compound

ECD CODE 587297

718050-01-5CM3, Sunstrand Aviation Rockford

-

_o

Molykote 7414 Dow Corning GmbH

CHAPTER 03 Page 6

Revision 25

,.'-

Oeurocopter

MAINTENANCE MANUAL SO 105

lI
CM

MATERIAL

SPECI FICATION

PRODUCT/SOURCE

CLEANING AGENTS

.-.,

".

..0'_"0.

201

Cleaning solvent (Degreasing agent), suitable for ultrasonic c1eaning

ECD CODE 109172

STAUBCO-T100, Brenntag AG TURCO 5948-DPM, Henkel Oberflachentechnik GmbH"

202

Dry c1eaning solvent (Washing benzin)

ECD CODE 036455 FED P-D-680 Type 1 oder/ or/ou 2 TL 6810-0012/1 a S-752 (NATO)"

Esso Varsol Shellsol D40ITYP1 oder/or/ou D60ITYP2 INTERTURBINE LOGISTIK

203

Aceton, tecnical (unsuitable for ultrasonic e/eaning)

FED 0-A-51 TL 6810-003

INTERTURBINE LOGISTIK

204

Trichlorethylene

FED 0-T-634 Type 2

INTERTURBINE LOGISTIK

205

Tetrachlorathylene (Perchlorethy- FED 0-T-236 lene)

INTERTURBINE LOGISTIK

209

Cleaner and degreasing agent

Produkt nicht mehr lieferbar, andere geeignete Reinigungsmittel verwenden, z.B. CM 220

210

Oil carbon solvent

Contrax 295 DV, Chemische Werke Kluthe GmbH

213

Paint remover

FED TI-R-248 (3) MIL-R-25134 (invalid)

N 53509/ MB 27877

214

Trichlorethane (Methyl chloroform)

FED 0-T-620

LPS Instant Super Cleaner

217

Methyl ethyl ketone (MEK)

FED TI-M-261VTL 6810--004

INTERTURBINE LOGISTIK

218

Cleaning solvent, general

FED o-T-620

Tiket, TEGEE--ehemie GmbH

219

Toluene

FED TI-T-548

INTERTURBINE LOGISTIK

220

Cleaning solvent

ECD CODE 53568

Nikutex 115, Kluthe GmbH

222

Naphtha

FED TI-N-95 Typ 2

INTERTURBINE LOGISTIK

225

Wetting agent

P3-T5130 Henkel und Cie GmbH

227

Aircraft interior cleaner

Tegesin-1033.369, TEGEEChemie GmbH

228

Plastic e/eaner

Kunststoff-lntensiv-Reiniger, Burnus GmbH

229

Degreasing agent

Eskapon S570, Haug Chemie GmbH

2002

Disinfectant

Dismozon pur, BODE Chemie GmbH & Co

Revision 25

CHAPTER 03 Page 7

o CM

eurocopter

MAINTENANCE MANUAL BO 105

anEA.OS~

MATERIAL

SPECIFICATION

-

PRODUCT/SOURCE

PROTECTANTS 303

UP-Putty, white including hardener

ECD CODE 42540 DAN 1090-01

N58479, PRC-DeSoto

304

Hardener for UP putty

ECD CODE 42541 DAN 1090-02

N59029, PRC-DeSoto

305

PUR filler, white

ECD CODE 15048 WL 5.7050

N57818-508, PRC-DeSoto

306

Hardener for PUR filler

ECD CODE 15836 WL 5.7057

N37514, PRC-DeSoto

311

Preservative oil

316

Chemical conversion material

MI L-DTL-81706 CMS N 8716206112 80-T-35-1101

Alodine No. 1200, Gerhard Collardin GmbH C.F.P.!.

CM

MATERIAL

SPECIFICATION

PRODUCT/SOURCE

Shell Ensis Oil L Deutsche Shell AG

PRIMER, PAINTS AND FINISH COATS 401

Primer, zinc chromate, alkyd resin base

MIL-P-8585 (invalid) FED TI-P-1757 TL 8010-001 Klasse 111, Typ 1

N 57034, PRC-DeSoto

402

Coating lacquer, mat, single layer, acrylic nitrocellulose, dust grey, RAL 7037

ECD CODE 50981 MIL-PRF-81352 TL 8010-013 WL 5.7005

CELEROL finish coat 962-12 783L RAL7037, Mankiewicz

404

Primer for two-component, fluorescent paint, purewhite, RAL 9010

CHAPTER 03 Page 8

N 58763 I T508, PRC-DeSoto

Revision 25

-

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MAINTENANCE MANUAL SO 105

un EAOS Compuny

CM

MATERIAL

SPECIFICATION

PROOUCT/SOURCE

PRIMER, PAINTS ANO FINISH COATS

...

405

PUR tinish coat, two-component, haltmat, pur white, RAL 901 O

ECO COOE 65366 MIL-PRF-85285 TL 8010-002, Class 11 Type 2 WL 5.7132

Alexit tinish coat 472-33, Mankiewicz

406

Flourescent paint, two-component, luminous orange, RAL 2005

ECO COOE 113094 WL 5.7135.0

Standox / Sikkens

407

Lacquer, mat, singlelayer, acrylic nitrocellulose, jet black, RAL9005

ECO COOE 113091 TL 8010-013 WL 5.7005

Alexit 962-13, RAL9005, Mankiewicz N 59676/RAL9005, PRC-OeSoto

408

Finishing varnish tor two component tluorescent paint, colorless

ECO COOE 83402 WL 5.7130

Autoclear / Clear Lacquer, Sikkens GmbH

409

Thinner tor two-component tluorescent paint

ECO COOE 100141

Standox-2K-Kurz 11128, Herberts GmbH

410

Lacquer single paint, mat, acrylic nitrocellulose, basalt grey, RAL 7012

ECO COOE 113086 TL 8010-013 WL 5.7005

Single layer lacquer, man, 962-12 752H, Mankiewicz N59676/RAL7012, PRC-OeSoto

411

Hardener tor two component tluorescent paint

ECO COOE 100140

Standox 2K-Harter-Kurz, Herberts GmbH

412

PUR tinish coat two-component, mat, basalt grey, RAL 7012

ECO COOE 38981 MIL-PRF-85285 TL 8010-002, Class 11, Type 2 WL 5.7054 LV1 05-1 0000.00.25

Alexit 406-23, Mankiewicz

413

Thinner tor two-component PUR paint

ECO COOE 72060/112603 WL 5.7059 LV1 05-1 0000.00.25

Alexit 901-45, Mankiewicz T187, PRC-Oesoto

"."

Revision 25

CHAPTER 03 Page 9

fteurocopter

MAINTENANCE MANUAL SO 105

en EADS 0:Jmpeny

CM

MATERIAL

SPECIFICATION

-

PRODUCT/SOURCE

PRIMER, PAINTS AND FINISH COATS 414

Thinner tor two-component prim- ECD CODE 113077 ers and one-eomponents paint FED TI- T-266, Type 2 TL-A-015 WL 5.7009

N 39/3010, PRC-DeSoto Mankiewicz

415

PUR tinish coat, two-component, haltmat, black, RAL 9005

WL 5.7053

Mankiewicz

416

PUR anti-slip lacquer, two-component

ECD CODE 1004776 WL 5.7056

N 53621/RAL9005, PRC-DeSoto (nicht NVG, Bestande autbrauchen) Alexit 472-25/RAL9021, Manciewicz Alexit 406-25/RAL9005, Manciewicz

417

Primer, zinc chromate, two-component, epoxy resin base, RAL6013

ECD CODE 113012 WL 5.7011

Seevenax Grundierung 113-25 RAL 6013, Mankiewicz N 53565/RAL6013, PRG-DeSoto

418

PUR tinish coat two-eomponent, mat, basalt grey, RAL 7012, was replaced by CM 412

419

Hardener tor two-component primers

ECD CODE 69567 TL 8030-018 WL 5.7003

N 37678, PRC-DeSoto

420

Hardener tor PUR paint

ECD CODE 83777n41443 TL 8010-002, Class 111, Type 2 WL 5.7052 LV1 05-1 0000.00.25

Alexit 400, Mankiewicz ACP65, PRC-Desoto

421

Lacquer single layer, Acrylic resin base, colorless

ECD CODE 61545 WL 5.7006

Mankiewicz N 39/1794, PRG-DeSoto

Wash primer, two component, Polyvinylbutyral base

ECD CODE 56839 TL 8030-018 WL 5.7002

N54628/MB518, PRC-DeSoto

423

-

~"

CHAPTER 03 Page 10

Revision 25

Oeurocopter

MAINTENANCE MANUAL BO 105

lIIl EADS Compony

CM

MATERIAL

SPECIFICATION

PRODUCT/SOURCE

PRIMER, PAINTS AND FINISH COATS 424

Heresite-paint, black

425

Lacquer single layer, mat, acrylic nitrocellulose, white aluminium, RAL 9006

ECD CODE 73931 TL 8010-013 WL 5.7005

Single layer lacquer, matt 962-12 RAL9006, Mankiewicz N 59676/RAL9006, PRC-DeSoto

426

PUR-Finish coat, mat dusty grey, RAL 7037

ECD CODE 1021742 MIL-PRF-85285 TL 8010-002, Class 11, Type 2 WL 5.7054

Alexit 406-23, Mankiewicz

427

Lacquer, mat, single layer, acrylic ECD CODE 45963 nitrocellulose, pure white, WL 5.7005 RAL 9010

Mankiewicz N 59676/RAL9010, PRC-DeSoto

428

Fluorescent paint, one-component, acrylic resin base, luminous orange,RAL 9005

MIL-P-21563 WL 5.7021

N 53550, PRC-DeSoto

429

Lacquer tor tluorescent paint, single layer, colorless

MIL-P-21563 WL5.7022

N 39959, PRC-DeSoto

430

Fire protective paint, white

ECD CODE 539905

N 56582 I T508, PRC-DeSoto

431

Thinner tor PUR tinishing varnish, tire protective paint

ECD CODE 72060 WL 5.7059

N 39 I 3091, N 39 I 3460, PRC-DeSoto

432

PUR tinishing lacquer tor tire ECD CODE 719508 protective paint, two-component, WL 5.7051 colorless

4232-0303, PRC-DeSoto

433

Paint remover tor tire protective paint

MIL-PRF-25134 FED TT-R-248 (3)

N 53509 I MB 27877, PRCDeSato

434

Thinner tor Heresite-Paint, denatured ethyl alcohol

FED O-E-760 (canceled) S-738 (NATO)

INTERTURBINE LOGISTIK

Revision 25

B-12, Heresite Saekaphen Incorp.

CHAPTER 03 Page 11

_eurocopter 8Il

CM

MAINTENANCE MANUAL SO 105

EADS Compeny

MATERIAL

SPECI FICATION

-

PRODUCT/SOURCE

PRIMER, PAINTS AND FINISH COATS 435

Hardener for two component EP resin base primer

ECD CODE 113013 WL 5.7013.0

Mankiewicz

436

Thinner for two component EP paint

ECD CODE 113015 WL 5.7019

Seevax Thinner 75, Mankiewicz N39956, PRC-DeSoto

437

PUR finishing lacquer for gearbox casings, Silver, RAL 9006

ECD CODE 102016 MIL-PRF-85285 WL 5.7051

Alexit 460-80 (RAL 9006), Mankiewicz

438

Hardener for two--component PUR finishing lacquer (see also CM 420)

S 66/8, Sikkens Lakfabrieken

439

Thinner for two--component PUR finishing lacquer (see also CM 413)

C 25/90S, Sikkens Lakfabrieken

440

Primer, zinc chromate, polyvenylbutyral-epoxy base, gray green, RAL 6010

LC02-6567, BASF Farben und Faser AG

441

Lacquer, finishing primer, alkyd resin base, grey, RAL 7012

BASF Farben und Faser AG

442

Thinner for lacquer, finishing primer

SV13-o341, BASF Farben und Faser AG

443

Lacquer-two--component gloss, epoxy resin base (alternatively CM424)

MIL-C-22750 WL 5.7012

Herbol Nr. 53-22095, BASF Farben und Faser AG

445

PUR finish coat, two--component, mat, Iight blue, RAL 5012

WL 5.7054

PU66 5462, PRC-DeSoto

450

Primer two--component, mat, RAL 9005

WL 5.7050

INTERTURBINE LOGISTIK

456

Primer, zinc chromat, two--component, epoxy resin base, green, RAL 6013

MIL-PRF-23377 WL 5.7011

Mankiewicz N 53565, PRC-DeSoto

459

Hardener for two-eomponent EP primer

ECD CODE 18130 WL 5.7014

Seevenax Hardener 115-22, Mankiewicz N39/1184, PRC-DeSoto

CHAPTER 03 Page 12

Revision 25

-,

...--..,

,,~

Oeurocopter

MAINTENANCE MANUAL BO 105

... fAD6 CooIpeny

CM

SPECIFICATION

MATERIAL

PRODUCT/SOURCE

PRIMER, PAINTS AND FINISH COATS 461

Antistatic PUR lacquer gloss, black

ECD CODE 72041 SAE AMS-C-83231 WL 5.7030

DA 4-653-93, Deutsche Airbus GmbH N 59111/ MB 37601, PRC-DeSoto

462

Hardener for anti-static PUR Lacquer, finishing primer

ECD CODE 56273

N 39/1327, PRC-DeSoto

463

Lacquer single layer, mat, acryIicnitrocellulose, flame red, RAL 3000

ECD CODE 113081 TL 8010-013 WL 5.7005

Mankiewicz N 59676/RAL3000, PRC-DeSoto

464

Lacquer single layer, mat, acryIícnitrocellulose, pure white, RAL 9010

TL 8010-13 WL 5.7005

Mankiewicz N 59676/RAL9010, PRC-DeSoto

465

Hanner tone finish, yellow olive, RAL 6014

466

PUR finish coat, two component, light grey, RAL 7035

ECD CODE 113001 MIL-PRF-85285 WL 5.7132.0

Alexit 472-33, Mankiewicz

467

PUR finish coat, two component, black

ECD CODE 711013 TL 8010-002, Class 11, Type 2

AL-86-9294, Becker Industrielack

468

Hardener for PUR finish coat , two-component

ECD CODE 711014

AZ-94-o007, Becker Industrielack

469

Thinner for PUR finish coat , two-component

ECD CODE 711015

AZ-97-o001, Becker Industrielack

470

PUR finish coat two-component, green

ECD CODE 681675 TL 8010-002, Class 11, Type2

PUR-Lack AI-86-6054, Becker Industrielack 45750, Herberts GmbH

471

Thinner for two-component PUR finish coat

472

EP primer, two-component, chromate free, RAL 1011

,,~

WN 53/1/3, Wandel und Goltermann GmbH

PUR-Thinner 11537, Herberts GmbH ECD CODE 92782 TL 8010-0001, Class 11, Type4 WL 5.7139

Revision 25

Seevenax Primer 113-24 118G, Mankiewicz 5809-1011, PRC-DeSoto

CHAPTER 03 Page 13

faeurocopter 8Il

CM

MAINTENANCE MANUAL 80 105

EAOS Compony

MATERIAL

SPECIFICATION

-,

PROOUCT/SOURCE

PRIMER, PAINTS ANO FINISH COATS 473

Paint, silver

478

PU-Lacquer tor ground terminals, two-eomponents

ECO COOE 1005339 HS 7072-718

CELOMER 4125 I 6407, PRCOeSoto

479

Hardener tor PU-Lacquer, twocomponent

ECO COOE 92933

CELOMER 0613 I 9000, PRCOeSoto

480

Thinner tor PU-Lacquer, twocomponent

ECO COOE 92934

CELOMER 0580 I 9000, PRCOeSoto

481

Lacquer

ECO COOE 62095

Spezialüberzugslack-F, G.Kaiser

482

Lacquer high-gloss, RAL 1007

ECO COOE 87696

Standocryl-2K-RAL1007, Standox I Sikkens Standohyd, Standox I Sikkens

483

Hardener tor high-gloss lacquer

ECO COOE 752419 ECO COOE 100140

83302 I Standox MS-Hardener, Standox GmbH

484

Thinner tor high-gloss lacquer

ECO COOE 709444 ECO COOE 100141

78090 I Standox 2K Thinner 11012, Standox GmbH

491

Synthetic enamal, chrome yellow, RAL 1007

ECO COOE 50749

200-11007, Spies-Hecker GmbH

492

Synthetic resin mat paste tor synthetic enamal

073-07213

Standox, Herberts GmbH

493

Thinner tor synthetic enamal

ECO COOE 606246

3810, PRC-OeSoto

494

2K elastic-additiv

ECO COOE 717872

84279 I Standox 2K elastic additive, Standox GmbH

Heresite Saekaphen Incorp. SermeTel1122 oder/or/ou SermeTel 196, Sermatech International

-

-

CHAPTER 03 Page 14

Revision 25

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MAINTENANCE MANUAL BO 105

nn EAOO 03mp&ny

CM

SPECIFICATION

MATERIAL

PRODUCT/SOURCE

CORROSION PREVENTIVE AGENTS 501

Lacquer, corrosion preventive tor ground terminals (replaced by PU-Lacquer tor ground terminals, two-component CM478)

ECD CODE 1005409

Nycote 7-11 BL, Nycote Laboratories

502

Corrosion preventive compound

MIL-PRF-16173, Grade I TL 8030-0015, Type 1 C-632 (NATO)

Nycoprotec 8131, Nyco S.A.

503

Corrosion preventive paste was replaced by CM 518

MIL-PRF-8116 WL 5.7070.0

Mastinox 6856 H, PRC-DeSoto

505

Corrosion preventive compound

MIL-e-11796 Class 3 TL 8030-0006 C-627 (NATO)

Nycoprotec 8136, Nyco SA Nycoprotec 19, Nyco S.A. Braycote 248, Air BP Lubricants

506

Corrosion preventive compound

MIL-C-23411 (invalid) MIL-C-81309

WD 40, Hugo Fingerle

508

Corrosion preventive compound

MIL-PRF-16173, Grade 11 TL 8030-015 C-620 (NATO)

LPS 3, Daniel und Jager Nycoprotec 8132 Braycote 137 Ardrox 3140

509

Corrosion preventive concentrate MIL-PRF-23699

510

Corrosion preventive paste (was replaced by CM 518)

512

Anti--eorossion agent

513

Corrosion preventive compound

MIL-PRF-16173, Grade 111

Dínitrol-AV5, Dinol

515

Varnish polyurethane

ECD Code 750535 CMS N4934983848

D148PTFE, Achesom France SA

518

Corrosion preventive compound

ECD CODE 62888 MIL-PRF-8116 WL 5.7070.0 CMS N4911651774 LN9368-5903 ASNA4188

Mastínox 6856K, PRC-DeSoto

Revision 25

Brayco 599, C. Scanlon und Co. Turbonycoil TN600, Nyco Corp.

Molykote Metal Protector, Dow Corning

CHAPTER 03 Page 15

_~!E,COpter CM

MAINTENANCE MANUAL 80 105

MATERIAL

SPECI FICATION

_.

PRODUCT/SOURCE

SEALANT AND ADHESIVES EC 1838 B/A, 3M

601

Adhesive, head proof

602

Adhesive

603

Adhesive film, heat proof

604

Adhesive film

605

Contact adhesive

MIL-A-1154 (invalid) QPL-MMM-A-129 ECS 6056-1029

EC 1300L, 3M

606

Adhesive, epoxy resin base

CMS C4966056362 DHS 172-171

Araldite AW 106, Vantico Sylamed

607

Hardener for CM 606

HV 953U, Harter für Kleber Araldite AW 106, Vantico

608

Masking tape, coarse crepe

Tesakrepp 4322, Beiersdorf AG

609

Masking tape, fine crepe

610

Adhesive

612

Silicone rubber and adhesive

613

Hardener for CM 610

614

Adhesive tape oliv green

615

Adhesive, colored

616

Adhesive paste, two-component epoxy resin

ECS 6054-1032 ECD CODE 743230

EA 9396A, LOCTITE

617

Hardener for Adhesive paste CM 616

ECS 6054-1032

EA 9396B, LOCTITE

619

Silicone rubber and adhesive

ECS 6056-1066 ECD CODE 764035

Elastosil RTV E41, Wacker Chemie GmbH

620

Sealing, locking and securing compound

ECS 6056-1048 ECD CODE 746530

Loctite 274, LOCTITE

ECD CODE 66275 MIL-A-52194 (invalid)

Technovit 2190, Kulzer und Co GmbH ECD CODE 26950

Tesa Nr. 54108, Beiersdorf AG Tesafilm Nr. 4154, Beiersdorf AG FM 123-5.06 PSF, American Cyanamid Co.

ECD CODE 42903 I 66009

Tesakrepp 4318, Beiersdorf AG

ECD CODE 20320 ECS 6056-1 067

Araldite AV 123 B, Vantico

......

Araldite HV 953B, Harter für Kleber Araldite AV 123B, Vantico ECD CODE 1005386 TL 7510-011 Type B Class 1

Tesaband 53799-50 (ersetzt 555-50), Beiersdorf AG Tesaband 4651, Beiersdorf AG

~

CHAPTER 03 Page 16

Revision 25

~¡(-

Oeurocopter

MAINTENANCE MANUAL BO 105

un EADS 03mpany

CM

SPECIFICATION

MATERIAL

PROOUCT/SOURCE

SEALANT ANO AOHESIVES

.........

CMS N4988238023

Loctite 222, LOCTITE

621

Sealing, locking and securing compound

622

Sealing, locking and securing compound

Loctite 764, LOCTITE

623

Sealing, locking and securing compound

Loctite 586, LOCTITE

624

Sealing, locking and securing compound

Loctite 221, LOCTITE

626

Sealing, locking and securing compound

Loctite 241, LOCTITE

628

Activator T

'Loctite 7471, LOCTITE

630

Epoxy resin adhesive

Elecolit 325A, Bostik GmbH

631

Hardener tor epoxy resin adhesive

Elecolit 325B, Bostik GmbH

633

Sealing compound

634

Adhesive tape

635

Sealing compound

LAC 40-776

PR 812, Le Joint Francais (ersetztlreplaces/substitue PR 810)

636

Sealing compound (replaced by CM 688)

MIL-S-7126 Type I

PR 1222, Le Joint Francais

637

Polyester resin

638

Adhesive

640

Adhesive

Araldite AV 138 M, Vantico

641

Hardener tor CM 640

Araldite HV 2978 M, Vantico

642

Hardener tor CM 640 (alternative)

Araldite HV 998, Vantico

643

Sealing compound

PR 1201 R, Le Joint Francais

644

Sealing compound

645

Locking and securing compound

647

Securing compound

Revision 25

ECO COOE 103332 WL 5.5913.1 MBBN3117-131/-121

PR 1720 F, Le Joint Francais PR 812, Le Joint Francais PR 1720 SM, Le Joint Francais Scotch 5453, 3M

Leguval K27, Bayer AG ECO CODE 55790

MIL-S-8784 Class A-1/2

Scotch Weld EC2216B/A, 3M Homag SA

PR 1773 A 1/2, Le Joint Francais Loctite 401 (ersetztlreplaces/ substitue Loctite 495), LOCTITE

ECS 6056-1047

Loctite 245, LOCTITE

CHAPTER 03 Page 17

dDeurocopter 811 EAOS

CM

MAINTENANCE MANUAL BO 105

Comp8ny

MATERIAL

SPECIFICATION

-.

PRODUCT/SOURCE

SEALANT AND ADHESIVES 651

Sealing, locking and securing compound

652

Adhesive tape

S1030, Raychem GmbH

653

Cement

RTA 40, F.P.T. Industries LTD

655

Sealing compound

Hylomar sa 32M 1 Hylomar M, Marston Olchemie GmbH

656

Adhesive for acrylic glass

Acrifix 90, Rohm GmbH

657

Adhesive for acrylic glass

Agomet M, Degussa

658

Polyurethane film adhesive

Scotch 8671 (ersetztlreplacesl substitue Y 8560-150), 3M

659

Polyurethane film adhesive

Scotch 8671 (ersetztlreplacesl substitue Y 8561-3049), 3M

661

Sealing compound

SAE AMS-S-8802 Class B-1/2 WL 5.5902.1

662

Sealing compound

SAE AMS-S-8802 Class B-2 PR 1422 B-2, Le Joint FranWL 5.5902.2 cais ECD CODE 77152/1005378 MC236 B2, Intertubine Logistik GmbH PR 1776 B-2, Le Joint Francais

663

Foam rubber adhesive tape, double-sided

4016 Scotchmount, 3M

664

Adhesive

EC 2216B-A, 3M

666

Compound

ECD CODE 072235

PR 1201

670

Sealing compound firewall

MIL-S-38249 Type 1

PR 812, Le Joint Francais

671

Adhesive, two component

ECS 6054-1012

SW 9323 B/A, 3M

672

Cement, epoxy type

CMS N4966396525

EA 9309 B/A EC 2216 B/A, LOCTITE

673

Adhesive silicone

674

Adhesive silicone transparent or black

676

Sealing, locking and securing compound

CHAPTER 03 Page 18

ECD CODE 35617

Loctite 270, LOCTITE

PR 1422 B-1/2, Le Joint Francais PR 17768-1/2, Le Joint Francais

a,

Le Joint Francais

KE 45 RTV DC 780, Dow Corning GmbH ECS 6056-1036 DHS 173-143.20 ECD CODE 743657 MIL-A-46106 TYP I

..-...,

Silastic RTV 732, Dow Corning GmbH

Loctite 290, LOCTITE

Revision 25

-

.-

CDeurocopter

MAINTENANCE MANUAL SO 105

un EAOS O:lmpony

CM

SPECIFICATION

MATERIAL

PROOUCT/SOURCE

SEALANT ANO AOHESIVES 677

Sealing, locking and securing compound

Loctite 672, LOCTITE

678

Adhesive

FM 73 K.06, American CyanamidCo.

679

Sealing, locking and securing compound

Loctite 932, LOCTITE

680

Safety lacquer blue

ECO COOE 584930/25018

320912BL, Sicherungslack Blau, Baeder GmbH

683

Securing compound

ECO COOE 53732

Loctite 242, LOCTITE

684

Sealing, locking and securing compound

Loctite 675, LOCTITE

685

PVC-adhesive tape, black

Fa. Coroplast

686

Sealing compound

687

Adhesive

688

Bonding and sealing compound

ECS 6046-1091 CMS N4988921829

PR 1829 B2, Le Joint Francais (ggf. ProSeal Primer PR142 separat bestellen)

694

Adhesive silicone

ECO COOE 015027

KE 42 RTV, Shin-Etsu Chemical Corp.

6026

PU film, grey

6028

Adhesive

ECO COOE 035298

Katalysator 20, Roehm GmbH

6029

Sealing compound

ECO COOE 540114 WL 5.5903.1"

PR1431G-Type 1, Le Joint Francais

6041

Adhesive paste, two-component

ECO COOE 678246 ECS 6054-1031

EA 9395A1B, Hysol, LOCTITE

MIL-S-8784 Class B SAE AMS-3267

PR 1773 B, Le Joint Francais EC 3532 BIA, 3M

8681-HS-SS-36173,3M

,~...-..•

Revision 25

CHAPTER 03 Page 19

Oeurocopter

MAINTENANCE MANUAL SO 105

"" EAOS Compony

CM

MATERIAL

SPECIFICATION

-

PRODUCT/SOURCE

MISCELLANEOUS 701

Passivating liquid

INTERTURBINE LOGISTIK

707

Nylon c1oth, black

Peel Ply Nr. 6499, Webstoffe Weiblingen GmbH

709

Parting and sliding agent

Sprühteflon 0-6-0, H. Costenoble KG

710

Sliding agent

711

Leak detection spray

713

Adhesive

ECD CODE 64681

Metalset-A4, SOOTH-GN INC

714

Vinyl tape, Adhesive

MIL-I-7798 (invalid) MIL-I-24391 LAC 24--426

INTERTURBINE LOGISTIK

715

Desicant

MIL-D-3436 TL 68501ID08

INTERTURBINE LOGISTIK

718

Silicone oil spray

719

Rubber tape

720

Lubricaring, sliding and seperating agent

Sprüh mit Teflon, Typ Plus 3, Saint-Gobain Pampus GmbH

721

Cleaner for transparent parts of cabin canopy

Pre Cleaner SPR 67, M. Weyer Import; Alternative CM 722

722

Water repellant I Cleaner

723

Parting wax

726

Glass fibre fabric

LN 9196 WL 8.4548.60

92110, Interglas Textil GmbH

727

Glass fibre fabric

LN 9196 WL 8.4554.60

92140, Interglas Textil GmbH

736

Wax pad, self-adhesive

Type I

Master-Wachsplatte, 4 mm dick, H.G. Forrer und Co.

739

Twine, lacing amd tying

MIL-T-43435 B Type 11, Size 5 Finish B (canceled) A-A-52081

INTERTURBINE LOGISTIK

750

Primer

Promotor 86, 3M

752

Tape (aluminium foil glass-woven)

P-100, J.J.P.

CHAPTER 03 Page 20

ECD CODE 68351

Hellerine, Paul Hellermann GmbH Galutec 3, F. A. Wobst KG

-.

Silikon61-Spray Nr. 838, Matrex Labor MIL-R-3065 (invalid) ASTM D 2000 WL 5.5505.5

ECD CODE 1224847 AMS 1535B I 1550B

INTERTURBINE LOGISTIK

3999 WESTFALlA Clean I Vision Pro-Tector Spray (Aufbrauchen von Bestiinden von REPCON erlaubt.) Trennwachs 826, Lechler Chemie GmbH

Revision 25

-

MAINTENANCE MANUAL BO 105

CM

SPECI FICATION

MATERIAL

PRODUCT/SOURCE

MISCELLANEOUS NY-1, INTERTURBINE LOGISTIK

753

Vínyl adhesive tape

758

Leak detection compound

759

Polishíng agent

Finesse-it, 3M Altuglas Polish 1 + 2

771

Polishing paste

Acrylglas-Polierpaste, Burnus GmbH

7007

Foam material

Art.-Nr. 13015, Fa. Zerzog

7016

Test wire dia. 0.025 mm (0.001 in)

102714-1, Innovated purchasing company SPIR-001-50, OMEGA Engineering Ine.

7017

Testwire dia. 0.075 mm (0.003 in)

102714-2, Innovated purchasing company SPIR-003-50, OMEGA Engineering Ine.

7022

Silicone oíl

MIL-PRF-25567 Type 1

ECD CODE 742458

INTERTURBINE LOGISTIK

Rhodorsil oil47V12500, Linke & Partner GbR

'."~

Revision 25

CHAPTER 03 Page 21

-------------_.-. _-- ._-_•._-------...

...__

-eurocopter .lIIIEAOO~ 03-6

MAINTENANCE MANUAL BO 105

ECD-APPROVED SUPPLlERS

This chapter is not used anymore.

CHAPTER 03 Page 22

Revision 24

HE1ICOPTERS - - - - - - - - - - - - MAINTENANCE MANUA1 MBB - BO 105

-------------MBB

04

S E 1 F - MA N U F A C T U R A B 1 E S P EC 1 A1 T OO1 S

Tab1e of Contents

Paragraph

Title

Page

04 - 1

1IST OF SE1F-MANUFACTURAB1E SPECIA1 T001S . . .

3

04 - 2

TECHNICA1 I11USTRATIONS OF SE1F-MANUFACTURAB1E SPECIA1 T0018 .

9

BO 105 CHAPTER 04 Page 1/2

::D

(1)

< ¡¡¡O

04-1

m

LlST OF SELF-MANUFACTURABLE SPECIAL TOOLS

e

JJ

eS" ::J

.....

These special tools can be substituted by different, but equivalent tools. Special tools to be locally fabricated can also be ordered from ECO • by quoting the respective part number.

(O

O () O

"'U

-i

Tool No.

Figure

Part Number

Nomenclature

Application

Application in Chapter

m JJ

04-1

deleted

2

04-2

105-13221 W1

Mounting tool kit

Assembly and disassembly of driving link assy

13

3

04-3

105-13241 W1

Orift

Removal and installation of bushings of fork link

13

4

04-4

105-42121 W7

Mounting tool

Removal and installation of ball bearings of control lever

41

5

04-5

105-42122 W2

Mounting tool

Removal and installation of bushings of control fork

41

Removal of bearings and f1ange bushings from hinged support

41

Z -i

Removal of spherical bearings from bearing block

41

z » z ()

6 7

04-6

04-7

105-42124 W4

105-42123 W4

Pushing-out tool

Pushing-out tool

.3:

»

m m

3:

» z e » r (')

IJ)

::I:

O ..... o

» -u

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cc::D (1)0

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m

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~

L1ST OF SELF-MANUFACTURABLE SPECIAL TOOLS (continued)

]J

~

(ir

o· ::::J

Application

105-31762 W4

Receptacle

Fixing of sliding sleeve to remove Shurlock nut

33

04-33

105-20001 W4

Mandrel

Pressing out oversize bushes from bearing blocks of engine mounts

22

34

04-34

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

Threading-out tool

Removal of screw plug from valve body manifold (System 1)

43

35

04-35

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

U-tube manometer

Pressure test-fuel system

62

36

04-36

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

Test mass

Testing the magnetic retaining force of chip detector on engine

02-14

37

04-37

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

Tapping hammer

For tap-testing of erosion protective shell on main and tail rotor blade

14,34

38

04-38

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

Template

For the inspection of the main rotor blade for bulging in the area of balance weight 1

Figure

Part Number

31

04-31

deleted

32

04-32

33

1\) 1\)

I

Application in Chapter

Nomenclature

Tool No.

14

--a ro e

8

~

ro ...,

s: »

z m -i

~

z O m

(')

:I:

»

~ -cm

~]J CO

......

o

~

s: » z e »r OJ

O

......

~

MAINTENANCE MANUAL 80 105

EUROCOPTER

BLANK PAGE

CHAPTER 04

Page 8

Revision 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 04-2

TECHNICAL ILLUSTRATIONS Of SELF-MANUFACTURABLE SPECIAL TOOLS

GENERAL DIN 7168 m (ltmedium lt ) standard applies to dimensions specified without tolerance limits, refer to Table 1.

Tolerance in mm for nominal dimension range in mm over Degree of Accuracy

m (medium)

over

over

over

over

over

6

30 te 120

120 te 400

400 te 1000

1000 te 2000

±0.3

±0.5

±0.8

±1.2

0.5 to 3

3 to 6

to 30

±0.1

±0.1

±0.2

Table 1

BO 105 CHAPTER 04 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Figure 04-1 BO 105 CHAPTER

Page 10

04

deleted

· - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

80 100

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100

XX

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Figure 04-2

~

Mounting tool kit, tool No. 2 (105-13221 W1) BO 105 CHAPTER 04

Page 11/12

~ ~

Material: Steel Dimensions in mm XX Marking

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

90

...¿

1

r--

0

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XX

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lx4S0

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08/25

Material: Steel Dimensions in mm XX Marking Figure 04-3

Drift, tool No. 3 (105-13241 W1)

BO 105 CHAPTER 04 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

70

x ,., Ó

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1 Support Drift

2

Material: Material:

Aluminum Stee1

Dimensions in mm XX Marking Figure 04-4 BO 105 CHAPTER 04 Page 14

Mounting tool, tool No. 4 (105-42121 W7)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

90

x N

,.,

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+

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Dimensions in mm XX Marking

08/21

Figure 04-5

Mounting tool, tool No. 5 (105-42122 W2) 80 105

04 Page 15

CHAPTER

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 30

XX ~/////

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08128

1 Thrust piece 2 Socket

Material: Aluminum Material: Steel

Dirnensions in mm XX Marking Figure 04-6 BO 105 CHAPTER 04 Page 16

Pushing-out tool, tool No. 6 (105-42124 W4)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

70

xx ~

-r-r-r

,,¡

'ii1---L

25

xx

13

"-----2

08129

1

Drift

2

Support

Material:

Steel

Dimensions in mm XX Marking Figure 04-7

Pushing-out tool, tool No. 7 (105-42123 W4) BO 105 CHAPTER 04

Page 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

60

---

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XX

8

U'l

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.

~

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.

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dia. 28.5. 0.1 dia. 32.2. 0.1 08/30

1 Drift 2 Support

Material: Steel

Dimensions in mm XX Marking Figure 04-8 BO 105 CHAPTER 04 Page 18

Mounting tool, tool No. 8 (105-42122 W1)

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 día. 36

dia.18

C)

U"I

Material: Aluminum Dimensions in mm

08/6

Figure 04-9

Support, tool No. 9

not il1ustrated

Figure 04-10

Puller, tool No. 10 BO 105 CHAPTER 04 Page 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 lb

15

18

xx "l

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08/31

1 Thrust piece Thrust piece Drift

2 3

Material:

Steel

Material:

Aluminum

Dimensions in mm XX Marking Figure 04-11

BO 105 CHAPTER 04 Page 20

Pushing out tool, tool No. 11 (117-80168 W1)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

/

70

LI'l

d

d

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23

70

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1 Pusher 2 Drift

Material: Material:

Alurninurn Steel

Dirnensions in mm XX Marking Figure 04-12

Mounting tool, tool No. 12 (117-80168 W2) BO 105 CHAPTER 04

Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

,

Figure 04-13 deleted

Figure 04-14 BO 105 CHAPTER

Page 22

04

deleted

fteurocopter

MAINTENANCE MANUAL BO 105

Figure 04-15 deleted

Revision 21

•

CHAPTER 04 Page23

MAINTENANCE MANUAL 80 105

• CHAPTER 04 Page 24

Figure 04-16 deleted

Revision 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Centering bore

X "l c:>

"l c:> I

I

"l

'" ..j

rO

:e

'",.; ..j

rO

:e

10

Material:

17

Steel

Dimensions in mm XX Marking

08/33

Figure 04-17

Support plate, tool No. 17 (105-31765 W1)

Figure 04-18

deleted BO 105 CHAPTER 04

Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

...c:

4

6 2

5

E

Bend hook around hose 'tJ

~ ~ --5

350

2

08122

Dimensions in mm XX Marking

NOTE

1

2

3 4

5 6

Item 6

= 350 mm

Item 4

=

2500 mm

For testing of leak oil of the tandem hydraulic unit Change of hydraulic fluid

Dust cap Aeroquip-Aircraft P/N 3209-6 Coupling half Aeroquip-Aircraft P/N 3205-6 Style 1 Clamp (-18 mm dial Hose (hose, P.V.C., transparent 16 x 2 mm dia.) Tube (tube, steel 12 x 1 mm dia.) Hose (hose, P.V.C., transparent 16 x 2 mm dia.) Figure 04-19

BO 105 CHAPTER 04 Page 26

Drain hose, tool No. 19 (105-45000 W1)

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

¡:::¡

N ni :,:;

ni

:,:;

100

-

1x4S0

XX

,., C> I

.

-

-

8

r--

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t

o,

<>.,.;

:,:; "'

08/35

XX Marking Dirnensions in mm Figure 04-20

1 Support sleeve 2

Material:

Steel

Drift

Pushing-out tool, tool No. 20 (117-46300 W2)

Figure 04-21

deleted BO 105 CHAPTER 04

Page 27

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3

o

'"

o

....

1--

28

08/39

Material: Steel Dimensions in mm XX Marking Figure 04-22 BO 105 CHAPTER 04 Page 28

Support, tool No. 22 (105-45041 W28)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - . MAINTENANCE MANUAL MEB - BO 105

., ~

)

[

XX

:

08/40

u=4

Material: Spring steel Dimensions in mm XX Marking Figure 04-23

Fixing spring, tool No. 23 (105-45041 W27)

r

50!1

XX

::J=4

08/41

Material: Steel or Aluminum Dimensions in mm XX Marking Figure 04-24

Mounting plate, tool No. 24 (105-45041 W26) BO 105 CHAPTER 04

Page 29

EUROCOPTER

• CHAPTER 04 Page 30

MAINTENANCE MANUAL 80 105

Figure 04-25 deleted

Revision 19

EUROCOPTER

MAINTENANCE MANUAL BO 105

Figure 04-26 deleted

Revision 19

•

CHAPTER 04 Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

tiO 1.450

25

leng1h 200 mm

Knot

90

08/42

3

XX Marking Dirnensions in mm

1 Mandrel (P.V.C. 16 mm dia.) 2 Loop (synthetic cord 3 mm dia.) 3 Adhesive tape, red (Width 25 mm)

Figure 04-27

BO 105 CHAPTER 04 Page 32

Connecting pin, tool No. 27 (105-14102 W2)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

60

20

60

lx4So

.-;

<:> 1

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08/43

1 Mandrel 2 Support

XX Marking Dimensions in mm Material: Mandrel: steel 32 dia. Support: aluminum 40 x 40 width Figure 04-28

Pushing-out tool, tool No. 28 (105-10155 W1) BO 105 CHAPTER 04

Page 33

cteurocopter

MAINTENANCE MANUAL BO 105

1100

soo

C) C)

.....

xx

XX Marking Dimensions in mm

Material: Spring steel sheet 0.3 mm thick

Figure 04-29

•

CHAPTER 04 Page34

Template. tool No. 29 (105-15103 W9)

Figure 04-30

deleted Revision 21

_eurocopter

MAINTENANCE MANUAL BO 105

Figure 04-31

66 31

'-

I I i XX

deletad

•

40

37 "_ 0.'

31

•

~

....o

t

140

Material: Aluminum Dimensions in mm

Figure 04-32 Revision 21

xx Marking

Receptacle. tool No. 32 (105-31762 W4) CHAPTER 04 Page35

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

ss 13

'X 'X ....

lI'lC!

-

---

1,,45°

... 0

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Mandrel, tool No. 33 (105-20001 W4)

2.4 -0.1

16!0.OS

20-22 000011

Square corresponds to square head drlve of socket wrench used

Material: Steel Dirnensions in mm Figure 04-34 BO 105 CHAPTER 04 Page 36

...."'!

o

....0

Threading-out tool, tool No. 34

ni

'6

MAINTENANCE MANUAL BO 105

EUROCOPTER

l:P-+T----

5

4---1

3---+-+1

XX Marking

1 Piece of wood, approx. 2000 x 200 x 20 mm 2 Piece of wood, approx. 500 x 200 x 20 mm 3 Glass tube or transparent hose, 8 mm 00, approx. 2 m long, bent to U-shape 4 Hose, 10 mm 00, 1 mm wall thickness, approx. 3 m long 5 Clamps

Figure 04-35

Revision 17

U-tube manometer, tool No. 35

CHAPTER 04 Page 37

MAINTENANCE MANUAL BO 105

EUROCOPTER

64

2,2 ~

(2.5231

(.085) ~5,5B

xx

(.2201

~~

~I

22,22 (0.8751

1.3101

7,1

~t--­

[,2801

Dimensions in mm (....) Dimensions in inches

Material: Steel XX Marking

Figure 04-36 Test mass, tool no. 36

CHAPTER 04 Page 38

Revision 17

EUROCOPTER

MAINTENANCE MANUAL SO 105

I

ce I

LO

I I

C\l

I

I

&3~: I

I I I I I I

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38

&

Items 2 and 3 bonded with CM 683

Dimensions in mm Material: Item 1 Item2 Item3

Steel (approx. 40g) Steel wire 0 2 mm Aluminum 0 6 mm

Figure 0~37

Revision 19

1 Hammer head 2 Handle 3 Grip

Tapping hammer

CHAPTER 04 Page 39

fteurocopter

MAINTENANCE MANUAL BO 105

28O - - - - - - - - - - - - - - ' - - t

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Mo

I I I I I I

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_15_ 265

Material: Aluminum, approx. 3mm thick XX: Marking (Template, tool no. 38 tor type 2 main rotor blade) Not to scale Al! dimensions in mm and tolerances La.w. D1N/ISO 2768m Figure 04-38

CHAPTER 04 Page40

Template, tool No. 38

Revision 22

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 05

H E L I C O P TER

GRO U N D

HANDL I NG

Table of Contents

Paragraph

Title

05 - 1

PUSHING - HELICOPTER

3

05 - 2

TOWING - HELICOPTER

5

05 - 3

PARKING - HELICOPTER

7

05 - 4

MOORING - HELICOPTER

8

05 - 5

JACKING - HELICOPTER

8

05 - 6

HOISTING - HELICOPTER

Page

12

BO 105 CHAPTER 05 Page 1/2

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 05 -1

PUSHING - HELICOPTER

Special tools: Ground Handling Wheels

p/N 105-82721 105-82722 105-82723 105-82766 105-82769

]

P IN 117-84421 -

CAUTION

1.

Configuration I Configuration II after Configuration I conversion with SB 80-71 Configuration III

TO AVOID DAMAGE TO ANY GYRO INSTRUMENTS INSTALLED ON THE HELICOPTER, DO NOT JOLT OR MOVE HELICOPTER FOR 10 MINUTES AFTER POWER IS REMOVED FROM THEM.

Position ground handling wheels (fig. 05-1) on left and right skid tubes (8), slide aft onto pickup pins (1) and lock into place with locking lever (2).

NOTE

Balance helicopter at tail skid during jacking and pushing operations.

2.

Close bleed valve (3) on hydraulic jack (7) using jacking handle (4) and operate jacking handle to raise helicopter. With configuration II and III wheels, operate jacking handle until piston is extended far enough to allow prop (6) or stop (5) to be pivoted downward to lock the piston.

3.

Open bleed valve (3) and release pressure in hydraulic jack.

CAUTION 4.

DO NOT PUSH OR PULL ON DOORS, WINDOWS OR END PLATES.

Push on helicopter at the following points only: a.

Landing gear crosstubes

b.

Left and right sides of engine deck aft edge

c.

Left and right cabin structure

d.

Tail skid

BO 105 CHAPTER 05 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Configuration 1 sarne as configuration 11, but without prop (6).

1

Configuration 11 6

Configuration 111

1

2 3

4 5

6 7 8

8

Pickup pin Locking lever Bleed valve Wheel jacking handle Stop Prop Hydraulic jack Skid tube

000026.1

Figure 05-1 BO 105 CHAPTER 05 Page 4

Installation of ground handling wheels

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5.

To lower helicopter equipped with configuration 11 or 111 ground handling wheels, close bleed valve (3), fully extend hydraulic jack piston, and pivot prop (6) or stop (5) upward.

6.

Slowly open bleed valve (3) and lower helicopter.

7.

Raise locking lever (2) to disengage ground handling wheels. Pull wheels forward and remove from skid tubes (8).

05 - 2

TOWING - HELICOPTER

Special tools: Ground Handling Wheels

Tow bar l.

P/N 105-82721 or 105-82722 105-82723 105-82766 105-82769 117-84421 105-W20

Install ground handling wheels on skid tubes (refer to para OS-l.

CAUTION

TO AVOID DAMAGE TO ANY GYRO INSTRUMENT5 IN5TALLED ON THE HELICOPTER, DO NOT JOLT OR MOVE HELICOPTER FOR 10 MINUTES AFTER POWER 15 REMOVED FROM THEM.

2.

Attach tow bar (1, fig. 05-2) to left and right skid tubes (2).

3.

Tow helicopter at less than 10 km/h. Minimum turning radius is 10 m.

4.

Remove tow bar after towing operation.

5.

Lower helicopter and remove ground handling wheels from skid tubes. Refer to para 05-1.

BO 105 CHAPTER 05 Page 5

- - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

1 Tow bar 2 Skid tube Figure 05-2 BOlOS CHAPTER 05 Page 6

Helicopter equipped with tow bar

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 05 - 3

PARKING - HELICOPTER

Special tools: Pitot tube cover Engine air inlet cover Ejector duct cover Compressor intake cover Main rotor blade tiedown (hook) Tail rotor blade tiedown (sleeve)

105-83106 105-83206 105-83211 105-83215 105-83221 105-83226

1.

Ground the helicopter using ground cable (7, fig. 05-3).

2.

Switch off all electrical loads. When parking the helicopter for a long period, disconnect the battery from the electrieal system.

3.

Close and loe k doors, sliding windows and access covers.

4.

Install proteetive covers on pitot tube (1), engine air inlet (2) and ejector duct (3). When the engine eowling is removed, the engine air inlet must be eovered with compressor intake cover (4).

NOTE

o If the helicopter is to be parked in the open for a long period, tie down main and tail rotor blades. o If wind velocities higher than 45 knots are forecast, park the helicopter in a hangar. If this is not possible tie down main and tail rotor blades and moor the helicopter as outlined in paragraph 05-4.

5.

Tie down main and tail rotor blades as follows: a.

Rotate main rotor until tail rotor blades are 'approximately parallel to the vertical fin and one main rotor blade is over the tail boom.

b.

Attaeh tie-down hook (5) to the main rotor blade pointing to the rear and fasten to the tail boom.

e.

Install tie-down sleeve (6) on the lower tail rotor blade and fasten to the tail boom.

BO 105 CHAPTER 05 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 05 - 4

MOORING - HELICOPTER

l.

Fill up fuel tanks.

2.

Tie rnain and tail rotor blades down as outlined in paragraph 05-3, step 5.

3.

Moor cross tubes of the landing gear with rnooring ropes (8) as shown in figure 05-3 or place sand bags on landing skids.

05 - 5

JACKING - HELICOPTER

Special tool: Jacks rnanufactured by Hydro-Geratebau, Biberach; or equivalent l.

Park helicopter on a solid and even surface.

2.

Position jacks (2, fig. 05-4) below jackingpoint fittings (1).

v·1ARNING

RAISE THE HELICOPTER EVENLY TO KEEP IT IN BALANCE.

3.

Operate the jacks (2) and raise the helicopter evenly. Lock jacks by screwing down respective spindle nuts.

4.

Before lowering the helicopter, rernove all objects likely to cause darnage to the helicopter.

S.

Unscrew spindle nut. Slowly open jack release valves and lower helicopter evenly.

6.

Rernove jacks frorn the helicopter.

BO 105 CHAPTER 05 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

\

'-

DETAlL

D

..

111---5

.1

DETAlL

DETAlL

A

F

.,

/"

';

DETAlLe

DETAlL

DETAlL

B

000029.2

Figure 05-3

Covers, tiedowns and mooring ropes BO 105 CHAPTER 05

Page 9/10

E

1 2 3 4 5 6 7 8

Pitot tube cover Engine air inlet cover Ejector duct cover Compressor intake cover Main rotor blade tiedown Tail rotor blade tiedown Grounding cable Mooring rope

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-"'.,.---- 2

1 Jacking point fitting 2 Jack

000059

Figure 05-4

Jacking the helicopter BO 105 CHAPTER 05

Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 05 - 6

HOISTING - HELICOPTER

Special tools: The following hoisting devices may be used depending on the maximum lifting capacity. Hoisting device

105-14101 W5

Hoisting sling

105 W2

Max. lifting capacity

20000 N

1121-14102 W1

117 W3 105 W27

23000 N

35000 N

36000 N

1.

If the rotor head is removed, install hoisting device 105 W27 and lift the helicopter (see fig. 05-5).

2.

If the rotor head is installed, attach hoisting device 117 W3 and lift the helicopter (see fig. 05-5).

BO 105 CHAPTER 05 Page 12

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

1 Hoisting device 2 Hoisting sling 3 Rotor mast

~

Attach crane hook to center hoisting eye when hoisting the helicopter Figure 05-5

Hoisting provisions BO 105 CHAPTER 05 Page 13/14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 06

R E F UE L 1 NG AND DE F UE L 1 NG

Table oí Contents

Page

Paragraph

Title

06 - 1

DESCRIPTION - REFUELING ANO DEFUELING

3

06 - 2

REFUELING

3

06 - 3

DEFUELING

5

BO 105 CHAPTER 06 Page 1/2

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 06 - 1

DESCRIPTION - REFUELING ANO DEFUELING

For fueling operations park the helicopter on level ground and establish electrical ground connection. Keep fire extinguisher ready at hand. To speed up refueling it is advisable to turn on the fuel purnps of thernain fuel tank. For fuel tank capacity, refer to table 06-1. For defueling of the fuel tanks use the fuel purnps. If possible an external power unit should be used in both cases to conserve the battery power. Position external power unit, if available, at a safe distance (approxirnately 10 rn) and connect. Establish electrical ground connection between helicopter, fueling vehicle and, if available, the external power unit. If a pick-up container is used to collect the fuel when defueling, an electrical ground connection rnust also be provided for the container.

06 - 2

WARNING

REFUELING

o TO PREVENT THE HAZARD OF FIRE AND EXPLOSION CAUSED BY SPARKS RESULTING FROM STATIC CHARGE{ ALWAYS ESTABLISH ELECTRICAL GROUND CONNECTION BEFORE STARTING REFUELING OPERATIONS AND DO NOT REMOVE UNTIL REFUELING IS OVERo o DO NOT CONNECT, DISCONNECT OR REMOVE THE BATTERY DURING OR IMMEDIATELY AFTER REFUELING.

1.

Connect external power unit if rnain tank fuel purnps are to switched on to speed the refuelling process.

2.

Connect ground wires to helicopter, fueling vehicleand, if used, external power unit (refer to figure 06-1).

3.

Unlock and rernove cap (3, figure 06-1) frorn fuel filler neck (1).

4.

Insert ground wire of filler grip (6) into the GROUND HERE receptacle (2) above the filler neck.

5.

Switch on fuel purnps of the rnain tank. As soon as the supply tank is filled, switch off the fuel purnps. Refuel the rnain tank until the fuel level reaches the edge of the filler neck.

6.

Close filler neck with cap (3) and secure.

7.

Turn off external power unit, if used, and disconnect frorn helicopter.

8.

Rernove electrical ground wire frorn fueling vehicle and external power unit.

BO 105 CHAPTER 06 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

2 DETAlL

3

,·········l:rn

B

DETAlL

000062

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1 2

3 4 5

6 7

8 9

Figure 06-1 BO 105 CHAPTER 06 Page 4

e

A

Tank filler neck GROUND HERE receptacle Cap Fuel feed line coupling Fuel feed line (right engine) Filler grip Ground wire of the helicopter Grounding terminal on the ground Ground wire of the fueling vehicle

Refueling and defueling

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 06 - 3

DEFUELING

WARNING

O

TO PREVENT THE HAZARD OF FIRE AND EXPLOSION CAUSED BY SPARKS RESULTING FROM STATIC CHARGE, ALWAYS ESTABLISH ELECTRICAL GROUND CONNECTION BEFORE STARTING REFUELING OPERATIONS AND DO NOT REMOVE UNTIL REFUELING IS OVER.

o DO NOT CONNECT, DISCONNECT OR REMOVE THE BATTERY DURING OR IMMEDIATELY AFTER REFUELING. l.

Connect external power unit.

2.

Connect ground wires to helicopter, external power unit, fueling vehicle and pick-up containers.

3.

Open engine access door and secure it in the open position.

4.

Disconnect fuel feed line (5, figure 06-1) of one of the engines from fuel feed line coupling (4) above the engine deck. To speed up defueling, the fuel feed lines of both engines may be disconnected. Disconnect both fuel lines in fuel systems containing a divided supply tank.

5.

Connect.defueling line to the fuel feed line coupling. Route the free end of the defueling line into the container.

6.

Turn on external power unit and fuel pumps of the main and supply tanks. If no external power unit is available, operate only one fuel pump at a time. Switch on both fuel pumps in the supply tank if supply tank is divided. Use fueling vehicle in the event that excess fuel must be collected from the container to prevent it from overflowing.

7.

Check fuel quantity indicator reading. If the fuel tanks have been emptied turn off fuel pumps.

8.

Disconnect and remove the defueling line from the fuel feed line coupling. Reconnect fuel feed line (5) to fuel feed line coupling (4).

9.

Close engine access door. Turn off external power unit, if used, and disconnect from helicopter.

10. Collect fuel residue from drain valves in pick-up containers. Empty pick-up containers. 11. Remove ground wires.

BO 105 CHAPTER 06 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Capacity

Usable fuel

Fuel tanks

Liter

Supply tank

95.5

76

93

74

Forward and rear main tank

484.5

388

477

382

AH tanks

580

464

570.

456

Kilogram

Liter

Kilogram

The above data are based on a fuel density of 0.8 kg per liter.

Table 06-1

SO 105 CHAPTER 06 Page 6

Fuel tank capacity

HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105

-------------MBB

11

MA 1 N

T R A N S M 1 S S ION

Tabie of Contents

Page

Paragraph

Title

11 - 1

DESCR1PT10N - MA1N TRANSM1SS10N

5

11 - 2

TROUBLESHOOT1NG - MA1N TRANSM1SS10N

9

11 - 3

1NSPECT10N FOR COND1T10N - MA1N TRANSM1SS10N

12

11 - 4

01L CHANGE - MA1N TRANSM1SS10N

17

11 - 5

REMOVAL - MA1N TRANSM1SS10N

18

11 - 6

D1SMANTL1NG - MA1N TRANSM1SS10N

25

11 - 7

BU1LD-UP - MA1N TRANSM1SS10N

26

11 - 8

1NSTALLAT10N - MA1N TRANSM1SS10N

27

11 - 9

Oi 1

32

11 - 10

Removai - oii fiiter

32

11 - 11

1nstaiiation - oii fiiter

32

11 - 12

Removai - fiiter eiement

37

11 - 13

1nspection and cieaning - fiiter eiement

37

11 - 14

1nstaiiation - fiiter eiement

38

11 - 15

E 1 e c tri c

39

11 - 16

Ma g n e tic d r a i n d r a i n val v e

f i 1 ter

c h i p

d e t e c t o r P 1 u g

a n d 39

11 - 17

Removai - magnetic drain piug and drain vaive

39

11 - 18

1nspection and cieaning - magnetic drain piug or eiectric chip detector . . . . . . . . . . ..

39

11 - 19

1nstaiiation - magnetic drain piug and drain vaive

42

11 - 20

oi

Revision 5

1 t e mp e r a t u r e switch .

wa r n i n g 42

BO 105 CHAPTER 11 Page 1

*

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Paragraph

Title

11 - 21

Replacement - oil temperature warning switch

42

11 - 22

oi 1

43

11 - 23

Replacement - oil temperature bulb

11 - 24

Lo w p r e s s u r e s wi t c h

Page

t e mp e r a t u r e

b u 1 b .

43

wa r n i n g 44

11 - 25

Replacement - low pressure warning switch

44

11 - 26

oi 1

45

11 - 27

Replacement - oil pressure transmitter

45

11 - 28

o

45

11 - 29

Removal - oil filler neck

45

11 - 30

Installation - oil filler neck

46

11 - 31

R epi a c e m e n t 1 e v e 1 s i g h t

i 1

P r e s s u r e

f i 1 1

e r

t r a n s m i t ter

n e c k

o f g a s k e t g 1 a s s

48

49

11 - 32

Ac c e s s o r y

11 - 33

Removal - accessory gearbox

49

11 - 34

Installation - accessory gearbox

50

11 - 35

Replacement of seals - accessory gearbox

51

11 - 36

Ro t a r y

54

11 - 37

Removal - rotary transmitter

54

11 - 38

Installation - rotary transmitter

56

11 - 39

S 1 i p

57

11 - 40

Removal and disassembly - slip ring retainer

57

11 - 41

Assembly and installation - slip ring retainer

60

11 - 42

F a n

a s s e mb 1 Y

62

11 - 43

Removal - fan assembly .

62

11 - 44

Installation - fan assembly

63

BO 105 CHAPTER 11 Page 2

g e a r b o x

o i 1

t r a n s m i t ter

r i n g

r e t a i n e r

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

Page

Paragraph

Title

11 - 45

Replacement of shaft seal - fan assembly

64

11 - 46

o

69

11 - 47

Removal - oil pump

69

11 - 48

Installation - oil pump

70

11 - 49

T r a n s m i s s ion V - s t r u t s .. . .

i 1

P u mP

mo u n t i n g 71

11 - 50

Removal - transmission mounting V-struts

71

11 - 51

Inspection and repair - transmission mounting V-struts

77

11 - 52

Installation - transmission mounting V-struts

81

11 - 53

Dr i v e

s h a f t

82

11 - 54

Removal - drive shaft

82

11 - 55

Inspection - drive shaft

84

11 - 56

Installation - drive shaft

89

11 - 57

R epI a e e m e n t o f s h a f t d r i ve. . . . t a i 1 r o t o r

s e a 1 91

D r i v e a s s e m b 1 Y - configuration 1 (Drive flange bolted to free~heel outer shaft)

93

Replacement of shaft seal - drive assembly (configuration 1) .

93

11 - 60

Removal - clutch assembly (configuration 1)

94

11 - 61

Installation - clutch assembly (configuration 1)

99

11 - 62

D r i v e a s s e m b 1 Y - configuration 11 (Drive flange integral with the freewheel shaft)

101

Replacement of shaft seal - clutch assembly (configuration 11) . . . . . . . . . . .

101

11 - 64

Removal - clutch assembly (configuration 11)

103

11 - 65

Installation - clutch assembly (configuration 11)

105

11 - 66

Functional test - clutch assembly

108

11 - 67

Inspection - clutch assembly, drive shaft and free wheel outer shaft . . . . . . . . . . . .

109

11 - 58 11 - 59

11 - 63

Revision 5

BO 105 CHAPTER 11 Page 3/4

* * *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

11 - 1

DESCRIPTION - MAIN TRANSMISSION

1. General

The main transmission (see figure 11-1) transmits the driving power of the two engines to the main rotor, the tail rotor and the accessory units. The main transmission is bolted to the transmission deck and supported at the top by two V-shaped mounting struts which transmit the main rotor forces to the fuselage. The accessory gearbox (12) drives two hydraulic pumps and the RPM tachometer. 2. Oil system (see fig. 11-3) The oil system provides continuous lubrication of the main transmission together with simultaneous cooling of the oil by the oil cooler. The oil pump, which is driven by one of the intermediate drive shafts, draws oil from the transmission sump and returns it via the fine filter with pressure bypass and the oil cooler to the distribution manifold in the main transmission. Within the main transmission the oil is distributed through various galleries, lines and oil jets to the gears, bearings and clutch assemblies from where it flows into the sump in the lower housing. Oil temperature and oil pressure indicators and a low pressure and high temperature warning light are provided on the instrument panel. 3. Technical data: Oil capacity Lubricating oil Max. oil pressure Max. oil temperature Weight

Revision 2

10.3 litres refer to chapter 101-2 LUBRICATION CHART 1. 75 bar 105 oC approx. 152 kg

* *

*

BO 105 CHAPTER 11 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

Main rotor mast 2 Swash plate 3 Flange 4 Planetary drive assy 5 Fan 6 Fan gearbox 7 Tail rotor drive assy 8 Freewheel drive assy 9 InteDmediate shaft with bevel gear 10 Oil pump 11 Collector drive assy 12 Accessory gearbox 1

~-----~---- 3

,---

4

It-----S

11 ------..

12 ~~~;:-,-----7

~--8

-------9 ~=l-------- 10

8 100249

Figure 11-1 Main transmission - sectional view BO 105 CHAPTER 11

Page 6

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~~-------- 13

.---'t-\---------- 12 2 ---¡f;;::,..o:::::-

~~===)\-

3 - - - - - - , 1 + -.......

_J~~:;I

11

U+-+-H!l---- 10

"----t+HHf--t---tt----- 4

cb I

5

,..., ~I. ,..., 11

c:

6--~

7---'

9 8

110030

Rotor mast 2 Tail rotor drive assy 3 Bevel gear 4 Accessory drive shaft 5 Freewheel unit 6 Bevel gear shaft 7 Bevel gear 1

Figure 11-2

8 Chip detector 9 Oi! pump 10 Fan assembly 11 Sun gear 12 Planetary gear 13 Planetary carrier 14 Accessory gearbox

Main transmission - gear train BO 105 CHAPTER 11 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Warning Iight on instrument panel

Upper housing of main transmission

Pressure indicator on instrument panel

Low pressure switch

on

pressure transmitter

Center housing of main transmission

Lower housing of main transmission

O¡I temperature warning switch

Sight glass Magnetic drain plug Pressure bypass

Oil pump

-Pressure lines Temperature indicator on instrument panel

Electrical wiring

100250

Figure 11-3 BO 105 CHAPTER 11 Page 8

Schematic - oil system

Oil cooler

MAINTENANCE MANUAL SO 105

11 - 2 NOTE

TROUBLESHOOTING - MAIN TRANSMISSION For further indications of trouble, probable causes and corrective actions, refer to chapter 91.

NO. TROUBLE SYMPTOM

Oil pressure too high

2

3

4

Oil pressure indication too low, but warning light T -OIL off

Oil pressure indication too low. Warning light T-OIL on.

PROBABLE CAUSE

CORRECTIVE ACTION

Oil pressure transmitter defective

Replace oil pressure transmitter with serviceable one

Oil pressure indicator defective

Replace oil pressure indicator with serviceable one

Warning light bulb defective

Replace bulb

Pressure switch defective

Replace pressure switch with serviceable one

Transmission oíl level too low

Check transmission oil level and service with oil, if necessary

Oil pump defective

Remove and inspect oil pump. Replace defective oil pump

O-rings on oil jets defective

Remove oil jets and replace 0rings

Unes or connections leaky

Inspect al! lines and connections for leaks and replace as necessary

Fine filter housing leaky

Replace defective parts

Fine filter and/or bypass clogged

Clean bypass

Suction filter clogged

Clean suction filter

Oil pressure and oil temperature Pressure switch defective indications are within permissible limits. T -OIL warning light on Suction filter clogged

5

No oil pressure indication

Replace pressure switch with serviceable one

Clean suction filter

For probable causes and corrective actions, refer to chapter

91.

6

Oil temperature indication too high. Warning Iight T -OIL off

Warning light bulb defective.

Replace bulb

Oil temperature warning switch defective.

Replace oil temperature warning switch with serviceable one

Table 11-1 Troubleshooting - main transmission (1 of 3)

Revision 24

CHAPTER 11 Page 9

MAINTENANCE MANUAL BO 105

NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

7

Transmission oil level too low

Check transmission oillevel; service with oil as necessary

Oil cooler dirty

Clean exterior surface of oil cooler; refer to chapter 63

Oil temperature indication too high. T -OIL warning light on

Clean oil passages of oil cooler; refer to chapter 63

8

Oil temperature indication too low

Oil temperature bulb defective

Replace oil temperature bulb with serviceable one

Temperature indicator defective

Replace temperature indicator with serviceable one

9

No oil temperature indication

For probable causes and corrective actions, refer to chapter 91.

10

Warning light T- PLUG on

Accumulation of metal chips on chip detector

Remove chip detector and inspect for metal chips. If chips are evident, assess in accordance with figure 11-14 and proceed in accordance with table 11-2 Remove oil filter and inspect for chips. If chips are evident, assess in accordance with figure 11-14 and proceed in accordance with table 11-2. Remove oil pump and clean screens

Defective chip detector

Inspect chip detector for damage and replace as necessary

11

Traces of oil on transmission input drive

Leaky shaft seal

Replace shaft seal(refer to para. 11-58 or 11-62)

12

Traces of oil around fan drive

Shaft seal or 0- ring of fan drive defective

Replace shaft seal or O-rings (refer to para. 11-45)

13

Traces of oil on tail tail rotor drive

Shaft seal of tail rotor drive defective

Replace shaft seal (refer to para. 11-57)

14

Traces of oil on accessory gear- Seals of accessory drive defective box

Replace seals (refer to para. 11-35)

15

Traces of oil on exterior of rotary transmitter drive shaft

Shaft seal of slip ring retainer defective

Replace shaft seal (refer to paragraph 11-39)

O-ring or shaft seal of rotary transmitter drive shaft defective

Replace O-ring and shaft seal (refer to paragraph 11-36)

Shaft seal or O-ring on rotor mast defective

Replace shaft seal or O-ring (refer to REM 103)

16

Traces of oil in vicinity of flange on transmission upper housing

Table 11-1 Troubleshooting - main transmission (2 of 3)

CHAPTER 11 Page 10

Revision 24

MAINTENANCE MANUAL BO 105

NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

17

Oil leakage from drain pipe below hydraulic unit

Accessory gearbox leaky

Replace accessory gearbox (refer to paragraph 11-32)

18

Abnormaly high vibration level

Crack in area of suport tube flange

Visually inspect area of support tube flange for cracks (refer to paragraph 11 -3.

Table 11-1 Troubleshooting - main transmission (3 of 3)

Revision 24

CHAPTER 11 Page 11

I

MAINTENANCE MANUAL BO 105

11 - 3

INSPECTION FOR CONDITION - MAIN TRANSMISSION

1. Visually inspect main transmission for mechanical damage, corrosion and damaged surface protection. Visually inspect housing for cracks. a.

Replace main transmission if cracks are detected in the housing.

b.

Repair mechanical damage and corrosion as outlined in chapter 02. Far damage and rework limits, refer to figure 11 -4.

c.

Touch up surface protection as outlined in chapter 02, using two-component PUR lacquer (CM 437).

2. Visually inspect for leakage at the following split lines: a.

Main transmission upper housing

- Support tube flange

b.

Main transmission upper housing

- Main transmission center section

c.

Main transmission center housing

- main transmission bottom section

d.

Main transmission center housing

- Accessory gearbox

e. Accessory gearbox

- Hydraulic pumps/RPM tachometer and cover of accessory drive

f.

Main transmission center housing

- Cooling fan drive

g.

Main transmission center housing

- Tail rotor drive

h.

Main transmission lower housing

- Input drive with clutch assembly

If leakage occurs, remove the affected part as outlined in MOM or in the applicable REM and replace seals. 3.

Inspect split lines between main transmission and accessory components, oil temperature warning switch, connection for oH pressure lines, and elbow of oil filler neck for leakage. If leakage occurs, remove the affected part and replace seals.

4.

Inspect split line between main transmission and oillevel sight glass for leakage and inspect oillevel sight glass for contamination. If leakage is evident, replace seal (refer to paragraph 11-31). Clean contaminated glass.

5.

Inspect split line between main transmission and oil pump for leakage. For this purpose, inspect oil drip pan below oH pump for traces of oi!. If leakage is evident, remove oil pump and replace seals (refer to paragraphs 11-47 and 11-48).

6.

Inspect split line between main transmission and slip ring retainer flange for leakage. For this purpose, remove cabin interior panelling and oil pan as necessary. If leakage is evident, replace seals (refer to paragraph 11-39).

7.

Remove half- shells of fire wall assembly as for as necessary to enable the following inspection of the drive shafts.

8.

Inspect drive shafts.

CHAPTER 11 Page 12

Revision 24

MAINTENANCE MANUAL BO 105 Configuration I (see figure 11-35) a.

Inspect drive shafts for mechanical and corrosion damage and damaged surface protection. Remove drive shafts exhibiting scratches, nicks, scares or corrosion according to paragraph 11-54, and subject to a thorough inspection according to paragraph 11-55. Touch up damaged surface protection according to paragraph 11-55.

b.

Inspect slippage marks between bolts (3, figure 11-35) and main transmission drive flange (6) for movement. If slippage marks are damaged, check torque of bolts and tighten as necessary to torque shown in figure 11--35. Apply slippage marks, using locking component (CM 620).

c.

Inspect anchor nuts for condition and secure installation. Replace damaged or loose anchor nuts according to paragraph 11-55.

d.

Inspect placards for damage and separation. Replace missing, damaged or separated placards according to paragraph 11-55.

Configuration 11 (see figure 11-35) IF SLlPPAGE MARKS ON FRAME CONNECTING HARDWARE ARE DAMAGED, DO NOT TIGHTEN THE CONNECTING HARDWARE. DAMAGED SLlPPAGE MARKS ARE AN INDICATION OF TORSION. REMOVE DRIVE SHAFT AND SEND TO MANUFACTURER FOR ASSESSMENT.

CAUTION

a.

Inspectframe connecting hardware (7) for movement of slippage marks. If slippagemarks are damaged, remove drive shaft according to paragraph 11-54 and send to manufacturer for assessment.

b.

Inspect slippage marks between bolts (3) and main transmission drive flange (6) for movement. If slippage marks are damaged, check torque of connecting bolts and tighten as necessary to torque shown in figure 11-35. Apply slippage marks, using locking compound (CM 620).

c.

Inspect anchor nuts for condition and secure installation. Replace damaged and loose anchor nuts according to paragraph 11-55.

d.

Inspect drive shaft for mechanical and corrosion damage and damaged surface protection. Polish out mechanical and corrosion damage using 400/600 grit abrasive cloth. Do not exceed repair Iimits specified in figure 11-38A. Round reworked and undamaged areas with a transition radius of at least 10 mm. -

9.

Prime reworked areas and areas where surface protection has been damaged, using two-component wash primer (CM 472) and apply topcoat (CM 473).

Reinstall half-shells of fire wall assembly.

Revision 24

CHAPTER 11 Page 13

O~.!a!~Pter

MAINTENANCE MANUAL BO 105

10. Inspect transmission mounting V-struts for deformation, cracks, mechanical damage, corrosion, missing or damaged sealant on rivet heads, and damaged surface protection. Using a 1O-power magnifying glass, inspect welds including their adjacent areas, for cracks. If areas to be inspected are protected by chafe guards, these shall be removed prior to inspection and reinstalled afier inspection has been completed. a.

If deformation is evident, replace affected V-strut. Refer to paragraphs 11-50 and 11-52.

b.

Ifcracks or fractu res are found, both V -struts must be replaced even if only one ofthem is cracked orfractured. Refer to paragraphs 11-50 and 11-52.

c.

Polish out mechanical damage and corrosion with 400 grit abrasive cloth. See figure 11-34 for damage and repair limits.

d. Touch up damaged surface protection, using two-component zinc chromate primer (CM 423) and PUR topcoat (CM 402). Refer to chapter 02. e.

If sealant on a rivet head is missing or damaged, remove the V-strut according to paragraph 11-50, examine interior ofV-strut leg for presence of moisture and corrosion, then reapply sealant. For procedural instructions, refer to paragraph 11-51, step 5..

11. Check that the attaching hardware connecting the transmission mounting V -struts to the transmission support flange and to the deck fittings is properly secured with split pins. If split pins are missing, check affected hardware for specified torque (refer to figure 11-31) and safety with split pins. •

12. Inspect support tube for condition. a.

Inspect surface of cylindrical portion of supporttubefor wear. To do so, operateswashplate to uppermost position. If wear is evident, proceed as follows: 1) Remove bolts and washers from support tube flange. 2) Rotate support tube 1800 , taking care not to damage the sealing ring between support tube and titanium flange. 3) Reinstall bolts and washers and tighten bolts evenly in two or three torque steps until final torque of 12.5-14.5 Nm is reached. 4) Secure bolts with lockwire.

I

b. Visually inspect area of support tube flange (see grey marked area of figure 11-3A) for cracks, using a magnifiying glass of at least 5-fold magnification). If a crack is found, inform ECO customer service before the next flight. 13. Inspect sealing compound on split line between main transmission flange and transmission deck for damage (refer to figure 11-5). Renew damaged sealing compound (CM 662). 14. Inspect electrical connectors of transmitters and switches for secure installation.

CHAPTER 11 Page 14

Revision 24

MAINTENANCE MANUAL 80 105 Accomplish step 15. only if main rotor head had been removed.

NOTE

15. Inspect lower surface of rotor mast flange. a. Visually inspect flange for cracks, especially in the webbed areas. Replace rotor mast if cracks are evidento b. Visually inspect webbed areas between bores, bores and surrounding areas, and washer bearing surfaces for corrosion. Polish out corrosion to a depth of 0.2 mm, using 600 grit abrasive cloth. The diameter of the bushing marking bores must not exceed 20.03 mm. c.

Apply protective finish to reworked areas. The base metal must not be covered in the washer bearing areas. Clean touched up surfaces with degreasing agent (CM 209), then apply two-component zinc chromate primer (CM 417), followed by two-component PUR topcoat (CM 426).

16. Inspect the interface protection (adhesive tape or sealant) on transmission upper housing assy for damage and/or separation. Replace missing, damaged or separated interface protection in accordance with Chapter 63-19.

Revision 24

CHAPTER 11 Page 14A

O~~pter

MAINTENANCE MANUAL 80105

Figure 11-3A Crack inspection - Area of support tube flange CHAPTER 11 Page 148

Revision 24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF OAMAGE

OAMAGE ANO REPAIR LIMIT5 ZONE

ZONE 2

1

ffiIIIIIIII]

1;:;:;;;;;;;;;;;;;;1

Mechanical

0.5

mm deep on 25 % of are a

mm deep on 25 % of are a

Corros ion

0.5 mm deep before and 1.0 mm deep after repair on 25 % of area

0.5 mm deep before and 0.75 mm deep after repair on 25% of area

0.5

~

Maximum permissible diameter 9.0 mm. It may be exceeded by 0.1 mm on one quarter of circumference.

~

70%

ZONE 2

of the original seating surface must remain intact in are a 4 mm around the mating holeo

I

í

& 100462

Figure 11-4 Damage and repair limits - transmission housings BO 105

CHAPTER 11 Page 15/16

- - - - - - - - - - - - ' - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 4

OIL CHANGE - MAIN TRANSMISSION

Special tools: Oil drain hose Oil drain hose

1x56 134 518 (for magnetic plug with knurled knob) 1x56 137 035 (for magnetic plug with star knob or electric chip detector)

1.

Remove engine cowling; refer to chapter 22.

2.

Open oil filler neck cap and remove screen. Clean and reinstall screen.

3.

Remove access cover from cargo compartment panelling below main transmission.

4.

Remove magnetic drain plug or, if installed, electric chip detector (refer to chapter 845). If a magnetic drain plug with knurled knob is installed, connect oil drain hose 1x56 134 518 and drain off oil. If a magnetic drain plug with star knob or if a chip detector is installed, use oil drain hose 1x56 137 035 to drain off oil.

5.

Inspect magnetic drain plug or chip detector for deposits and clean per paragraph 11-18. Replace damaged O-ringo

6.

Remove filter element from oil filter on oil cooler and inspect, clean and reinstall in accordance with paragraphs 11-12 through 11-14.

7.

Remove oil drain hose and install magnetic drain plug or chip detector.

NOTE

Shake oil cans before use to mix the antifoam additives with the oil.

8.

Service main transmission with lubricating oil (for CM refer to chapter 101-2 LUBRICATION CHART) (amount of oil 10.3 litres), and close filler neck.

9.

Perform ground run in accordance with chapter 105. Inspect oil system for leakage and check oil level; add oil if necessary (for CM refer to chapter 101-2 LUBRICATION CHART) .

10.

Install access cover of cargo compartment panelling underneath main transmission.

11.

Install engine cowling, refer to chapter 22.

Revision 2

BO 105 CHAPTER 11 Page 17

* * * * * * * *

- - - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 5

REMOVAL - MAIN TRANSMISSION

Special tools: Hoisting device

*

105-14101 W5 or 1121-14102 W1 or 117 W3 (with main rotor head installed)

or Hoisting device Pushing-out and pressing-in tool

1121-10151 W3

Dolly Locking rings

105-10101 W3 or 1x56 136 385 1x56 150 123

NOTE

105-W27 or 1x56 136 240 (with main rotor head removed)

Main transmission preservation requires the engines to be run at operating rpm for approx. 10 minutes at zero blade pitch. This is why preservation is performed before the main transmission is removed.

1.

Preserve main transmissions which are to be shipped; refer to chapter 02.

2.

Make sure neither battery nor external power unit is connected.

3.

Remove engine cowling; refer to chapter 22.

4.

Remove main rotor blades; refer to chapter 14.

5.

Remove cabin panelling as necessary and detach oil drip pan.

6.

Drain transmission oil; refer to paragraph 11-4.

NOTE ------

The main transmission can be removed together with the main rotor head. If this procedure is used, omit step 7.

7.

Remove rotating control rods, driving link assy and main rotor head; refer to chapter 13.

8.

Remove forward fire wall; refer to chapter 64.

9.

Remove snow deflector (5, figure 11-5) if installed (refer to chapter 65) .

10.

Remove splash guard (2, figure 11-8), guard plate (4), support bracket (24, figure 11-5) and oil baffle. oil baffle is not installed in combination with ram air ventilation.

BO 105 CHAPTER 11 Page 18

Revision 2

- - - - - - - - - - - - - M a B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MaB - BO 105

1 2 3 4

5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

27 28 29 30

31 32 33 34 35 36

37 38

Main rotor head Main rotor blade Driving link assy Transmission mounting V-strut Snow deflector Air baffle Brake caliper Ram air duct Rubber duct Fitting for oil supply lines Flange Accessory gearbox Laminum ring RPM tachometer Washer Nut Main transmission attach fitting Bolt SpIit pin Nut Washer Bolt Mixing Iever assembIy Support bracket Transmission deck Nut Washer Washer Bolt Nut Washer Bolt Washer Drain val ve Magnetic plug Nut Washer Connection pI ate

Figure 11-5

A:l130'

)

DETAlL

E DETAlLA

~--2

posltlon - after tlghtening

23----/ DETAlL

F

3 35 4

8

s---+-

34

~A

~~~.--.1

123'2~ I Nm

6

14 4-----....~

7

Removal and instaIIation - main transmission BO 105 CHAPTER 11

Page 19/20

DETAlL

O

12

DETAlL

B

7-8 Nm

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

CAUTION

PRIOR TO REMOVAL OF CONTROL RODS BETWEEN MIXING LEVER ASSY AND HYDRAULIC UNIT, SECURE THE SWASH PLATE TO PREVENT IT FROM SLIDING DOWN.

11.

Fit clamping ring 1x56 150 123 to support tube on main transmission so that it is directly below the swash plate sliding sleeve.

12.

Remove control rods between hydraulic unit and mixing lever assy.

13.

Remove mounting plate for hydraulic lines from main transmission housing.

14.

Remove hydraulic pumps from accessory gearbox; refer to chapter 43. Do not detach lines from hydraulic pumps as bleeding of the hydraulic system will then become necessary.

15.

Remove air baffle (6, figure 11-5) (not installed in combination with ram air ventilation) .

16.

Loosen clamp on fan and remove rubber duct from fan.

17.

Loosen oil cooler on oil cooler rack and pull outboard as far as possible.

18.

Remove drive shafts; refer to paragraph 11-54.

19.

Depending on the configuration, remove forward short drive shaft or forward short drive shaft and coupling of tail rotor drive; refer to chapter 32.

20.

Disconnect hose line from mounting bracket of brake caliper (7, figure 11-5). Blank fitting and hose lineo

21.

Disconnect oil lines (1 and 2, figure 11-7) from connecting piece (3). Blank fitting and oil lines.

22.

Disconnect connector from RPM tachometer (14, figure 11-5).

23.

Remove all clamps from transmission mounting V-struts.

24.

Remove bolt (3, figure 11-6) from N2 lever (6) of N2 controls.

25.

Remove bolts (1 fig. 11-6) and remove N2 cable mounting bracket (2) together with Teleflex cables from transmission flange.

26.

Disconnect electrical connector (5, figure 11-10) of oil temperature warning switch (3) from receptacle (2).

27.

Disconnect electrical connector (5, figure 11-9) from rotary transmitter (4) •

BO 105 CHAPTER 11 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

6

3

I 5.5-6.'5 Nm

Configuration 11 Configuration I

110031.1

5 Nut 6 N2 lever (hydraulic unit) 7 Teleflex cables 8 Tube guide

·1 Bolts 2 Mounting bracket (N2 cable) 3 Bolt 4 Split pin

Figure 11-6

N2 control cable attachment to hydraulic unit

3----.

2----9.-../

100253

110031

1 Oil pressure line 2 Oil feed Ene 3 Fitting 4 Oil pressure transmitter 5 Low pressure warning switch 6 Fitting Figure 11-7 BO 105 CHAPTER 11 Page 22

Oil supply and oil pressure monitoring

Transmission mounting strut 2 Splash guard 3 Tandem hydraulic unit 4 Guard plate

1

Figure 11-8

Protective covers

~"

EUROCOPTER

MAINTENANCE MANUAL 80 105

28. If the same main transmission is to be reinstalled without removing the attached flange ring (11, fig. 11-5), mark position of flange ring relative to transmission deck using color pencil. 29. Unscrew nuts (26) and remove screws (29) with washers (27, 28). 30. Remove lockwire, then remove banjo bolt (3, figure11-9) and detach oilline (1), Discard sealing rings. Blank openings of oilline and oil pump. 31. Attach hoisting device 105-14101 W5 or 1121-14102 W1 or 117 W3 to main rotor head or, if main rotor head has been removed, attach hoisting device 105 W27 or 1x56 136 240 to rotor mast. 32. Lift the main transmission only by the amount necessary to relieve the load on the transmission mounting V-struts. 33. Remove attaching hardware (15,16,18 and 19, fig. 11-5).

CAUTION

IF FOR ANY REASON THE MAIN TRANSMISSION IS LOWERED AGAIN, TAKE CARE THAT ITS WEIGHT IS NOT SUPPORTED BY THE TRANSMISSION DECK.

34. Lift main transmission without causing damage to oil pump and transmission deck. 35. Place main transmission on dolly 105-10101 W3 or 1x56 136 385 and remove hoisting device. 36. Using plugs or covers, blank off all openings produced during main transmission removal procedure. 37. Remove laminum ring (13) from transmission deck only if the ring is damaged or if another main transmission is to be installed. 38. If shipment of main transmission is ¡ntended (e.g. for purpose of repair or overhaul), dismantle main transmission in accordance with paragraph 11-6. 39. Following the removal of the main transmission, inspect spherical bearings and claw bushings in the main transmission mounts per para 21-3, step 6.

Revision 18

CHAPTER 11 Page 23

l.

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

10

2

3 9 8

6

7

4

1 OH line 2 Oil pump 3 Banjo boH 4 Rotary transmitter 5 Electrical connector (rotary transmitter) 6 Oil temperature bulb S/N 161 and subsq. 7 Electrical connector 8 Sealing ring 9 Adapter 10 Double banjo fitting

5

100267

Figure 11-9

Oil pump, rotary transmitter and oil temperature bulb

5 1

2

Figure 11-10 BO 105 CHAPTER 11 Page 24

Angle bracket Receptacle OH temperature warning switch 4 Union 5 Electrical connector

1 2 3

Oil temperature warning switch

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 11 - 6

DISMANTLING - MAIN TRANSMISSION

Specia1 tool: Hoisting device Hoisting device Do11y

lOS W27 or 1xS6 136 240 10S-14101 WS or 1121-14102 W1 or 117 W3 10S-10101 W3 or 1xS6 136 38S

1. If still connected to the main transmission, rernove the following assemblies: a.

Rotating control rods¡ refer to chapter 41.

b.

Driving link assy¡ refer to chapter 13.

c.

Mixing lever assy¡ refer to chapter 41.

d.

Main rotor "head¡ refer to chapter 13.

2. Rernove transmission rnounting V-struts (4, fig. 11-S)¡ refer to para 11-S0. 3. Rernove air duct (8) for ram air ventilation¡ refer to chapter 63. 4. Rernove rotor brake caliper (7)¡ refer to chapter 12. S. Rernove nuts (36), washers (37) and remove RPM tachorneter (14) frorn accessory gearbox. 6. Rernove lockwire and connecting piece (10). Retain existing washerls for re-installation if connecting piece is to be reinstalled on same rnain transmission. 7. Rernove oil temperature warning switch (3, figure 11-10). Blank off opening. 8. Rernove lockwire frorn drain valve (34, figure 11-S) and rernove drain valve together with electric chip detector or rnagnetic plug, as applicable. 9. Rernove rotary transrnitter (4, figure 11-9)¡ refer to paragraph 11-37. 10. Install the following protective covers for shipment: split ring above and below swash plate, covers for accessory gearbox cover for rotary transrnitter, plates for flanges of freewheel shafts. 11. Install hoisting device lOS W27 or 1xS6 136 240 to rotor rnast flange and lift rnain transrnission. 12. Rernove sealing cornpound frorn bolts (32) and remove attaching hardware (30 thru 33, figure 11-S) and flange (11). 13. Place main transmission into shipping and storage container and rernove hoisting device. 14. Install rotor mast cover. BO lOS CHAPTER 11 Page 2S

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 7

BUlLO-UP - MAIN TRANSMISSION

Special tools: Hoisting device Hoisting device Do11y

105 W27 or 1x56 136 240 105-14101 W5 or 1121-14102 W1 or 117 W3 105-10101 W3 or 1x56 136 385

l. Lift main transmission out of shipping and storage container, using hoisting device 105 W27 or 1x56 136 240. Place transmission on dolly 105-10101 W3 or 1x56 136 385 and detach hoisting device. 2. Remove protective covers; refer to paragraph

~1-6,

step la.

3. If the same main transmission is reinstalled, install fitting (la, fig. 11-5) with original washer/s. For installation position, refer to Detail F in fig. 11-5. If combination of main transmission and fitting is no longer that present at removal, install fitting as follows: Add washer/s of the appropriate thickness so that when the fitting is handtightened it is in the 25° position. Tighten fitting to final position of approx. 130°. 4. Install rotor brake caliper; refer to chapter 12. 5. Install RPM tachometer (14) on accessory gearbox after coating the faying surfaces with corrosion preventive paste (CM 503) and applying corrosion preventive compound (CM 506) to the drive pinion. NOTE

Steps 6. thru 9. may al so be accomplished after the main transmission has oeen installed.

6. Install mixing lever assembly; refer to chapter 41.

7. Install main rotor head; refer to chapter 13.

a.

Install driving link ass'embly; refer to chapter 13.

9. Insta11 rotating control rods; refer to chapter 41. 10. Attach either hoisting device 105-14101 W5 or 1121-14102 W1 or 117 W3 to main rotor head, or hoisting device 105 W27 or 1x56 136 240 to flange on main transmission, depending on main transmission build-up. 11. Install rotary transmitter (4, figure 11-9); refer to paragraph 11-38. 12. Install drain valve (34, figure 11-5) together with magnetic plug (35) or electric chip detector (depending on configuration) and torquetighten. Safety drain valve with lockwire. 13. Apply corros ion preventive compound (CM 505) to bores of transmission lower housing and flange (11) and to both flange faces. BO 105 CHAPTER 11 Page 26

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 14. Install flange (5, figure 11-11) as follows: a.

App1y corrosion preventive paste (CM 503) to bolts (7).

b.

position and align flange (5) on main transmission so that the key on the transmission lower housing is above the highest point of the flange.

c.

Install washers (6) on bolts (7) with the countersunk side facing the bolt head and install bolts, except bolts (l,figure 11-6) for attaching the N2 cable support.

d.

If necessary, unscrew union (4, figure 11-10) of oil temperature warning switch just enough to allow bolts (7, figure 11-11) and washers (6) to be installed.

e.

Position mounting plate (1) as shown in fig. 11-11, instal1 washers (4) and nuts (3) and torque-tighten nuts (7). Observe~ - notes in fig. 11-11. Tighten union if loose.

15. Install oil temperature warning switch (3, figure 11-10) in union (4). Safety union with lockwire. 16. Install air duct (8, figure 11-5) for raro air ventilation; refer to chapter 63. 17. Install transmission mounting V-struts (4). Refer to paragraph 11-52. 18. Clean heads of bolts (7, figure 11-11), washers, nuts (6), all split lines and bare metal areas of housing with acetone (CM 203) and coat with two-component PUR lacquer (CM 437) . 11 - 8

INSTALLATION - MAIN TRANSMISSION

Special tools: Hoisting device Centering device Guide sleeve Hoisting device Engine alignment device Locking rings CAUTION

105-14101 WS or 1121-14102 W1 or 117 W3 105-10101 W4 -100/-200 105-10151 w2 105 W27 or 1xS6 136 240 105-60101 W4 1xS6 150 123

WHEN INSTALLING THE MAIN TRANSMISSION DO NOT ALLOW IT TO REST ON THE TRANSMISSION DECK BECAUSE THE LATTER IS NOT DESIGNED TO SUPPORT THE WEIGHT OF IT.

l. Attach hoisting device 105-14101 WS or 1121-14102 W1 or 117 W3 to main rotor head. If main rotor head is removed, attach hoisting device 105 w27 or 1xS6 136 240 to rotor mast flange.

BO 105 CHAPTER 11 Page 27

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2. If either a new main transmission, a new flange (5, fig. 11-11), or a new laminum ring (2) is installed, the thickness of the laminum ring (2) must be redetermined according to step 7. If the same transmission is to be reinstalled, clean existing ring (2) and flange (5) mating surfaces with acetone (CM 203) . 3. Apply corrosion preventive compound (CM 505) to boreholes and hardware mating areas on flange (5). 4. Using a crane, lower main transmission in position above transmission deck so that the clevis ends of the attached mounting V-struts (4, figure 11-5) engage with the deck-mounted mating lugs (17) and the attaching hardware can be installed. 12

~:

Main transmission Index marks

Installation position 01 mounting plate

4~

3

~

18-20 Nm

~ '8-20 Nm

100256

1 Mounting plate (N 2 cable mounting bracket) 2 Laminum ring 3 Nut 4 Washer

5 Flange 6 Washer 7 Bolt 8 Bolt

9

10 11 12

10

11

!

Washer Washer Nut Flange

~

If flange (12, figure 11-11) has been reworked to the extent that attaching hardware (3, 4, 6, and 7) cannot be installed tightly, place two washers (6) under bolt head.

~

Install mounting flange (1) so that its first bore aligns with the sixth bore in flange (5). The bores are consecutively numbered from O upwards, beginning at the highest point of the flange. Figure 11-11

BO 105 CHAPTER 11 Page 28

Installation of main transmission on transmission deck

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5. Fit guide sleeves 105-10151 W2 onto end of bolts (10, figure 11-31), coat them with grease (CM 101 or 120) and insert thern into clevises (9). 6. Rernove guide sleeves frorn bolts (10, figure 11-31) and secure bolts (10) with nuts (13) and washers (11). If step 7. is not to be accornplished,

safety nuts (13) with split pins (12). Refer to para 11-52 (Installation - transmission rnounting V-struts) for inforrnation on securing nuts (13). NOTE

Steps 7. and 8. are only required if a new main transrnission, a new flange or a new laminurn ring is to be installed.

7.

Measure gap between flange (5, fig. 11-11) and transrnission deck, using a feeler gage. Peel off larninurn ring (2) to required thickness.

8.

Remove hardware attaching transrnission mounting V-struts to deck-mounted lugs, then lift main transmission and install larninurn ring (2). Reinstall main transmission in accordance with steps 4. to 6.

I

lI ' \

t--jt-

I /

/

I

/ ./

I

I

/

i

I

6

3

259.2

1 2 3

Centering rod Adjustrnent fixture Engine mounts

Figure 11-12

Tail rotor drive Main transmission 6 Rotor brake disk

4 5

Alignment of rnain transmission and engines, using tool 105-10101 W4 BO 105 CHAPTER 11 Page 29

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAlNTENANCE MANUAL MEB - BO 105 9.

Coat all bolts (8) with corrosion preventive compound (CM 506) prior to installation. lnsert bolt (8) with washer (9), countersunk side next to bolt head, in each of two opposing bores on flange (5) and install washers (10) and nuts (11). Do not tighten nuts (11) at this time.

10. Install angle bracket (1, figure 11-10) together with receptacle (2) for connector (5) of the oil temperature warning switch (3). NOTE

If engines are removed, align main transmission with tool 105-10101 W4-100. With engines installed, use tool 105-10101 W4-200 of tool 105-10101 W4-100. When using the tool 105-10101 W4-200, the half-shells of the engine mounts have to be removed.

11. Install centering device as shown in figure 11-12. 12. Align main transmission with engines. If necessary, turn transmission until centering rod (1, figure 11-12) and the pointer of adjustment fixture (2) align. Tighten bolts (29, figure 11-5) with specified torque. Install remaining bolts together with washers and nuts and tighten. 13. Remove centering device 105-10101 W4 and, if previously removed, install half-shells of engine mounts; refer to chapter 61. 14. Check that main transmission and engines align, using tool 105-60101 W4; refer to chapter 61. 15. Install N2 cable mounting bracket (2, figure 11-6) together with teleflex cables (7) on transmission. Torque-tighten bolts (1). 16. Install Teleflex cables (7) to N2 lever (6) and check N2 setting in accordance with chapter 65. 17. Applya fillet seal on split line of flange (11, figure 11-5) and transmission deck using sealing compound (CM 662). Seal split line of bolt heads and flange by applying two-component finishing lacquer (CM 437) on bolt heads and adjacent flange areas. 18. Attach connector to RPM tachometer and safety with lockwire. 19. Install hydraulic line support bracket on main transmission at split line of center housing and lower housing and tighten nuts to specified torque load; see figure 11-5, DETAlL C. 20. Install support bracket (24) on tandem hydraulic unit. 21. Install hydraulic pumps on accessory gearbox; refer to chapter 43. 22. Install oil baffle (not installed in combination with ram air ventilation), splash guard (2, figure 11-8), guard plate (4) and support bracket (24, figure 11-5).

BO 105 CHAPTER 11 Page 30

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 23. Install control rods between tandem hydraulic unit and mixing lever assy (23). For installation procedure refer to chapter 41. Remove locking ring 1x56 150 123. 24. Attach oil lines (1 and 2, figure 11-7) to fitting (3). 25. Connect connector (5, figure 11-10) for oil temperature warning switch to receptacle (2). 26. Connect hose line to bracket of brake caliper (7, figure 11-5) and bleed the rotor brake 'system; refer to chapter 12. 27. Install oil cooler on oil cooler rack. 28. Slide rubber duct (9) onto fan housing and fasten with clamp. 29. Install all lines, hoses and clamps previously removed from the transmission mounting V-struts. 30. Reinstall snow deflector if previously removed (refer to chapter 65). 31. Depending on the configuration, remove forward short drive shaft or forward short drive shaft with coupling (refer to chapter 32). 32. Install drive shafts for main transmission; refer to paragraph 11-56. Install drive shaft covers. 33. If previously removed, install main rotor head (1) and driving link assy (3); refer to chapter 13. 34. If previously removed, install rotating control rods; refer to chapter 41. 35. Connect connector (5, figure 11-9) to rotary transmitter (4) and safety with lockwire. 36. Install oil line (1) together with banjo bolt (3) to oil pump (2) and safety banjo bolt (3) with lockwire. 37. Install oil drain pan and cargo compartment panelling.

* *

38. Service with transmission oil; refer to paragraph 11-4.

*

39. Install main rotor blades; refer to chapter 14. 40. Install fire wall assy; refer to chapter 64. 41. Check for foreign objects. 42. Check adjustment of main rotor controls; refer to chapter 102. 43. Install air baffle (6, figure 11-5) (not installed in combination with ram air ventilation) .

Revision 2

BO 105 CHAPTER 11 Page 31

MAINTENANCE MANUAL BO 105

EUROCOPTER

44. Install engine cowling; refer to chapter 22.

* 45. Check main transmission as follows:

* *

a.

Main transmission removed only temporarily and not preserved

*

- Perform ground run (without load) for 10 minutes and check for leakage.

*

* * * *

b.

Preserved main transmission - Perform ground run (without load) for 10 minutes and check for leakage.

* * * * * *

- After completing ground run, remove magnetic plug or chip detector (if installed) and check for metal deposits. If metal deposits are found, proceed according to Table 11-2. 46.. Perform ground run and functional test flight; refer to chapter 105. 11 -

oi 1

9

NOTE

f i 1 ter

The oil temperature bulb can be installed on the oil filter (configuration 1) or below the main transmission (configuration 11), depending on the configuration in use.

11 - 10

Removal - oil filter

1.

Remove engine cowling as necessary.

2.

Remove lockwire from attaching hardware.

3.

If configuration 1 is present, proceed as follows:

4.

a.

Remove lockwire and unscrew and remove connector (1, fig. 11-13).

b.

Unscrew and remove banjo bolt (12) from oil filter (11) and discard sealing rings (9 and 15). the oil temperature bulb (14) shall remain installed in banjo bolt (12).

c.

Unscrew and remove banjo bolt (3) from oil filter (11) and discard sealing rings (4 and 6) .

If configuration 11 is present, proceed as follows: a.

Unscrew and remove banjo bolt (16) from oil filter (11) and discard sealing rings (9 and 15) .

b.

Unscrew and remove banjo bolt (3) from oil filter (11) and discard sealing rings (4 and 6) .

BO 105 CHAPTER 11 Page 32

Revision 13

EUROCOPTER

MAINTENANCE MANUAL BO 105

5.

Blank all openings with plugs.

6.

Remove clamp (21) from oil cooler and oil filter.

7.

Remove nuts (7) and washers (8) and detach oil filter from oil cooler. Installation - oil filter

11-11

1.

Install oil filter on oil cooler with nuts (7) and washers (8).

2.

Install clamp (21) on oil cooler and oil filter.

3.

Remove plugs.

4.

If configuration 1 is present, proceed as follows: a.

5.

b.

Screw rings Screw rings

banjo bolt (3) in oil filter (11), together with new sealing (4 and 6) . banjo bolt .(12) in oil filter (11), together with new sealing (9 and 15) ~

c.

Screw connector (1) onto oil temperature bulb (14) and safety with lockwire.

If configuration 11 is present, proceed as follows: a.

Screw banjo bolt (3) in oil filter (11) together with new sealing rings (4 and 6) .

b.

Screw banjo bolt (16) in oil filter (11) together with new sealing rings ( 9 and 15).

6.

Safety all attaching hardware with lockwire.

7.

Perform ground run and inspect oil filter connections for leakage. Tighten connections to eliminate any l~akage.

8.

Install engine cowling.

Revision 13

BO 105 CHAPTER 11 Page 33/34

EUROCOPTER

&

& &

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

MAINTENANCE MANUAL BO 105 Connector Oi1 co01er Banjo b01t Sea1ing ring Banjo union Sea1ing r ing Nut Washer Sealing ring Banjo union Oil fil ter Banjo bol t Sealing ring Oil temperature bulb Sealing ring Banjo bol t Hose line Bol t i'¡asher Nut Clamp Bolt i'¡asher Nut Hose line Bolt Fi1ter cover Sealing ring Filter e1e~ent Spring Sealing r ing Filter housing

2

l r f l - r - - - 26 [20-25 Nm

DETAlL

B

&

/,/

I

I

2

¡

/:'

1./

/.i

¡ ,

----.-- . & 16

~~--30

~:a---31

32

DETAlL

600242-01

&

J

A

Configuration 1 Oi1 ternperature bulb (14) is installed on oil Filter in i:elicopters S/N 160 and prior.

B

Configuration 11 Wi th helicopters S/N 161 and subsequent, the oil temperature bulb is installed on the oil pump below the main transmission. See figure 11-9. 25

17

Figure 11-13

Revision 16

Oil filter - main transmission 80 105 CHAPTER 11 Page 35/36

EUROCOPTER

11 - 12

MAINTENANCE MANUAL BO 105

Removal - filter element

1.

Remove engine cowling as necessary.

2.

Remove clamp (21, figure 11-13) from oil cooler and oil filter.

3.

Remove bolt (26). Remove filter housing (32) together with filter element (29).

4.

Discard sealing ring (28). Inspection and cleaning - filter element

11-13

1. Inspect filter element (29, figure 11-13) for deposits. a. b.

Identify magnetic deposits in accordance with figure 11-14 and proceed in accordance with table 11-2. If the deposits include coarse-grained, non-magnetic particles (e.g. bronze chips), or if a definite identification in accordance with table 11-2 and figure 11-14 is either impossible or doubtful, . proceed as follows: 1)

Divide the deposits into two parts, identical in quantity, material and particle size, and pack them into plastic bags.

2)

Send one half and a sample of oil (approx. 200 cm3 ) to the transmission manufacturer (ZF) OR MEB together with the following data: transmission serial number, helicopter serial number, and number of operating hours (TSN, TSO).

3)

Retain the other half as a reference.

4)

Change oil of the main transmision irrespective of the maintenance interval (refer to paragraph 11-4) .

5)

Inspect filter element again for deposits after a maximum of 10 flight hours.

CAUTION

6)

Revision 16

IF THE AMOUNT OR PARTICLE SIZE OF THE DEPOSITS HAS INCREASED SINCE THE PREVIOUS EXAMINATION, REMOVE THE HELICOPTER FROM SERVICE. WAIT FOR ASSESSMENT OF TRANSMISSION MANUFACTURER OR REMOVE MAIN TRANSMISSION ANO REPAIR.

If the deposits do not differ in size and type from those particles of the retained reference sample, or if they are smaller, the helicopter may be retained in servicefor another 10 flight hours maximum.

BO 105 CHAPTER 11 Page 37

* * *

_eurocopter

MAINTENANCE MANUAL 60 105

7) Pending the results of the manufacturer's assessment, steps 5) and 6) may be repeated, provided the specified requirements therein are met. Clean filter element (29), filter housing (32) and compression spring (30) in an ultrasonic cleaner with dry cleaning solvent (CM 202), blow with compressed air and allow to dry. 3.

Inspect filter element (29), filter housing (32), compression spring (30) and sealing ring (31) for condition. a. Replace filter element (29) if damaged or clogged. b.

Replace filter housing (32) if severely damaged.

c.

Replace compression spring (30) if damaged.

d. Replace sealing ring (31) if damaged.

11 - 14

Installation - filter elemant

1. Assemble oil filter with new seal (28, figure 11-13) in accordance with parts sequence (26) thru (32). For torque value on bolt (26) refer to figure 11-13. 2. Attach filter housing (32) to oil cooler (2) with clamp (21). 3.

Perform ground run according to chapter 105.

4.

Perform leakage test.

5. Install engine cowling.

CHAPTER 11 Page38

Revision 22

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 15

E lec t r i c

c h i P

d e t e c t o r

l.

For removal, installation, troubleshooting, maintenance procedures and functional test of electric chip detector, refer to chapter 845, Optional Equipment.

2.

For inspection and cleaning of electric chip detector, refer to paragraph 11-18.

11 - 16

M a 9 n e tic

d r a 11 - 17

~

n

d r a i n val v e

p 1 u 9

a n d

Removal - magnetic drain plug and drain valve

l.

Remove access cover of cargo compartment panelling.

2.

Unscrew and remove bayonet-type magnetic plug. Discard damaged O-rings.

3.

Remove damaged or leaking drain valve as follows: a.

Remove cargo compartment panelling and oil drip pan.

b.

Drain transmission oil; refer to

c.

Remove lockwire, then unscrew and remove drain valve and discard O-ringo

d.

Discard damaged drain valve.

11 - 18

par~graph

11-4.

Inspection and cleaning - magnetic drain plug or electric chip detector

1.

Inspect magnetic plug or electric chip detector for metal chips. If chips are evident, identify in accordance with figure 11-14 and proceed as outlined in table 11-2.

2.

Clean magnetic plug or electric chip detector with dry cleaning solvent (CM 202) .

3.

Inspect magnetic plug or electric chip detector for damage. Discard damaged magnetic plug/chip detector.

BO 105 CHAPTER 11 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A

DETAlL

o .

DETAlL

B

DETAlL

DETAlL

E

DETAlL

e

DETAlL

F

G

100285

Figure 11-14 BO 105 CHAPTER

Page 40

11

Types of deposits to be found on magnetic plug/electric chip detector

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

FIG. 11-14

PROBABLE CAUSE

CORRECTIVE ACTION

Detail A/B

Normal wear

None

2. Considerable amount of fine particles

Detail C

Excessive wear

Carefully check for presence of minute chips in the debris. If chips are not presento flush rnain transmission, clean fi1ter and change oil. If chips are present, proceed according to step 3. In addition, inspect oil filter for deposits per para. 11-12 thru 11-14.

3. Single chip of triangular or trapezoidal shape; one smooth surface, frequently with too1 marks or scores and scratches, the opposite surface with grain texture

Detail D/E

Gear wheel damage

Remove rnain transmission and repair in accordance with REM 103. Clean oi1 filter, oil cooler and hoses according to chapter 63.

4. Several thin chips, with a bright appearance on one side together with considerable amount of fine particles

Detail F/G

Bearing damage

Remove rnain transmission and repair it in accordance with REM 103. Clean oil filter, oil cooler and hoses according to chapter 63.

DESCRIPTION

1. Fine particles in

normal condition and normal quantity

Table 11-2

Corrective action required for contamination found on magnetic plug or electric chip detector of rnain transmission

BO 105 CHAPTER 11 Page 41

-----------------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB -BO 105 11 - 19

Installation - magnetic drain plug and drain valve

1.

If drain valve has been removed, reinstall it in main transmission, together with new sealing ringo Tighten to specified torque value and secure with lockwire.

2.

Coat new O-ring with grease (CM 101) and install on magnetic plug. Insert magnetic plug and check for secure installation (bayonet pins engaged) .

3.

Service with lubricating oil; refer to paragraph 11-4.

4.

Perform ground run test in accordance with chapter 105.

5.

Perform leakage test.

6.

Install oil drip pan and cargo compartment panelling together with access cover.

11 - 20

Oi 1

t e mp e r a t u r e

wa r n i n g

11 - 21

Replacement - oil temperature warning switch

s wi t c h

1.

Remove engine cowling.

2.

Drain transmission oil as described in paragraph 11-4.

3.

Disconnect connector (5, figure 11-10) from receptacle.

4.

Remove oil temperature warning switch (3) from union. Plug opening with blank.

5.

Unsolder electric wire from defective oil temperature warning switch and solder on new oil temperature warning switch.

6.

Remove blank and install oil temperature warning switch (3) in union (4) •

7.

Connect connector (5) to receptacle.

*

* 8. Service with transmission oil; refer to paragraph 11-4. * 9.

Perform ground run in accordance with chapter 105. Warning light T-OIL must not come on. If illuminated, troubleshoot in accordance with para. 11-2.

10. Perform leakage test. 11. Install engine cowling.

BO 105 CHAPTER 11 Page 42

Revision 2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

11 - 22

o

11 - 23

Replacement - oil temperature bulb

l.

2.

i 1

t e mp e r a t u r e

b u 1 b

Configuration 1: oil temperature bulb is installed on oil filter (refer to figure 11-13). a.

Remove engine cowling.

b.

Remove lockwire from connector (1) and remove connector.

c.

Remove lockwire and remove oil temperature bulb (14).

d.

Discard sealing ring (13).

e.

Install oil temperature bulb (14) together with sealing ring (13) in banjo bolt (12) and safety with lockwire.

f.

Connect connector (1) and safety with lockwire.

g.

Perform ground run in accordance with chapter 105. Check oil temperature indicator for correct functioning. If oil temperature indication exceeds the permissible limits, troubleshoot in accordance with paragraph 11-2.

h.

Perform leakage test.

i.

Install engine cowling.

Configuration 11: oil temperature bulb is installed on oil pump below main transmission (refer to figure 11-9): a.

Remove engine cowling.

b.

Remove cargo compartment panelling as necessary. Remove oil drip pan.

c.

Detach lockwire from connector (7) and remove connector.

d.

Remove lockwire and remove oil temperature bulb (6). Catch draining transmission oil in a container.

e.

Discard sealing ring (8).

f.

Connect oil temperature bulb (6) together with sealing ring (8) to adapter (9) and safety with lockwire.

g.

Connect connector (7) and safety with lockwire.

h.

Check transmission oil level and add oil (CM 103) as necessary.

BO 105 CHAPTER 11

Page 43

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

i.

Perform ground run in accordance with chapter 105. Check oil temperature indicator for proper functioning. If oil temperature exceeds the permissible limits, troubleshoot in accordance with paragraph 11-2. .

j.

Perform leakage test.

k.

Install oil drip pan and cargo compartment panelling.

l.

Install engine cowling. o w

p r e s s u r e

wa r n i n g

11 - 24

L

11 - 25

Replacement - low pressure warning switch

SW1tch

1.

Remove engine cowling as necessary.

2.

Remove lockwire from connector and remove connector (refer to figure 11-7) .

3.

Remove lockwire from low pressure warning switch (5), and unscrew oil pressure warning switch from fitting (6). Plug opening with blank.

4.

Discard O-ringo

5.

Remove blank from fitting (6) and install low pressure warning switch (5) together with O-ring in fitting. Safety low pressure warning switch with lockwire.

6.

Install connector on low pressure warning switch and safety with lockwire.

7.

Check transmission oil level and add oil (CM 103) as necessary.

8.

Perform ground run in accordance with chapter 105. Warning light T-OIL must not come on. If illuminated, troubleshoot in accordance with paragraph 11-2.

9.

Perform leakage test.

10.

Install engine cowling.

BO 105 CHAPTER 11 Page 44

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 p r e s s u r e

t r a n s rn i t t e r

11 - 26

Oi 1

11 - 27

Replacernent - oil pressure transrnitter

l.

Rernove engine cowling as necessary.

2.

Rernove protective cap frorn oil pressure transrnitter (4, figure 11-7). Rernove nut together with circlip to gain access to the electrical connection.

3.

Disconnect electrical connection.

4.

Rernove lockwire frorn oil pressure transrnitter and unscrew and rernove oil pressure transrnitter frorn fitting (6). Plug opening with blank.

5.

Inspect sealing ring for darnage and replace if necessary.

6.

Rernove blank. Screw oil pressure transrnitter together with sealing ring in fitting (6) and safety with lockwire.

7.

Connect electrical cable to oil pressure transrnitter with nut and circlip and cover connection with protective cap.

8.

Check transrnission oil level and add oil (CM 103) if necessary.

9.

Perforrn ground run in accordance with chapter 105. Check oil pressure indicator for proper functioning. If oil pressure indication exceeds the perrnissible lirnits, troubleshoot in accordance with paragraph 11-2.

10.

Perforrn leakage test.

11.

Install engine cowling.

e r

n e c

11 - 28

Oi 1

11 - 29

Rernoval - oil filler neck

f i 1 1

k

l.

Rernove engine cowling as necessary.

2.

Open cover (1) of oil filler neck (4) and inspect O-ring (2) for condition. Replace damaged O-ringo

3.

Inspect springs (3) for condition and replace if defective.

4.

Unscrew and rernove oil filler neck (4, figure 11-16) and clean strainer (5) with dry cleaning solvent (CM 202) .

BO 105 CHAPTER 11 Page 45

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 30

Installation - oil filler neck

1.

Install O-ring (2, figure 11-16) in cover (1). If installing a new O-ring, first lubricate it with grease (CM 101) .

2.

Screw oil filler neck (4) together with shim (6) in elbow (8) and tighten. Check installed position and correct as necessary by either replacing the shim or by peeling it to the appropriate thickness. For correct installation position, see fig. 11-15.

10-" mm

2----

4 --4--H4-JII

8

-t---' ~----t=---5

Transmission housing Straightedge Oil filler neck 4 Screw 5 Elbow

1 2 3

100440

Figure 11-15

BO 105 CHAPTER 11 Page 46

Installation position - oil filler neck

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - -__ MAINTENANCE MANUAL MBB - BO 105

4 - - - - - - - " t " - - -__

3 -----u.,~~

5---~~--

6 ------t----\...:;;;;;;......7 -------t---

8 --------1,---..-.,.;'t-

9-----A-------..::::s;¡~~

~ 110034

1 2 3 4 5

Cover O-ring Spring OH filler neck Strainer

Figure 11-16

Shirn Transrnission housing 8 Elbow 9 Screw 6 7

Removal and installation - oil filler neck

BO 105 CHAPTER 11 Page 47

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANuAL MBB - BO 105 11 - 31

R e p 1 a e e me n t s i g h t g 1 a s s

o f

o i 1

g a s k e t

1 e v e 1

1.

Drain transmission oil according to paragraph 11-4.

2.

Remove engine cowling as necessary.

3.

Straighten the tabs of the locking plates (2, figure 11-17) and remove scréws (1). 5

Screw Locking plate 3 Level marker 4 Oil level sight glass 5 Seal 6 Housing 1 2

Figure 11-17

Removal and installation - oil level sight glass

4.

Remove oil level sight glass (4), level marker (3) and gasket (5) from housing (6). Discard gasket (5).

5.

Clean sealing surfaces of housing (6) and oil level sight glass (4) with dry cleaning solvent (CM 202) .

6.

Install level marker (3), oil level sight glass (4) and new gasket (5) on housing (6), using screws (1) and new locking plates (2). Safety screws (1) with locking plates (2).

7.

Service with transmission oil according to paragraph 11-4.

8.

Inspect split line of oil level sight glass and housing for leakage.

9.

Install engine cowling.

BO 105 CHAPTER 11 Page 48

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 32

Ac c e s s o r y

11 - 33

Removal - accessory gearbox

g e a r b o x

Special tools: Locking ring 1.

1x56 150 123

Remove engine cowling as necessary. NOTE

If bolt (3) is installed in place of stud (4, fig. 11-18), omit steps 2. thru 4.

CAUTION

BEFORE REMOVING THE CONTROL RODS FROM BETWEEN THE MIXING LEVER ASSEMBLY AND THE TANDEM HYDRAULIC UNIT, SECURE THE SWASH PLATE IN POSITION TO PREVENT IT FROM SLIPPING DOWN THE ROTOR MAST.

& 4

8

I 6

110029

&

zR

1 Nut 2 Washer 3 Bolt 4 Stud

5 Accessory gearbox 6 Transmission center housing 7 O-ring 8 Shim

Configuration - main transmission housing attached by four studs Configuration - main transmission housing attached by three studs and one bolt Figure 11-18

Removal and installation - accessory gearbox BO 105 CHAPTER 11 Page 49

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 2.

Fit clamping ring 1x56 150 123 to support tube on main transmission so that it is directly below the swash plate sliding sleeve.

3.

Remove control rods from between tandem hydraulic unit and mixing lever assy; refer to chapter 43. NOTE

Do not disconnect hydraulic lines from hydraulic pumps as this will require bleeding of the hydraulic system.

4.

Remove hydraulic pumps and RPM tachometer.

5.

with configuration~ shown in fig. 11-18, remove tandem hydraulic unit according to chapter 43; with configuration~ , remove tandem hydraulic unit only to the extent necessary for removing accessory gearbox (5).

6.

Remove accessory gearbox and discard O-ring (7).

7.

Remove shim (8) and retain for reinstallation of accessory gearbox.

11 - 34

Installation - accessory gearbox

1.

Clean flange faces with dry cleaning solvent (CM 202) .

2.

If a new accessory gearbox is to be installed, check backlash and if necessary, take corrective action described in REM 103.

3.

Coat new O-ring (7) with grease (CM 101) and install in accessory gearbox (5).

4.

Brush-coat mounting fa ce of accessory gearbox with corros ion preventive compound (CM 505) and inse~t accessory gearbox together with shim (8) into transmission center housing (6).

5.

Attach accessory gearbox in accordance with configuration requirements (see fig. 11-18).

6.

Cover nuts (1), head of bolt (3) and split line of transmission center housing and accessory gearbox with two-component finishing lacquer (CM 437) .

7.

Install tandem hydraulic unit.

8.

Remove c1amping ring 1x56 150 123 and install control rods between tandem hydraulic unit and mixing lever assembly as described in chapter 43.

9.

Perform ground run in accordance with chapter 105 and inspect main transmission for leakage.

10. Install engine cowling.

BO 105 CHAPTER 11 Page 50

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 35

Replacement of seals - accessory gearbox

Special tools: lx56 136 236 1x56 136 373 1x56 136 374

Assembly screws Drift Drift or Drift Drift

lx56 134 516 lx56 136 514

1.

Remove engine cowling as necessary.

2.

If necessary, remove components from tandem hydraulic unit and transmission mounting V-strut to enable access to accessory gearbox.

Hydraulic pump drive. system 11

t------ RPM tachometer drive

~.

I 1

4

jJ

s 7 8 -!

SNm

I

110033

1 2 3 4 5 6

Circlip Circlip Shaft seal Housing O-ring Cover

Figure 11-19

7 Washer Screw 9 Ring 10 O-ring 11 Shaft seal 8

Replacement of seals - accessory gearbox

BO 105 CHA!?TER 11 Page 51

- - - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 3.

Replace shaft seal (3, figure 11-19) of hydraulic pump drive as follows: NOTE

4.

Do not disconnect hose lines frorn hydraulic pump as this will require bleeding of the hydraulic systern.

a.

Rernove hydraulic pump according to chapter 43.

b.

Rernove circlips (1 and 2) .

c.

Rernove shaft seal (3) with a suitable tool.

d.

Apply a thin coat of grease (CM 101) to new shaft seal (3) and insert with sealing lip pointing towards the bushing, using drift 1x56 136 514. See figure 11-20.

e.

Insert circlips (1 and 2, figure 11-19).

f.

Clean faying surfaces of hydraulic pump and accessory gearbox with dry cleaning solvent (CM 202) and apply corrosion preventive paste (CM 503) .

g.

Install hydraulic pump according to chapter 43.

Replace shaft seal (11) and O-rings (la) in the RPM tachorneter drive as follows: NOTE

Do not disconnect hose lines frorn hydrau1ic pump as this will require bleeding of the hydraulic systern.

a.

Rernove hydraulic pump of systern 11 according to chapter 43.

b.

Rernove ring (9) frorn housing (4) with a suitable tool.

c.

Discard O-ring (la).

d.

Using drift 1x56 136 374, press shaft seal (11) frorn ring (9). Discard shaft sea1.

e.

Apply a thin coat of grease (CM 101) to new shaft sea1 (11) and insert with lip pointing towards ring (9), using drift 1x56 136 374.

f.

Apply a thin coat of grease (CM 101) to new O-ring (10) and install on ring (9).

g.

Fit ring (9) into housing bore, using drift 1x56 136 373.

h.

Clean faying surfaces of RPM tachorneter and accessory gearbox with dry cleaning solvent (CM 202) and then apply corros ion preventive paste (CM 503) .

BO 105 CHAPTER 11 Page 52

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

100457

Figure 11-20 i.

Application - drift 1x56 136 514

Apply corrosion preventive compound (CM 505) to pinion of RPM tachometer and install RPM tachometer. For torque load of nuts, see fig. 11-5.

j. 5.

Install hydraulic pump of system 11 on accessory gearbox according to chapter 43.

Replace O-ring (5, figure 11-19) of cover (6) as follows: a.

Remove screws (8) and washers (7).

b.

Remove cover (6), using assembly screws 1x56 136 236. Discard O-ring (5) •

c.

Apply a thin coat of grease (CM 101) to new O-ring (5) and fit into cover (6).

d.

Install cover (6) together with new O-ring (5), screws (8) and washer (7). Apply two-component finishing lacquer (CM 437) to split lineo

6.

Reinstall components previously removed from hydraulic unit and transmission mounting V-strut.

7.

Perform ground run in accordance with chapter 105.

8.

Perform leakage test.

9.

Install engine cowling. BO 105 CHAPTER 11 Page 53

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

11 -

36

11 - 37

Ro t a r y

t r a n s m i t ter

Removal - rotary transmitter

l. Remove cargo compartment panelling as necessary and detachoil drip pan. 2. Disconnect connector (6, figure 11-21) from receptacle (8). 3. Index mark rotary transmitter in relation to main transmission, using felt-tip pen or similar. 4. Remove screws (5) and washers (4). Pull rotary transmitter (3) downward, then disconnect connector (1) from receptacle (9) and remove coupling sleeve (2). 5. Cap connector (6), receptacles (8 and 9) and shaft (7) with blanks.

BO 105 CHAPTER 11

Page 54

_.

Oeurocopter

MAINTENANCE MANUAL SO 105

en EAD6 Company

10

+---t----2 9

--_=-.=-_~

7 --J'-------jH

3

1.5 Nm

8

1 2 3 4 5

Connector Coupling sleeve Rotary transmitter Washer Hex Screw

Figure 11-21

6 7 8 9 10

Connector Shaft Receptacle Receptacle Main transmission lower housing

Removal and installation - rotary transmitter CHAPTER 11 Page 55

-euroeopter

. . en EAffi Com!lenI'

I

11 - 38

MAINTENANCE MANUAL 80105

Installation - rotory transmitter

CAlITION

AN INDIVIDUAL REPLACEMENT OF THE MAST MOMENT INDICATOR OR OF THE ROTORY TRANSMITTER IS NOT ALLOWED. MAST MOMENT INDICATOR ANO ROTORY TRANSMITTER CAN ONLY BE REPLACED BY TWO OTHERS WITH IDENTICAL SERIAL NUMBERS. MAST MOMENT INDICATOR ANO ROTORY TRANSMITTER MUST BE ALlGNED (SEE SI-B0105-22 REVISION 2).

1. Remove protective covers. 2.

Fit coupling sleeve (2, figure 11-21) on shaft (7) and connect electrical connector (1) to rotary transmitter.

3.

Connect rotory transmitter to drive shaft by means of coupling sleeve, while taking care to align index marks; fasten with hex screws (5) and washers (4). Receptacle (8) must paint in direction of flighí.

-

4. Connect connector (6) to receptacle (8). 5.

Perform functional test in accordance with chapter 705.

6.

Coat split lines and bare metal surfaces of housing with corrosion preventive compound (CM 505).

7.

Install cargo compartment panelling and oil drip pan.

-

CHAPTER 11 Page 56

Revision 25

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

11 - 39

S1 i P

11 - 40

Removal and disassernbly - slip ring retainer

r i n g

r e t a i n e r

Special tools: Pusher screws (3 off) Drift Drift Bushing Drift Support

1x56 1x56 1x56 1x56 1x56 1x56

131 134 136 150 136 136

399 516 285 135 371 426

1.

Drain transmission oil according to paragraph 11-4.

2.

Remove rotary transmitter according to paragraph 11-37.

3.

Remove screws (6 and 7, figure 11-23) together with washers (5).

4.

Using pusher screws 1x56 131 399, remove slip ring retainer (4) from transmission lower housing (1), whilst carefully pulling wiring harness out of drive shaft (2).

5.

Remove O-ring (3) from housing (4) and discard.

6.

Remove circlips (13 and 14) .

7.

Remove drive shaft (2) from housing (4), using drift 1x56 136 371 and support 1x56 136 426; see figure 11-22.

8.

Using drift 1x56 136 285, remove bushing (12, fig. 11-23) together with shaft seal (11) and O-ring (10), ball bearing (9) and shim (8) from housing (4); see fig. 11-22.

9.

Press shaft seal (11, figure 11-23) out of bushing (12), using drift 1x56 134 516 and bushing 1x56 150 135. Discard O-ring (10).

BO 105 CHAPTER 11 Page 57

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

100458

Rernoval of ball bearing and shaft seal using

Rernoval of drive shaft using

Drift 1x56 136 285

Drift 1x56 136 371 Support 1x56 136 426

Figure 11-22

BO 105 CHAPTER

Page 58

11

Application - Drift 1x56 136 285 Drift 1x56 136 371 Support 1x56 136 426

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

I?t----

~----2

! 8-10 Nm

rn

3

~.

4

5

5

7 8

6 9

11

10

2

8

9 10 13

12 11

14

4

12 13

3

14 110035

1 Transmission bottom housing 2 Drive shaft 3 O-ring 4 Housing, slip ring retainer 5 Washer 6 Screw 7 Screw Figure 11-23

8

9

10 11

12 13

14

Shim Ba1l bearing O-ring Shaft seal Bushing Circlip Circlip

Removal and installation - slip ring retainer

BO 105 CHAPTER 11 Page 59

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 41

Assembly and installation - slip ring retainer

Special tools: Drift Protective sleeve Drift

1xS6 131 396 1xS6 136 292 1xS6 136 373

l.

Apply a thin coat of grease (CM 101) to outer circumference of shaft seal (11, figure 11-23) and press into bushing (12), using drift 1x56 136 373.

2.

Coat new O-ring (10) with grease (CM 101) and install on bushing (12).

3.

Fit shim (8) into housing (4) and then press ball bearing (9) into housing(4), using drift 1xS6 131 396.

4.

Press bushing (12) and shaft seal (11) into housing (4), using drift 1x56 131 396.

5.

Install circlip (13).

6.

Insert protective sleeve 1x56 136 292 (1, figure 11-24) into shaft seal (3) until it seats against ball bearing (2).

7.

Press drive shaft (4) into ball bearing (2) until it abuts, and remove protective sleeve (1).

.~ 4------~

) ,

2----..¡,..:,¡~

3----...y.:."

110012LS

Figure 11-24 BO 105 CHAPTER 11 Page 60

1 Protective sleeve (lxS6 136 292) 2 Ball bearing 3 Shaft seal ring 4 Drive shaft Installation of drive shaft in slip ring retainer

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. Install circlip (14,figure 11-23) in annu1ar groove of drive shaft (2). 9. Coat new O-ring (3) with grease (CM 101) and insta1l on housing (4). 10. Feed wiring harness through drive shaft (2) and position the slip ring retainer in the main transmission so that the upper splines of the drive shaft (2) engage with the rotor masto 11. Secure slip ring retainer with screws (6 and 7) and

wa~hers

(5).

12. Install rotary transmitter in accordance to paragraph 11-38. 13. Service with transmission oil; refer to paragraph 11-4. 14. Perform ground run in accordance with chapter 105 and visually inspect around perimeter of rotary transmitter mounting face for oil leaks. 15. Check mast moment indication system for correct functioning according to chapter 705. 16. Apply corrosion preventive compound (CM 505) to split lines and bare metal surfaces of housing. 17. Install cargo compartment panelling and oil drip pan.

Revision 2

BO 105 CHAPTER 11 Page 61

* * *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 42

F a n

a s s e mb 1 Y

11 - 43

Removal - fan assembly

l.

Remove engine cowling.

2.

Loosen clamp on fan assembly (7, figure 11-25) and remove rubber sleeve from fan assembly (7).

3.

Remove hydraulic line of rotor brake system from transmission mounting V-strut.

4.

Loosen oil cooler and move outboard as far as necessary.

5.

Remove ram air ventilation system, if installed: refer to chapter 63.

6.

Remove nuts (5), washers (4) and detach fan assembly (7).

7.

Remove input shaft (1), centering ring (2) and O-ring (3). Discard O-ringo

7

1 2

¡---s

7

8

100019.1

Figure 11-25

BO 105 CHAPTER 11 Page 62

3 4 5 6

Input shaft Centering ring O-ring Washer Nut Cast fin Fan assembly Main transmission center housing

Removal and installation - fan assembly

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 44

Installation - fan assembly

1.

Install new fan assembly in accordance with REM 103.

2.

Install previously removed fan assembly as follows: a.

Clean faying surfaces of fan assembly and main transrnission with dry cleaning solvent (CM 202) .

b.

Inspect lubrication bores on faying surfaces of main transrnission and fan assembly for contarnination. Clean, if necessary.

c.

Coat new O-ring (3, figure 11-25) with grease (CM 101) and install in annular groove of fan assembly.

d.

Position centering ring (2) against ball bearing in fan assembly. Coat drive shaft (1) with grease (CM 101) and install in position.

e.

Coat mounting face of fan housing with corrosion preventive paste (CM 503). Install fan assembly (7) with the cast fin (6) pointing upward. Tighten nuts (5) to specified torque load.

f.

It ram air ventilation system was previously removed, reinstall it in accordance with chapter 63.

g.

Secure oil cooler.

h.

Secure hydraulic line of rotor brake system to leg of transrnission mounting V-strut.

i.

Slide rubber sleeve onto fan assembly and fasten with clamp.

j.

Perform ground run in accordance with chapter 105 and visually inspect split line for leakage.

k.

Install engine cowling.

BO 105 CHAPTER 11 Page 63

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 11 - 45

Replacernent of shaft seal - fan assernbly

Special tools: Puller Socket wrench Sleeve or Bushing Drift Fixture

1x56 122 267 1x56 136 233 1x56 136 372 1x56 150 135 1x56 134 516 1x56 136 528

1.

Rernove fan assernbly according to paragraph 11-43.

2.

Rernove retaining plates (8, figure 11-28) frorn guide wheel (22) and rernove guide wheel.

3.

Rernove spacers (21) frorn fan assernbly (7) and retain for reinstallation.

4.

Attach fixture 1x56 136 528 to fan assernbly and clamp fixture in a vise. Extract lockwasher (20) incorporating puller thread frorn shaft nut (19), using tool 1x56 122 267; refer to figure 11-26, or use a screw driver to rernove lockwasher (20) without puller thread.

5.

Rernove shaft nut (19, figure 11-28), using socket wrench 1x56 136 233; refer to figure 11-26.

6.

Detach bushing (18, figure 11-28), rernove cylindrical pin (17) and fan wheel (16).

7.

Rernove screws (15) and washers (14).

8.

Rernove cover (13) and discard O-ring (11).

9.

Rernove shaft seal (12) frorn cover (13), using bushing 1x56 150 135 and drift 1x56 134 516.

10. Rernove barrel ring (10) and O-ring (9) frorn shaft of fan assernbly (7). Discard O-ring (9). 11. Apply a thin coat of grease (CM 101) to new O-ring (9) and slide it onto shaft until it abuts. 12. Apply grease (CM 101) to outer and inner circurnferences of barrel ring (10), and slide it, with the recess on the inside diarneter facing the O-ring (9), over shaft and O-ring (9) until it abuts. 13. Apply a thin coat of grease (CM 101) to outer circurnference of shaft seal (2, figure 11-27). Position cover (3) on sleeve 1x56 136 372 and press shaft seal (2) into cover (3), using drift 1x56 134 516.

BO 105 CHAPTER 11 Page 64

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

\. \ ..

/

~O .,

, -~'""

'-

/

100460

Puller lxS6 122 267 Figure 11-26

Socket wrench lxS6 136 233 Application - puller lxS6 122 267 socket wrench lxS6 136 233

14. Apply grease (CM 101) to new O-ring (5, fig. 11-27) and fit O-ring into annular groove of cover (3). 15. Secure cover (13, figure 11-28) to fan housing (7) with screws (15) and washers (14). Apply two-cornponent finishing lacquer (CM 437) to split lines between screwheads and cover and between cover and rnating surface on fan assembly. 16. Fit fan wheel (16, fig. 11-28) onta shaft of fan assembly (7) and turn fan wheel to align bores in the shaft with groove in fan wheel.

BO 105 CHAPTER 11

Page 65

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

5

1 Drift 1x56 134 516 2 Shaft sea1 3 Cover 4 Sleeve 1x56 136 372 5 O-ring

100288

Figure 11-27

Installation of shaft seal

17. Fit cylindrical pin (17) into shaft of fan housing (7) so that an equal length of pin protrudes on both sides. 18. Insert bushing (18) so that cylindrical pin (17) is covered. 19. Install shaft nut (19) and tighten to specified torque load with socket wrench 1x56 136 233. Check if bushing (18) contacts the fan hubo If it contacts the fan hub, rework inner rim of bushing (18). 20. Install lockwasher (20) on shaft nut (19), using puller 1x56 122 267. Make sure that the tabs are properly fitted in the nut grooves and engaged behind the nut.

BO 105 CHAPTER 11 Page 66

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

22

9

10

11

12

13

8 7

6 3

2

~I

14 15

~

100019.2

1 Input shaft 2 Centering ring 3 O-ring 4 Washer 5 Nut 6 Cast fin 7 Fan assembly 8 Retaining plate 9 O-ring 10 Barrel ring 11 O-ring 12 Shaft seal Figure 11-28

13 14 15 16 17 18 19 20 21 22

Cover Washer Hex screw Fan whee1 Cylindrical pin Bushing Shaft nut Lockwasher Spacer Guide wheel

Fan assembly - partial disassembly BO 105 CHAPTER 11 Page 67

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 21. Apply two-component finishing lacquer (CM 437) to split lines between bushing (18), shaft nut (19), lockwasher (20) and thread of fan assembly (7) shaft. 22. Install spacers (3, figure 11-29) onto guide wheel (5). Fit guide wheel (5) into fan assembly (1). Retaining plates (4) must engage. 23. Measure clearance between guide wheel (5) and fan wheel (2), using a feeler gauge. There must be a uniform clearance of between 0.3 and 1.5 mm around the entire circumference. Obtain required clearance by adding or removing spacers (3). 24. Install fan assembly according to paragraph 11-44.

4

-,.---5

100291

0.3-1.5 mm

Fan assembly Fan wheel Spacer 4 Retaining plate 5 Guide wheel 1 2 3

Figure 11-29

BO 105 CHAPTER 11 Page 68

Installation - guide wheel

- - - - - - - - - - - - : ' - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

P u mP

11 - 46

Oi l

11 - 47

Removal - oil pump

Special tools: Special wrench

105-10101 W1

1.

"Remove engine cowling.

2.

Remove cargo compartment panelling and oil drip pan.

3.

Drain transmission oil according to paragraph 11-4.

4.

Unscrew oil line (1, fig. 11-9) end fitting from double banjo fitting (10) .

5.

Remove lockwire and unscrew and remove banjo bolt (3).

6.

Discard freed gaskets and plug open ends.

7.

Remove lockwire and remove screws (7, fig. 11-30) using special wrench pIN 105-10101 wL Then detach washers (6) and oH pump (5) and discard O-ring (4).

8.

Pull assembled shaft (2) and oil strainer (3) out of transmission housing and detach shaft (2) from oil strainer (3).

9.

Inspect oil strainer (3), shaft (2) and oil pump (5) for deposits and contamination,and clean with dry cleaning solvent (CM 202) if necessary.

10. In the event of deposits or contamination, remove and clean main transmission oil filter according to paragraph 11-9.

1

2 3 4 2

5 6 7

Transmission lower housing Shaft OH strainer O-ring OH pump Washer Screw

3-----t 4----~

A'"t_ 5---~

6

7-1

4 6Nm -

I

"0028

Figure 11-30

Removal and installation - oil pump BO 105 CHAPTER 11

Page 69

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 48

Installation - oil pump

Special tools: Special wrench

105-10101 W1

lo

Insert shaft (2, figure 11-30) into intermediate shaft located in transmission bottom housing.

2.

Slide oil filter (3) on shaft (2) until it abuts.

3.

Coat O-ring (4) with grease (CM 101) and install on oil pump (5).

4.

Insert oil pump (5) so that splines of oil pump and shaft (2) engage one another.

5.

Install oil pump (5) with screws (7) and washers (6) and torque-tighten, using special wrench 105-10101 W1.

6.

Remove plugs from open ends.

7.

Screw banjo bolt (3) into oil pump, together with new gaskets and double banjo fitting.

8.

Lockwire banjo bolt (3).

9.

Attach oil line (1, figure 11-9) to double banjo fitting (10).

* * 10. Service with transmission oil; refer to paragraph 11-4. *

11. Perform ground run according to chapter 105 and visually inspect area around oil pump for leakage. 12. Apply two-component finishing lacquer (CM 437) to split line of oil pump and transmission housing and to bolt heads. 13. Install oil drip pan and cargocompartment panelling. 14. Install engine cowling according to chapter 22.

BO 105 CHAPTER 11 Page 70

Revision 2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 49

T r a n s m i s s ion

mo u n t i n g

11 - 50

Removal - transmission mounting V-struts

V- s t r u t s

Special tools: Hoisting device Hoisting sling Pushing-out and pressing-in tool Pushing-out device

105-14101 W5 or 1121-14102 W1 or 117 W3 or 105 W27 or 1x56 136 240 1121-10151 W3 oder 105-10151 W3 105-10151 W4

l.

Remove engine cowling.

2.

Remove main rotor blades; refer to chapter 14.

3.

Attach hoisting device 105-14101 W5 or 1121-14102 W1 or 117 W3 to main rotor head or, if main rotor head has been removed, attach hoisting device 105 W27 or 1x56 136 240 to flange on top of rotor masto Lift main transmission as necessary to relieve the load on the transmission V-struts.

4.

When removing the LH transmission mounting V-strut (viewed in direction of flight), remove the following parts: a.

Remove hardware attaching hinged support to bearing bracket of mixing lever assembly. Remove bearing bracked.

b.

Remove clarops from transmission mounting V-strut.

5. When removing the RH transmission mounting V-strut (in direction of flight), detach the following parts: a.

Remove air baffle (6, figure 11-5); however, it is not installed in combination with raro air ventilation.

b.

Remove raro air duct (raro air ventilation) as necessary.

c.

Remove oil cooler support bracket from transmission mounting V-struts.

d.

Disconnect rotor brake hose line from brake caliper.

e.

Remove all clarops and lines from transmission mounting V-strut.

6. Remove split pin (4, figure 11-31), nut (5) and washer (6).

BO 105 CHAPTER 11 Page 71/72

- - - - - - - - - - - - - M a B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MaB - BO 105

1 Transmission mounting V-struts, LB 2 Transmission mounting V-struts, RH 3 Bolt 4 Split pin 5 Nut 6 Washer 7 Shim &&8 Transmission mounting V-strut fitting (top) 9 Transmission mounting V-strut clevis· (bottom) 10 Bolt 11 Washer 12 Split pin 13 Nut 14 Main transmission deck fitting 15 Bushing 16 Transmission flange 17 Guide sleeve 105-10151 W1 18 Guide sleeve 105-10151 W2

&

2

/

15

Configuration I

DETAlL

Transmission mounting V-strut fitting without bushing

& Configuration

A

:....-.----4

....-----5 '-------6

Ir

----12

:-'~li----7

Transmission mounting V-strut fitting with bushing (15)

....---- 13 ---11

DETAlL 10

3 100257.3

Figure 11-31

Removal and installation - transmission mounting V-struts BO 105 CHAPTER 11 Page 73/74

17

7

18

9

14

B

-1 8-12 Nm i

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Applicalion

& B

7

3

2

apply grease (CM 102) al assembly

Applicalion

&

8

7

5

6

4

100010

& ill

Loosening and removing of jarnmed transmission strut bolts Loosening and removing of jarnmed transmission strut bolts, using hydraulic press (6) 1 2 3 4

Frame Quil1 Bolt Centering piece

Figure 11-32

Thrust piece Hydraulic press 7 Main transmission flange 8 Transmission mounting V-strut fitting

5

6

Application - pushing-out device 105-10151 W4 BO 105 CHAPTER 11 Page 75

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2

4

6

o Pressing- in procedure

s

4

3

6

o Pressing-out procedure

7

S

1 Spind1e 2 Pushing-out jaws 3 Pressing-in jaws 4 Locking nut 5 End support 6 Extractor 7 Guide sleeve 105-10151 W2

100011

Figure 11-33 BO 105 CHAPTER 11 Page 76

Application - pushing-out and pressing-in tool 1121-10151 W3/105-10151 W3

- - - - - - - - - - - - - M B B HELICOPTERS.------------MAINTENANCE MANUAL MEB - BO 105 CAUTION

TO PREVENT DAMAGE TO TRANSMISSION DECK, DO NOT LOWER MAIN TRANSMISSION ONTO DECK AFTER ACCOMPLISHMENT OF STEP 7.

7. Remove bolt (3). If bolt is jarnmed, do not drive it out with a harnmer. Remove it with pushing-out device 105-10151 W4 according to figure 11-32. 8. If installed, remove shims (7, figure 11-31) and retain for reinstallation of same mounting V-strut and transmission flange combination. 9. Remove split pin (12), nut (13) and washer (11).

10. Remove bolts (10). If bolts are jarnmed, do not drive it out with a hammero Remove them with pushing-out and pressing-in tool 1121-10151 W3 or 105-10151 W3 according to figure 11-33. NOTE

If the sealant on the rivet heads in the apex end fitting or on the grub screws in the clevises is missing or damaged, the interior of the V-strut legs must be inspected for the presence of moisture or corrosion, refer to paragraph 11-51. If water has ente red the legs, this can be evidenced by an accumulation of water above the grub screws in the clevis ends. Therefore, it is important to support the V-strut in the upright position during and after removal to prevent any accumulated water from flowing back up the V-strut legs and avoiding detection.

11. Pull apex end of the transmission mounting V-struts away from the mating flange on the main transmission enough to allow the V-struts to be removed upwards. 11 - 51

Inspection and repair - transmission mounting V-struts

Special tools: Pressing-in tool Pushing-out tool l.

105-21832 W1 tool no. 28 (105-10155 W1)

refer to chapter 04

Inspect transmission mounting V-struts for deformation, cracks, mechanical damage, corros ion, missing or damaged sealant on rivet heads and on the grub screws in the clevis ends, and damaged surface protection. a.

b.

Using a magnifying glass, inspect welds and adjacent areas for cracks. If presence of cracks is uncertain, perform penetrant crack inspection per MIL-STD-6866. If cracks or fractures are evident, the opposite transmission mounting V-strut must also be replaced. In the case of deformation, replace only the affected V-strut. Polish out mechanical damage to within the permissible limits specified in figure 11-34, and final polish with polishing cloth 400.

Revision 5

BO 105 CHAPTER 11 Page 77

* *

*

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2.

c.

Touch up damaged surface protection with two-component wash primer (CM 423) and single-Iayer lacquer (CM 402) in accordance with chapter 02.

d.

Inspect bore of transmission mounting V-strut clevises (9, figure 11-31) for mechanical damage and corrosion. Polish out damage with polishing cloth 400. For max. permissible bore diameter, see figure 11-34.

e.

Inspect bore of transmission mounting V-strut apex fitting (8, figure 11-31, configuration I) for mechanical damage and corrosion. Polish out damage with polishing cloth 400. For max. permissible bore diameter, see figure 11-34.

f.

Inspect bore of bushing (15, figure 11-31, configuration II) for mechanical damage and corros ion Polish out damage with polishing cIoth 400. For max. permissible bore diameter, see fig. 11-34. If Iimit is exceeded, repIace bushing in accordance with step 4.

g.

Inspect grub screws in cIevis ends and rivet heads for missing or damaged seaIant. If sealant is missing or damaged, inspect interior of V-strut legs for presence of moisture or corrosion, then reapply sealant, refer to step 5.

CIean bolt (3) with dry cleaning solvent (CM 202) and inspect as follows: a.

Inspect bolt for cracks (magnetic particle inspection in accordance with MIL-STD-1949 or penetrant inspection in accordance with MIL-STD-6866). RepIace bolt if cracks are evident.

b.

Inspect bolts for mechanical damage. Minor mechanical damage to bolt shank if ease of installation is not affected (it must be possible to insert the bolt manually into transmission flange and strut bushing) .

c.

Remove severe mechanical damage (e.g. scratches, nicks and marks) which affects ease of installation, using polishing cloth 400/600, provided the surface Iayer of the bolt is not worn down to the base material.

d.

Replace bolt if surface layer is worn down to the base material or if diameter is less than the minimum permissible diameter of 14.95 mm.

e.

Replace bolt if thread flanks are deformed or broken. Remove minor thread damage with a suitable tool.

3.

Inspect bolt (10) for mechanical and corrosion damage. Polish out mechanical damage, such as scratches, nicks and scores, and local corrosion spots using 400 grit abrasive cIoth. Thread damage is permissible only if the bolt can be screwed in easily by hand.

4.

Replace bushing (15, figure 11-31) as follows: a.

Press out bushing (15), using pushing-out tool no. 28 (105-10155 W1).

BO 105 CHAPTER 11 Page 78

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Contiguration 1

Contiguration JI

weld

110040

TYPE Of DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

IfI?¡:r::¡::iW!

I

Mechanical

0.1 mm in depth on 25% of the surface

0.1 mm in depth on 30% of the surface

Cor:osive

0.05 mm in depth before and 0.1 mm afte: :epair on 25% of the surface

0.05 mm in depth before and 0.1 mm after repair on 30% of the surface

I

~

Maximurn perrnissible bore diarneter is 12.03 mm. It may be exceeded by 0.01 mm on one quarter of the circurnference.

~

50% of the initial contact surface must be retained in an area of 4 mm around the bore.

[1 ~ Maximurn perrnissible bore diameter is 15.02 mm. It may be exceeded by 0.01 mm on one quarter of the circurnference. Configuration 1

V-strut fitting without bushing

Configuration 11

V-strut fitting with bushing

Figure 11-34

Transmission mounting V-struts - darnage and repair limits BO 105 CHAPTER 11 Page 79

RELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

-------------MEB

5.

b.

Inspect bore in V-strut apex fitting for mechanical damage and corrosion·;· Polish out damage with polishing cloth 400. Maximum permissible bore diameter is 17.52 mm. It may be exceeded by 0.01 mm on one quarter of the circumference.

c.

Coat bore of transmission mounting V-strut apex fitting (8) with corrosion preventive paste (CM 503) .

d.

Chill bushing (15) to -50 oC and press into bore.

e.

Rone bushing to obtain the required diameter of 15 + 0.011 mm and deburr.

If the sealant on the grub screws in the clevis ends or on the rivet heads is missing or damaged, inspect interior of the V-strut legs for presence of moisture or corrosion. a.

Remove sealant from the grub screws in the clevis ends and, if damaged, from the rivet heads.

b.

Unscrew and remove the grub screws from the clevis ends and inspect the inboard face of the grub screws for corrosion deposits, corrosion marks and moisture. If any of the above conditions are found, do not reinstall the V-strut. Instead, send it to MEB for further evaluation.

BO 105 CHAPTER 11 Page 80

_ _ _ _ _ _ _ _ _ _ _ _ _ MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

If the condition of the grub screw does not clearly indicate the presence of corros ion and/or moisture, examine the interior of the V-strut legs for corrosion and moisture, using a borescope in accordance with step e.

d.

If there is no evidence of corrosion products, corrosion marks or moisture on the inboard fa ce of the grub screw, insert a piece of wire (approx; 3 mm dia.) through the grub screw hole to check whether the inside of the V-strut leg is clear or whether it contains a plug made from sealing compound (see figure 11-34A).

e.

1)

If there is no plug and the presence of corrosion and moisture can definitely be ruled out, the V-strut can be reinstalled following represervation according to step g. and subsequent sealing of the grub screws and, if necessary, the rivet heads.

2)

If a plug is present, examine the interior of the V-strut leg for corros ion and moisture using a borescope in accordance with step e.

Inspection using borescope. NOTE

o If this inspection cannot be performed because a borescope is not available, the V-strut must not be reinstalled. Instead, it must be sent either to MBB or to an aircraft service facility having the appropriate test equipment. o The grub screw hole can accomodate borescopes with insertion tube diameters up to 4.5 mm. The size of the grub screw hole can be increased from M6 to M8 to accomodate borescopes up to 6 mm in diameter. It is not permitted to use either drilling or cutting fluids when drilling and tapping the holeo The original grub screw shall be replaced by a DIN913-M8X8-A2-70 grub screw.

1)

If a plug made from sealing compound is present in the V-strut leg, use a piece of wire (approx 3 mm dia.) to push it approx. 100 mm further inward (see figure 11-34A). If the plug cannot be moved, thus preventing this inspection from being performed, do not reinstall the V-strut. Instead, send it to MBB for further evaluation.

2)

Using borescope, examine interior of V-strut leg for corrosion and moisture as shown in figure 11-34A. a)

If moisture or corrosion is detected, do not reinstall the V-strut. Instead, send it to MBB for further evaluation.

BO 105 CHAPTER 11 Page 80A

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b)

If neither moisture nor corrosion has been detected, the V-strut can be reinstalled after represervation according to step g. and subsequent sealing of the grub screws and, if necessary, rivet heads.

f.

Seal the rivet heads as necessary. First degrease rivet heads and adjacent areas with MEK (CM 217) and then seal off with silicone rubber (CM 619) as shown in figure 11-34B.

g.

Represerve the V-strut, using corrosion preventive compound (CM 513) . NOTE

o The corrosion preventive compound (CM 513) retrieved from the V-strut after the reaction time can be reused after it has been filtered. o Corrosion preventive compound (CM 513) is compatible with every corrosion preventive compound used so far during the production of the transmission mounting V-strut. If represervations were carried out by the operator in the meantime, using his own corrosion preventive compounds, he must check the compatibility of corrosion preventive compound (CM 513) with that present in the V-strut at the time of represervation. If this is not possible, it is recommended that the V-strut be flushed of all corrosion preventive compound using MEK (CM 217) and then represerved with corrosion preventive compound (CM 513) .

1)

Fill each leg of the V-strut through the grub screw bore with 1/4 litre of corrosion preventive compound (CM 513) .

2)

Clean appropriately-sized grub screws with MEK (CM 217) and screw them in until f1ush. Shake and turn V-strut to wet its entire inner surface with the corrosion preventive compound.

3)

Prop up V-strut on its clevis ends so that the corrosion preventive compound col1ects in these ends.

4)

Wait several minutes to allow corrosion preventive compound to act on these ends, then turn the V-strut onto its apex end and wait several minutes to allow the corrosion preventive compound to act here too. Subsequently, unscrew and remove the grub screws and pour out the corrosion preventive compound.

5)

Prop up V-strut vertically on its clevis ends so that the grub screw holes face down and allow the corrosion preventive compound to dry for 24 hours at room temperature. Leave grub screw holes open during the drying process.

6)

Brush-coat appropriately-sized grub screws with locking compound (CM 621) and screw them into mating bores until flush. Degrease grub screws and adjacent areas with MEK (CM 217) and seal off with silicone rubber (CM 619) as shown in figure 11-34B.

BO 105 CHAPTER 11 Page SOB

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - -_ _ MAINTENANCE MANUAL MBB - BO 105

Plug made of sealing compound

Use wire to push sealing compound plug approx. 100 mm ¡nte the tube

...

approx. JO mm ..._ ~ ~

"

Inspect this area with borescope fer corros ion and the remaining visible area lor moisture

100507

Figure 11-34A

Inspection using borescope

BO 105 CHAPTER 11

Page

aoc

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

_ _ o

I

! I

"

I

I

/

I

~~

Grub screw

'~ Degrease sealing area with MEK(CM 217) and seal with silicone rubber (CM 619)

......

lo;"

Degrease rivet and adjacent area with MEK (CM 217) and seal with silicone rubber (CM 619)

Configuration 1

Configuration 11

100508

Figure 11-34B

BO 105 CHAPTER 11

Page 800

Sealing of rivet heads and grub screws

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 52

Installation - transmission mounting V-struts

Special tools: Guide sleeve Guide sleeve Pushing-out and pressing-in tool

105-10151 W1 105-10151 W2 1121-10151 W3 or 105-10151 W3

o Install transmission mounting V-struts with the long leg aft and with the identification plates on lower end of short leg facing outboard.

NOTE

o When reinstalling the removed transmission mounting V-struts (1 and 2) to the same mating flange on the transmission, reuse removed shims (7). 1.

Place transmission mounting V-struts (1 and 2, figure 11-31) into installation position. NOTE

Step 2. shall only be accomplished upon installation of new transmission mounting V-struts or new mating flange.

2.

Measure play between transmission mounting V-strut fitting (8) and rnating flange (16) on transrnission. If play exceeds 0.05 mm, shirn both sides equally.

3.

Connect guide sleeve 105-10151 W1 (17) to bolt (3), coat with grease (CM 101) and insert bolt in aft direction through transmission flange (16), shirns (7) and transrnission mounting V-strut fitting (8).

4.

Rernove guide sleeve 105-10151 W1 (17). Install bolt (3), washer (6) and nut (5), but do not torque at this time.

5.

Connect guide sleeve 105-10151 W2 (18) to bolt (10) and coat with grease (CM 101) .

6.

Using tool 1121-10151 W3 or 105-10151 W3, connect transrnission mounting V-strut clevis (9) to rnating deck fitting (14) with bolt (10), nut (13) and washer (11). Tighten nut (13) as follows: Torque nut to at least 8 Nrn and secure with cotter pino If the cotter pin cannot be inserted at this torque valve, advance nut until it can be inserted. If this means torqueing above 12 Nm, use another nut and repeat torque procedure.

BO 105 CHAPTER 11 Page 81

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 7. Torque nut (5) and safety with split pin (4). 8. Spray corros ion preventive cornpound (CM 508) on transrnission rnounting strut clevis (9). 9. Lower rnain transrnission and rernove hoistingdevice. 10. Install following cornponents on transrnission rnounting V-struts (viewed in direction of flight) : a.

Install clarnps for snow deflector, guard plate and support plateo

b.

Install bearing bracket of rnixing lever assembly and connect to hinged support with attaching hardware (refer to chapter 41).

11. Install the following parts on the RH transrnission rnounting V-strut (viewed in direction of flight) : a.

Instal1 rotor brake hose line free of stress to transrnission rnounting V-strut, using clarnps. Connect hose line to brake housing.

b.

Instal1 oi1 cooler support bracket.

c.

Insta1l rarn air duct (rarn air ventilation) if installed, according to chapter 63.

d.

Insta11 air baffle (not insta1led in combination with rarn air venti1ation systern) .

12. Bleed rotor brake systern according to chapter 12. 13. Insta11 rnain rotor blades according to chapter 14. 14. Insta1l engine cowling according to chapter 22.

* 11 - 53

D r i ves h a f t

11 - 54

Rernoval - drive shaft

CAUTION

PROTECT DRIVE SHAFT WITH SUITABLE MATERIAL TO PREVENT DAMAGING IT DURING REMOVAL.

1.

Rernove engine cowling.

2.

Rernove half shells of firewall assy.

3.

If necessary, disconnect N2 Teleflex cable frorn quick-disconnect on firewall.

4.

Rernove forward firewall and bellows if necessary.

5. Loosen screws (3, figure 11-35) and washers (4) and rernove drive shaft (1) together with thrust plate (5). BO 105 CHAPTER 11 Page 82

Revision 5

---..;".,.----------MBB HELICOPTERS - - - - - : - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

*

* * * * *

* * * * *

* *

3

11:161Nm

*

I

* * * *

Configuration I

* * * *

* * *

7

* * *

*

3

112~161Nm I

* *

Configuration II ~

see reference at installation

~

Modified by SB 60-54 or S/N 551 and subsq. For additional configuration, see figure 61-9.

1 2 3

600071-01

Drive shaft Engine drive shaft BoU

* * * * * * * *

4 Washer Thrust plate 6 Main transmission drive flange 7 Frame connecting hardware

5

* *

*

* * * * * * *

* *

* *

*

Figure 11-35

Revision 5

* *

Removal and installation - drive shaft BO 105 CHAPTER 11 Page 83

MAINTENANCE MANUAL BO 105

11 - 55

INSPECTION - DRIVE SHAFT

A-Configuration I (see figure 11-35) 1. Clean outer circumference of drive shaft, using dry cleaning solvent (CM 202) and a suitable cloth. Do not allow solvent to enter the drive shaft and get into the space between the diaphragms.

2. Inspect shank of shaft for mechanical and corrosion damage. a.

Sha~ged damage such as nicks, grooves, scratches of up to a depth of 0.40 mm and slight traces of corrosion can be polished out, using polishing cloth 400/600. Remove shaft ifdepth Iimitis exceeded.lt is not necessary to polish out smooth-edged pressure marks.

b. Round out reworkedarea into surrounding undamaged area with a transition radius of at least 10 mm. c. Clean reworked areas with dry cleaning solvent (CM 202) and apply lacquer without any further preparatory treatment. Oamaged lacquer may be touched up with: Heresite paint 8-12 (CM 424), drying time: at least 1 hour at 95 oC, or single layer-laquer (CM 443),

r

drying time: at least 2 hours at 65 oC

Visually inspeet outside of diaphragms (see figure 11-36) for mechanicaJ, corrosion and coating damage. a. In case of coating damage (e.g.lacquer-cracks) inspeet diaphragm surface with magnifying glass and contaet an approved ECD-service station, regarding further measures. b. If scratches or nicks in the diaphragm surface extend to the base material, discard shaft. When assessing such a damage, careful distinetion must be made between metal and silver-coloured primer. The use of magnifying glass is advised. c. Polish out nicks and scratches on the outer edges of up to depth of 0,4 mm and remove Iight corrosion using polishing cloth 400/600. Touch up paintwork in accorclance with step 2. d. Ifthe diaphragm surface is buckled, the shaft must be discarcled even ifthepaint is notdamaged. Aaking paint on diaphragm surfaces is an indication of excessive torsion. Shafts with such diaphragms must be discarded.

CHAPTER 11 Page84

Revision 20

MAINTENANCE MANUAL BO 105

NOTE e.

During production, the individual diaphragms are painted silver (CM 473). The finished assembly is subsequently painted on the outside with brown primer and black topcoat. Inspect diaphragm surface for corrosion. A shaft with traces of corrosion in this area must be discarded. When assessing the diaphragm surface, take care that the brown primer is not mistaken for corrosion.

~I '"~I

~

'8'

&

Diaphragm surface

&

Outer edge

o ID

Figure 11-36

Diaphragm, sectional view

4. Deleted

Figure 11-37

Revisíon 21

Deleted

CHAPTER 11 Page 85

o

eurocopter

MAINTENANCE MANUAL SO 105

en EADS CompIIny

5. Visually inspect triangular flanges for mechanical damage and corrosion.

I

a. Use a magnifying glass (1 O-fold magnification) to visually inspect the flanges for cracks. No cracks are permitted. If the visual inspection reveals any cases where it is not clearwhether a crack or a scratch has been found, send the drive shaft to the manufacturer for specialist examination.

•

b. Visually inspect flanges for fretting corrosion. If corrosion pits are deeper than 0.15 mm, send shaft to manufacturer for rework. Remove light pitting to 0.15 mm in depth, using 600 grit abrasive cloth.

•

c.

Visually inspect flanges for grooving. Polish out grooves up to a depth of 0.2 mm, using polishing cloth 600. If grooves are deeper, return drive shaft to ECD or manufacturer for further inspection and assessment.

d. Treat reworked surface, using corrosion preventive compound. Refer to step 11. 6. Visually inspect thrust plates (5, figure 11-35) for damage such as fretting corrosion and grooving. Polish out grooves up to a depth of 0.2 mm, using 600 grit abrasive cloth; replace thrust plate if grooves are deeper. Polish out fretting corrosion to 0.15 mm deep with 600 grit abrasive cloth. 7.

Check shaft runout. Support both tube ends in veeblocks and slowly rotate shaft by hand. Shaft runout must not exceed 0.55 mm. Discard any shaft with greater shaft runout.

8.

Inspect drive shaft for damaged, separated or missing placards. Replace damaged or separated placards as follows: a. Apply heatto placard, using a hot air gun, and remove placard from drive shaft with a non-metallic spatula.

9.

b.

Remove residual adhesive with acetone (CM 203).

c.

Attach new placard to drive shaft.

d.

If placards are missing, c1ean drive shaft with acetone (CM 203) and attach new placards at appropriate locations.

Inspect anchor nuts for condition and secure connection to flange. a.

Replace loose rivets in accordance with step c.

b.

Check anchor nuts for secure installation. It must not be possible to screw in theflange bolts all the way by hand. Replace non-Iocking anchor nuts in accordance with step c., and replace other damaged nuts (corroded, deformed threads, etc.).

CHAPTER 11 Page 86

Revision 24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Drive shaft

DETAlL

A

*

Configuration 1

--.·A )

¡. ~

--r t

~

.

t

1 Flange 2 Blind rivet 3 Anchor nut

Drive shaft Configuration 11

Configuration 1 ~ ~

Anchor nut LN29679 AM8 Blind rivet MS20601 MP4 W2 or MS20601 MP4 W3, according to flange thickness

Configuration 11 600151-01

~

~

Figure 11-38 c.

Anchor nut NS202721-M8 Blind rivet MS2ü427M4-G-5

Anchor nut - drive shaft

Replace anchor nuts as follows: CAUTION

o DRY ORILL TO PREVENT CUTTING OIL OR LUBRICATING OIL FROM ENTERING INSIDE THE SHAFTS OR COUPLINGS. o SEAL THE SHAFT BORE WITH A SUITABLE CORK OR PLASTIC PLUG. o COVER THE DIAPHRAGMS UNDERNEATH THE ANCHOR NUTS TO BE ORILLED OUT, SO THAT THEY CANNOT BE DAMAGEO BY THE DRILL.

1)

Drill out blind rivets with a 3.3 mm dia. drill.

2)

Check anchor nuts for satisfactory securing effect prior to installation. It must not be possible to screw in the flange bolt all the way by hand.

3)

Rivet the anchor nut (3, figure 11-38) to flange. Use only the riveting tool designed for that type of rivet. Check anchor nut for snug fit.

Revision 5

BO 105 CHAPTER 11 Page 87

* * * * *' * * * * * * * * * * * * * * * * * * * * *

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

* 10. Inspect bolts (3) for mechanical and corros ion damage, cracks and wear. If there are signs of any one of the above damage conditions, replace the bolts. 11. Corrosion prevention of flanges and diaphragms.

* CAUTION

* * * * *

* * * * * * *

a. Dip shaft end, flange and diaphragms into anti-corrosion agent (CM 512) diluted with 10% tetrachloroethylene (CM 205). Drain off excess anti-corrosion agent. b. Evenly distribute anti-corrosion agent over inner surfaces of diaphragms with clean, compressed airo Use spray nozzle U7945 (Bendix) to spray the air; The air pressure should be 6.5 - 8 bar. The drying time is 8 hours at room temperature or 15 minutes at 65 OC.

* * *

* * * * * * * * * * * * * * * * * * * * * * * * * * * * *

ANTI-CORROSION AGENT (CM 512) CONTAINS PERCHLOROETHYLENE. ITS USE SHOULD BE CONFINED TO WELLVENTILATED AREAS ANO SUBJECT TO THE PRECAUTIONS PERTAINING TO CHLORINATED SOLVENTS. SOLVENTS USED TO THIN AND REMOVE CORROS ION PREVENTIVE COMPOUNO, AS WELL AS ALKALINE CLEANERS, SHOULD ALSO BE USEO ONLY IN WELLVENTILATED AREAS.

B. CONFIGURATION 11 (see figure 11-35) CAUTION

THE DRIVE SHAFT MUST NOT BE DISASSEMBLED NOR THE FRAME CONNECTING HARDWARE DISTURBED E.G. UNSCREWED OR TIGHTENEO. DISASSEMBLY OF THE DRIVE SHAFT OR DISTURBANCE OF THE FRAME CONNECTING HARDWARE WOULD REQUIRE REPLACEMENT OF THE DRIVE SHAFT.

1.

Inspect frame connecting hardware for movement of slippage marks. Damaged slippage marks are an indication of torsion. In this case, send drive shaft to manufacturer for assessment.

2.

Inspect drive shaft for cracks, other mechanical damage, corros ion and damaged surface protection. a. Replace drive shaft if cracked. b. Using 400/600 grit cloth, polish out other mechanical damage and corros ion provided damage is within the damage and repair limits specified in figure 11-38A. Round of reworked areas with a transition radius of at least 10rnm. c. Prime reworked areas and areas where surface protection has been damaged, using two-component wash primer (CM 472) and apply topcoat (CM 473) .

3.

Inspect anchor nuts for condition and secure installation to flange. a. Replace loose rivets according to paragraph A, step 9.c ..

BO 105 CHAPTER 11 Page 88

Revision 5

MAINTENANCE MANUAL BO 105 b.

Check anchor nuts for secure installation. It must not be possible to screw in the flange bolts all the way by hand. Replace non-Iocking anchor nuts in accordance with paragraph A, step 9.c., and replace other damaged nuts (corroded, deformed threads etc.).

4. Visually inspect thrust plates (5, figure 11-35) for damage such as fretting corrosion and grooving. Polish out grooves up to a depth of 0.2 mm, using 600 grit abrasive cloth; replace thrust plate if grooves are deeper. Polish out fretting corrosion to 0.15 mm deep with 600 grit abrasive c1oth. 5.

Inspect bolts (3) for mechanical and corrosion damage, cracks and wear. If there are signs of any one of the aboye damage conditions, replace the bolts.

6.

Use a magnifying glass (10- fold magnification) to visually inspect the flanges for cracks. No cracks are per-I mitted. If the visual inspection reveals any cases where it is not clear whether a crack or a scratch has been found, send the drive shaft to the manufacturer for specialist examination.

Revision 24

CHAPTER 11 Page SSA

O~~pter

MAINTENANCE MANUAL 80105

Frame cannecting hardware

~I

o,....

J:

~,o o al

TYPE OF DAMAGE

DAMAGE AND REPAIR L1MITS

m

ZONE2

ZONE3

~

[illJ

ZONE 4 drive shaft inner surface

Mechanical

0.025 mm befare and after repair

0.125 mm befare and after repair

0.125 mm befare and after repair

0.375 mm befare and after repair

Carrosian

Na carrosian pitting an surface

0.125 mm befare and after repair

0.125 mm befare and after repair

0.25 mm befare and after repair

Maximum rewark area

&

65mm 2

&

Number af rewark areas

1 per frame

Depth limit af edge dents and nicks

0.025 mm

0.25 mm

0.25 mm

ZONE 1

NOTE

& &.

1. 2. 3. 4.

30mm2

160 mm 2

D

160 mm2

0.625 mm

Cracks an drive shaft are nat permitted. Distance between rewark areas must nat be less than 25.4 mm. Na rewark is permitted within 12.5 mm af the frame cannecting hardware. Flange faying surface must be free from raised areas.

Figure 11-38A Damage and repair Iimits - drive shaft

CHAPTER 11 Page 888

Revisian 24

EUROCOPTER

11 - 56

MAINTENANCE MANUAL BO 105

Installation - drive shaft

Special tools: Torque kit

105-60701 W6 If a new drive shaft is to be installed on configuration I engine with permanently installed stub shaft (refer to Chapter 61, fig. 61-9), check fitting dimension of the drive shaft and redetermine if necessary, in accordance with Chapter 61-7.

NOTE

1. Coat flange of engine stub shaft (2, figure 11-35) and main transmission drive flange (6) with corrosion preventive compound (CM 505).

CAUTION

DO NOT DAMAGE ORIVE SHAFT DURING INSTALLATION.

2. Coat drive shaft (1) f1anges and thrust plate (5) with corrosion preventive compound (CM 505). The attaching hardware at all three flange holes on transmission input drive shaft flange must be of the same configuration.

NOTE

3.

Fit drive shaft (1) and thrust plate (5) in position and connect to engine stub shaft flange with screw (3), P/N 105-60701.16 or P/N 105-60701.17 and one washer (4) under each screw.

4.

Install screws (3) and washers (4) on transmission input drive shaft f1ange and note the following: a.

Configuration I drive shafts bearing a thrust plate require two washers LN 9016-08K to be installed on bolts 105-60701.16 or 105-60701.17.

b. Configuration 11 drive shafts bearing a thrust plate require only one washerLN 9016-08Kto be installed on bolts 105-60701.16 or 105-60701.17. c.

If the thrust plate is not installed, bolts 105-60701.15 shall be installed togetherwith only one washer LN 9016-o8K.

5. Tighten screWS (3), using tool P/N 105-60701 W6. Fortorque, see figure 11-35. 6. Mark position of heads of screws (3) relative to corresponding flanges with sealing, locking and retaining compound (CM 620).

Revision 18

CHAPTER 11 Page 89

I

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

----- -

~r----I

1

3---+-

VIEwA El00012-01

~

* ~

*

1 Handle with adjustable claw 2 Drive shaft 3 Torque wrench with insert

Only configuration

Figure 11-39

1

drive shaft is shown.

Application - torque kit 105-60701 W6

7.

Install firewall assy and bellows, if removed.

8.

Attach half-shells to firewall assy with quick-release fasteners and to main transmission with clamp.

9.

If previously disconnected, reconnect N2 Teleflex cable and check setting in accordance with chapter 65.

10. Install engine cowling; refer to chapter 22. BO 105 CHAPTER 11 Page 90

Revision 5

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R epI a e e m e n t o f s h a f t t a i 1 r o t o r d r i v e

s e a 1

Special tools: Split ring Tube Drift Pusher screws

1xs6 1xs6 1xs6 1xs6

136 136 112 131

951 952 756 399

1. Remove engine cowling.

2. Remove forward short drive shaft and, depending on the configuration, coupling of tail rotor drive; refer to chapter 32. 3. Remove brake caliper; refer to chapter 12. 4. Remove connecting flange (11, figure 11-40) together with brake disk (9); refer to chapter 12. 5. Remove bolts (5) and washers (4). 6. Press cover (3) from transmission housing, using pusher screws 1xs6 131 399.

7. Remove spring ring (7) and O-ring (2) from cover (3). Discard O-ring (2). 8. Position cover (3) on split ring 1xs6 136 951 and tube 1x56 136 952 and drive out shaft seal (6), using a plastic mandrel. 9. Apply grease (CM 101) to outer circurnference of new shaft seal (6), press into cover (3), using drift 1xs6 112 756 and insert spring ring (7). For relative position of spring ring to cover, see figure 11-40. 10. Coat new O-ring (2) with grease (CM 101) and fit into cover (3). 11. Position cover (3) on bearing bushing (1) and fasten with bolts (5) and washers (4). Tighten bolts (5) to specified torque load. 12. After installation, coat split line and bolt heads with two-component finishing lacquer (CM 437) . 13. Apply grease (CM 101) to splines of connection flange (11). 14. Install connecting flange (11) together with brake disk (9) according to chapter 12. 15. Install forward drive shaft, and, depending on the configuration, coupling of tail rotor drive according to chapter 32.

BO 105 CHAPTER 11 Page 91

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 16. Perform ground run in accordance with Chapter 105, and visually inspect tail rotor drive for leakage. 17. Install engine cewling.

9

!a-10NmI16

67 -1

LY1'

5 4

1 14

"

2

100466

6

6

1 2 3 4 5 6 7

Bearing housing O-ring Cover Washer Belt Shaft seal Spring ring 8 Screw

Figure 11-40

EO 105 CHAPTER 11 Page 92

Use spring ring (7) only in combination with cover (3) P/N 4619 301 042.

9 10 11 12

Brake disk Screw Connecting flange O-ring 13 Screw 14 Locking plate 15 Coupling - tail rotor drive 16 Main transmission

Replacement of shaft seal - tail rotor drive

EUROCOPTER

MAINTENANCE MANUAL 80 105

11 - 58

D r i v e a s s e rn b 1 Y - configuration 1 (Drive flange bolted to freewheel outer shaft)

11 - 59

Replacernent of shaft seal - drive assembly (configuration 1)

Special tools: Support Drift Drift Socket wrench Puller

1x56 1x56 1x56 1x56 1x56

136 112 103 136 136

362 756 766 232 286

1.

Rernove drive shaft; refer to paragraph 11-54.

2.

Rernove freewheel housing (7, figure 11-41) as follows: a.

Rernove locking plate (14) frorn screw (6).

b.

Rernove screws (1) together with washers.

c.

Insert socket wrench 1x56 136 232 in puller 1x56 136 286 and fasten puller to transrnission housing of drive assy, using 3 screws.

d.

Loosen screw (6).

e.

Rernove screw (6) and drive flange (4), using puller. Discard O-ring (5).

f.

Rernove freewheel housing (7). Discard O-ring (8).

3.

Rernove circlip (9). Rernove shaft seal (12) frorn freewheel housing (7), using drift 1x56 112 756 (10) and support 1x56 136 362 (11).

4.

Apply grease (CM 101) to outer circurnference of new shaft seal (12) and fit into freewheel housing (7), using drift 1x56 103 766. Insert circlip (9) •

5.

Apply grease (CM 101) to new O-ring (8) and fit O-ring into freewheel housing (7).

6.

Install freewheel housing (7): a.

Slide freewheel housing (7) onto freewheel outer shaft (13) by turning it slightly, but avoid darnaging the sealing lip of shaft seal (12).

b.

Apply grease (CM 101) to new O-ring (5) and fit into annular groove of screw (6).

BO 105 CHAPTER 11 Page 93

EUROCOPTER

MAINTENANCE MANUAL 80105

c. position drive flange (4) against freewheel shaft (13) and secure with screw (6). d. Insert seocket wrench 1x56 136 232 (2) in puller 1x56 136 286 (3), position puller over drive flange and fasten to transmision housing, using 3 screws. e. Tighten screw (6) to specified torque load (see fig. 11-42). The screw must mot protrude from drive flange (4). f. Look through opening in puller to ensure that locking plate (14, fig. 11-41) can be inserted to engage with screw (6). If necessary, loosen screw (6) and tighten with new torque, observing the tolerance limits. g. Remove puller and secure freewheel housing (7) to transmission housing, using screws (1) "and washers. Tighten screws (1) to specified torque load (see fig. 11-42). h. Apply two-component finishing lacquer (CM 437) to split linbe and screw load heads. i. Insert locking plate into screw (6, fig. 11-41). 7.

Install locking shaft according to paragraph 11-56.

8.

Perform ground run in accordance with Chapter 105 and visually inspect faying surface for leakege.

9.

Install engine cowling according to chapter 22.

11 - 60 Removal - clutch assemlby (configuration I) Special tools: Counter support Puller Puller or Puller Socket wrench Socket wrench Support Drift Drift Puller

1x56 122 232 1x56 122 209 1x56 122 271 1x56 1x56 1x56 1x56 1x56 1x56 1x56

122 136 136 136 112 103 136

270 232 231 362 756 766 286

* 1. Rernove drive shaft, refer to para. 11-54. * 2.

Rernove freewheel housing (7, fig. 11-41) according to paragraph 11-59, step 2.

BO 105 CHAPTER 11 Page 94

Revision 14

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

3

2

#-----10

IH---7

""----12 4---11

100268

Screw 2 Socket wrench 1x56 136 232 3 Puller 1x56 136 286 4 Drive flange 5 O-ring 6 Screw 7 Freewheel housing 1

Figure 11-41

8 9

10 11 12 13 14

O-ring Circlip Drift 1x56 112 756 Support 1x56 136 362 Shaft seal Freewheel shaft Locking plate

Removal and installation - shaft seal

BO 105 CHAPTER 11 Page 95

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

r-tlH-t--12113.5.16.5 Nm rl--1f;!---

-'~-10

19

9

16

8

18-~~

2

3

15

4

5

I

11

198·102 Nm I

6

14 13

100465

1 Screw 2 Freewheel outer shaft 3 Circlip 4 Freewheel housing 5 Shaft seal 6 Lock ring 7 Drive flange with locking plate 8 O-ring 9 Screw 10 Lubricating pipe

11 12 13 14 15 16 17 18 19 20

Locking plate Shaft nut Washer Deep groove ball bearing Clutch assembly Deep groove ball bearing O-ring Bearing bushing Driving pinion shaft Thrust plate

Figure 11-42 Drive assy with clutch assembly Configuration 1 with drive flange bolted to freewheel outer shaft

BO 105 CHAPTER 11 Page 96

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3.

Extract locking plate (11, figure 11-42) from shaft nut (12), using puller lxS6 122 271.

4.

Remove shaft nut (12), using socket wrench lxS6 136 231 and detach washer (13).

5.

Fasten puller lxS6 136 286 to transmission housing with 3 screws and remove freewheel outer shaft (2) together with deep grooveball bearings (14 and 16) and clutch assembly (15), using the puller.

6.

If deep groove ball bearing (16) remains on the driving pinion shaft (19), leave it there. If it remains in the freewheel outer shaft, proceed as follows: a.

Position support 1xS6 136 362 over freewheel outer shaft (4, figure 11-43) .

b.

Attach drive flange (7) to freewheel outer shaft (4), using screw (6) •

c.

Position pu11er lx56 122 209 behind deep groove ball bearing (3), install counter support lxS6 122 232 and extract deep groove ball bearing (3) from freewheel outer shaft (4).

o

2 ---+-+---y...

3

---+--+-.......

1 2 3 4 5

Counter support 1xS6 122 232 Puller lxS6 122 209 Deep groove ball bearing Freewheel outer shaft Support lxS6 136 362 6 Screw 7 Drive flange

100441

Figure 11-43

Removal of deep groove ball bearing from freewheel outer shaft BO 105 CHAPTER 11 Page 97

- - - - - - - - - - . - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 CAUTION

WHEN REMOVING THE CLUTCH ASSEMBLY FROM THE FREEWHEEL OUTER SHAFT, TAKE PARTICULAR CARE NOT TO PRESS OUT ANY OF THE SPRAGS. THIS PRECAUTION DOES NOT APPLY IF THE CLUTCH ASSEMBLY IS BEING REMOVED BECAUSE ITS IN-SERVICE LIMIT HAS BEEN REACHED.

7. Remove thrust plate (20, figure 11-42) and clutch assembly from free wheel outer shaft (2).

* * *

8. Discard clutch assemblies which have reached their in-service limitation. Inspect clutch assemblies P/N 4638 202 007 for condition; refer to paragraph 11-67. 9. Remove and discard shaft seal (5). Refer to para 11-59, step 3. 10. Clean all removed parts, except for the clutch assembly, with dry cleaning solvent (CM 202) and dry with compressed airo 11. Inspect drive flange: a.

Inspect teeth for galling. Polish out lightgalling with abrasive cloth. If galled to the extent that they contact the bottom land of the freewheel outer shaft, discard drive flange.

b.

Inspect drive flange (7) for cracks (magnetic particle inspection per MIL-STD-1949 or penetrant inspection per MIL-STD-6866). Drive flange must be totally free of cracks.

* 12. Inspect input pinion for condition; refer to paragraph 11-67, point 7.

* * 13. Inspect free wheel outer shaft for condition; refer to paragraph 11-67, point 8. *

100289

Figure 11-44 BO 105 CHAPTER 11 Page 98

Potential crack formation areas Revision 2

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 61

Installation - clutch assembly (configuration 1)

Special tools: Puller Mounting ring Socket wrench Puller Socket wrench Drift CAUTION

1xS6 1xS6 1x56 1x56 1x56 1x56

122 136 136 136 136 103

271 428 231 286 232 766

o ENSURE THAT THE CLUTCH ASSEMBLY IS POSITIONED CORRECTLY BY INSERTING IT INTO THE FREEWHEEL OUTER SHAFT SO THAT THE FLANGED END OF THE CLUTCH OUTER GAGE FACES UP. SEE ARROW IN FIG. 11-45. o WHEN THE CLUTCH ASSEMBLY IS INSTALLED IN THE FREEWHEEL OUTER SHAFT, EXTREME CARE MUST BE TAKEN NOT TO PRESS OUT ANY OF THE SPRAGS.

1.

Insert clutch assembly (15, figure 11-42) into freewheel outer shaft (2), using mounting ring 1x56 136 428. Staked side must point upward; refer to figure 11-45.

2.

If deep groove ball bearing (16, figure 11-42) has not remained on driving pinion shaft (19) during removal, heat deep groove ball bearing (16) to approx. 35 oC and slide it onto driving pinion shaft (19).

3.

Apply grease (CM 101) to thrust plate (20) and insert it into freewheel outer shaft (2) with the oil grooves facing upward.

4.

Heat freewheel outer shaft (2) to approx. 85 oC, and, turning it counterclockwise, slide it onto driving pinion shaft (19).

5.

Slide washer (13) over lubricating pipe (10). Install shaft nut (12) and tighten to specified torque, using socket wrench 1x56 136 231.

6." Install locking plate (11) so that the broad recesses are positioned above the milled surfaces of shaft nut (12). Drive locking plate (11) on shaft nut (12), using puller 1x56 122 271. The tabs of the locking plate (11) must fully lock around the shaft nut (12). 7.

Lubricate outer circurnference of new shaft seal (5) with grease (CM 101), then press it into freewheel housing (4), using drift 1x56 103 766. Install lock ring (6).

8.

Lubricate new O-ring (17) with grease (CM 101) and insert it in freewheel housing (4).

9.

Install freewhee1 housing (4) according to paragraph 11-59, step 6.

BO 105 CHAPTER 11 Page 99

HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

--------------MBB

10. Perforrn functional test of clutch assembly according to paragraph 11-66. 11. Install drive shaft according to paragraph 11-56. 12. Perforrn ground run in accordance with chapter 105 and visually inspect drive assembly for leakage. 13. Install engine cowling according to chapter 22.

/11"..----2

."~~--3 2

__4

""",,,~

~'----5

I-----,d' ~~'-----6

100~45.1

~

Insert clutch assembly in freewheel shaft so that the flanged end of the clutch outer cage is facing up (see arrow) .

~

The inner cage of the clutch assembly is arranged according to the configuration of the clutch assernbly. 1 Mounting ring 1x56 136 428 2 Freewheel shaft 3 Clutch assembly Figure 11-45

BO 105 CHAPTER 11 Page 100

Circlip Deep groove ball bearing 6 Washer

4

5

Installation of clutch assembly in freewheel shaftConfiguration I

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 62

D r i vea s s e m b 1 Y configuration II (Drive flange is integral with the freewheel shaft)

11 - 63

Replacement of shaft seal - drive assembly (configuration II)

Special tools: Support Drift

1x56 136 915 1x56 103 765

1. Remove drive shaft¡ refer to paragraph 11-54. 2. Remove freewheel shaft (3, figure 11-46)¡ refer to paragraph 11-64, steps 2. through 6. 3. Remove shaft seal (6) from cover (5), using support 1x56 136 915 and a plastic mandrel. 4. Apply grease (CM 101) to outer circumference of new shaft seal (6) and fit into cover (5), using drift 1x56 103 765. 5. Coat new O-ring (13) with grease (CM 101) and fit into cover (5). 6. Install cover (5) to transmission housing with screws (1) and washers. Tighten screws (1) to specified torque load. 7. Install freewheel shaft¡ refer to paragraph 11-65, steps 4. through 11. 8. Install

dri~e

shaft¡ refer to paragraph 11-56.

9. Perform ground run in accordance with Chapter 105 and visually inspect drive assembly for leakage. 10. Install engine cowling¡ refer to chapter 22.

BO 105 CHAPTER 11 Page 101/102

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 64

Removal - clutch assembly (configuration 11)

Special tools: Socket wrench Support Orift Puller or Puller Thrust piece Puller Counter support

1x56 1x56 1x56 1x56

136 136 103 122

231 663 765 271

1x56 lx56 1x56 1x56

122 136 122 122

270 916 209 232

* *

'-l1'Hi-- 10 '--#+t-- 9

14

!+H--12

16 -ifjl::¿2~~~~~~~-11 17

13

18

_...AY/...,

118-10 Nm

100464

1 2 3 4 5

6 7 8 9

I

Screw, washer Thrust plate Freewheel shaft Clutch assembly Cover Shaft seal Oeep groove ball bearing Washer Shaft nut

13.5-16.5 Nm

10 11

12 13 14 15 16 17

18 19 20

Locking plate O-ring Sealing washer O-ring Oriving plnlon shaft Lubrication pipe Shim Oeep groove baH bearing Bearingbushing Circlip Shim (corrugated spring washer)

Figure 11-46 Orive assy with clutch assembly Configuration 11 - drive flange integral with freewhee1 shaft

Revision 3

BO 105 CHAPTER 11 Page 103

* *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS l.

Remove drive shafts according to paragraph 11-S4.

lA. If the freewheel outer shaft has a retaining groove, remove circlip (19, fig. 11-46). 2.

Remove sealing washer (12) using pu11er 1xS6 122 209 and discard O-ring (11).

* * 2A. Remove shim (20) from freewheel shaft (3). Shim (20) is only installed if circlip (19) secures sealing washer (12). * * 3.

Remove locking plate (10) from shaft nut (9), using puller 1xS6 122 271 or 1xS6 122 270.

4.

Remove shaft nut (9), using socket wrench 1xS6 136 231 and detach washer (8).

5.

Slide thrust piece 1xS6 136 916 over lubrication pipe (15). Remove freewheel shaft (3) together with deep groove ball bearing (7) and clutch assembly (4) from driving pinion shaft (14), using a three-arm puller.

6.

Remove screws and washers (1) and detach cover (5). Discard O-ring (13).

7.

deleted

8.

If deep groove ball bearing (17) remains on the driving plnlon shaft (14) leave it there. If it remains in the freewheel shaft (3) proceed as follows:

* *

*

a.

position support 1xS6 136 663 (4, figure 11-47) over freewheel shaft (5).

b.

Locate puller 1xS6 122 209 behind deep groove ball bearing (3), position counter support 1xS6 122 232 and extract deep groove ball bearing (3) from freewheel shaft (5); refer to figure 11-47.

2 --+...;-----1

3--+-'¡-'

4

5

1 2 3 4 5

Counter support 1xS6 122 232 Puller 1xS6 122 209 Deep groove ball bearing Support 1xS6 136 663 Freewheel shaft

110016

Figure 11-47 BO 105 CHAPTER 11 Page 104

Removal of deep groove ball bearing from freewheel shaft

Revision 3

HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105

-------------MBB

CAUT10N

WHEN REMOVING THE CLUTCH ASSEMBLY FROM THE FREEWHEEL OUTER SHAFT, TAKE PARTICULAR CARE NOT TO PRESS OUT ANY OF THE SPRAGS. THIS PRECAUT10N DOES NOT APPLY 1F THE CLUTCH ASSEMBLY IS BEING REMOVED BECAUSE 1TS IN-SERVICE LIMIT HAS BEEN REACHED.

9. Remove thrust plate (2, figure 11-46) and clutch assembly (4) from freewheel shaft (3). 10. Discard clutch assemblies which have reached their in-service limitations.Inspect clutch assemblies p/N 4638 202 007 for condition; refer to paragraph 11-67. 11. Clean all removed parts, except for clutch assembly, with dry cleaning solvent (CM 202) and dry with compressed airo 12. Inspect input pinion for condition; refer to paragraph 11-67, point 7. 13. Inspect free wheel outer shaft for condition; refer to paragraph 11-67, point 8. 11 - 65

Instal1ation - clutch assembly (configuration 11)

Special tools: t-lounting ring Socket wrench Puller l. 2.

*

1x56 136 428 lx56 136 231 1x56 122 271

*

Apply grease (CM 101) to shaft seal (6, figure 11-46) and new O-ring (13) and fit O-ring (13) in cover (5).

*

*

Install cover (5) on transmission housing, using screws (1) and washers. Tighten screws (1) to specified torque load. CAUTION

o ENSURE THAT THE CLUTCH ASSEMBLY IS POS1TIONED CORRECTLY BY INSERTING IT 1NTO THE FREEWHEEL SHAFT SO THAT FLANGED END OF THE FREEWHEEL OUTER CAGE FACES UP. SEE FIG. 11-48.

*

* *

o WHEN INSTALL1NG THE CLUTCH ASSEMBLY IN THE FREEWHEEL OUTER SHAFT, EXERCISE EXTREME CARE NOT TO PRESS OUT ANY OF THE SPRAGS. 3.

Insert clutch assembly (3, figure 11-48) into freewheel shaft (2), using mounting ring 1x56 136 428.

4.

If deep groove ball bearing (17, figure 11-46) has not remained on the driving pinion shaft (14) during removal, heat deep groove ball bearing (17) to approx. 35 oC and slide it onto driving pinion shaft (14).

5.

Apply grease (CM 101) to thrust plate (2) and insert into freewheel shaft (3) with the oil grooves facing upward.

* * Revision 3

BO 105 CHAPTER 11 Page 105

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

100444

1 Mounting ring 1xS6 136 428 2 Freewheel shaft 3 Clutch assembly

Insert clutch assembly in freewheel shaft so that the flanged end of clutch outer cage is facing up (see arrow) .

Figure 11-48

BO 105 CHAPTER 11 Page 106

Installation of clutch assembly into freewheel shaft Configuration II

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

B

E

n

II

)1 ---i

-+--_.-- -

-------,~

110027

o

with the freewheel shaft inserted to full extent, determine dimensions A and B and calculate the length C of the oil tube protruding from the bearing. C

=A-

B

o

Determine dimension O of the sealing washer. O must be 0.1 to 0.2 mm less than A. If O is greater, machine the sealing washer at ~ to obtain the required dimensions.

o

Determine dimension E. E must be at least 0.3 mm greater than C. If not, rework the sealing washer at ~

Figure 11-49

* * *

* * *

Orive assembly - installation position of the sealing washer (without circlip) BO 105 CHAPTER 11

Revision 3

Page 107

*

*

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

*

ENSURE BEFORE INSTALLATION OF FREEWHEEL SHAFT(3), THAT NOT ANY * CAUTION SHIM (20) IS INSTALLED IN ADDITION TO THRUST PLATE (2). * * * 6. Heat freewhee1 shaft (3) to approx. 85 oc and, turning it counter-clock* wise by hand, slide it onto driving pinion shaft (14) until it abuts. * * 7. Fit washer (8) on lubrication pipe (15) with charnfer facing outward. * Thread on shaft nut (9) with milled surfaces facing outward, using socket * wrench 1x56 136 231, and tighten to specified torque, while pressing * freewheel shaft (3) so that it abuts. 8. Align locking piate (10) so that the broad cutouts rest above the milled surfaces of shaft nut (9). Drive locking plate (10) onto shaft nut (9), using puller 1x56 122 271. The tabs of the locking plate (10) must fully lock around the shaft nut (9).

*

* NOTE

Only perform step 9., if sealing washer (12) is not secured with circlip (19).

*

* *

9. Push freewheel shaft (3) in by hand until it abuts in order to remo ve

* possib1e bearing play, and provisionally fit sealing washer (12) without * O-ring into freewheel shaft (3). A gap of 0.1 to 0.2 mm must exist * between the sealing washer and the drive flange. Rework sealing washer if * specified dimensions are not obtained; refer to figure 11-49. * Only perform step 10., if sealing washer (12) is secured with * NOTE circlip (19). * * * 10. Insert shim (20) into freewheel shaft (3). * * 11. Apply grease (CM 101) to new O-ring (11) and install on sealing washer * (12). Insert sealing washer (12) into freewheel shaft (3). If the free-

*

wheel shaft has a retaining groove, install circlip (19) in groove.

*

* 12. Coat split line and screw heads with two-component finishing lacquer * (CM 437) after installation. *

* 13. Functionally test clutch assembly; refer to paragraph 11-66. * **. 14. Install drive shaft; refer to paragraph 11-56. * 15. Perform ground run in accordance with Chapter 105 and visually inspect drive assembly for leakage. *

*

*

16. Install engine cowling; refer to chapter 22.

* 11 - 66

Functional test - clutch assembly

Turn drive flanges of LH and RH clutch assemblies by hand in both directions. When the drive flanges are turned CW, the clutch assemblies must engage. When turned CCW the driveflanges must rotate freely. BO 105 CHAPTER 11 Page 108

Revision 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11 - 67

Inspection - c1utch assembly, drive shaft and free wheel outer shaft

NOTE

Only the clutch assembly p/N 4638 202 007 is affected by this inspection.

CAUTION

DO NOT DISASSEMBLE THE CLUTCH ASSEMBLY. APPLY PROCEDURE 6d. IF A SPRAG HAS BEEN INADVERTANTLY PRESSED OUT DURING INSPECTION OF THE CAGE CUTOUT.

1 Sprag 2 Inner cage 3 Drag strip (not il1ustrated) 4 Energizing ribbon 5 Outer cage 6 Drag clip Figure 11-50

C1utch assembly

Inspect clutch assembly for cracks, breakage, deformation and wear as follows: CAUTION

REJECT THE CLUTCH ASSEMBLY, IF THE FOLLOWING LIMITS ARE EXCEEDED!

l. Drag clip ( figure 11-51) No breakage of drag clip permitted. Maxirnurn permitted wear = one third of the original thickness of drag clip. Min. thickness

= 0.20 mm. 100510

Figure 11-51

Revision 2

Drag clip BO 105 CHAPTER 11 Page 109

- - - - - - - ' - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

2. Energizing ribbon (figure 11-52)

No breakage and deformation of the energizing ribbon permitted.

Figure 11-52 Energizing ribbon

3. Drag strip (figure 11-53)

No breakage of the drag strip permitted.

Maximum permitted wear = 50 % of the original thickness of drag strip. Min. thickness

= 0.35 mm.

100513

Figure 11-53

Drag strip

BO 105 CHAPTER 11

Page 110

Revision 2

fteurocopter

MAINTENANCE MANUAL MBB - BO 105

4. Sprags (figure 11-54)

* * * * * * * * * *

Scuff marks

No visible and perceptible wear in load areas of sprags perrnitted (e.g. no scuff rnarks, scores or grooves perrnitted) .

Outer side of s~rag (free wheel outer shaft): Load patterns on sprag rnust stop 0.8 mm frorn sprag edge. 100515

Inner side of sprag (input pinion) : Load patterns on sprag rnust stop 0.8 mm frorn sprag edge. 100516

CAUTION

DO NOT CONFUSE THESE MARKS (LINES) WITH CRACKS.

Isolated irregular rnarkings (lines) could appear on the sprag surface as a result of the rnanufacturing process. These lines are harrnless and are not cause for rejection of free wheel.

*

* * *

* * *

100517

Figure 11-54 Sprag

Revision 9

BO 105 CHAPTER 11 Page 111

MAINTENANCE MANUAL MBB - BO 105

5. Outer cage (5, figure 11-50) No breakage and deformation of the outer cage permitted. 6. Inner cage (figure 11-55)

*

. No breakage and no excessive wear of the inner cage permitted.

*

a. Place a suitab1e rubber band on circumference of the clutch assembly

over the sprags CAUTION

SPRAGS SHOULD NOT BE PRESSED OUT FURTHER THAN SPRING RESISTANCE OF ENERGIZING RIBBON. OTHERWISE SEE POINT d.

t. Push sprag outward only to the extent that the surfaces A and B of the inner cage become visible. Acceptable contact markings

*' *' *

* * * *

Rubbér band

*

*

* * * * *

Cage

:A-~~ * * * *

El00S18

*

Wear step

50'~ Cut

Wear step

e-e

*

Figure 11-55

BO lOS CHAPTER 11 Page 112

Inspection for wear - inner cage

Revision 9

_eurocopter CAUTION

MAINTENANCE MANUAL MBB - BO 105

CLUTCH ASSEMBLY MUST BE REJECTED EVEN IF ONLY ONE SINGLE CAGE CUTOUT EXCEEDS THE GIVEN WEAR LIMITS!

c. Inspect the surface A and B of the 22 cage cutouts for wear. Slight contact rnarkings on the surface A and B are acceptable (see figure 11-55) . Wear shown as a wear-step in the cage surface that exceeds 50% of the cage cutout surface is not acceptable (see figure 11-55, cut C-C). In this case the free wheel rnust be ejected. d. If a sprag has been inadvertantly pressed out of the clutch assembly during inspection, sprag is to be inserted as follows: CAUTION

SPRAG MUST BE INSERTED FROM INSIDE ONLY! OTHERWISE THE ENERGIZING RIBBON COULD BE DAMAGED!

1) Insert sprag frorn INSIDE, so that rnarking-point is on the outboard

(drag clip) side (see figures 11-56 and 11-57). 2) Inspect clutch assembly for correct installation position of sprags (see figure 11-57).

~""

Al

Marklng-polflt

..

100520

Figure 11-56

Insertion - sprag

Marklng point

100521

Figure 11-57

Revision 9

Installation position - sprags

BO 105 CHAPTER 11 Page 113

* *

* * * *

_eurocopter

MAINTENANCE MANUAL MBB - BO 105

7. Input piriion (figure 11-58)

A = mino 49.716 mm diameter. B = Surfaee for eluteh sprags:

Aeeeptable: light eireumferential seo res and eontaet markings from sprags. Not aeeeptable: tangible wear (gripping marks) on the eontaet surface of the sprag. C = Contact surfaee for drag strips:

Pclish out wear in "c" on eireumferenee of the input pinion using polishing eloth 400.

Figure 11-58

Input pinion

8. Free wheel outer shaft (figure 11-59)

A = max. 66.39 mm diameter.

B

B = Surfaee for elutch sprags:

Aeeeptable: light eircurnferential seo res and contaet markings from sprags. Not aceeptable: tangible wear (gripping marks) on the eontaet surfaee of·the sprag.

C

~

e

eontaet surfaee for ball bearing:

Polish out wear (eold welding) in "C" on eireurnferenee of bearing area using polishing cloth 400.

100m

Figure 11-59 Free wheel outer shaft

BO 105 CHAPTER 11 Page 114

Revision 2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

12

ROT OR

BRAKE

S YS T EM

Table of Contents

Paragraph

Title

Page

12 - 1

DESCRIPTION - ROTOR BRAKE SYSTEM

3

12 - 2

TROUBLESHOOTING - ROTOR BRAKE SYSTEM

3

12 - 3

INSPECTION FOR CONDITION - ROTOR BRAKE SYSTEM

7

12 - 4

REPLACEMENT BRAKE PADS (LININGS)

10

12 - 5

BLEEDING - ROTOR BRAKE SYSTEM

10

12 - 6

Removal - brake caliper

11

12 - 7

Installation - brake caliper

11

12 - 8

Removal - brake disk

15

12 - 9

Installation - brake disk

19

12 - 10

Removal - high-pressure relief valve

22

12 - 11

Disassembly - high-pressure relief valve

22

12 - 12

Assembly - high-pressure relief valve

24

12 - 13

Installation - high-pressure relief valve

25

12 - 14

Removal - master cylinder

26

12 - 15

Installation - master cylinder

27

BO 105 CHAPTER 12 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 12 - 1

DESCRIPTION - ROTOR BRAKE SYSTEM

1.

The rotor brake system permits fast dece1eration and stopping of main rotor and tail rotor when the engines are shut down. The brake system is operated by a handle which incorporates a detent mechanism and is located on the RH side of the pilot's seat. The handle must not be operated before rotor speed has dropped to 50% NRo. At this speed the time it takes for the rotor to stop must not exceed 50 seconds nor be less than 25 seconds.The rotor brake is a hydraulically operated disk brake with automatic adjustment to a pre-set clearance between brake pads (linings) and disk.

2.

The rotor brake system (figure 12-1) consists of the brake handle assy (29), master cylinder (17), high-pressure relief valve (32), oil reservoir (33), hose lines and assembled brake caliper (2) and brake disk (9). Two disk brake types are available for installation i.e., configuration 1 (Goodrich) or configuration 11 (Dunlop).

12 - 2

TROUBLESHOOTING - ROTOR BRAKE SYSTEM

NO.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Braking effect too weak (it takes more than 50 secs for rotor to stop completely after brake is applied at 50% NRo)

Trapped air in rotor brake system

Bleed rotor brake system. For work procedure, refer to paragraph 12-5.

Leak in rotor brake system

Check rotor brake system for condition. For work procedure, refer to paragraph 12-3

One or both brake pistons jarnrned

Remove brake caliper according to para 12-6 and manufacturer's documentation

High-pressure relief valve opens prematurely

Remove and functionally test relief valve. If required, disassemble relief valve and replace compression spring or reset crack pressure (latter applies to configuration 11 only) . For work procedure, refer to paras 12-10 thru 12-13.

Table 12-1

Troubleshooting

(1 of 2)

BO 105 CHAPTER 12 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Troubleshooting (continued) NO.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

2

Braking effect too strong (it takes less than 25 secs for rotor to stop completely after brake is applied at 50% NRo)

Delayed opening of high-pressure relief valve

Remove and functionally test relief valve. If required, disassemble relief valve and replace compression spring (latter applies to configuration 11 only). For work procedure, refer to paras 12-10 thru 12-13.

3

When brake pressure is released, the main rotor is either hard to turn or cannot be turned at all by hand

Brake pads (linings) contact brake disk

Inspect brake disk for condition per paragraph 12-3

Pistons jarnmed in brake caliper

Remove brake caliper per paragraph 12-6 and repair according to manufacturer's documentation

Table 12-1

BO 105 CHAPTER 12 Page 4

Troubleshooting

(2 of 2)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 1 2 3

4 ~ 5 6 7 8 9 10 11

12 13 14 15 16

17 18 19 20 21 22 23

24 25 26 27

28 29 30

& &

31 32 33 34 35 36

37 38

Bleed screw Brake caliper Bolt Flange, maintransmission Laminated shim Washer Nut Hose line Brake disk Screw Screw Bolt Bol t Washer Nut Spli t pin Master cylinder assy Washer Nut Sealing ring Banjo fitting Banjo bolt Plate Washer Nut Hose line Hose line Screw Rotor brake actuating system Screw Nut High-pressure relief valve Oil reservoir Cabin rearwall Washer Washer Washer Clamp

/

-3\r----33

8

6---'--7--~--=

26

11---27

DETAlL

22

818---31

Conflguratlon I

B

,.

20

' I ! l I - - - - 24

21 20 ~--12

~

5--4==l~

6---~"

7-----+--

"'-'ilt--- 28

--13

22 20 21

I (non-adjustable, refer to figure 12-8) Configuration II (adjustable, refer to figure 12- 9)

4---;.,\

6

20

& Configuration

Conflguratlon 11

DETAlL

11 only 100425.1

Figure 12-1

e

9

~ Only if required (refer to paragraph 12-7)

& Configuration

DETAlL -----4

3

Rotor brake system BO 105 CHAPTER 12 Page 5/6

D

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

INSPECTION FOR CONDITION - ROTOR BRAKE SYSTEM

12 - 3 l.

Remove engine cow1ings (refer to chapter 22) .

2.

Inspect configuration 1 (Goodrich) brake caliper and brake disk as follows:

3.

a.

Inspect brake disk (9, fig. 12-1) for wear, flatness and cracks. In the event of cracks, grooves, out-of-flatness in excess of 0.7 mm or residual thickness of less than 4.3 mm, replace disk in accordance with paras 12-8 and 12-9.

b.

Check wear limit of brake pads by measuring their residual thickness (see fig. 12-2). If the pads are less than 1.3 mm thick, replace them according to manufacturer's (Goodrich) instructions.

c.

Inspect brake caliper (2) for general condition and for oil leakage in piston areas. Check connecting hardware for tight installation. 1)

If there is evidence of oil leakage, remove brake caliper according to para 12-6 and repair according to manufacturer's instructions.

2)

Remove mechanical damage and corrosion to a max. depth of 0.7 mm, using 400 grit abrasive cloth. Touch up damaged surface protection, using chemical conversion material (CM 316), two-component zinc chromate primer (CM 417) and single-layer lacquer (CM 402). Refer to chapter 02.

3)

Tighten loose hardware.

4)

Inspect threaded cover (11, fig. 12-3) for presence of lockwire. If lockwire is broken or missing, check that the cover is screwed in tightly before installing new lockwire.

Inspect configuration 11 (Dunlop) brake caliper and brake disk as follows: a.

Inspect brake disk (9, fig. 12-1) for wear, flatness and cracks. In the event of cracks, grooves, out-of-flatness in excess of 0.7 mm or residual thickness of less than 5.8 mm, replace disk in accordance with paras 12-8 and 12-9.

b.

To check the wear limit of the brake pads (see fig. 12-2), pull the brake handle to move the brake pads (2) against the disco If the pad retaining plate on either pad contacts the pad retainer (1), the pads must be replaced with new ones. Dimension A in fig. 12-2 indicates the thickness of usable pad.

c.

Using hand pressure, check brake pads (2) for free movement. If the pads are jammed, inspect condition of disk according to step a. If the disk is undamaged, remove brake caliper (2, fig. 12-1) as described in para 12-6 and repair according to manufacturer's instructions. BO 105 CHAPTER 12 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

Inspect brake caliper (2) for general condition and for oi1 leakage in piston areas. Check connecting hardware for tight insta1lation. 1)

If there is evidence of oil leakage, remove brake caliper according to para 12-6, and repair according to manufacturer's instructions.

2)

Remove mechanical damage and corros ion to a max. depth of 0.7 mm, using 400 grit abrasive cloth. Touch up damaged surface protection, using chemical conversion material (CM 316) two-Component zinc chromate primer (CM 417) and single-layer lacquer (CM 402) . Refer to chapter 02.

3)

Tighten loose hardware. "A"

nA"

2

1 Pad retainer 2 Brake pad assembly

Conflguratlon 11

1 Brake linings

Conflguratlon 1 100370.1

103 mm mino thickness

Figure 12-2 3.

Inspection of brake pads (linings) for wear

Where possible, inspect brake hydraulic lines for chafe marks and hose clamps for tight connection. Replace chafed hoses and tighten loose clamps.

BO 105 CHAPTER 12 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5.

Inspect high-pressure relief valve (32, figure 12-1) for general condition and leakage. If leakage is present, remove and disassemble relief valve and replace O-rings (refer to paras 12-10 thru 12-13) .

6.

Inspect brake fluid level in oil reservoir. It must be between the mino and max. markings. Top up with lubricating oil (CM 103) if level is below the mino marking.

7.

Check rotor brake system for leakage as follows:

8.

a.

Pressurize rotor brake system by pulling the brake handle several times in succession, then lock brake handle in its uppermost position.

b.

If the brake fluid level in the oil reservoir has dropped and there is no clear evidence that the fluid loss was caused by damage to either the brake caliper or the relief valve, remove hose line fairings and brake actuating system in the cabin and inspect hose lines and master cylinder for oil leakage.

c.

If there is leakage, tighten hose line fittings or replace affected parto Remove master cylinder as described in para 12-14 and repair according to manufacturer's instructions.

Test braking efficiency of rotor brake on rotating main rotor. a.

Allow main rotor to coast down to a speed of 50% NRo.

b.

Apply rotor brake. The optimum braking effect is achieved by repeatedly pulling on the brake handle. The time it takes for the rotor to stop after brake pressure is applied at 50% NRo must not exceed 50 seconds nor be less than 25 seconds. If the stopping time is not within these limits, check the cracking and reseating pressures of relief valve (32, fig. 12-1). If necessary, reset relief valve (configuration 11 rotor brake only) or disassemble relief valve and replace compression spring in accordance with paras 12-10 thru 12-13.

BO 105 CHAPTER 12 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 12 - 4 1.

2.

REPLACEMENT - BRAKE PADS (LININGS)

Rep1ace Dunlop brake pad assemblies as follows: a.

Remove engine cowling (refer to chapter 22) .

b.

Remove pad retainer (1, fig. 12-2) and withdraw pad assemblies (2) from caliper.

c.

Press pistons back until they abut, then insert new pad assemblies (2) and install pad retainer (1).

d.

Repeatedly pull on the brake handle until the pad assemblies come into contact with the brake disk.

e.

Install engine cowling (refer to chapter 22) .

Replace Goodrich brake linings as described in the Goodrich Overhaul Manual.

12 - 5

BLEEDING - ROTOR BRAKE SYSTEM

1.

Remove engine cowlings (refer to chapter 22) .

2.

Check brake fluid level in oil reservoir (33, fig. 12-1) and add lubricating oil (CM 103) as necessary.

3.

Connect one end of a transparent hose to bleed screw (1) on brake caliper (2) and irnmerse the other end in a container (e.g., bottle or similar) that is half-filled with lubricating oil (CM 103) .

4.

Slacken bleed screw (1) on brake caliper (2).

5.

Repeatedly pull and release brake handle until no more air bubbles are visible in the transparent hose. While doing this, keep oil reservoir topped up to prevent further ingress of air in the system.

6.

With the brake handle applied, tighten bleed screw and remove transparent hose.

7.

Check fluid level in oil reservoir (33) and add lubricating oil (CM 103) as necessary.

8.

Install engine cowling (refer to chapter 22).

BO 105 CHAPTER 12 Page 10

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 12 - 6

Remova1 - brake caliper

1.

Remove engine cowling (refer to chapter 22) .

2.

Disconnect hose line (8, figure 12-1) from brake caliper (2) and plug openings. Catch draining oil in a suitable container, but do not reuse it.

3.

Remove caliper (1) attaching hardware (3, 5, 6 and 7, fig. 12-3) and rernove caliper from main transmission. Washer (4) is only installed on configuration 11 brake. If shirns (5) are installed, retain them for reinstallation.

12 - 7 NOTE

Installation - brake caliper Only install brake calipers in combination with brake disks made by the same manufacturero Intermixing brake calipers and disks from different rnanufacturers is not permitted. See figs. 12-1 and 12-3 for caliper distinguishing features. Brake disk distinguishing features: Goodrich-type disks are of uniform thickness (see fig.12-1). Dunlop-type disks are recessed on both sides in the area of the outer ring of bores (see fig. 12-1).

1.

Check main transmission rnounting surface on caliper for presence of corros ion preventive paint. If paint is missing, apply it as instructed in chapter 02.

2.

Press back pistons (10, fig. 12-3) until they make contacto NOTE

Proceed according to step 3. if same caliper is reinstalled, or according to step 4. if new caliper is installed.

3.

position caliper (1) on main transmission and secure to latter with bolts (3), washers (6 and, if configuration 11, 4), nuts (7) and, if previously installed, shims (5). Tighten nuts to specified torque load.

4.

position new caliper (1) on main transmission and secure to latter with bolts (3), washers (6 and, if configuration 11, 4) and nuts (7). Measure to ensure that both brake pads (linings) are equidistant from the disk. If the pads (linings) are equidistant and are at least 0.6 mm from the disk to accomodate piston return (configuration 11 brake only) , tighten nuts (7) to specified torque load.

BO 105 CHAPTER 12 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 If both pads (linings) are not equidistant from the disk, proceed as follows: a.

Measure clearance between each pad (lining) and disk.

b.

Remove brake caliper and, using shims (5), adjust position of caliper until the disk is centered between the pads (linings). Ensure that there is at least 0.6 mm clearance between each pad (lining) and the disk to allow for piston return (configuration 11 brake only) .

c.

Secure caliper to main transmission with bolts (3), washers (6 and, if configuration 11, 4), nuts (7) and shims (5).

d.

Tighten nuts to specified torque load.

5.

Connect hose line to inlet connection.

6.

Cover split line of caliper to main transrnission, bolt heads and nuts with two-component PUR topcoat (CM 437) .

7.

Bleed rotor brake system as outlined in para 12-5.

8.

Install engine cowling (refer to chapter 22).

BO 105 CHAPTER 12 Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - . MAINTENANCE MANUAL MBB - BO 105

Configuration I

I 3.2-3.6

Nm

I

12 12

7 -__

-1

3.2-3.6 Nm

I

11

I 112-14 Nm

+----2

I

"--- 91 6

8

23-25 Nm

I

5

& 10 Configuration 11

.,

I I I I I

I

I I I I I I

8 --+--.....

I I ....................._....1

I

I

-iR-iH- -ff--If....~ I I

1 12 - 14

Nm

f-

1 7

100370.2

1

2 3

4 5 6 7

Dimensions in mm

2

~91

6 5

&

0.6 mino

4

3

23-25 Nm

I

lJ

&

Brake caliper Brake disk Bolt Washer (configuration II brake only) Shim (only as required) Washer Nut Figure 12-3

8 Mounting flange on main transmission 9 Bolt 10 Brake linings (pads) 11 Cover 12 Nut

Installation - Brake caliper BO 105 CHAPTER 12 Page 13/14

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 12 - 8

Remova1 - brake disk

Special tools: Assembly/Disassembly fixture Puller Puller Square drive wrench Fixture Socket wrench

J

105-31501 WS 105-31501 W6 & 1xS6 136 393 Cornmercial 1xS6 136 287. 1xS6 131 403--1 ~

&

For use with configuration 1 (Goodrich) and 11 (Dunlop) rotor disks.

~

For use with configuration 1 (Goodrich) rotor disks only.

1.

Remove engine cowling.

2.

Remove forward short drive shaft or coupling, depending on rotor brake configuration (refer to chapter 32) .

3.

Remove brake caliper according to para 12-6.

4.

Using tools P/N 1xS6 136 287 and 1xS6 131 403, remove Goodrich brake disk as described in step 5. Using tools P/N 105-31501 WS and 105-31501 W6, remove Dunlop or Goodrich brake disk as follows: a.

Using screws, attach assembly/disassembly fixture (P/N 105-31501 WS) to output flange (2) as shown in fig. 12-4.

b.

Insert a square drive wrench (cornmercial item) in the assembly/ disassembly fixture and loosen retaining screw (3).

c.

Remove assembly/disassembly fixture.

d.

Unscrew and remove retaining screw (3) and discard O-ring (6).

e.

Attach puller (P/N 105-31501 W6) to output flange (2) with screws as shown in fig. 12-4.

f.

Insert a square drive wrench (cornmercial item) in puller and press assembled output flange (2) and brake disk (4) from output pinion shaft.

g.

Remove shims from output pinion shaft and retain them for reinstallation.

h.

Remove puller.

i.

Remove lockwire, then unscrew and remove screws (7) and detach brake disk (4) from output flange (2).

BO 105 CHAPTER 12 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5.

Using tools P/N 1x56 136 287 and 1x56 131 403, reroove Goodrich brake disk as follows: a.

Insert socket wrench P/N 1x56 131 403 in holding fixture P/N 1x56 136 287.

b.

Position assembled socket wrench and holding fixture against the brake disk so that the socket wrench engages the retaining nut and the caros on each end of the holding fixture project through the bores in the disk. Then turn the knurled-head screws so that the caros grip behind the disk (see fig. 12-5).

c.

Insert square drive wrench (commercial itero) in hole in socket wrench (2) and loosen retaining screw (3, fig. 12-49.

d.

While holding holding fixture (1, fig. 12-5) with a conventional spanner, continue unscrewing retaining screw until the assembled brake disk and output flange are pressed from the output pinion shaft .

e.

Reroove O-ring (6, fig. 12-4) from retaining screw (3) and discard O-ringo

f.

Remove shims froro output pinion shaft and retain thero for reinstallation.

g.

Remove socket wrench and holding fixture from brake disk.

h.

Remove lockwire, then unscrew and reroove screws (7) and detach brake disk (4) froro output flange (2).

BO 105 CHAPTER 12 Page 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2__~~m~t--4 .....,;.w:'1!1¡..;¡--7

-1

chamfer

23-25 Nm

35-50 Nm

I DETAlLA

6 5

1 Assembly/Disassembly fixture p/N 105-31501 WS 2 Output flange 3 Retaining screw 4 Brake disk Figure 12-4

2

5 Puller P/N 105-31501 W6 6 O-ring 7 Screw

Removal - brake disk, using tools p/N 105-31501 W5 and p/N 105-31501 W6

------O:'f-II--~

1------3

100279

Figure 12-5

1 Holding fixture P/N 1xS6 136 287 2 Socket wrench P/N 1x56 131 403 3 Knurled-head screw Removal/lnstallation - brake disk, using tools p/N 1xS6 136 287 and p/N 1xS6 131 403 BO 105 CHAPTER 12 Page 17/18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Installation - brake disk

12 - 9

Special tools: Puller Assembly/Disassembly fixture Square drive wrench Holding fixture Socket wrench

& &

PIN 1xS6 136 393 ---r PIN 105-31501 WS--.J Commercial PIN 1xS6 136 287 ---r PIN 1xS6 131 403--.J

&

&

For use with configuration I (Goodrich) and Ir (Dunlop) rotor disks. For use with configuration I (Goodrich) rotor disks.

NOTE

Only install brake disks in combination with calipers made by the same manufacturero Intermixing of brake disks and calipers from different manufacturers is not permitted.

l.

Fit brake disk on output flange with chamfered edge of disk against flange (see detail A in fig. 12-4).

2.

Insert screws (7, fig. 12-4) and, alternating diametrically, tighten them to specified torque load and lockwire them in pairs. NOTE

3.

Proceed according to step 3. if installing the same type brake disk (i.e., Dunlop or Goodrich) or according to step 4. when changing from a Goodrich to a Dunlop disk, or vice versa.

Insta1l brake disk as follows: a.

Fit previously removed shims on output pinion shaft. Take care to seat them against the inner race of the tapered roller bearing and not in the groove of the output pinion gear. To prevent the latter from occurring, it is recornmended to lubricate the shims with grease (CM 101 or 102) so that they adhere to the inner race.

b.

Using hand pressure, press the assembled disk and output flange as far as possible on the output pinion shaft.

c.

Screw the puller p/N 1xS6 136 393 into the output p~n~on shaft until the brake disk makes solid contact (see fig. 12-6).

d.

Remove puller.

e.

Measure clearance between brake disk and mounting flange on main transmission (see fig. 12-7).

BO 105 CHAPTER 12 Page 19

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 4. Install brake disk as follows: a.

Initally place only one shim on the output pinion shaft. Make sure it seats against the inñer race of the tapered roller bearing and not in the groove of the pinion shaft. To prevent latter from occurring, it is recornmended to lubricate the shim with grease (CM 101 or 102) so that it adheres to the inner race.

b.

Using hand pressure, push assembled disk and output flange as for as possible on pinion shaft.

c.

Screw puller P/N 1xS6 136 393 in output pinion shaft until brake disk makes contact (see fig. 12-6).

d.

Remove puller.

e.

Measure the clearance between brake disk and mounting flange on main transmission (see fig. 12-7). Add additional shims as necessary to obtain this clearance. At least one but not more than five 0.3-rnm-thick shims must be installed.

f.

If more shims are required, remove brake disk again and install shims. Then reinstall brake disk and remeasure the clearance.

5. Fit new O-ring (6) on retaining screw (3, fig. 12-4). 6. Lubricate retaining screw (3) threads with grease (CM 101) and tighten retaining screw to specified torque load, using a square drive wrench (cornmercial item) together with either assembly/disassembly tool P/N 105-31501 WS or tools P/N 1xS6 136 287 and 1xS6 131 403 (both these tools are for use with Goodrich disks only). 7. Fit locking plate (4, fig. 12-6) in the output flange groove and check whether its teeth can properly engage those of the retaining screw. If not, slacken the retaining screw and tighten it to a different torque load. The teeth must engage within the torque load limits. The retaining screw (5) must not protrude from the output flange. 8. Install brake caliper as outlined in para 12-7. 9. Install forward short driveshaft or coupling, depending on the configuration (refer to chapter 32) . 10. Install engine cow1ing (refer to chapter 22).

BO 105 CHAPTER 12 Page 20

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

2 ---4--......f+.--I.'

1 2

12/4

3

4 5

Figure 12-6

Puller p/N 1xS6 136 393 Output flange Brake disk Locking plate Retaining screw

Installation - brake disk, using puller p/N 1xS6 136 393

Reference plane

lN.'r

-& & 31.7tO.3¡t-

4--~

Dimensions in mm

120000

3

Figure 12-7

2

1 2 3 4

Brake disk Shim (s) Roller bearing Flange on rnain transrnission

Brake disk rnounting dimension BO 105 CHAPTER 12 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 12 - 10

Removal - high-pressure relief valve

l.

Remove engine cowling.

2.

Disconnect hose (8, figure 12-1) and hose leading to oil reservoir (33) from relief valve fittings. Catch draining oil in a suitable container, but do not reuse it.

3.

Disconnect relief valve (32) from elbows fittings on hoses (26 and 27) and detach relief valve from cabin rear wall (34).

12 - 11 l.

2.

Disassembly - high-pressure relief valve

Disassemble configuration 1 relief valve (see fig. 12-8) as follows: a.

Disassemble relief valve in accordance with the index number sequence shown in fig. 12-8.

b.

Discard O-rings (3 and 9).

c.

Clean parts with dry cleaning solvent (CM 202) .

Disassemble configuration 11 relief valve (see fig. 12-9) as follows: a.

Back off set screw (8) and disassemble relief valve in accordance with the index number sequence shown in fig. 12-9.

b.

Discard O-ring (3).

c.

Clean parts with dry cleaning solvent (CM 202).

BO 105 CHAPTER 12 Page 22

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

2 3

1 Circlip Plug 3 O-ring 4 Compression spring 5 Sealing cone assy 6 Hex nut 7 Washer 8 Guide 9 O-ring 10 BoU 11 Housing 12 Union nut 2

Figure 12-8

B

100284

High-pressure relief valve - configuration I (non-adjustable)

7

1 End cap 2 Piston 3 O-ring 4 Compression spring

Piston 6 Housing 7 Union nut 8 Setscrew 5

Figure 12-9

D 100284.2

B

High-pressure relief valve - configuration II (adjustable) BO 105 CHAPTER 12 Page 23

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 12 - 12 l.

2.

Assembly - high-pressure relief valve

Assemble configuration I relief valve (see fig. 12-8) as follows: a.

Compress spring with a force of 100-110 N. If the compressed spring length is between 24 and 27.5 mm, continue to use the spring. Replace it if it is less than 24 mm long.

b.

Wet new O-rings (3 and 9) with lubricating oil (CM 103) .

c.

Fit O-ring (9) on guide (8) and then assemble sealing cone (5) as shown in fig. 12-8.

d.

Fit O-ring (3) on plug (2).

e.

Install sealing cone (5), compression spring (4) and plug (2) in housing (11) and fit circlip (1).

f.

Check relief valve for leakage and correct operation as follows: 1)

Blank off ports B, C and D.

2)

Apply a pressure of 25 bar to port A and maintain this pressure for at least 5 minutes. There must be no leakage in the area of plug (2). Replace O-ring if leakage occurs.

3)

Open port D and apply a pressure of 10 bar to port A. There must be no oil flow from port D. Replace compression spring if oil flow occurs.

4)

Increase pressure to 10.5 bar. There must be a steady flow of oil from port D. If not, increase pressure until steady flow is obtained. However, the required pressure must not exceed 13.5 bar, otherwise compression spring (4) must be replaced.

Assemble configuration 11 relief valve (see fig. 12-9) as follows: a.

Wet O-ring with lubricating oil (CM 103) and fit it on piston (2).

b.

Install piston (5), compression spring (4) and piston (2) in housing (6) and screw end cap (1) in housing to full extent.

c.

Inspect relief valve for leakage as follows: 1)

Blank off ports B, C and D.

2)

Apply a pressure of 25 bar to port A and maintain this pressure for at least 5 minute. There must be no leakage in the area of end cap (1). Replace end cap if leakage occurs.

BO 105 CHAPTER 12 Page.24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

12 - 13 1.

Check relief valve for correct operation as follows: 1)

Open port D and apply a pressure of 11.9 bar to port B. There rnust be no oil flow frorn port D. Increase pressure to 13 bar and back off end cap until there is a steady flow of oil frorn port D. Reduce pressure and then increase it again to check the crack pressure. The relief valve rnust open at between 12 and 13 bar.

2)

Slowly decrease pressure again until the valve reseats. It rnust reseat at between O and 1 bar below cracking pressure.

3)

Secure end cap (1) with setscrew (8). Installation - high-pressure relief valve

Connect relief valve (32, fig. 12-1) to elbow fittings on hoses (26 and 27) •

2.

Connect hose (8) and hose on oil reservoir (33) to relief valve.

3.

Service oil reservoir (33) with lubricating oil (CM 103) .

4.

Bleed rotor brake systern as described in para 12-5.

5.

Install engine cowling (refer to chapter 22) .

BO 105 CHAPTER 12 Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 12 - 14

Removal - master cy1inder

1.

Remove access cover located below the rotor brake actuating system on the right (exterior) side of the fuselage.

2.

Remove lockwire from banjo bolts (22, fig. 12-1).

3.

Disconnect banjo bolts and remove them together with sealing rings (20) and banjo fittings (21) with attached hoses (26 and 27). Catch draining oil in suitable container, but do not reuse it.

4.

Remove plate (23) by removing nuts (31) and washers (24) and screws (28 and 30) .

5.

Remove floor plate above cable duct and loosen cable duct as necessary to facilitate removal.

6.

Withdraw rotor brake actuating system (29) and plug open ends of hoses.

7.

Remove attaching hardware (8, fig. 12-10) then rotate actuating rod 45 0 and remove attaching hardware (1).

~-=-..---:---------­ ----~---=-.

6 7

9

5 100423

1 2 3 4 5 6

4

3

2

BoH, washer, nut, split pin BoH Washer Nut Master cylinder Rotor brake handle Figure 12-10

BO 105 CHAPTER 12 Page 26

8

Projecting length 01 thread must not exceed 4 mm

7 8 9 10 11

Console BoH, washer, nut, split pin Actuating rod Clevis Jamnut

Rotor brake actuating system

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. Remove bolts (2), washers (3) and nuts (4) and detach master cylinder (5) from console (7). 9. Inspect and repair master cylinder per manufacturer's documentation.

12 - 15

Installátion - master cylinder

1. Secure master cylinder (5, figure 12-10) to console (7) using bolts (2), washers (3) and nuts (4). 2. Attach actuating rod (9) to master cylinder (5) using attaching hardware (1). Finger-tighten nut and secure with split pin. 3. Attach actuating rod (9) to brake handle (6) with attaching hardware (8). Do not safety nut. 4. Measure clerance between brake handle (6) and console (7) and measure the length of projecting piston rod thread. See fig. 12-10 for required dimensions and, if necessary, adjust as follows:

a.

Back off jamnut (11) on clevis (10) and remove attaching hardware (8) •

b.

Adjust clearance by turning actuating rod (9).

C.

Attach actuating rod (9) to brake handle (6) with attaching hardware (8). Finger-tighten nut and safety with split pin.

d.

Tighten jamnut (11).

5. Place rotor brake actuating system (fig. 12-10) in position in cabin. 6. Connect hose lines (26 and 27, figure 12-1) to master cylinder using banjo fittings (21), banjo bolts (22) and sealing rings (20). 7. Install cable duct and floor plateo 8. Secure plate (23) and rotor brake actuating system (29) to cabin floor.

9. Tighten banjo bolts (22) and safety with lockwire. 10. Replenish the reservoir (33) with lubricating oil (CM 103) . 11. Bleed rotor brake system per paragraph 12-5. 12. Install access cover on exterior side of fuselage.

BO 105 CHAPTER 12 Page 27/28

EUROCOPTER

MAINTENANCE MANUAL 80105

13

MA 1 N R O T O R S Y S T E M

Table of Contents

Paragraph

Title

13 - 1

DESCRIPTION - MAIN ROTOR SYSTEM

3

13 - 2

TROUBLESHOOTING - MAIN ROTOR SYSTEM

5

13 - 3

INSPECTION - MAIN ROTOR SYSTEM

7

13 - 4

BLADE TRACKING - MAIN ROTOR SYSTEM

9

13 - 5

BALANCING - MAIN ROTOR SYSTEM

9

13 - 6

Ma i n

13 - 7

Removal - main rotor head

10

13 - 8

Installation - main rotor head

11

13 - 9

P r i ma r y

13 - 10

Removal - primary bolts

13-11

Inspection - primary bolts

13 - 12

Disassembly - primary bolts

13-13

Assembly - primary bolts

13 - 14

Installation - primary bolts

18

13 - 15

S e e o n dar y bol t s

18

13 - 16

Removal - secondary bolts

13 - 17

Inspection - secondary bolts

19

13 - 18

Installation - secondary bolts

19

Revision 12

Page

r o t o r

h e a d

10

* * 13 * * 13 * * 16A * * 17 *

bol t s

13

.

18

BO 105 CHAPTER 13 Page 1

EUROCOPTER

MAINTENANCE MANUAL BO 105

Page

Paragraph

Title

13 - 19

Or i v i n g 1 i n k a s s y

21

13 - 20

Removal - driving link assy

21

13 - 21

Disassembly -

23

13 - 22

Inspection and repair - driving link assy

24

13 - 23

Assembly - driving link assy

32

13 - 24

Installation - driving link assy

32

13 - 25

L u b r i e a t ion h o u sin g

33

13 - 26

Disassembly - lubrication housing

33

13 - 27

Inspection - lubrication housing

33

13 - 28

Assembly - lubrication housing

35

BO 105 CHAPTER 13 Page 2

driving link assy

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 13 - 1

DESCRIPTION - MAIN ROTOR SYSTEM

The main rotor system consists of main rotor head, main rotor blades, rotating control rods and driving link assy. 1.

The four-armed main rotor head (1, figure 13-1) consists mainly of the rotor star (6) and four inner sleeves (7) incorporating blade mounting forks. The main rotor head is rigidly attached to the rotor mast of the . main transmission with 12 titanium studs and special nuts (5). The inner sleeves rotate on needle bearings in the rotor arms (figure 13-2) .The needle bearings are lubricated with lubricating oil (CM 103) which is supplied from the lubrication housing via bores in the rotor star. Control levers (4, figure 13-1) are installed on the blade mounting forks of the inner sleeves. The rotating control rods (3) are connected to the control levers. The main rotor blades are attached by primary and secondary bolts (8 and 9). The primary bolts (8) are hollow to accommodate the balance washers required for main rotor balancing.

2.

The driving link assy (2) consists of the mounting flange, driving link and fork link, and ensures synchronous rotation of the main rotor and the rotating bearing ring of the swash plateo

3.

The rotating control rods (3) connect the swash plate to the control levers on the blade mounting forks and transmit control movements from the cockpit controls to the main rotor blades (refer to chapter 41).

4.

For description and maintenance instructions of main rotor blades refer to chapter 14.

BO 105 CHAPTER 13 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

9 - - - -......

5--_ 4

----~~?~~~ ...,..L,;~~~ __a....,\~L"".:m.,,;,' - ' I t - - 2

3

1 Main rotor head Driving link assembly Rotating control rods 4 Control lever

2 3

Figure 13-1

BO 105 CHAPTER 13 Page 4

Special nut 6 Rotor star 7 Inner sleeve 8 Primary boH 9 Secondary bolt

5

Main rotor system

MAINTENANCE MANUAL M88 - 80 105

13 - 2

TROUBLESHOOTING - MAIN ROTOR SYSTEM

NO.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Traces of oH around the lubrication housing

O-rings of lubrication housing darnaged

Replace O-rings (refer to paragraphs 13-25 thru 13-28)

Sight glass darnaged

Replace sight glass (refer to paragraphs 13-25 thru 13-28)

Sealing washer of oH drain screw or vent screw darnaged

Replace sealing washer

OH drain screw or vent screw loose

Torque screw (refer to figure 13-2) and secure with lockwire

Outer shaft seal darnaged

Replace shaft seal (refer to REM 106)

*

Sealing surface on needle bearing inner ring darnaged

Replace needle bearing inner ring (refer to REM 106)

*

Shaft seal not suitable for the ambient ternperatures in which it is used

When operating predorninantly in low ternperature environrnents use Perbunan shaft seals. When operating predorninantly in high ternperature environrnents use Viton shaft seals (also refer to SI 89).

O-ring in needle bearing inner ring darnaged

Replace O-ring (refer to REM 106)

2

3

Traces of oH around the oH drain or vent screws of the rotor arrns

Traces of oH on the blade rnounting fork of the inner sleeve and on the blade fitting of the rotor blade

Table 13-1

Revision' 8

Troubleshooting

(1 of 2)

BO 105 CHAPTER 13 Page 5

*

EUROCOPTER

NO.

4.

MAINTENANCE MANUAL BO 105

TROUBLE SYMPTOM

Splashes of oil on canopy windows after starting the helicopter and traces of oil around outer nut

PROBABLE CAUSE

Inner shaft seal damaged

CORRECTIVE ACTION

Replace shaft seal (refer to REM 106)

Damaged sealing surface of ring Replace ring (refer to REM 106) on inner sleeve

5.

Oil loss without apparent leakage

Oil deflector damaged or not installed

Replace oil deflector (refer to REM 106 or retrofit per SB 10-28)

Sinking oillevel due to air· escaping during flights immediately following servicing with new oil

Service with oil (refer to paragraph 13-3, step 1.)

Inner shaft seal damaged

Replace shaft seal and inspect tension-torsion straps for condition (refer to REM 106)

Damaged sealing surface of ring Replace ring (refer to REM 106) on inner sleeve

I

6.

WARNING

THE DESIGN OF THE MAIN ROTOR BLADE IS SUCH THAT DAMAGE NOT IMMEDIATELY DETECTABLE ON THE BLADE EXTERIOR WILL BECOME EVIDENT THROUGH DISTINCT CHANGES IN THE BALANCE AND TRACK BEHAVIOR OF THE BLADE.

Vibrations on the helicopter

Deviations of blade track

Perform tracking (refer to paragraph 13-4)

Unbalance of main rotor system

Balance main rotor system (refer to paragraph 13-5)

RolI oscillations; separating layer between fitting and blade root damaged

Remove blade fitting from main rotor blade and inspect for condition, refer to chapter 14-8

Table 13-1 Troubleshooting (2 of 2)

CHAPTER 13 Page 6

Revision 17

EUROCOPTER

13 - 3

1.

MAINTENANCE MANUAL BO 105

INSPECTION - MAIN ROTOR SYSTEM

Check oH level. The oH level mustbe between the "MIN." and "MAX." marks on the oil level placard. If

oH level is below "MIN." mark, service with oil as follows:

a.

Remove lockwires and remove vent screws (4, figure 13-2).

b.

Replenish with oil (CM 103) to the "MAX." mark through one of the threaded holes in cover (3) of the lubrication housing.

c.

Install vent screws (4) and secure with lockwire to screw (5) and to ring nut or cap nut (both 6), as applicable.

2.

Inspect area adjacent to sight glass (2) of lubrication housing for leaking oil and visual clarity. Presence of oil indicates damage to either the sight glass or the O-rings. Remove damaged part according to para 13-25. Clean contaminated glass with cleaning agent (CM 721) or if glass is clouded, replace according to para 13-25.

3.

Inspect silicone rubber seal on split line of cover (3) and locking nut (16) for damage. Replace damaged seal as follows: a.

Remove seal, using a plastic or wooden scraper.

b.

Remove locking nut (16) and inspect for corrosion; refer to REM 106.

c.

Install locking nut (refer to REM 106) and seal split line with silicone rubber (CM 612) in accordance \üth fig. 13-2.

4.

Inspect area adjacent to screws (1 and 9) for leaking oil (see fig. 13-2). If leakage is evident, retighten screws. If oil continues to leak following a ground run, replace gaskets.

5.

Check outboard area of shaft seal (12) for presence of leaking oil (see fig. 13-2). If leakage is present, it is caused either by damage to shaft seal (12), inner ring of needle bearing (11) or O-ring (10), or by using a shaft seal unsuitable for the local operating temperatures (refer to para 13-2). Replace affected part accvrding to PBM 106.

6.

Inspect split line area of outer nut (13) and blade mounting fo~k for leakage (see fig. 13-2). If leakage is present, it is caused by damage to shaft ring (7), ring (8) or deflector (15). Replace affected part according to REM 106.

7.

Inspect main rotor head for mechanical damage and corrosion. Polish out mechanicaldamage and corrosion with polishing cloth 400. For darnage limits refer to REM 106.

Revision 10

BO 105 CHAPTER 13 Page 7

* * *

MAINTENANCE MANUAL BO 105

EUROCOPTER

1-1

3-5 Nm

I

13

12

DETAlL

8

11 10 9

I 3-~

7 14

Nm

A

-

16

&

I'~~I

3

*

100075.2

~ Areas susceptible to leakage

&

Silicone rubber seal (CM 612) Figure 13-2

BO 105 CHAPTER 13 Page 8

1 2 3 4 5 * 6

7 8 9 10 11 12 13 14 15 16

Oil Scr€w Sight glass Cover Vent screw Screw Ring nut or cap nut Shaft seal Ring Screw O-ring Needle bearing ilmer ring Shaft seal Nut Disk Oil deflector Locking nut

Sectional view - rnain rotor head

Revision 10

EUROCOPTER

MAINTENANCE MANUAL BO 105

8.

Inspect primary bolts for proper security (presence of lockwire and hook spring ring). If damaged, renew locking device. If locking device is missing, check torque of primary bolt and secure with appropriate locking device.

9.

If lockwashers (11, fig. 13-5) are not used to prevent the secondary bolts from rotating, check integrity of lockwires connected between the primary and secondary bolts. Replace damaged or missing lockwires (refer to para 13-18).

10. Inspect all other lockwires for integrity. If lockwires are damaged or missing, check torque of corresponding bolts or nuts and install new lockwire. 11. Inspect oillevel placard and name plate (P/N and serial No.) for legibility and replace if necessary. 12. Inspect driving link assy (2, fig. 13-1) wherever possible in instailed position for mechanical damage, corrosion, damaged surface protection, and check bearings for play. For damage and repair limits refer to paragraph 13-22. If corrective action is not possible in the installed condition, remove affected parts of the assemblyand repair in accordance with paragraphs 13-19 thru 13-24.

13 - 4 WARNING

BLADE TRACKING - MAIN ROTOR SYSTEM • CONSIDERABLE CHANGES IN BLADE TRACK AFTER A FEW FLlGHT HOURS OR TRACKING PROBLEMS WHICH CANNOT BE CORRECTED MAY BE AN INDICATION OF LATENT, ANO POSSIBLY SERIOUS, TECHNICAL DEFECTS, WHICH CAN POSSIBLY RESULT IN FAILURE OF THE MAIN ROTOR SYSTEM. • IF IRREGULARITIES OR UNKNOWN PROBLEMS OCCUR DURING BLADE TRACKING, CONSULT THE ECO CUSTOMER SERVICE PRIOR TO NEXT FLlGHT.

1. Blade tracking is performed prior to balancing the main rotor system and must be performed after repair or replacement of the main rotor head, main rotor blades, rotating control rods or if severe vibrations are reported by the pilot. 2. For blade tracking instructions, refer to chapter 106.

13 - 5 WARNING

BALANCING - MAIN ROTOR SYSTEM • CONSIDERABLE CHANGES IN BALANCE AFTER A FEW FLlGHT HOURS OR BALANCING PROBLEMS WHICH CANNOT BE CORRECTED MAY BE AN INDICATION OF LATENT, ANO POSSIBLY SERIOUS, TECHNICAL DEFECTS, WHICH CAN POSSIBLY RESULT IN FAILURE OF THE MAIN ROTOR SYSTEM. IF NO MORE BALANCE WEIGHTS CAN BE INSERTED INTO THE MAIN BOLT TO ELlMINATE UNBALANCE, THIS MAY ALSO BE AN INDICATION OF A SERIOUS TECHNICAL DEFECT. • IF IRREGULARITIES OR UNKNOWN PROBLEMS OCCUR DURING BALANCING, CONSULT THE ECO CUSTOMER SERVICE PRIOR TO NEXT FLlGHT.

1. Balancing of the main rotor system shall be performed after blade tracking. 2. For blade balancing instructions, refer to chapter 106. Revision 17

CHAPTER 13 Page 9

MAINTENANCE MANUAL 80 105

EUROCOPTER

Ma i n r o t o r

13 - 6

h e a d

13 - 7 Removal - main rotor head Special tools: Hoisting device Connecting pins (four) or blade folding bolts

105-14101 WS or 1121-14102 W1 or 117 W3 Tool no. 27 (105-14102 W2). Refer to chapter 04

1.

Remove main rotor blades; refer to chapter 14.

2.

Prevent inner sleeves from rotating by rigidly fixing them with connecting pins, tool no. 27 (p/N 105-14102 W2) or blade folding bolts, and remove rotating control rods as outlined in chapter 41.

3.

Remove driving link assy; refer to paragraph 13-20.

4.

Attach crane hook to main rotor head (3) by means of hoisting device 117 W3 (1) or hoisting device 105-14101 WS or 1121-14102 W1 (2) as shown in fig. 13-3, or attach hook directly to ring nut (11) on main rotor head.

5.

Remove lockwires from special nuts (6), remove special nuts and washers (7).

SA. Inspect washers (7) for corrosion. Replace corroded washers with new ones. CAUTION

*

*

WHEN LIFTING THE MAIN ROTOR HEAD, BUSHINGS (8) MAY FALL OUT ANO BE OAMAGEO. RETAINER (5) MAY STICK IN THE ROTOR HEAD ANO TEAR OFF WIRING OF MAST MOMENT SYSTEM.

6.

Carefully lift main rotor head. Take care that retainer (5) remains on rotor mast and that studs (10) are not damaged during lifting procedure.

7.

Protect studs (10) with caps and carefully put down main rotor head.

8.

Remove bushings (8) from rotor mast (9) and inspect as follows: a.

Inspect inner surface (bore) of bushings for mechanical damage. Polish out damage using polishing cloth 400.

b.

Inspect outer diameter and end faces of bushings for damaged silver plating. Damage is permissible, provided the silver plating is not worn down to the base material and ease of installation of the bushing is not impaired.

c.

Inspect end faces of bushings for deformation. If deformation is evident, consult ECO Customer Service for advice on how to proceed.

BO 105 CHAPTER 13 Page 10

Revision 14

EUROCOPTER

MAINTENANCE MANUAL BO 105

9. Remove silver shim (4) and inspect for cracks, other mechanical damage and corrosion. Discard if necessary. 10. Remove sealing compound from flange of rotor mast (9) and from main rotor head using a plastic scraper or an equivalent tool. 11. Clean main rotor head with dry cleaning solvent (CM 202). 12. After removing main rotor head, inspect underside of rotor mast flange for cracks and corros ion per chapter 11, paragraph 11-3.

Revision 14

BO 105 CHAPTER 13 Page 10A/B

MAINTENANCE MANUAL BO 105

EUROCOPTER

13 - 8

Installation - main rotor head

Special tools: Hoisting device 105-14101 W5 or 1121-14102 W1 or hoisting device 117 W3 Extractor, comprising housing CG 500-2 and collet CG 500-60, manufactured by: Snap On Tool GmbH, Rudolf-Diese1-Str. 6 or SNAP-ON TOOL CORPORATION KENDSHA, WISCONSIN WI 53140, USA D 74182 Obersulm, W-GERMANY

*

*

*

....

NI - ' ; - \ ' ; - - - - - - - - - 2

11

----t-t:---T~nr.-_F'o......._:

...I

~i=~'------3

10-------'

9------.. .

8------.. . . 7------.. . 6------__

---------- 4

~~~~7~-l Bushings lor installation

,(.

of maln rotor head

:--:......:::.a:~Q----------

5

Attachment fl..lnge for drlving link assy 100241.4

1 Hoisting device 117 W3 2 Hoisting device 105-14101 W5 or 1121-14102 W1 3 Main rotor head

Figure 13-3 Revision 10

4 5 6 7

Silver shim Retainer Special nut Washer

8 Bushing 9 Rotor mast 10 Stud 11 Ring nut or cap nut

Removal and installation - main rotor head BO 105 CHAPTER 13 Page 11

* * *

EUROCOPTER

MAINTENANCE MANUAL 80105

1. Attach crane hook to main rotor head (3) by means of hoisting device 117 W3 (1) or hoisting device 105-14101 W5 or 1121-14102 W1 (2) as shown in fig. 13-3, or directly to ring nut (11), and raise main rotor head. NOTE

*

Step 2. shall be omitted if the main rotor head has been repaired or if a periodical inspection per REM 106 has been performed.

2. Apply grease (CM 101 or CM 120) to collet CG 500-60, attach collet together with housing CG 500-2 to stud and check torque (60 Nm) of all studs in turno 3. Degrease flange faces of rotor mast (9), main l'otor head (3) and silver shim (4) if same shim is being reused, using methyl ethyl ketone (CM 217) or acetone (CM 203) . 4. Position silver shim (4) on the rotor mast (9) and secure in place with three evenly spaced bushings (8) as shown in fig. 13-3. NOTE

Make sure that the retainer used is correct for main rotor head type; refer to figure 13-4.

5. Position main rotor head on flange of rotor mast so that rotor arm "No. 3" is located above the attachment flange for the driving link assy. When putting down the main rotor head, take care to preclude damage to studs (10, figure 13-3) and canting of the main rotor head and retainer (5). 6. Apply grease (C!4 102) to threads of studs (4, figure 13-4) and contact surfaces of special nuts (7).

* NOTE *

Only install washers (6) that are not corroded (also refer to 13-7, step SA) .

7. Insert bushings (5), place washers (6) on bushings (5) with the rounded side pointing towards the rotor mast flange and install special nuts (7) on studs (4). Hand-tighten nuts. 8. Protect rotor mast around flange with adhesive tape to avoid damaging the rotor mast with the torque wrench when tightening the special nuts. 9. Using torque wrench, tighten diametrically opposite special nuts (7) in increments until specified torque is reached. 10. Remove adhesive tape from rotor masto 11. Secure each special nut (7) to adjacent stud (4) with lockwire (refer to figure 13-4). Bend lockwire end to prevent the driving link assy from being damaged.

BO 105 CHAPTER 13 Page 12

Revision 8

EUROCOPTER

MAINTENANCE MANUAL 80 105

12. Degrease split line area of main rotor head and rotor mast with acetone (CM 203) . 13. Wrap adhesive tape around main rotor head and rotor mast flange on an area 5 mm around each side of split lineo 14. Seal split line area with silicone rubber (CM 612) (refer to figure 13-4). Allow silicone rubber to cure for approximately 10 minutes and remove adhesive tape. 15. Install driving link assy. Refer to paragraph 13-24. 16. Install rotating control rods. Refer to chapter 41. 17. Remove connecting pins, tool no. 27 (105-14102 W2) or blade folding bolts. 18. Install main rotor blades. Refer to chapter 14. 19. Perform tracking and balancing of main rotor system (refer to chapter 106) after repair or replacement of main rotor head.

BO 105 CHAPTER 13

Revision 10

Page 12A

MAINTENANCE MANUAL 80105

EUROCOPTER

Sillcone rubber (CM 612)

EFFECTIVITY

~í7t:~¿Y----2

& Main

rotor head p/N 105-14101 only

&

IWJ-----3

~t::-::::---4 1~::::~--5

~----6

~-----7 1152-168 Nm ~---'v

~-00..'I--------

8

VIEW

A

Silicone rubber (CM 612)

EFFECTIVITY 10.."",,~--':lí-777~---

~==:j--_"-III6---i~!fii

9

~~--- 3 ~t=-::::--- 4 ~!===----5

~

~All

rnain rotor heads except for p/N 105-14101

lMa!J:...------ 6

~-----7 1152-168~ ~"""" \.1-------- 8

100455

&-.

1 2 3 4

Main rotor head Retainer Silver shirn Stud

Figure 13-4 BO 105 CHAPTER 13 Page 12B

Bushing Washer 7 Special nut 8 Rotor mast ~-9 Retainer 5

6

Attachment and sealing - main rotor head

Revision 10

MAINTENANCE MANUAL BO 105

EUROCOPTER

13 - 9

P r i m a r y bol t s

13 - 10

Removal - primary bolts

1. Identify primary bolt with its corresponding rotor armo 2. Remove lockwire and hook spring ring (1, figure 13-5). NOTE

Step 3. is not applicable if lockwasher (11) has been installed.

3. Remove lockwire (12) connecting primary to secondary bolt. 4. If installed, remove attaching hardware (14, 17, 18). If the rotor blade is to be removed, attaching hardware (5, 6, 9, fig. 13-5A) on angle bracket (7) of main rotor head (8) must be removed as well. 5. Remove special nut (2 or 9, fig. 13-5) and remove primary bolt (7, 8 or 13), while supporting blade attip to remove weight of blade. 6. Clean primary bolt with dry cleaning solvent (CM 202) . 13-11

Inspection - primary bolts If a damaged primary bolt is replaced by one of the same configuration, the balance washer assembly of the damaged primary bolt can be reused.

NOTE

1. Inspect nitrided bolts for cracks, mechanical and corros ion damage. a.

Polish out mechanical and corros ion damage on bolt shank with polishing cloth 600. Permissible minimum diameter is 37.92 mm in local areas, but not over the entire shank length. Rework is permissible at three corrosion spots distributed over approximately 100 mm2 and each having a surfa ce area of 4 mm2 • Minimum distance of groups of corrosion spots from one another must be 30 mm.

b.

Discard bolts if threads are deformed or broken in the area which is covered by the nut.

c.

Perform magnetic particle inspection per MIL-STD-1949 or penetrant inspection per MIL-STD-6866. Discard bolt if cracks are evident.

Revision 10

BO 105 CHAPTER 13 Page 13

* * * * * * * *

MAINTENANCE MANUAL 80105

EUROCOPTER

19

Configuration 1 Configuration 11 Configuration 11 with bonding jumper Locking feature 1 (lockwasher (11)) Locking feature 11 (lockwire (12) attachment to primary bolt) Installed only in combination with locking feature 11 (lockwire) Installed in place of secondary bolts if blade folding system is being used

1

Hook spring ring Special nut 3 Split pin 4 Nut &5 Washer 6 Secondary bolt 1

&2

Figure 13-5 BO 105 CHAPTER 13 Page 14

~ 2 2

* *

7

7 8 9 10

&11

~ 12

Primary bolt Primary bolt Special nut Locking lever assembly Lockwasher Lockwire

&13 14 15 16 17 18 19

Primary bolt Screw Angle bracket Clamp Washer Nut Bonding jumper

Removal and installation - primary and secondary bolts

Revision 12

MAINTENANCE MANUAL 80105

EUROCOPTER

* *

13 - 5 Nml

12

11,1318 -12

*

Nml

4

DETAlL

13/11

A

1 2 3 4 5 6 7 8 9 10 11 12 13

Clamp Bonding jumper Angle bracket Primary bolt Screw Washer Angle bracket Main rotor head Nut Screw Washer Split pin Nut

~ Length from edge of clamp to center of lug terminal on main rotor head shall be 130 ±S mm. Ensure that white marking on bonding jumper (2) is underneath clamp (1). Figure 13-SA Removal and installation - bonding jumper

Revision 10

BO 105 CHAPTER 13 Page 15

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

* * *

* * * * * *

*

* * * * * * * *

EUROCOPTER

2.

*

*

Inspect nickel-plated bolts for cracks, mechanical damage and damage to nickel plateo a.

Minor mechanical damage to bolt shank which does not affect ease of installation (bolts must be easy to insert by hand through flange bushings of blade mounting fork) is permissible.

b.

Remove more severe mechanical damage (e.g. scratch ridges, raised material around nicks) which affects ease of installation, with polishing cloth, provided the nickel plating is not worn down to the base material.

c.

If nickel plating is worn down to the base material, the bolt must not be reused. It may be returned to the manufacturer (ECD) for assessment of damage, as replating is possible within certain damage limits.

d.

Replace bolt if threads are deformed or broken in the area which is covered by the mating nut in its end position adjacent to bolt shank.

e.

Perform magnetic particle inspection per MIL-STD-1949 or penetrant inspection per MIL-STD-6866. Discard bolt if cracks are evident.

*

* * * * * * * * * * * * * * * * * * * * * * * *

3.

MAINTENANCE MANUAL BO 105

Inspect primary bolt coated with solid film lubricant (p/N 105-14101.10) for cracks, mechanical damage and condition of solid film lubricant coat. NOTE When the penetrant method of crack inspection is used, the solid ------ film lubricant coat must be removed completely from the bolt. If the solid film lubricant coat is to be retained, it is preferable to use the magnetic particle method. a.

Perform crack inspection using the magnetic particle method per MILSTD-1949 or penetrant method per MIL-STD-6866, as applicable. Discard cracked bolts.

b.

Mechanical damage such as individual scores, nicks and scratches which extend through the solid film lubricant coat and penetrate the base metal shal1 be polished out using 400 grit abrasive cloth.

c.

Replace bolts if threads are deformed or broken in the area which is covered by the mating nut in its end position adjacent to bolt shank.

d.

The solid film lubricant coat may be worn down to the base metal of the bolt on the entire coated surface. Polish out scores, nicks and scratches in the solid film lubricant coat using 400 grit abrasive cloth. The diameter of the bolt shank shall not be less than 37.955 mm.

BO 105 CHAPTER 13 Page 16

Revision 12

EUROCOPTER

13 - 12 1.

2.

MAINTENANCE MANUAL BO 105

Disassemb1y - primary bolts

Disassemble primary bolt '(1, figure 13-6) (configuration

1)

as follows:

a.

Rernove cap screw (4).

b.

Remove compression spring (3), and washers (2), if installed, frorn primary bolt (1).

c.

Tie up washers (2) in bundles, identify them with their corresponding primary bolt and store thern for reinstallation.

Disassemble primary bolt (7) (configuration 11) as follows: a.

Rernove split pin (5), riut (6), screw (11) and cover (10). If configuration 11 with bonding jumper, also rernove angle bracket (12) and washer (13).

b.

Rernove cornpression spring (8) and washers (9) from primary bolt (7).

c.

Tie up washers (9) in bundles, identify them with their corresponding primary bolt and store them for reinstallation.

Revision 12

BO 105 CHAPTER 13 Page l6A/B

MAINTENANCE MANUAL 80 105

EUROCOPTER

Configuration Ir

Configuration 1

¿fIP- 5

I 3-5 Nm

~---6 ~

1-6Nm

I

~'ifI---13

3--~~

1---7 7

2

)C)~---

8

130002

---11

* *

~ Configuration 11 with bonding jumper

Primary boH Washers (balance washers) Compression spring 4 Cap screw 5 Split pin 6 Nut 1 2 3

Figure 13-6 13 - 13 1.

2.

7 8 9

10 11

12 13

Primary bolt Compression spring Washers (balance washers) Cover Screw Angle bracket Washer

Disassembly and assembly - primary bolts

Assembly - primary bolts

Assemble configuration 1 primary bolt (1, figure 13-6) as follows: a.

Insert washers (2) and compression spring (3) into primary bolt (1).

b.

Install and tighten cap screw (4).

Assemble configuration 11 primary bolt (7) as follows: a.

Insert screw (11), cover (10), washers (9), and compression spring (8) into primary bolt (7).

Revision 10

BO 105 CHAPTER 13 Page 17

*

* * *

MAINTENANCE MANUAL BO 105

EUROCOPTER

b.

If configuration 11 with bonding jumper, install washer (13) and angle bracket (12) on end of screw (11).

c.

Install nut (6) and tighten and secure it with split pin (5).

13 - 14 NOTE ------

Installation - primary bolts The two opposite primary bolts must be of the same configuration.

Special tools: Torque wrench

* *

105-13101 W8 or 105-13101 W1

1.

Apply grease (CM 101, CM 102 or CM 120), corrosion preventive compound (CM SOS) or lubricant (CM 146) to primary bolt (7,8 or 13, figure 13-5) which are not coated with solid film lubricant.

2.

If installing a bolt coated with solid film lubricant, degrease bolt and mating bores in blade fork and blade fitting, using dry cleaning solvent (CM 202), and dry install bolt. Apply lubricant (CM 146) to previously installed bolt coated with solid film lubricant.

3.

Before installing the primary bolt in the blade mounting fork with the corresponding marking, unload the main rotor blade by lifting its tip and then positioning it so that the mating bores in the blade fork and blade fitting align. Insert primary bolt without applying force and press in by hand until it abuts.

4.

Install special nut (2 or 9), tighten with specified torque value and it with hook spring ring (1). Additionally secure special nut (9) to primary bolt (8), using lockwire. If locking feature 11 is used to secure the secondary bolt, wire-lock secondary bolt to primary bolt (see fig. 13-7, 2 of 2).

* *

~ecure

S.

If configuration 11 with bonding jumper, attach bonding jumper (19, fig. 13-5) to angle bracket (15), using clamp (16) and attaching hardware (14, 17 and 18). For clamp orientation, see fig. 13-5A. If the rotor blade was removed, bonding jumper (2, fig. 13-5A) must also be attached to angle bracket (7) of main rotor head (8). Then measure continuity resistance (refer to chapter 14-4).

13 - 15

S e con dar y bol t s

13 - 16

Removal - secondary bolts

l.

With bolt locking feature 1 (fig. 13-7, 1 of 2): Remove split pin (3, fig. 13-5) and nut (4), and withdraw secondary bolt (6) and lockwasher (11) while at the same time supporting blade at tip to remove weight of blade.

BO 105 CHAPTER 13 Page 18

Revision 12

EUROCOPTER

2.

MAINTENANCE MANUAL 80 105

With bolt locking feature 11 (figure 13-7, 2 of 2): Remove lockwire (12, figure 13-5), split pin (3), nut (4) and washer (5), and withdraw secondary bolt (6) while at the same time supporting blade at the tip to remove weight of blade.

13 - 17

Inspection - secondary bolts

1.

Inspect nitrided bolts in accordance with paragraph 13-11, step 1. Minimum permissible diameter of secondary bolt is 17.93 mm in local areas but not over the entire shank length.

2.

Inspect nickel-plated bolt in accordance with paragraph 13-11, step 2.

3.

Inspect solid filmlubricant-coated secondary bolts (p/N 105-14101.11 or p/N 105-14101.111) for cracks, mechanical damage and condition of the

* * solid film lubricant coat. * * NOTE When the penetrant method of crack inspection is used, the solid * film lubricant coat must be removed completely from the bolt. * If the solid film lubricant coat is to be retained, it is * preferable to use the magnetic particle method. * * a. Perform crack inspection using the magnetic particle method per MIL- * STD-1949 or penetrant method per MIL-STD-6866, as applicable. Discard *

*

cracked bolts. b.

Mechanical damage such as individual scores, nicks or scratches which extend through the solid film lubricant coat and penetrate the base metal shall be polished out using 400 grit abrasive cloth.

c.

Replace bolts if threads are deformed or broken in the area which is covered by the mating nut in its end position adjacent to bolt shank.

d.

The solid film lubricant coat may be worn down to the base metal of the bolt on the entire coated surface. Polish out scores, nicks and scratches in the solid film lubricant coat using 400 grit abrasive cloth. The diameter of the bolt shank shall not be less than 17.965 mm.

13 - 18

NOTE

* * * * * * * * * * * * * *

Installation - secondary bolts

o Make sure that the correct combination of castle nut and secondary bolt is installed (also refer to IPC). o Locking lever assembly (10, figure 13-5) may be installed in place of secondary bolts (6). For installation of locking lever assembly, refer to chapter 854. o Make sure that either all bolts or opposite bolts are of the same configuration.

Revision 12

BO 105 CHAPTER 13 Page 19

* *

EUROCOPTER

l.

* *

MAINTENANCE MANUAL BO 105

Apply grease (CM 101, CM 102 or CM 120) or corros ion preventive compound (CM 505) or lubricant (CM 146) to secondary bolts (6) which are not coated with solid film lubricant.

* 2. If a new secondary bolt coated with solid film lubricant is to be * installed, it must be degreased together with its mating bores in the * blade fork and blade fitting, using dry cleaning solvent (CM 202), and * then dry installed. Apply lubricant (CM 146) to previously installed * bolts coated with solid film lubricant.

Figure 13-7 (1 of 2)

3.

4.

Anti-rotational locking of secondary bolt using lockwasher (locking feature 1)

When using locking feature 1 (fig. 13-7, 1 of 2), install secondary bolt as follows: a.

Take up weight of blade by ralslng it at the tip, and adjust blade position so that mating bores in blade fork and blade fitting align. Insert secondary bolt together with lockwasher without using force and press in by hand until it abuts.

b.

Screw nut (4, figure 13-5) on secondary bolt (6) until it just contacts the flange of the bushing. Back off nut by 30 0 to 60 0 from this position so that split pin can be inserted. Secure nut with split pin (3).

When using locking feature 11 (fig. 13-7, 2 of 2), install secondary bolt as follows: a.

Take up weight of blade by ralslng it at the tip, and adjust blade position so that mating bores in blade fork and blade fitting align. Insert secondary bolt without using force and press in by hand until it abuts.

b.

Screw nut (4, figure 13-5) together with washer (5) on secondary bolt (6) until washer and nut just contact the flange of the bushing. Back off nut by 30 0 to 60 0 from this position so that split pin can be inserted. Secure nut with split pin (3).

BO 105 CHAPTER 13 Page 20

Revision 12

EUROCOPTER

c.

MAINTENANCE MANUAL 80 105

Lock secondary bolts as follows (see fig. 13-7, 2 of 2). 1)

If primary bolts (Configuration 1) are installed¡ turn secondary bolt so that the head of the split pin points towards the primary bolt. Install lockwire (0.8 mm) between head of split pin and that borehole in the outermost end of the primary bolt which is located nearest to the secondary bolt.

2)

If primary bolts (Configuration 11) are installed, turn secondary bolt so that the head of the split pin in the castle nut on the secondary bolt points towards the mainbolt. Install lockwire (0.8 mm) through head of split pin and secure to the nearest hole in the nut of the primary bolt.

Configuration 1

Configuration 11

Figure 13-7 (2 of 2) Anti-rotational locking of secondary bolt using lockwire (locking feature II)

13 - 19

Dr i v i n g l i n k a s s y

13 - 20

Removal - driving link assy

1.

If configuration 1 swash plate is installed (see fig. 13-8), remove driving link assy (5) as follows: a.

Remove split pin (8), nut (7) and washer (6).

b.

Remove split pins (4), nuts (3), washers (2) and hex. bolts (1) and detach driving link assy (S). 30 lOS CHAPTER 13 Page 21

MAINTENANCE MANUAL 80105

EUROCOPTER

16--+

3-5 Nm

¡

Configuration I ~

II

&

400620.1

&

Configuration J:: Driving link assy attached to swash plate witn boH

(12).

~ Configuration 11: Driving link assy attached to swash plate with boH (14).

* * & For application, refer to IPC. * * * * * * *

1 Hex. bolt 2 Washer 3 Nut 4 Split pin 5 Driving link assy &6 Washer Figure 13-8 BO 105 CHAPTER 13 Page22

~7

Nut 8 Split pin 3 9 Mounting flange 10 Driving link 11 Fork link ~ 12 BoH 1

13

~ 2

&

14 15 16 17 18

Washers (installed only if required) BoH Screw Rotor mast flange Bushing Mounting flange

Removal and installation - driving link assembly

Revision 10

MAINTENANCE MANUAL 80 105

EUROCOPTER

2.

If configuration 11 swashplate is installed (see fig. 13-8), remove driving liúk assy (5) as follows: a.

Remove lockwire from screws (15).

b.

Remove screws (15), bolt (14) and, if installed washers (13).

c.

Remove split pins (4), nuts (3), washers (2) and hex. bolts (1), and detach driving link assy (5).

13 - 21

Disassembly - driving link assy

1.

Disassemble driving link assy per figure 13-9.

2.

Clean driving link assy with dry cleaning solvent (CM 202).

4---1

_'Y----6

((1_'\",/111---·

,.0050,.

2

3

~ 2

3

I

1-3 Nm

* * *

~ For application, refer to IPC Split pin Nut 3 Washer ~ 4 Mounting flange 1 2

Figure 13-9

Fitted boH 6 Washer 7 Driving link 8 ~'ork link ~ 9 Mounting flange 5

* *

*

Disassembly and assembly - driving link assy

BO 105 CHAPTER 13

Revision 10

Page 23

MAINTENANCE MANUAL 80 105

EUROCOPTER

13 - 22

Inspection and repair - driving link assy

Special tools: Milling cutter Staking tool Staklng tool retainer Mounting tool kit Orin

1.

Inspect mounting flange (4, figure 13-9): a.

2.

105-13141 W3 105-13141 W5 105-40001 W1 Tool no. 2 (105-13221 W1). Refer to chapter 04 Tool no. 3 (105-13241 W1). Refer to chapter 04

Visually inspect mounting flange for crncks, deformation, mechanical damage, corrosion and damaged surface protection. 1)

Replace if there are signs cracks or deforrnation.

2)

Polish out darnage within permissible limits stated in figure 13-11 and final polish wi th polishing cloth 400.

3)

Touch up damaged surface protection with zinc chromate primer (CM 456) and single-layer lacquer (CM 402) .

b.

If bores in mounting flange show signs oí wear, or have been reworked, check bore dirnensions. For maximurn perrnissible bore diameters, refer to figure 13-11.

c.

Check floating bushing in borehole of rnounting flange for free movement. If floating bushing is jamrned, proceed as follows: 1)

Press out bushing with drift tool No. 3 (105-13241 W1) .

2)

Inspect bores in mounting flange and fork link for mechanical damdg"e afld corros ion . Polish out darnage with polishing cloth 400. Maximurn bore diameter of 12.03 mm may be exceeded by 0.01 rrm on one quarter of the bore circumference.

3)

Inspect outer diameter of bushing for corrosion. Polish Oüt corrosiol1 with pollshing cloth 400. Outer diameter o[ bushing must not be less than 1l.99 mm.

4)

Coat bushing with corrosion preventive paste (CM 510) and install by hand.

Inspect fork link (8, figure 13-9): a.

Check fork link in accordance with steps 1.a and 1.b. See fig. 13-13 for darnage and repair lirnits.

b.

Check spherical bearing for play, binding and corrosion. Replace spherical bearing per step 5., if bearing is damaged, binds or if play is unacceptable. Permissible radial play is 0.1 mm.

BO 105 CHAPTER 13 Page 24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

3.

4.

5.

Inspect flanged bushing for mechanical damage and corrosion. Polish out damage with polishing cloth. Maximum permissible bore diameter is 7.94 mm. Replace bushing per step 6. if out of dimensiono

Inspect driving línk (7, figure 13-9): a.

Inspect driving link in accordance with step 1.a. See fig. 13-12 for damage and repair limits.

b.

Inspect deep groove ball bearing for play, roughness and signs of corrosion. Replace deep groove ball bearing per step 7. if any such damage is evident.

Inspect fitted bolts (5, figure 13-9) for cracks and mechanical damage. a.

Minor mechanical damage to bolt shank which does not affect ease of installation (bolts must be easy to insert by hand through bushings of fork link) are permissible.

b.

Remove more severe mechanical damage (e.g. scratch ridges, raised material around nicks), which affects ease of installation, using polishing cloth, provided the nickel plating is not worn down to the base material.

c.

Discard bolt if nickel plating is worn down to base material.

d.

Discard bolt if threads are deformed or broken in the area covered by the nut.

e.

Perform magnetic particle inspection per MIL-STD-1949 or penetrant inspection per MIL-STD-6866. Discard fitted bolt if cracks are evident.

Replace spherical bearing in fork link as follows: a.

MilI off the outward staked portion of bearing outer ring, using milling cutter 105-13141 W3. position spherical bearing on a suitable support and remove bearing, using a mandrel.

b.

Inspect bore in fork link for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The maximum permissible diameter of 23.02 mm may be exceeded by 0.01 mm along one quarter of the bore circumference.

c.

Coat bore in fork link with corros ion preventive paste (CM 510) .

d.

Install spherical bearing in fork link and stake, using staking tool 105-13141 W5 and staking tool retainer 105-40001 W1. For detailed instructions refer to chaper 02.

BO 105 CHAPTER 13 Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 6.

7.

Replace flanged bushing in fork link as follows: a.

Press out flange bushing with drift No. 3 (105-13241 W1) .

b.

Inspect bore in fork link for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The maximum permissible bore diameter of 12.025 mm may be exceeded by 0.01 mm along one quarter of the bore circurnference.

c.

Chill flanged

d.

Coat bore in fork link with corros ion preventive paste (CM 510) .

e.

Press in flange bushing so that it abuts, using drift No. 3 (105-13241 W1). Check flange bushing for dimensional accuracy and rework if necessary (e.g. using honing tool). Finished size is 7.92 + 0.012 mm dia.

bushing to approximately -50 oC.

Replace deep groove ball bearing in driving link, using mounting tool kit No. 2 (105-13221 W1) as follows: a.

Place driving link (9, figure 13-10) on support ring (1) under a press.

b.

Insert drift (2) through oblong hole of driving link and into borehole of spacer (7).

c.

Insert bolt (3) through deep groove ball bearing (6) so that it contacts the transverse drift (2) and press out deep groove ball bearing (6).

d.

Remove spacer (7) and inspect for mechanical damage and corrosion. Polish out damage with polishing cloth 400 if necessary.

e.

Press out opposite deep groove ball bearing with drift (5).

f.

Inspect flanged bushings (8) for mechanical damage and corrosion. If damage is evident, proceed per step g. If not, install new deep groove ball bearings as follows: 1)

Place driving link (9) on a suitable support. Place deep groove ball bearing (6) on flange bushing (8) and press in until it abuts using drift (5)

2)

Install spacer (7) so that its recess contacts the deep groove ball bearing inner ringo

3)

Using drift (5), press in second deep groove ball bearing, until it rests against spacer free of play.

BO 105 CHAPTER 13 Page 26

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 g.

Polish out darnage to flanged bushing (8) with polishing cloth 400. The rnaxirnurn perrnissible diarneter is 20.63 mm. If diarneter is exceeded, replace flange bushing as follows: 1)

Place driving link (9) on support ring (1).

2)

Insert thrust piece (4) through oblong hole of driving link so that it rests on flange bushing (8). Position drift (5) on thrust piece (4) and press out flanged bushing.

3)

If necessary also press out the opposite flange bushing, using thrust piece (4) and drift (5).

4)

Inspect flange bushing rnating bore in driving link for rnechanical darnage and corrosion. Polish out darnage with polishing cloth 400. The rnaxirnurn perrnissible diarneter of 24.02 mm rnay be exceeded by 0.01 mm along one quarter of the bore circurnference.

5)

Coat flanged bushing rnating bore in driving link with corros ion preventive cornpound (CM 502) .

6)

Chill flange bushing to approxirnately -50 OC and press in place with drift (5).

7)

Press deep groove ball bearing in place per step f.

BO 105 CHAPTER 13 Page 27

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1---6

3----1

8----, 9 6 --r-Ti7

~l:lffT~~~~~

9 2

Removal of deep groove ball bearing

Installation of deep groove ball bearing

1-----6--------i 8 LlIo.;I--9

9 4

~f---8

100456

Removal of flange bushing

1 Support ring 2 Drift 3 BoU 4 Thrust piece 5 Drift Figure 13-10

BO 105 CHAPTER 13 Page 28

Installation of flange bushing 6 7 8 9

Deep groove ball bearing Spacer Flanged bushing Driving link

Removal and installation - deep groove ball bearing and flanged bushing in driving link, using mounting tool kit tool No. 2 (105-13221 W1)

EUROCOPTER

MAINTENANCE MANUAL BO 105

*

CONFIGURATION 1

* *

2 ' r - - - -......

.&-_....: 13/8

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

I Mechanical and co.rrosion

0.2 mm in depth on 30% of the surface

I

0.3 mm in depth on 50% of t-he surface

Maxirnurn perrnissible bore diarneters:

~ dia

7.95 mm

& & &

dia

6.02 mm

dia

6•3 mm

dia

6. 9 mm

They rnay be exceeded by 0.01 mm along one quarter of the circurnference

~ dia 12.03 mm Figure 13-11

Mounting flange - damage and repair lirnits (1 of 2)

*

* *

Revision 10

BO 105 CHAPTER 13 Page 29

MAINTENANCE MANUAL BO 105

EUROCOPTER

* . CONFIGURATION

11

* * * * * * * * * * *

*

* .* * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * *

13/12

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS

Mechanical

0.3 mm in depth on SO% of the surface

Corrosion

0.3 in depth on SO% of the surface

Maximum permissible bare dlameters:

& &

dia

&

dia

6.02 mm

&

dia

6.3

7.9S mm

The specified bare diameters may be exceeded by 0.01 mm an ane quarter af the bare circumference.

dia 12.03 mm

mm

Figure 13-11 80 lOS CHAPTER 13 Page 30

Mounting flange - damage and repair limits (2 of 2)

Revision 10

EUROCOPTER

TYPE OF DAMAGE

MAINTENANCE MANUAL BO 105

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

L=:=J

Mechanical

0.4 mm in depth on 30% of the surface

0.7 mm in depth on 50% of the surface

Corresien

0.35 mm in depth before and 0.4 mm in depth after repair on 30% of the surface

0.65 mm in depth befo re and 0.7 mm in depth after repair en 50% ef the surface

Figure 13-12

Revision 10

Driving link - damage and repair limits

BO lOS CHAPTEP. 13 Page 30A/B

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

&--~

13/10

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

fi:¡~jrJiJ%~ml

I

Mechanical

0.4 mm in depth on 30% of the surface

O. 7 mm in depth on 60% of the surface

Corros ion

0.35 mm in depth befare and 0.4 mm in depth after repair on 30% of the surface

0.65 mm in depth before and 0.7 mm in depth after repair on 60% of the surface

I

Maximum permissible bore diameters:

& &

dia 12.03 mm dia

They may be exceeded by 0.01 mm along one quarter of the circumference

7.94 mm Figure 13-13

Fork link - damage and repair limits BO 105 CHAPTER 13

Page 31

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 13 - 23

Assembly - driving link assy

1.

Coat fitted bolts (5, figure 13-9) with corrosion preventive paste (CM 510) .

2.

Install fitted bolts (5) together with washers (3, 6) in mounting flange (4), driving link (7) and fork link (8) and secure with nuts (2).

3.

Safety nuts with split pins (1).

13 - 24

Installation - driving link assy

1.

Install driving link assy to rotor mast flange with hex. bolts (1, figure 13-8), washers (2) and nuts (3). Safety nuts with split pins (4).

2.

Install fork link (11) on configuration 1 swash plate as follows: WARNING

THE CURVED WASHER (6) MUST BE INSTALLED WITH ITS HOLLOW SIDE POINTING TOWARDS THE NUT (7) TO ENSURE THAT THE FREE MOVEMENT OF THE DRIVING LINK ASSY WILL NOT BE IMPAIRED.

Install fork link (11) on bolt (12) with washer (6) and nut (7). Safety nut (7) with split pin (8). 3.

Install fork link (11) on configuration 11 swash plate as follows: a.

Check that bushing (17) is installed in the fork link attachment flange on the bearing ringo

b.

Insert end of fork link (11) in attachment flange on bearing ring per figure 13-8, and insert bolt (14) through aligned bores until it abuts. Measure the gap between faying surfaces of attachment flange and head of bolt (14). Use washers (13) to achieve a residual play of 0.1 - 0.2 mm.

c.

Install screws (15), tighten and secure with lockwire. Bend lockwire up against bolt (14).

BO 105 CHAPTER 13 Page 32

MAINTENANCE MANUAL 80105

EUROCOPTER

13 - 25

L u b r i e a t ion

h o u sin g

13 - 26

Disassembly - lubrication housing

1.

Remove lockwire and vent screws (4, figure 13-14) from cover (5).

2.

Drain oil from lubrication housing (10) with a suitable tool (e.g. syringe) through one of the threaded boreholes of the vent screws (4).

3.

Remove ring nut (1) or cap nut (15) from bolt (12).

4.

Remove screws (2) and unscrew cap nut (3) with adjustable face spanner (pin diameter 6.5 mm).

5.

Remove cover (5) together with sight glass (8).

6.

Discard O-rings (6, 7 and 9) .

7.

Remove residual oil from main rotor head, using dry cleaning solvent (CM 202) and mask boreholes (14) with adhesive tape. Inspection - lubrication housing

13 - 27 1.

*

Inspect ring nut (1, figure 13-14), cap nut (3) and cover (5) for mechanical damage and corrosion. a.

Polish out minor surface damage and local corros ion with polishing cloth 600. Touch up surface protection per chapter 02.

b.

Replace parts if damaged threads or deformation are evident. Replace cover (5) lf faying surfaces are damaged.

2.

Check bolt (12) for corrosion and damaged thread. Replace bolt if thread is extensively damaged or if corrosion pitting is evident (refeL to REM 106) .

3.

Check

4.

Inspect cylindrical pin (11) for mechanical damage. Remove main rotor head (refer to paragraph 13-7) if pin shows evidence of shearing, and check nut of bolt (12) for specified torque (50-55 Nm) . Replace cylindrical pino

5.

Check sight glass (8) for damage, visual clarity, and separated or missing oil placard (13).

bcrehole~

of vcnt screws (4) for clogging ana clear it necessary.

a.

Replace sight glass if damaged or clouded.

b.

Remove separated placard. Clean bonding surface with dry cleaning solvent (CM 202) and attach new self-adhesive placard.

Revision 10

BO lOS CHAPTER 11 Page 33

* *

MAINTENANCE MANUAL 80105

EUROCOPTER

--110-12 Nm

I

- --i

3-5 Nm

I

-1

3-5 Nm

I

5 10

6 7

8

6:.13~

9

11

1 Ring nut 2 Screw 3 Cap nut 4 Vent screw 5 Cover 6 O-ring 7 O-ring 8 Sight glass 9 O-ring 10 Lubrication housing 11 Cylindrical pin 12 Bolt 13 Oil placard * 14 Bore * 15 Cap nut

* 6:.

Oil placard (13) only in combination with sight glass (8) p/N 105-14101.17

Figure 13-14

Disassembly and assembly - lubrication housing

BO 105 CHAPTER 13

Page 34

Revision 10

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•

13 - 28

MAINTENANCE MANUAL BO 105

Company

Assembly - lubrication housing

1.

Remove adhesive tape from boreholes (14, figure 13-14).

2.

Coat new O-rings (6, 7 and 9) with silicone compound (CM 104). Insert O-rings (6 and 7) in cover (5) and O-ring (9) in sight glass (8).

3.

Position sight glass (8) and cover (5) on main rotor head so that the cylindrical pin (11) of the main rotor head fits into the recess of the center bore of the cover.

4.

Install cap nut (3) with adjustable face spanner (pin diameter 6.5 mm) until it is seated and then back off until its boreholes align with the threaded boreholes of the cover (5).

5.

Secure cap nut (3) to cover (5) with screws (2).

6.

Install ring nut (1) or cap nut (15) on bolt (12) and tighten as specified.

CAUTION

• ONLY USE PERMITIED TYPES OF 01L. DO NOT MIX DIFFERENT TYPES OF OIL. •

7.

Service with lubricating oil (CM 103) through one of the two threaded vent screw mating bores (4) to maximum marking.

8.

Install vent screws (4) and secure with lockwire to screw (2) and to ring nut (1) or cap nut (15).

9.

Check lubrication housing (10) for leakage.

Revision 25

CHAPTER 13 Page 35/36

_euro 00 pter

MAINTENANCE MANUAL 80 105

14 MAIN ROTOR BLADE Table of Contents

Page

Paragraph Title 14-1

DESCRIPTION - MAIN ROTOR BLADE ••••••••••••••••••••••••••••••••.••••••

3

14-2

INSPECTION - MAIN ROTOR BLADE, TYPE 1 •.••••••••••••.••••.•••••••••••

4

14-3

INSPECTION - MAIN ROTOR BLADE, TYPE 2 •...••.....•.••.•.•.•••.••.....

15

14-4

REMOVAL - MAIN ROTOR BLADE ••••••••••.•••••••••..••.•...•••••••••••••

24B

14-5

INSPECTION - MAIN ROTOR BLADE REMOVED ••.••••.•.••••••••••••••.•.••

25

14-6

INSTALLATION - MAIN ROTOR BLADE ••••••••.•••.•••••••••••••••••••••••.

26

14-7

REPAIR - MAlN ROTOR BLADE ••••••••.•.••••••••••.•••••••••••.•••••.••••.

29 •

14-8

Replacement of bushings - blade root fitting •••..••••••••.••••••.•••••.•••••

29

14-9

Replacement of DU guard washers - blade root fitting •.•.....•..•••••••••••••

40

14-10

Disassembly - blade root fitting ••....•••••••••.••.••.•.•.••••.•••••••••••••

41

14-11

Inspectlon and repair - blade root fitting and blade thimble ••••••••.•.•...•..•

41

14-12

Assembly - blade root fitting ••••••••••.•.•••••••••••.••••••••••••••..•.••••

44

14-13

Bonding - PUR erosion protection tape in tip area of Type 1 main rotor blade ...•...•••••••••••••••..••••••••••.••••••••••••••••••••••.•.•....••••

45

14-14

Replacement - PU film ••••••••.•••••••.•.••••••••••••••••••••••••••••..••••

47

14-15

Riveting - trim tab ...••••.••...••••••••.•.••••••••••••••••••••...••.•.•••.•

51

14-16

Replacement - trim tab ••.••••.....•••••••.••....•••.••••....•.•..•..•••••••

51

14-17

Repalr of damage on main rotor blade ••••..••..••••.•.•.•...•.•..•...••••••.

55

14-18

Renewal - resin coating •••••...•••••••.•..•..••••••.••••...•.••.......••...

57

14-19

Restore protective coating and inspection marking in the balance weight areas - main rotor blade type 2

.

61

STORAGE, PACKAGING ANO SHIPPING - MAlN ROTOR BLADE .....•••.•.••.

63

14-20

Revision 22

CHAPTER 14 Page 1

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BLANK PAGE

CHAPTER 14 Page2

Revision 19

_eurocopter 14-1

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DESCRIPTION - MAIN ROTOR BLADE

The rotor blades generate the Iift and propulsion required for flight, and permit control of the helicopter about its lateral and longitudinal axes. They are manufactured from glassfiber reinforced plastics (GRP) and are flexible enough to eliminate the need for flapping and lead lag hinges. The C-shaped blade spar consists of layers of glassfiber strands. The blade root is fitted in the two-piece blade root fitting (1, figure 14-1 or 1, figure 14-5). An erosion protective shell (6 or 10) is bonded to the leading edge of the blade. The trim tabs (9 or 11) can be adjusted to correct an out-oftrack condition when the blades are not all flying in the same tip path plane. Pendulum absorbers (20 or S), when installed, serve to reduce the vibrations occurring during flight in the lowspeed range and when the helicopter is flared. Two main rotor blade types are documented in this Chapter 14: EFFECTIVITY

80 10S A, C, O and S, model helicopters, except for 80 10S CB-S, C88-S and D88-S

Type1

Rectangular blade with a uniform chord length a10ng the entire blade span (see figure 14-1).

EFFECTIVITY

80 10S CB-S, C88-S and D88-S model helicopters.

Type2

Rectangular blade with a tapered tip (2S% of blade spanwise length) (see figure 14-S).

Revision 21

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MAINTENANCE MANUAL BO 105

INSPECTION - MAIN ROTOR BLADE, TYPE 1

WARNING

IF THE INSPECTIONFOR CONOITION REVEAL8 THAT THE ALLOWABLE OAMAGE L1MIT8 HAVE BEEN EXCEEOEO, ANO NO BLAOE REPAIR PROCEOURE 18 OESCRIBEO IN CHAPTER 14, THE MAIN ROTOR BLAOE 8HALL BE REPAIREO BY ECO, THE MANUFACTURER, OR BY A REPAIR FACILlTY AUTHORIZEO BY ECO.

NOTE

Refer to para. 14-1 for explanatory notes on type 1 blade.

8pecial tools:

Tapping hammer

Toolno.37

refer to Chapter 04

• AII inspections shall be performed on both sides of the blade.

• NOTE

• It is recommended to repair even damage that does not exceed the specified zonal damage Iimits as described in para 14-17, and also repair eroded butt joints as described. This prevents the damage from spreading and thus requiring the blade to be repaired or replaced earlier than necessary. • If butt joints are eroded, moisture may penetrate the bonding joint of the erosion protective shells (in leading edge area), causing premature debonding. 1. If polyurethane erosion protection tape is installed in the blade tip area (see fig. 14-21), remove it. 2. Clean main rotor blade, using either dry cleaning solvent (CM 202) or degreasing agent (CM 209), then wipe dry. 3. Inspect main rotor blade for erosion damage: a. Erosion damage in ZONE 1 (see fig. 14-1) is only permissible if the erosion protective shells (6) and the end cap (8) have not been penetrated. Erosion ofthe skin on the blade body in ZONE 2 is only permissible if not more than one ply ofthe laminate has been damaged. Referto para. 14-17 for ply repair procedure. b. Eroded butt joints between adjacent metal parts (only if no PU-fiIm has been applied) and between metal parts and body are permissible. Eroded butt joints between erosion protective shells must not exceed 5 mm in length. To prevent damage from spreading, it is recommended to fiU eroded butt joints as follows: 1) Oegrease butt joints with acetone (CM 203). 2) Fill butt joints with 2K adhesive paste (CM 671) and mask with adhesive film (CM 603). 3) Allow adhesive to cure, then peel off adhesive film and carefully sand excessive adhesive by hand, using 180 grit abrasive cloth. 4) Apply topcoat, refer to para. 14-17.

CHAPTER 14 Page4

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MAINTENANCE MANUAL SO 105

4. Inspect main rotor blade for impact damage. a. Impact damage on tne erosion protective shells (6) and on the end cap, refer to step 15. b. Impact damage in lONE 1 (figure 14-2) is only permissible if it is not deeper than 2 pUes and does not exceed 15 mm in diameter. A maximum of 4damaged areas is permissible, but they must notbe within 30 mm of each other, otherwise the main rotor blade must be repaired. If skin plies are damaged, repair per para 14-17. c. A maximum ofthree impact damage areas are permitted in lONE 2providedthey do not exceed2 pUes in depth and total damage area does not exceed 10 cm 2 . d. Impact damage is permissible in lONE 3 if individual damage areas are not deeperthan 2 pUes and have adiameterthat does not exceed 30 mm. Upto 6 impact damage areas are permitted, provided they are at least 200 mm aparto e. Impact damage and damage such as chipping, debonding and cracks on blade trailing edge in lONE 4 are not permissible. 5. Visually inspect main rotor blade for general damage. a. If installed, inspect visible parts of conductive strip (22, figure 14-1) and bonding jumperfor condition and tight connections. Have damaged conductive strip repaired and replace damaged bonding jumper. Tighten loose connections. For torque values, see figure 14-20. b. Inspect screw (13, figure 14-1), locking plate (7), cap (14 or 15), depending from the rotor blade configuration, and associated lockwirefor secure installation and condition.lf lockwire is missing, checktorque of screw (13) (fortorque value, referto fig. 14-1) and securewith lockwire. Replace damaged cap and lokking plate. c. Inspecttrim tabs (9) for cracks and secure attachment. Replace cracked trim tabs (referto para 14-16).lf non-riveted trim tab attach tabs have separated from the blade, they can all be secured by rivets instead of rebonding (refer to para 14-15). d. Inspect cuff (2), (if installed), for debonding ofthe laminate plies.lf the third laminate ply is damaged, replace cuff or repair laminate plies. 6. Visually inspect main rotor blade in the blade fitting area (see figure 14-2, DETAlL A) for cracks and delamination. If Iimits are exceeded, inform ECO Customer Service or have blade repaired. a. Cracks in the edges of neck shell and nose shell bondUnes are permissibleifthey do not exceed 20 mm in length (spanwise) per bond line. b. Cracks in lONE 1 that originate at the blade root fitting or cuff (if installed) and propagate at random are permissible if they do not exceed a length of 20 mm. c. Delaminations in lONE 1, neck shell and nose shell, that originate at the blade root fitting or cuff (if installed) are only permissible if a single delamination or the total area of all delaminations does not exceed 15 cm 2 on each side of the blade.

Revision 21

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MAINTENANCE MANUAL 80 105

7. With the main rotor blade installed, inspect blade root fitting, where possible, for mechanical damage, screws for correct safetying and for obstruction of the drain hales, if latter are present. a. Polish out mechanical damage if within permissible Iimits shown in figure 14-19 and final polish with 400 grit abrasive cloth. Rework of surface protection is not necessary. b. Clear obstructed drain hales with a suitable tool. c.

If screw locking devices are missing, check torque values and install new screw locking devices. For torque values, refer to figure 14-20.

8. If installed, visually inspect static discharger (18) for condition and tigth installation. Replace damaged static discharger in accordance with para 14-6. Tigthen loase screw connections. Torque value 0.6 to 0.8 Nm.

1 2 3 4 5 6

7 8 9 10 11 12

Blade root fitting Cuff (if installed) Nose shell PU film (for main rotor blade with sleeve) Blade body Erosion protective shell Locking plate Endcap Trim tab Blade trailing edge Neck shell Sleeve, only in combination with pendulum absorber.

13 14 15 16

17 18 19 20 21 22 23

Screw Cap Cap PUfilm Balance weight Static discharger (if installed) PU film (for main rotor blade with sleeve) Pendulum absorber (if installed) PU film (for main rotor blade with sleeve) Conductive strip (if installed) Bonding jumper (if installed)

Erosion inspection zones ZONE1

Figure 14-1

CHAPTER 14 Page6

ZONE2

Main rotor blade, type 1 (1 of 2)

Revision 21

EUROCOPTER

MAINTENANCE MANUAL 80 105

1

23

I~

2

3 21

~4

o

-o ~

5 11---1-

o

10--

'f}.

DETAlL

A

16

(Typical main rotor blade configurations)

-:----6

; a:

7

g

8

A

Dimensions in mm Figure 14-1 Main rotor blade, type 1 (2 of 2) Revision 19

CHAPTER 14 Page7

EUROCOPTER

MAINTENANCE MANUAL 80 105

BLANK PAGE

CHAPTER 14 Page8

Revision 19

EUROCOPTER

MAINTENANCE MANUAL SO 105

DETAlLA

Delamlnatlon ----III\;~\

r..r-~-Crack

Bondllne - - - - t - - + I

maln rotor blade without cuff

DETAlLA

--+---Cutf Delaminatlon ---~mr:r~~rr1 't+--Crack Bondline ----t-~

main rotor blade wlth cutt

approx. 80

Figure 14-2

Revision 19

ZONE1

~

ZONE2

~

ZONE3

~

ZONE 4 (Trailing edge)

Dlmensions In mm

Inspection zones on main rotor blade, type 1

CHAPTER 14 Page9

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eurocopter

MAINTENANCE MANUAL BO 105

9. If installed, inspect PU film (16, 19 and 21, figure 14-1) for debonding and damage. Replace debonded or worn-through PU film (16, 19 and 21) par paragraph 14-14. If the PU film (16) is missing or has been worn through, inspect the adhesive butt joint of the erosion protective shell (6) for erosiono FUI eroded bonding joint to a maximum depth of 5 mm as described in the following . If erosion is deeper, have blade repaired. a. Oegrease buttjoints with acetone (CM 203). b. FUI butt joints with 2K adhesive paste (CM 671) and mask with adhesive film (CM 603). c. Allow adhesive to cure, then peel off adhesive film and carefully sand away excessive adhesive by hand, using 180 grit abrasive cloth. 10. Inspect PU film (4, figure 14-1) for general condition and evidence of bond separation.lf damage such as PU film penetration or bond separation is present, replace PU film (refer to para 14-14) and inspect the underlying nose shell (3) for damage (refer to step 6.). 11. If installed, inspect pendulum absorbers (20, figure 14-1) for condition in accordance with Chapter 844. 12. Inspect erosion protective shell (6, figure 14-1) for debonding. If there is unacceptable bond separation, have the erosion protective shell replaced by ECO. CAUTION

EXCEEOING THE OAMAGE L1MITS CAN RESULT IN THE LOSS OF THE EROSION PROTECTIVE SHELL ANO CAUSE SEVERE MAIN ROTOR IMBALANCE. THE VIBRATIONS CAUSEO BY THE UNBALANCEO CONOITION CAN OAMAGE THE HELlCOPTER • Maintenance personnel engaged in testing the bonding of the erosion protective shell must have necessary practice and experience.

NOTE

• A bonded PU-erosion protective film need not be removed for the tapping test. a. Oebonds are acceptable and no inspection is required in: -

ZONE 1 (figure 14-4), beginning and end of erosion protective shell, if PU-erosion protective film is applied.

-

ZONE 2, leading edge area of erosion protective shell.

b. Inspect bonded joint of erosion protective shell in ZONE 1,if no PU-erosion protective film is applied, and in ZONE 3 and ZONE 4 (figure 14-4): NOTE

CHAPTER 14 Page 10

The sound caused by tapping the erosion protective shell at both ends and in the balance weight area (17 figure 14-1) is duller than in the remaining areas. Care must be taken to differentiate between this sound and the sound of a debond.

Revision 21

_eurocopter

MAINTENANCE MANUAL BO 105

1) Using special tapping hammer, tool no. 37 or a coin weighing approx. 10g, tap along the erosion protective shell in these zones and listen to the resulting sound: -

a good bond will sound Iight and hard,

-

debonds sound dull without resbnance.

2) If a debond is detected in lONE 1 (beginning and end of erosion protective shell) during the tapping test: -

Oebonds which do not exceed 50% of total area on each aft edge area ofthe erosion protective shell are acceptable.

-

If debonds exceed 50% of total area on each aft edge area of the erosion protective shell, have the erosion protective shell replaced by ECO

3) If a debond is detected in lONE 3 (warning area) during the tapping test, have the erosion protective shell replaced by ECO: a) immediately, especially always when debonds extend into lONE 4 and cause the acceptable debonding area in this zone to be exceeded, or b) at a later time in conjunction with "Special inspections after maintenance activity" per chapter 101-11. However, in this case, if any debonds extend into lONE 4, they must not cause the acceptable debonding area in this zone to be exceeded. If the erosion protective shell is to be replaced at a later time, use a water-resistant felt-tip pen to mar\< the extent of the debond on the erosion protection, and make an accurate sketch of the debonded area. This will enable any increase in the debonded area to be detected at the next inspection. 4) If debonding is detected in lONE 4 (aft edge areas) during the tapping test: a) Oebonds which do not exceed a total area of 5 cm 2 on each aft edge area of the erosion protective shell are acceptable. b) If debonds exceed a total of 5 cm 2 on each aft edge area of the erosion protective shell, have the erosion protective shell replaced by ECO: -

either immediately or

-

at a later time if ECO Service Engineering issues a special permit allowing the main rotor blade to be kept in service. For this purpose, details must be given of all debonds and damage to the erosion protective shell. If the erosion protective shell is to be replaced at a later time, use a water-resistant felt-tip pen to mark the extent of the debond on the erosion protective shell, and make an accurate sketch of the debonded area. This will enable any increase in the debonded area to be detected at the next inspection.

13. Inspect erosion protective shell for cracks. a. Cracks in base material of erosion protective shell are not acceptable. b. Cracks are acceptable in the lacquer on the edge of erosion protective shell (the erosion protective shell extends 34 mm chordwise from the leading edge on the upper surface of the blade and approx. 44 mm chordwise from the leading edge on the lower surface of the blade). Revision 21

CHAPTER 14 Page 11

I

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euro00pter

MAINTENANCE MANUAL BO 105

14. Inspect end cap (S, figure 14-1) for debonding. Debonding of the end cap is only permissible if it does not exceed 10% of its entire bonding area. There must be no bond separation at the edges of the end cap. If debonding Iimits are exceeded or edge separation is present, have main rotor blade repaired. 15. Inspect erosion protective shell (6, figure 14-1) and end cap (S) for impact damage. Impact damage (dents) is permissible if: -

not more than one impact damage area is present, impact damage area has no sharp edges, erosion protective shell not penetrated, impact damage area at least 100 mm from beginning or end of erosion protective shell, impact damage area is not more than 30 mm long spanwise and not more than 3 mm deep chordwise, and the resultant ridging is not more than 10 mm long chordwise on upper and lower surfaces (measured from the blade leading edge to aft upper and lower edges of the erosion protective shell, see fig. 14-4.).

If damage Iimits have been exceeded, have main rotor blade repaired. •

16. If PU film was attached in the blade tip area (see figure 14-21), attach new PU film according to para. 14-14.

CHAPTER 14 Page 12

Revision 21

EUROCOPTER

MAINTENANCE MANUAL 60105

Figure 14-3

Nose area 15

Damage limits - erosion protective shell

Leg area

20 Nose area

Leg area

Dimensions in mm Figure 14-4 Inspection zones - erosion protective shell (1 of 2)

Revision 19

CHAPTER 14 Page 13

"'0(')

m

1l)::I:

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-a.t...

EBOSION PBOTECTIVE SHELLA

~

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EBOSION PBOTECTIVE SHELL B

~

. ~ f'//////////i

t

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"" I l)

I

"1J

-i

/" End PU-Film

I~

-¡

- ---f.T----Ill-a1

B>

I

Leg area

Nose area PU-Fílm area

:J CO (1)

EBOSION PBOTECTIVE SHELLC

~

I

End PU-Fílm

IP

~

EBOSION PBOTECTIVE SHELL o

(1)

a

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o

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:J

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~~:%:'7.~"r7~7?~"'~'7.~"r77?:%:"'~

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s.

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o

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z » z (")

m

_

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c::J

ZONE 1

ZONE2

ZONE3

(Area al lhe beginning/end 01 lhe erosion prolective shell)

(Nose area)

(Warning area)

ZONE4 (Leg area)

Dimensions In mm

N

::o

z-1

m

(1)

~

~

»

B0105_WAH_0027_R

~

» z e » r OJ

...

O o

01

fteurooopter 14 - 3

MAINTENANCE MANUAL BO 105

INSPECTION - MAIN ROTOR BLADE, TYPE 2

WARNING

IF THE INSPECTION FOR CONDITION REVEALS THAT THE ALLOWABLE DAMAGE L1MITS HAVE BEEN EXCEEDED, AND NO BLADE REPAIR PROCEDURE IS DESCRIBED IN CHAPTER 14, THE MAIN ROTOR BLADE SHALL BE REPAIRED BY ECD, THE MANUFACTURER, OR BY A REPAIR FACILlTY AUTHORIZED BY ECD.

NOTE

Refer to para. 14-1 for explanatory notes on type 2 blade.

Special tools:

Tapping hammer Template

NOTE

Toolno.37 Tool no. 38

refer to Chapter 04 refer to Chapter 04

• AII inspections shall be performed on both sides of the blade. • It is recommended to repair even damage that does not exceed the specified zonal damage limits as described in para 14-17, and also repair eroded butt joints as described. This prevents the damage from spreading and thus requiring the blade to be repaired or replaced earlier than necessary. • If butt joints are eroded, moisture may penetrate the bonding joint of the erosion protective shells (in leading edge area), causing premature debonding.

1. Clean main rotor blade, using either dry cleaning solvent (CM 202) or degreasing agent (CM 209), then wipe dry. 2. Inspect main rotor blade for erosion damage. a. Erosion damage in ZONE 1 (see figure 14-5) is only permissible if the erosion protective shells (10) have not been penetrated. Erosion of the skin on the blade body in ZONE 2 is only permissible if not more than one ply of the laminate has been damaged. Refer to para 14-17 for ply repair procedure. b. Eroded buttjoints between metal parts and body are permissible. To prevent damage from spreading, it is recommended to fill eroded butt joints as follows: 1) Degrease butt joints with acetone (CM 203). 2) Fill butt joints with 2K adhesive paste (CM 671) and mask with adhesive film (CM 603). 3) Allow adhesive to cure, then peel off adhesive film and carefully sand excessive adhesive by hand, using 180 grit abrasive cloth. 4) Apply topcoat, refer to para. 14-17. 3. Inspect main rotor blade for impact damage. a. For impact damage on the erosion protective shells (10), referto step 12. b. Impact damage in Zone 1 (figure 14-6) is only permissible if it is not deeper than 2 plies and does not exceed 15 mm in diameter. A maximum of 4 damaged areas is permissible, but they must not be within 30 mm of each other, otherwise the main rotor blade must be repaired. If skin plies are damaged, referto para 14-17.

Revision 22

CHAPTER 14 Page 15

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_eurooopter

MAINTENANCE MANUAL BO 105

c. A maximum of three impact damage areas are permitted in lone 2 provided they do not exceed 2 plies in depth and total damage area does not exceed 10 cm 2 . d. Impact damage is permissible in lone 3 if individual damage areas are not deeper than 1 ply and have a diameter that does not exceed 30 mm. Up to 6 impact damage areas are permitted. provided they are at least 200 mm aparto e. lmpactdamage and damage such as chipping, debonding and cracks on bladetrailing edge in lone 4are not permissible. 4. Visually inspect main rotor blade for general damage. a. lnspect bonding jumper (23 and 24, figure 14-5), if installed, for condition and tight connections. Replace damaged bonding jumper. Tighten loose screw connection. For torque value, see figure 14-20. b. Inspect trim chamber (13) for condition. 1) Check cover attaching screws for tightness. 2) Remove and clean loose screws. brush-eoat them with locking compound (CM 683), then reinstall with 3 Nm torque load. c. Inspect trim tabs (11) for condition and tight installation. Replace loose rivets and damaged trim tabs per para. 14-15 or 14-16. d. Visually inspect tab (20) for damage such as chipping orcracks. Damage not exceeding 10%oftotal area isacceptable. otherwisethe main rotorblade mustbe repaired. Smoothen damaged plies with sandpaper (180). e. Inspectcuff (2) fordelamination between plies.lfthird ply isdamaged, the main rotorblade mustbe repaired. 5. Visually inspect main rotor blade in the blade root fitting area (see figure 14-6, DETAlL A) for cracks and delamination. If limits are exceeded, inform ECD Customer Service or have blade repaired. a. Cracks in the edges of neck shell and nose shell bondlines are permissible ifthey do not exceed 20 mm in length (spanwise) per bondline. b. Cracks in lone 1 (see figure 14-6) that originate at the cuff and propagate at random are permissible if they do not exceed a length of 20 mm. c. Delaminations in lone 1. neckshell and nose shell. that originate atthe cuff are only permissible if asingle delamination or the total area of all delaminations does not exceed 15 cm2 on each side of the blade. 6. With the main rotor blade installed, inspect blade root fitting. where possible, for mechanical damage. screws for correct safetying and for obstruction of the drain holes. if latter are present. a. Polish out mechanical damage if within permissible limits shown in figure 14-19 and final polish with 400 grit abrasive cloth. Rework of surface protection is not necessary. b. Clear obstructed drain holes with a suitable tool. c. lf screw locking devices are missing. check torque values and install new screw locking devices. For torque values. refer to figure 14-20. CHAPTER 14 Page 16

Revision 21

_eurocopter

MAINTENANCE MANUAL 80 10S

7. Visually inspect static discharger (18, figure 14-5) for condition and tight installation. Replace damaged static discharger i. a. w. para. 14-6. Retigten loose screw connection. Torque value 0.6 to 0.8 Nm. 8. Inspect PU film (3,6 and 21, figure 14-5) for debonding and damage. Replace debonded orworn-through PU film (3,6 and 21) per paragraph 14-14.lfthe PU film (21) is missing or has been worn through, inspect the adhesive butt joint of the erosion protective shell (10) for erosiono FiII eroded bonding joint to a maximum depth of 5 mm as described in the following . If erosion is deeper, have blade repaired. a.

Degrease butt joints with acetone (CM 203).

b.

FUI butt joints with 2K adhesive paste (CM 671) and mask with adhesive film (CM 603).

C.

Allow adhesive to cure, then peel off adhesive film and carefully sand away excessive adhesive by hand, using 180 grit abrasive cloth.

9. Inspect pendulum absorber (5, figure 14-5) for condition, refer to Chapter 844.

1 2 3 4 5 6 7 8 9 10 11 12 13

Blade root fitting Cuff PU film Identification plate Pendulum absorber PU film Nose shell Neck shell Balance weight 1 Erosion protective shell Trim tab Blade trailing edge Trim chamber

14 15 16 17 18 19 20 21 22 23 24 25

Hole for trim tab (blade underside) Balance weight 2 - Lead insert Roving Static discharger Base Trim tab PU film Conductive adhesive Bonding jumper Bonding jumper (if installed) Attaching hardware for bonding jumper

Erosion inspection zones ZONE1

Figure 14-5

Revision 21

ZONE2

Main rotor blade, type 2 (1 of 2)

CHAPTER 14 Page 17

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EUROCOPTER

MAINTENANCE MANUAL SO 105

DETAlLA

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Figure 14-6

Revision 19

Inspection zones on main rotor blade, type 2

CHAPTER 14 Page 19

_eurocopter

MAINTENANCE MANUAL 80 10S

10. Inspect erosion protective shell (10, figure 14-5) for debonding. If there is unacceptable bond separation, have the erosion protective shell replaced by ECO. EXCEEOING THE OAMAGE L1MITS CAN RESULT IN THE LOSS OF THE EROSION PROTECTIVE SHELL ANO CAUSE SEVERE MAIN ROTOR IMBALANCE. THE VIBRATIONS CAUSED BY THE UNBALANCEO CONOITION CAN OAMAGE THE HELlCOPTER

CAUTION

• Maintenance personnel engaged in testing the bonding of the erosion protective shell must have necessary practice and experience.

NOTE

• The bonded PU-erosion protective film need not be removed for the tapping test. a. Oebonds are acceptable and no inspection is required in: -

ZONE 1 (figure 14-8), beginning and end of erosion protective shell.

-

ZONE 2, leading edge area of erosion protective shell.

b. Inspect bonded joint of erosion protective shell in ZONE 3 and ZONE 4 (figure 14-8): The sound caused by tapping the erosion protective shell at both ends and in the balance weight area (9, 15 figure 14-5) is duller than in the remaining areas. Care must be taken to differentiate between this sound and the sound of a debond.

NOTE

1) Using special tapping hammer, tool no. 37 or a coin weighing approx. 10g, tap along the erosion protective shell in these zones and listen to the resulting sound: -

a good bond will sound Iight and hard,

-

debonds sound dull without resonance.

2) If a debond is detected in ZONE 3 (warning area) during the tapping test, have the erosion protective shell replaced by ECO: a) immediately, especially always when debonds extend into ZONE 4 and cause the acceptable debonding area in this zone to be exceeded, or b) at a later time in conjunction with "Special inspections after maintenance activity" per chapter 101-11. However, in this case, if any debonds extended into ZONE 4, they must not cause the acceptable debonding area in this zone to be exceeded.

11 the erosion protective shell is to be replaced at a later time, use a water-resistant felt-tip pen to mark the extent of the debond on the erosion protection, and make an accurate sketch of the debonded area. This will enable any increase in the debonded area to be detected at the next inspection.

CHAPTER 14 Page20

Revision 21

eeurooopter

MAINTENANCE MANUAL 80 105

3) If debonding is detected in ZONE 4 (aft edge areas) during the tapping test: a) Oebonds which do not exceed a total area of 5 cm 2 on each aft edge area of the erosion protective shell are acceptable. b) If debonds exceed a total of 5 cm 2 on each aft edge area of the erosion protective shell, have the erosion protective shell replaced by ECO: -

either immediateJy or at a Jater time if ECO Service Engineering issues a special permit allowing the main rotor blade to be kept in service. For this purpose, details must be given of all debonds and damage to the erosion protective shell. If the erosion protective shell is to be replaced at a later time, use a water-resistant felt-tip pen to mark the extent of the debond on the erosion protective shell, and make an accurate sketch of the debonded area. This will enable any increase in the debonded area to be detected at the next inspection.

11. Inspect erosion protective shell (10, figure 14-5) for cracks a. Cracks in the erosion protective shell are not permissible. b. Cracks are acceptable in the lacquer on the aft edge of the erosion protective shell (the erosion protective shell extends approx. 45 mm chordwise from the leading edge on upper and lower surfaces ofthe blade). 12. Inspect erosion protective shell (10, figure 14-5) for impact damage. Impact damage (dents) is permissible if: -

not more than one impact damage area is present, impact damage area has no sharp edges, erosion protective shell not penetrated, impact damage areas at least 100 mm apart from beginning to end of erosion protective shell, impact damage area is not more than 30 mm long spanwise and not more than 3 mm deep, and the resultant ridging is not more than 10 mm long chordwise on upper and lower surfaces (measured from the blade leading edge to aft upper and lower edges of the erosion protective shell, see fig. 14-3).

If damage Iimits have been exceeded, replace erosion protective shell. 13. Check for bulging on upper and lower surfaces of main rotor blade in the vicinity of balance weight1 (9, figure 14-5) by using template (tool no. 38), see figure 14-8A. If the respective marking and/or protective coating is no longer visible, restore markinglcoating first (refer to para 14-19). Bulging is acceptable up to a maximum height of 1.5 mm. If bulging limits are exceeded, consult ECO Customer Service or AEC in the USA prior to the next flight for advice on how to proceed. 14. Inspect protective coating on the upper surface of main rotor blade in the vicinity of balance weights (9,15, figure 14-5) for damage. Restore damaged protective coating (refer to para 14-19).

Revision 22

CHAPTER 14 Page 21

EUROCOPTER

MAINTENANCE MANUAL 80 105

Figure 14-7

Damage Iimits tor impact damage - erosion protective shell

20 Nose area

Leg area

20 Nose area

Leg area

Dimensions in mm Figure 14-8 Inspection zones - erosion protective shell (1 ot 2)

CHAPTER 14 Page22

Revision 19

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_eurooopter

MAINTENANCE MANUAL SO 105

BLANK PAGE

CHAPTER 14 Page24

Revision 22

_euro 00 pter

MAINTENANCE MANUAL 80 105

Not to scale AII dimensions in mm

DETAlL

A

Weight 1

1 2 3 4

Template (tool no. 38) Area of balance weight 1 (2 separate weights) Main rotor blade Top coat edge on the erosion protective shell

&

&

Sean area of balance weight 1 in chordwise direction as shown (upper and lower blade surfaces), and determine the highest point of any existing bulge. On main rotor blades, where the protective coat has been applied just up to the top coat edge at the erosion protective shell, additionally sean an at least 2 cm wide area in front of the top coat edge.

Figure 14-8A Inspection for bulging in the vicinity of balance weight 1

Revision 22

CHAPTER 14 Page24A

_eurooopter 14-4

MAINTENANCE MANUAL BO 105

REMOVAL - MAIN ROTOR BLADE

Special tools:

CAUTION

Blade retainer 105-15103 W13

• DO NOT BEND TRIM TABS WHEN SETTING DOWN MAIN ROTOR BLADE AS THIS COULD CHANGE THE BLADE TRACK. • IF A STATIC DISCHARGER IS INSTALLED ON THE MAIN ROTOR BLADE, REMOVE IT FIRST TO PREVENT IT FROM BEING DAMAGED.

1. Remove primary bolt per Chapter 13-10. 2. Remove secondary bolt per Chapter 13-16 or, if blade folding bolts are installed, remove these per Chapter 854. 3. If installed, remove static discharger (18, figure 14-1 or 18, figure 14-5) and attach it to the main rotor blade for reinstallation, using adhesive tape. 4. Raise main rotor blade at its tip and remove il. 5. Place main rotor blade in blade retainer

NOTE

10~15103

W13 or in suitable equipmenl.

• The following shall be observed when replacing or repairing main rotor blades: Opposite blades (blade pair) must have the same GTL. The GTL is the static spanwise balance moment and is recorded in the historical record. By use of balance weights, two classes of type 1 main rotor blades have been created, each with a different GTL, due to production-related differences in blade weight and weight distribution. Type 1 main rotor blade: Class 1 GTL = 14.710 kp or Class 2 GTL = 14.780 kp Type 2 main rotor blade: GTL = 19.391 kp • Blade repairs may cause the blade GTL to change. This requires that the GTL of the blade opposite the repaired blade be readjusted by the repair facility to that of the repaired blade. Otherwise they will be impossible to balance dynamically as a sel. • When returning main rotor blades for repair, include either the complete blade set (4 blades) for main rotor blade type 1 or at least opposite blade pairs for main rotor blade type

2.

CHAPTER 14 Page24B

Revision 22

EUROCOPTER

MAINTENANCE MANUAL BO 105

INSPECTION - MAIN ROTOR BLADE REMOVED

14-5

1. Inspect main rotor blade, type 1 in accordance with paragraph 14-2 or main rotor blade, type 2 in accordance with paragraph 14-3. 2. Inspect DU guard washers (1, figure 14-20) for condition. Replace both DU guard washers in accordance with paragraph 14-9 jf debonded, coating is worn down to the steel base, or depth measured from DU guard washer to DU guard washer on blade root fitting is less than the acceptable minimum of 74.70 mm. 3. Inspect teflon bushing (2) or DU dry bushings (20) for mechanical damage and wear. For the purpose of inspection, clean the bushings with acetone (CM 203). a. Scores and surface defects in the teflon coating are permissible, provided base material is not visible. If necessary, replace bushings per paragraph 14-8. b. Scores and surface defects in the coating of DU dry bushings (20) are permissible, provided base material is not visible. If necessary, replace bushings per paragraph 14-8. c.

Measure diameter of bushings. Maximum permissible diameter of bushings is 38.15 mm. If this dimension is exceeded, replace bushings per paragraph 14-8.

4. Inspect elastjc or teflon bushings (15) for mechanical damage, corrosion and wear.

I

a. Elastic bushings only: Remove mechanical damage and small spots of corrosion with 40Q-grit abrasive cloth. If corrosion is more extensive or rubber is separating, replace bushing per paragraph 14-8.. b. Measure diameter of bushing bores. Maximum permissible bore diameter 18.1 mm. It may be exceeded by 0.1 mm on 1/4 of the bore circumference. Replace bushings as necessary per paragraph 14-8. c. Teflon bushings only: Clean bushing with acetone (CM 203) priorto inspection. Scoring orchipping ofthe teflon coating is insignificant provided it does not expose the base material of the bushing. Replace bushings as necessary per paragraph 14-8. 5. Inspect blade root fitting for mechanical damage, screws for correct safety and for obstruction of the drain holes, if latter are present. a. Polish out mechanical damage jf within permissible Iimits shown in figure 14-19 and final polish with 400 grit abrasive cloth. Rework of surface protection is not necessary. b. Clear obstructed drain holes with a suitable tool. c.

If screw locking devices are missing, check torque values and install new screw locking devices. For torque values, refer to figure 14-20.

Revisjon 19

CHAPTER 14 Page25

I

-eurocopter

MAINTENANCE MANUAL 80 105

. . 11ft EADS

Company

14 - 6

INSTALLATION - MAIN ROTOR BLADE

Special tools: Torque wrench

NOTE

105-13101 W8

• When installing the main rotor blade, take note of the following: • Although blades can be replaced singly, it is recommended to replace the diametrically opposite blade at the same time in order to preclude track and balance problems. • If rotor blades to be installed are new or have been repaired, they must be tracked prior to the main rotor system being balanced (refer to Chapter 106). • Blade folding bolts may be installed instead of secondary bolts, refer to chapter 854. • Make sure that all bolts and bushings in a blad set or in pairs of opposite blades are of the same configuration. • A blade set (4 blades) may consist of any combination of the main rotor blade configurations approved for use on BO 105 helicopters, provided that opposite blades have the same GTL. Blades type 1 (see Chapter 14-1) and blades type 2 must not be used together.

I

-

• If pendulum absorbers are used, they must be installed on all four main rotor blades. • If PUR erosion protection tape is used, it must be installed on all four main rotor blades.

THE BALANCE WEIGHTS CONTAINED IN THE TRIM CHAMBERS AND USED FOR ADJUSTING THE BLADE GTL'S MUST NOT BE CHANGED. THIS WOULD EFFECTIVELY CHANGE THE DYNAMIC CHARACTERISTICS OF THE MAIN ROTOR BLADE. MOREOVER, THERE IS THE DANGER OF DAMAGING THE TYPE 1 MAIN ROTOR BLADE IF EXCESSIVE TORQUE IS APPLlED TO A POSSIBLY CORRODED SCREW WHEN OPENING THE TRIM CHAMBER. THIS WOULD THEN REQUIRE REPAIR WORK.

WARNING

1. Clean primary bolt and secondary bolt mating bores in the blade mounting fork of the main rotor head and in the blade end fitting, using dry cleaning solvent (CM 202) and wipe dry. 2.

Fit main rotor blade in blade mounting fork of the main rotor arm to which is coded.

3.

Fit primary and secondary bolts as described in Chapter 13. If blade folding bolts are installed, referto Chapter 854 for installation procedure.

4.

If previously removed, reinstall static discharger (18, figure 14-1 or 18, figure 14-5) as follows: a.

Clean thread of static discharger with acetone (CM 203).

b.

Coat outer end third of static discharger thread (see figure 14-9) with locking compound (CM 683) and screw static discharger to mating fitting. Torque value 0.6 to 0.8 Nm.

c.

Measure contact resistance between static discharger and mating fitting (see figure 14-10, Detail A). 1) The resistance must not exceed 5 ohms. 2)

-

If the resistance exceeds 5 ohms, remove, clean and reinstall static discharger.

CHAPTER 14 Page 26

-

Revision 25

EUROCOPTER

MAINTENANCE MANUAL 80 105

5. After main rotor blade is installed, check contact resistance as follows: a. Using a multimeter, measurethe contact resistance between the static discharger on the main rotor blade (for main rotor blade type 1only if static discharger is installed) and attaching hardware of blade root fitting (see figure 14-10). It must not exceed 1Ma. 1) If only one of the rotor blades is found to have a contact resistance in excess of 1Mil, make a note to this eftect in the historical record and correct at next opportunity. 2) If a contact resistance in excess of 1Mil is measured on more than one rotor blade, contact ECD for advice on how to proceed. b. Using a multimeter, measure contact between attaching hardware of blade root fitting and a bare metal area on main rotor head. The resistance must not exceed 5 il. If the resistance exceeds 5 inspect bonding jumper for condition and bonding jumper connections for tight fit. If necessary, remove attaching hardware, clean and reinstall (see figure 14-10).

n.

3

&

Locking compound (CM 683)

4

1 2 3 4

Mating fitting Thread Static discharger Trailing edge

Figure 14-9 Installation - static discharger

Revision 19

CHAPTER 14 Page27

I

MAINTENANCE MANUAL BO 105

EUROCOPTER

Measurement between static discharger and mating fitting

& DETAlL

A

Do nottake measurement on carbon part

Measurement between mating fitting and screw head on blade fitting

Measurement between screw head on blade fitting and rotor star

Figure 14-10

CHAPTER 14 Page 28

Measurement of the contact resistance

Revision 19

tteurooopter

MAINTENANCE MANUAL 80 105

14-7

REPAIR - MAIN ROTOR BLADE

14-8

Replacement of bushings - blade root fitting

Special tools:

Press Dismounting tool

•

commercial item P/N 117-15004 W6 or P/N 105-15103 W5

• Dismounting tool P/N 117-15004 W6, is used in the procedure described below. The procedure remains the same for dismounting tool P/N 105-15103 W5.

NOTE

• Two types of bushings are available for installation in the primary bolt mating bore in the blade fitting: Configuration 1: Configuration 11:

Teflon bushing 2 DU dry bushings and steel bushing

• When replacing the bushings, do not remove DU guard washers unless they are either debonded, worn down to the steel base, or the depth measured from guard washer to guard washer on the blade fitting is less than 74.70 mm. • Secondary bolts may be installed with either elastic bushings or teflon bushings. However, diametrically opposite blades must be fitted with the same type of bushings. When replacing the bushings in one blade, check the type of bushings installed in the opposite blade. The replacement bushings must be of the same type as in the opposite blade. 1. Replacement - teflon bushing (Configuration 1) for primary bolt. a. Remove DU guard washers (2, figure 14-11), if damaged, in accordance with paragraph 14-9. b. Place main rotor blade on a suitable support and align with press. c. Press out teflon bushing (3), using support (7) and drift (1) of tool P/N 117-15004 W6. d. Inspect bore in blade root fitting for silver plate residues and mechanical damage. Polish out silver plate residues and mechanical damage, using 400/600 grit abrasive cloth. Maximum permissible bore diameter is 46.03 mm.lt may be exceeded by 0.01 mm on a quarter ofthe bore circumference.lfthese Iimits are exceeded, replace blade root fitting. NOTE

• When installing the teflon bushings, take into account whether or not the DU guard washers are present on the blade root fitting and use the tools in accordance with figure 14-12. • Only teflon bushings with silver-plated outer diameter shall be installed.

e. Cool new teflon bushings (2, figure 14-12) or reusable removed bushings to - 50 oC.

1.

Using drift (1), support (6) and guide ring (5), align teflon bushing (2) with blade rootfitting bore and press into bore (see figure 14-12).

g. If the DU guard washers were previously removed, install new ones (refer to para 14-9). Revision 22

CHAPTER 14 Page 29

EUROCOPTER

MAINTENANCE MANUAL 80 105

Configuration I

r---2

5 "'~,*----

6

rA-----7

1 2 3 4

Drift DU guard washer Teflon bushing Roving (Blade)

Figure 14-11

CHAPTER 14 Page30

5 Blade root fitting 6 Guide ring 7 Support

Removal- Teflon bushing

Revision 19

EUROCOPTER

MAINTENANCE MANUAL BO 105

Conflguration I

M-------2

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7---___,. 3 ~--4

4 --t-"'\.

5

5

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Application of tool if DU guard washers are not installed

1 2 3 4

Drift Teflon bushing Blade root fitting Roving (Blade)

Figure 14-12

Revision 19

5 Guide ring 6 Support 7 DU guard washer

Installation - teflon bushing

CHAPTER 14 Page 31

MAINTENANCE MANUAL SO 10S

EUROCOPTER

2. Replacement - DU dry bushings (Configuration 11) for primary bolt These work steps shall be accomplished only upon removal of the dry bushings. For removal of dry bushings together with the steel bushings, refer to step 3.

NOTE

a. Remove DU guard washers (2, figure 14-13), if damaged, in accordance with paragraph 14-9. b. Place main rotor blade on a suitable support and align with press. c. Press out DU dry bushings (6), using support (8) and drift (1). d. 1nspect bore of steel bushing (4) for silver plate residues and mechanical damage. Polish out silver plate residues and mechanical damage,using 400/600 grit abrasive cloth. Maximum permissible bore diameter is 42.05 mm.lt may be exceeded by 0.01 mm on a quarter ofthe bore circumference.lf these limits are exceeded, replace steel bushing in same way as Teflon bushing (referto step 1.). e. If steel bushings was replaced, check diameter of steel bushing and, if necessary, ream to 0 42,03 ~~016 mm diameter . Deburr as necessary.

NOTE

1.

When installing the DU dry bushings, take into account whether or not the DU guard washers are present on the blade root fitting and use the tools in accor. dance with figure 14-14.

Cool new DU dry bushings or reusable removed bushings to - 50 oC.

g. Using drift (1, figure 14-14) support (8) and guide ring (7), align DU dry bushing (2) with bore of steel bushing (3) and press into bore. h. Turn main rotor blade over and install the second DU dry bushing. If there are no DU guard washers (6) bonded to the blade root fitting, fit spacer ring (9) over the end of the support so that the DU dry bushings (2) are made to protrude from the blade root fitting by an equal amount on both ends. i.

If the DU guard washers were previously removed, install new ones (refer to para 14-9).

CHAPTER 14 Page 32

Revision 19

MAINTENANCE MANUAL BO 10S

EUROCOPTER

Configuration 11

2 3 4

5 6

7 a:, io,

8

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2 DU guard washer 3 Blade root fitting 4 Steel bushing

Figure 14-13

Revision 19

5 Roving (Blade) 6 DU dry bushings 7 Guide ring 8 Support

Removal - DU dry bushings

CHAPTER 14 Page33

EUROCOPTER

MAINTENANCE MANUAL SO 105

Configuratlon 11

11-----2

r-----

3

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5

6 7

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1 Drift DU dry bushings Steel bushing Blade root fitting Roving (Blade)

2 3 4 5

Figure 14-14

CHAPTER 14 Page 34

Application of tool if DU guard washers are not installed

6 7 8 9

DU guard washers Guide ring Support Spacerring

Installation - DU dry bushings

Revision 19

EUROCOPTER

MAINTENANCE MANUAL 80 105

3. Replacement - DU dry bushings together with steel bushing (Configuration 11) for primary bolt. a.

•

Remove DU guard washers (2, figure 14-15), if damaged, in accordance with paragraph 14-9.

b. Place main rotor blade on a suitable support and align with press. c.

Using support (6, figure 14-15) and drift (1), press out steel bushing (8) and DU dry bushings (7).

d. Inspect bushing seat in blade root fitting for silver plate residues and mechanical damage. Polish out silver plate residues and mechanical damage, using 400/600 grit abrasive cloth. Maximum permissible bore diameter is 46.03 mm. It may be exceeded by 0.01 mm on a quarter of the bore circumference. If these limits are exceeded, replace blade root fitting.

NOTE

When installing the assembled steel bushing and both DU dry bushings, take into account whether or not the DU guard washers are present on the blade fitting and use the tools in accordance with figure 14-16.

e. Cool assembled steel bushing and DU dry bushings to approx. - 50 oC.

f.

Using drift (1, figure 14-16) and support (6), align assembled steel bushing and DU dry bushing with blade root fitting bore and press ¡nto bore.

g.

If the DU guard washers were previously removed, install new ones (refer to para 14-9).

Revision 19

CHAPTER 14 Page35

•

EUROCOPTER

MAINTENANCE MANUAL BO 105

Configuration 11

r----2

4 /~N----5

:'t-----6

a:

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g

1 2 3 4

Drift DU guard washer Roving (Blade) Blade root fitting

Figure 14-15

CHAPTER 14 Page36

5 Guide ring 6 Support 7 DU dry bushing 8 Steel bushing

Pressing-out - DU dry bushings with steel bushing

Revision 19

EUROCOPTER

MAINTENANCE MANUAL SO 105

Conflguration 11

t=~}--9

r---!----if-----9 ~-----8

-r=t--3 ~--4

L-74lI?o,J.----- 5

...~----6

Application of tool if DU guard washers are not installed

1 Drift

2 Teflon bushing 3 Blade root fitting

4 Roving (Blade) 5 Guide ring

Figure 14-16

Revision 19

3

4--+-"'-

5----f>.
6-----If'\.1

Application of tool if DU guard washers are installed

6 Support 7 DU guard washer 8 DU dry bushings 9 Steel bushing

Installation - DU dry bushings togetherwith steel bushing

CHAPTER 14 Page37

EUROCOPTER

MAINTENANCE MANUAL SO lOS

4. Replace elastic or teflon bushings for secondary boJt.

NOTE

Either elastic bushings or teflon bushings may be installed for secondary bolts. However, diametrically opposite blades must be fitted with the same type of bushings. When replacing the bushings in one blade, check the type of bushings installed in the opposite blade. The replacement bushings must be of the same type as in the opposite blade.

a. Place main rotor blade on support (6, fig. 14-17), then align with bench press and remove elastic or teflon bushings (4) together with bushing (5), using thrust piece (1) and pusher (2). b. If the bushings were installed with adhesive, remove all remaining adhesive from the bores. c. Visually inspect bore in blade root fitting for silver plate residues or solid film lubricant and for mechanical damage. Remove silver plate residues or solid film lubricant and mechanical damage with polishing cloth 400/600. Maximum permissible bore diameter is 25.02 mm. It may be exceeded by 0.01 mm on a quarter of the bore circumference. If these Iimits are exceeded, replace blade root fitting. d. Cool new elastic or teflon bushings (4) and bushing (5) to approx. -50 oC.

I

e. Align bushing (5) and either elasticorteflon bushings (4) with bore and install flush with blade fitting, using tool P/N 117-15004 W6.

CHAPTER 14 Page 38

Revision 19

EUROCOPTER

MAINTENANCE MANUAL BO 105

..---- 4

2-------H

5

3 4

3

5 4

6 l"-'t---

6

a::,

...

Olí o

I

J:

«

3,

g'" o

Removal of bushings

1 Thrust piece 2 Pusher 3 Blade root fitting Figure 14-17

Revision 19

Installation of bushings

4 Elastic bushing or teflon bushing

•

5 Bushing 6 Support Removal and installation - elastic bushings or teflon bushings

•

CHAPTER 14 Page39

MAINTENANCE MANUAL SO 105

EUROCOPTER

14-9

Replacement of DU guard washers - blade root fitting

Special tools: Bonding device

P/N 105-15103 W6

1. Remove DU guard washers (2, figure 14-18) with suitable tool and discard them. 2. Remove residues of adhesive from both halves of blade root fitting with abrasive cloth (400) and clean with trichlorethylene (CM 204). 3. Roughen bonding surfaces of new DU guard washers with steel wool and clean with trichlorethylene (CM 204). 4. Apply a thin coat of adhesive (CM 671) to bonding surfaces of blade fitting and DU guard plates. 5. Position DU guard washers on blade root fitting. Install bonding device P/N 105-15103 W6 as shown in figure 14-18 and hand-tighten nut. 6. Allow the adhesive compound to cure for approximately 6 hours at room temperature. 7. Remove bonding device and inspect DU guard washers for proper adhesion.

__- - 2 /~f-----3

----- 2

&

1 2 3 4

Bonding device DU guard washer Blade root fitting Teflon bushing

Two DU dry of bushings with steel bushing can be installed in place of Teflon bushing.

Figure 14-18

CHAPTER 14 Page40

Bonding - DU guard washers

Revision 19

EUROCOPTER

14 -10

NOTE

MAINTENANCE MANUAL BO 10S

Disassembly - blade root fitting

When disassembling the blade root fitting, it is recommended to remove the DU dry bushings (20, fig. 14-20), if these are installed and undamaged. together with the corresponding steel bushing (21) using tool set P/N 117-15004 W6 or locally manufactured tool set P/N 105-15103 W5.

1. Remove teflon bushing (primary bolt) and either eiastic or teflon bushings (secondary bolt) per paragraph 14-8.

I

2. Remove lockwires and split pins. 3. Remove attaching hardware. Drive out bolts with a soft metal drift and a hammer if necessary. 4. To prevent conductive strip (5, figure 14-20) or bonding jumper (22) (only for main rotor blade type 2) from being tom off, secure it to main rotor blade with adhesive tape. If bonding jumper (19) is installed, retain it for reinstallation. 5. Separate the two halves of the blade root fitting (16) by tapping them with a plastic maJlel. If necessary, drive plastic or wooden wedges between the two halves of the blade root fitting.

14-11

Inspection and repair - blade root fitting and blade thimble

1. Inspect necked-down bolts (4, figure 14-20) for condition. Polish out corrosion and scores with polishing cloth (400). 2. Inspectteflon bushing (2) or steel bushings (21), elastic orteflon bushings (15) and bushing (17) for damage to the silver plating or solid film lubricant coal.ln addition, inspect inner diameter of bushing (17) for mechanícal and corrosion damage. a. Separation of the silver plating or solid film lubricant coat on not more than 10% of the surface area and minor scores are permissíble without rework. Replace bushíng if damage is more severe. b. Polish out mechanical damage and corrosion on bushing (17) with polishing cloth (400). Max. permissible innerdiameter is 18.8mm.lt may be exceeded by 0.1 mm along aquarterof itscircumference.lftolerance is exceeded, replace bushing. 3. Inspect blade root for damage, polish out and round off any scores or pressure marks. 4. Inspect resin coating on blade root for condition. If the damaged resín coating area exceeds 5% of the entíre blade root area, have blade repaired or repair per paragraph 14-18. If damage is 5% or less, proceed as follows: a. Using a file or abrasive cloth, carefully remove loose resín coating without damaging the GRP skin of the blade rool. b. Clean blade root with acetone (CM 203) and wipe dry. Revision 19

CHAPTER 14 Page41

I

MAINTENANCE MANUAL SO 10S

EUROCOPTER

a:

!~I o

g

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1 ZONE 2 B1¡f[@f@!~ ~

Mechanical

0.2 mm in depth

Figure 14-19

1 2 3 4 &15 6 7 8 9 10 11 12

&

&

CHAPTER 14 Page42

Blade root fitting - damage and repair Iimits

DU guard plate Teflon bushing Bolt Necked-down bolt Conductive strip (if installed) Cuff Washer Nut Split pin Washer Nut Split pin Bild 14-20

0.4 mm in depth

& & &

13 14 15 16 17 18 19 20 21 22 23 24

Nut Washer Elastic or teflon bushing Half of blade root fitting Bushing Screw Bonding jumper (if installed) DU dry bushing Steel bushing Bonding jumper (if installed) Screw Washer

1

1

I

Blade reot fitting, disassembled (1 of 2)

Revision 19

EUROCOPTER

MAINTENANCE MANUAL BO 105

lIIE.'I"'---

5

8-12 Nm

~

22------,.5-----..,.

21

20~

Lh Cuff (6), depending on the configuration of main rotor blade &

Depending on the configuration, the blade root fitting can be equipped with teflon bushing (2) or with DU dry bushings (20) and steel bushing (21) .

.6.. Depending on the configuration, the main rotor blade can be equipped with conductive

ffi

strip (5) or bonding jumper (22), if installed

Figure 14-20

Revision 19

Blade root fitting, disassembled (2 of 2)

CHAPTER 14 Page43

EUROCOPTER

14 - 12

MAINTENANCE MANUAL 80105

Assembly - blade root fitting

1. Coat blade root fitting mating area with a thin and even film of parting and sliding agent (CM 720) and allow to dry. Repeat this procedure three times. Polish blade root fitting mating area afier each application of the sliding agent.

r

Fit both halves of blade root fitting over blade thimble and attach together with screws. At same time, if present, install conductive strip (5, fig. 14-20) ) or bonding jumper (22), only for main rotor blade type 2, and bonding jumper (19). Tighten nuts (8,11 and 13) to torque as indicated in fig. 14-20 and safety nuts with split pins (9 and 12).

3.

Install teflon bushing (2) or DU dry bushings (20) with steel bushing (21) per paragraph 14-8.

4.

Install elastic bushings or teflon bushing (15) and bushing (17) per paragraph 14-8.

5.

If DU guard washers (1) have been removed, reinstall new ones per paragraph 14-9.

6. The following check only applies to main rotor blade, type 1. a. If static discharger was installed, using multimater, measure contact resistance between static discharger (18, fig. 14-1) and bonding jumper (23). -

The resistance must not exceed 1MQ.

-

If the resistance exceeds 1MQ, check conductivity at static discharger and at blade fitting. If necessary, improve conductivity by reworking respective contact surfaces.

7. The following check or measurement only applies to main rotor blade, type 2. a.

b.

If bonding jumper (22, fig. 14-20) was installed, using multimeter, measure contact resistance between static discharger (18, fig. 14-5) and bonding jumper (23). -

The resistance must not exceed 1MQ.

-

If the resistance exceeds 1MQ, check conductivity at static discharger and at blade fitting. If necessary, improve conductivity by reworking respective contact surfaces.

If no bonding jumper (22, fig 14-20) was installed, apply fillet of conductive sealant (CM 669) to between joint area of blade root fitting and main rotor blade as follows: 1) Clean blade root fitting halves (15) and neck of rotor blade, using acetone (CM 203). 2) Sand neck of blade at junction to the blade root fitting to expose bare metal of silver conductive paint coating. 3) Apply conductive sealant (CM 669) around entire edge of blade root fitting at the junction to the blade. 4) Using multimeter, measure contact resistance between static discharger (18, fig. 14-5) and blade root fitting (1). -

The resistance must not exceed 1MQ.

-

If the resistance exceeds 1MQ, check conductivity at static discharger and at blade root fitting. If necessary, improve conductivity by reworking respective contact surfaces.

CHAPTER 14 Page44

Revision 19

EUROCOPTER

14-13

MAINTENANCE MANUAL 80 10S

Bonding - PUR erosion protection tape in tip area of Type 1 main rotor blade

Special tools: Template

Tool No. 29 (105-15103 W9)

refer to Chapter 04

1. General The polyurethane erosion protection tape (PUR tape) seNes to protect the erosion protective shells and the blade leading edge against erosion, and provides the erosion protective shells with a longer seNice life.

• AII the blades of a main rotor must be fitted with PUR tape.

NOTE

• If PUR tape is being applied for the first time, step 2.b. and c. are not applicable. However, before bonding the PUR tape to the blade, the erosion protective shells and the area to be covered by the tape should be examined for signs of damage. 2. Bonding PUR tape on blade. a. If necessary, remove main rotor blade per para. 14-4. b. Using hot-air blower, heat PUR tape to max. 50 oC and peel it from blade. c.

Remove adhesive residue, using toluene (CM 219).

d. Clean main rotor blade with dry cleaning solvent (CM 202). e. Cut PUR tape (CM 659) to size using template tool no. 29 (105-15103 W9).

1.

Place center marks on main rotor blade and PUR tape as shown in figure 14-21, using a felt-tip peno

g. Clean PUR tape bonding area on main rotor blade with acetone (CM 203). h. Remove protective backing from cut-to size PUR tape.

• The bonding surface on PU R tape and main rotor blade must be free of foreign matter,

NOTE

• During the bonding process, the ambient temperature and the temperature of the parts to be bonded should not be below + 20 oC. The relative air humidity must not exceed 60%. • Adhesion will ¡ncrease if the main rotor blade is stored for 24 hours after bonding.

i. . Align center marks and, beginning at the extreme leading edge, attach PUR tape to main rotor blade per figure 14-21 while working our wrinkles and air bubbles at the same time.

j. ·If removed, install main rotor blade (referto para. 14-6).

Revision 19

CHAPTER 14 Page45

I

MAINTENANCE MANUAL BO 105

EUROCOPTER

Center line

//r----+----rcJl'---- Adhesive tape Center mark

=

=

VIEW

Figure 14-21

CHAPTER 14 Page 46

A

Bonding of erosion protection tape

Revision 19

EUROCOPTER

14 -14

MAINTENANCE MANUAL BO 105

Replacement - PU film

NOTE

• The PU film (erosion protective film) must be applied in the same place on all four blades of a sel. • The PU film protects the bonding joints at the ends of the erosion protective shells on the main rotor blades against erosion (washouts).

1. Peel damaged PU film from main rotor blade, remove residual adhesive and clean bonding area on blade for attachment of new PU film, using acetone (CM 203). 2. Allow cleaned area on blade to air dry for at least 10 minutes. 3. Using felt-tip pen, mark the dimensions for PU film bonding area on blade per figure 14-23, then coat the area for the new Pu film with primer (CM 750) and allow to air dry for least 30-60 minutes. 4. Cut PU film. Main rotor blade Type 1 Figure 14-23 (1 of 2)

Type2 Figure 14-23 (2 of 2)

Item

Qty

Size of PU-Film

(1), Nose area

1x

Length 230 mm, Width 150 mm (provide cutout for placard)

(2), Nose area

1x

Length 297 mm, Width 150 mm

(3), Erosion protective shell

3x

Length 150 mm, Width 110 mm

(4), Nose area

1x

Length 590 mm, Width 150 mm for main rotor blade without sleeve (provide cutout for placard)

(4), Nose area

1x

Length 645 mm, Width 150 mm for main rotor blade without sleeve and cuff (provide cutout for placard)

(4), Nose area

1x

Length 230 mm, Width 150 mm

(5), Nose area

1x

Length 297 mm, Width 150 mm

(6), Erosion protective shell

2x

Length 150 mm, Width 110 mm

5. Mark center line of erosion protective shell on blade, using felt-tip peno 6. Mark center line of PU film per figure 14-22, using felt-tip peno 7. Peel protective backing from PU film (see figure 14-22). 8. Apply PU film along length of erosion protective shell on the extreme leading edge of the blade. 9. Work out any bubbles under the PU film away from the extreme leading edge spanwise towards the trailing edge. Any bubbles remaining under the PU film may be removed by pricking them with a pin and pressing down the PU film.

I

10. Peel off remaining sections of protective backing and apply PU film bubble-free in spanwise direction. Revision 19

CHAPTER 14 Page47

MAINTENANCE MANUAL 80 10S

EUROCOPTER

'"

PU-film, front

tr

Mari<

Widt h

/1

'"

~R5

Length

------------------------------------------------------------------------_

PU-film, backing

_

=------------------------------------~

~r~r::,~ri~e

X ___________________________________

Mari< on front

backing

~------------------------------------

Figure 14-22

CHAPTER 14 Page48

Marking of PU film, P/N 8681-HS-SS-36173

Revision 19

MAINTENANCE MANUAL 80105

EUROCOPTER

l:!I>

Main rotor blade, Type 1

I

IJ I

I

)< )< )<

3

U I I

3

Main rotor blade without cuff and without sleeve

U

~Ir

--r--------J

)<

I I I I I I I I I I I

55·3

3

It-----&X -X

S' !2.

...

lt)


(X)

'
C')

lt)

Main rotor blade without sleeve

Ñ

'
lt)

N

2

~

/i-t----l

)( )<

lt)

ci)

...

O)

><x ><x

lt)

X

Dimensions in mm

-0

1

)<

c:?

o

;¡; )< N

...

O

(X)

20.2

-,I I

_1

ro--

¿~~ri» \.~(Jjf"

Bild 14-23 Bonding PU film on main rotor blade Type 1 (1 of 2)

Revision 19

CHAPTER 14 Page49

EUROCOPTER

MAINTENANCE MANUAL BO 105

Main rotor blade, Type 2

,,I , I

I

I

I

I

, , ,, , ,, I

I

I

I

I

I

I

I

Dimensions in mm

Figure 14-23 Bonding PU film on main rotor blade Type 2 (2 of 2)

CHAPTER 14 PageSO

Revision 19

EUROCOPTER

14 -15

MAINTENANCE MANUAL BO 105

Riveting - trim tab

1. Transfer rivet pattern to all trim tab attach tabs. Retain existing edge clearance. 2. Drill a 2.2 mm dia. hole for rivet to be installed. 3.

Ream rivet hole to 2.5 mm dia. and deburr as necessary;

4. Insert rivet (LN 9198-2406B) in hole so that it can be headed on the trim tab. 5. Attach all trim tabs with rivets. 6. Coat rivet heads on both sides of trim tab with single-Iayer lacquer (CM 410) (also available in aerosol cans).

14 -16

Replacement - trim tab

Special tools: Bonding tool P/N 105-15103 W4 Commercial equipment and work aids: Vertical boring mili Spiral drills, 2.2-, 2.5-mm-diameter Chisel Steel scraper File Polyethylene container or non-paraffin-base carton Rinsing container with destilled water Rivet crushing tool Abrasive cloth, 180 grit Cloth (dry, clean, lint-free) Circulating air oven Thermal insulation Block of wood 1. Remove main rotor blade, refer to paragraph 14-4. 2. Drill out rivets (1, figure 14-25) in trim tab, using a 2.2 mm dia. drill, then remove all traces of rivets. CAUTION

DO NOT ALLOW ADJACENT BLADE SKIN TO BE DAMAGED BY THE HEAT FROM THE HOT-AIR BLOWER. DIRECT HOT AIR BLAST AWAY FROM THE BLADE SKIN.

3. Mask adjacent area of blade skin with thermal insulation as shown in fig. 14-24. Directthe hot-air blower (4) as shown in fig 14-24, so that the hot-air blast strikes the trim tab (1) only. Slowly warm the trim tab (1) with the hot-air blower (4), then pry it off with a chisel. Discard removed trim tab (1).

Revision 19

CHAPTER 14 Page 51

MAINTENANCE MANUAL 80105

EUROCOPTER

--+-----2 ..,,-----3

;fffl~~---4

,,--+----- 5

.. .. -.:: .. 1 2 3 4 5

Trim tab Main rotor blade Thermal insulation Hot-air blower Adhesive film (CM 603)

Figure 14-24

Removal of trim tab

4. Remove residual adhesive and paint with a scraper, and sand bonding surface on the blade trailing edge with 18Q-grit abrasive cloth. 5. Inspect blade trailing edge in the trim tab area for damage. If delamination, cracks or chipped areas are evident, have main rotor blade repaired.

CHAPTER 14 Page 52

Revision 19

EUROCOPTER

MAINTENANCE MANUAL BO 105

6. Prepare trim tab for bonding. a. If installing prefabricated trim tabs, remove black peel ply. Do not touch exposed bonding surface. The bonding surfaces of anodized and primed trim tabs shall not be touched either.

I

7. Clean bonding surfaces on blade trailing edge with acetone (CM 203). 8.

Prepare 2K adhesive paste (CM 671) or mix adhesive (CM 640) with hardener (CM 641) in accordance with manufacturer's instructions.

I

9. Apply a thin coat of adhesive to the bonding surface of blade trailing edge and trim tab. 10. Place trim tab on blade trailing edge so that: a. if the existing rivet holes in the trailing edge are used, these align with the bores in the trim tab.Spacing dimensions in fig. 14-25, as applicable, must be complied with. b. if there are no rivet holes (e.g. after repair of the blade trailing edge) in the trailing edge, these must be dril!ed to meet the spacing dimensions in fig. 14-25 as applicable. 11. After aligning the trim tab, attach it firmly to the main rotor blade with adhesive tape (CM 603). 12. Spray the grips of bonding tool, P/N 105-15103 W4, with parting agent (CM 709). 13. Press trim tab onto blade trailing edge, using bonding too1105-15103 W4. 14. Allow adhesive to cure at room temperature for approx. 24 hours. 15. After the adhesive has cured, remove bonding tool and remove high spots of adhesive, using a file or chisel. 16. Dril! 2.5 mm dia. rivet holes in blade trailing edge. Use block of wood as a back-up to prevent the dril! breaking out pieces of the trailing edge when it comes through the other side. 17. Insert rivets (LN 9198-2406B) in the rivet holes so that they can be headed on the trim tab.

Revision 19

CHAPTER 14 Page 53

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MAINTENANCE MANUAL BO 105

EUROCOPTER

18. Clean surfaces to be painted. using acetone (CM 203). 19. Cover blade area around surface to be painted. using masking tape (CM 609). 20. Mix two-component zinc chromate primer (CM 417) with hardener (CM 435) and thinner (CM 436) in accordance with manufacturer's instructions and apply to trim tab. Allow to cure at room temperature. 21. Mix two-component PUR topcoat (CM 412) with hardener (CM 420) and thinner (CM 413) in accordance with manufacturer's instructions and apply to repair area. Allow to cure at room temperature. 22. Remove masking tape 1 to 4 hours after paint application.

Maln rotor blade. Typ 1

4

3065 ± 3

3

3

2

Maln rotor blade, Type 2 1 2 3 4

Dimensions in mm

Figure 14-25

CHAPTER 14 Page54

Rivet (LN 9198-2406B) Main rotor blade Trim tab Blade trailing edge

Replacement - trim tabs

Revision 19

EUROCOPTER

14 - 17

MAINTENANCE MANUAL BO 105

•

Repair of damage on main rotor blade

1. Repair of damage to surface protection.

Local damage can be repaired by spot-painting with single-Iayer lacquer (CM 41 O) or spray. The surround-I ing areas of the blade must be suitably masked. Alternatively, a two-component PUR top coat may be used (refer to step 2.). a. Mask area adjacent to damage area with commercial adhesive tape. b. Sand damaged area of surface protection by hand, using 220 grit or finer abrasive cloth. c. Wipe off sanding residues, clean damaged area with PUR thinner (CM 413) and wipe dry.

•

d. Apply single-Iayer lacquer (CM 410) or two-component PUR top coat (refer step 2). e. Allow lacquer to dry at room temperature for approx. 12 hours.

1.

Final polish the edges of the lacquer coat using commercial polish.

•

2. Repair of damaged glass fiber laminate (damage less than 2 plies). a. Thoroughly clean main rotor blade with dry cleaning solvent (CM 202). b. Using abrasive cloth (220 or finer), abrade by hand the damaged fibre layers. c. Remove abrasion residues and clean damaged area with acetone (CM 203). d. Mask with adhesive tape any areas not being repaired. e. Prime the abraded damaged area twice with UPfiller, made up from UP putty (CM 303) and UP hardener (CM 304) in a ratio of 100: 1.5 or 2 K adhesive paste (CM 671). Apply a thin layer of UP filler, working towards the trailing edge of the blade. The glass fibre surface should remain visible.

1.

After about 1.5 hours, apply the second, thin layer of UP filler, working towards the erosion protective shell, and allow to cure for 5 hours at room temperature.

g. Wet-grind the primed area with wet abrasive paper (320). Remove abrasion residue and clean repaired area with PUR thinner (CM 413) and a Iint-free cloth. h. Before applying surface protection, check whether erosion protective shell and end cap (depending on the main rotor blade configuration) also require a fresh coat of paint. If so, prime the parts as specified in steps i. to k., then proceed in accordance with steps 1. to o. i.

Clean erosion protective shell or erosion protective shell and end cap (depending of the main rotor blade configuration) with degreasing agent (CM 209).

j.

Mix wash primer (CM 423) with hardener (CM 419) in a ratio of 4:1,then add thinner (CM 414) to achieve a spray viscosity of 14-16 seconds, measured in a DIN standard measuring beakerwith a funnel diameter of4mm.

Revision 19

CHAPTER 14 Page55

EUROCOPTER

MAINTENANCE MANUAL 80 10S

k. After a 3O-minute pre-reaction time, apply wash primer to the surface to be primed, using a spray pressure of 3 to 5 bar and a spray nozzle with a diameter of 1.2 mm. Allow a drying time of 30 minutes at room temperature.

1.

Make up surface protection from PUR topcoat (CM 412) and hardener (CM 420) in a ratio of 5:1, then add thinner (CM 413) to achieve a spray viscosity of 14-18 seconds, measured in a DIN standard measuring beaker with a funnel diameter of 4 mm.

m. After a 3D-minute pre-reaction time, apply surface protection to the surface being repaired, using a spray pressure of 3 to 5 bar and a spray nozzle with a diameter of 1.2 mm. n. Dry the surface protection for approx. 24 hours at room temperature. o. Final polish the edges of the surface protection with commercial polish.

CHAPTER 14 Page56

Revision 19

EUROCOPTER

14 - 18

MAINTENANCE MANUAL BO 105

Renewal - resin coating

NOTE

This bonding process may only be performed by personnel who have been trained for this purpose by the manufacturer, and have the prescribed tools for the jobo

Special tools: Resin applicator, Blade root fitting Alignment device

105-15181 W22 105-15181 W50 TAKE CARE NOT TO DAMAGE THE BLADE ROOT WHEN REMOVING THE ADHESIVE LAYER.

CAUTION

~_--2

; a:I

4

g

1 2 3 4

3

Figure 14-26

Roving laminate Nose shell Neck shell Fabric skin

Blade root structure

1. Mask cuff (2, fig. 14-27) using adhesive film (CM 603). 2. Using a file or abrasive cloth, carefully remove resin coating to a depth of not more than 1 mm. 3. Fit blade root ¡nto blade root fitting halves: a. Place blade root fitting upper half (16, fig. 14-20) on bolts of alignment device 105-15181 W50. b. Place main rotor blade, top side facing down, in the blade retainers of alignment device. Revision 19

CHAPTER 14 Page57

MAINTENANCE MANUAL 80 105

EUROCOPTER

c.

Using feeler gauge, measure clearance between blade root and blade root fitting. Clearance all round must be 0.2 to 1.0 mm. If the clearance exceeds 1.0 mm, consult Customer Service on how to proceed.

d.

Remove blade root fitting upper half from alignment device and fit blade root fitting lower half (16) in its place. Place main rotor blade, top side facing up, in the blade retainers of the alignment device.

e.

Repeat step c.

4. Clean blade root and both halves of blade root fitting with acetone (CM 203). After cleaning, do not touch cleaned surfaces with bare hands. 5. Affix ten spacing stickers as shown in fig.14-27. For the bonding process, do not use the bolts, washers and nuts intended for final assembly.

NOTE

6. Apply a thin, uniform all-round film of parting and sliding agent (CM 709) to both halves of the blade root fitting and on all associated bolts, washers and nuts. Allow to dry and then polish. Lightly lubricate bolt shanks (not threads) and all bores with grease (CM 101). 7. Cut PVC film (0.1 mm thick) to match the outline of the mating faying surfaces of blade root fitting halves and place it on the lower half of the blade root fitting. 8. Mix 180 9 of resin: - resin (CM 640) - hardener (CM 641) HEALTH PRECAUTIONS: The hardener causes irritation of the eyes and mucous membranes. Therefore, wear protective gloves and goggles during the mixing procedure. If hardener gets on skin, wash immediateIy with soap and warm water. If it gets into eyes, flush them immediately with water for 15 minutes, then obtain immediate medical attention. For additional health and safety information in this respect, consult CIBA GEIGY Publication No. 24264/d.

Mixing instructions: Mixing ratio by weight: -

Resin 100 parts Hardener 20 parts

Thoroughly mix both components carefully to a uniform consistency (no streaks). For this purpose, use clean beakers and stirring rods only. The working Iife of the mixture is approx. 65 minutes at 25°C. Heat resin to approx. 60 oC. Coat root end uniformly with 120 9 of the resin and assemble the root end halves on root end. For torque value, refer to fig. 14-20. 10. Wipe off excessive resin squeeze-out. 11. Immediately fit main rotor blade in resin applicator 105-15181 W22. a.

Fit heating pin (4, fig. 14-28) and rigging pin (3) through blade root fitting bores.

b. Using detent (2), clamp main rotor blade in position on resin applicator so thatthe scale pointer is between both red markings. c.

Heat heating pin to approx. 80 oC. for 2 hours. Pour in additional resin as necessary.

CHAPTER 14 Page58

Revision 19

EUROCOPTER

MAINTENANCE MANUAL 80 105

d. Allow heating pin to cool until it can be pulled out without force. e. Remove main rotor blade from resin applicator.

1.

Detach root end fitting and remove PVC film.

g. Clean root end fitting halves and root end of blade with acetone (CM 203). h.

Remove bead of resin all round so that it protrudes only Oto 0.7 mm above the resin coating.

i.

Inspect resin layer. Single shrinkage cavities are permissible as long as their total area does not exceed 10% of the total resin layer.

j.

Remove adhesive film from cuff.

k.

Assemble blade root fitting per para.14-12.

VIEW 2

50

5

1 Blade root 2 Cuff marked with adhesive film (CM 603) 3 Spacing stickers (10 off)

Figure 14-27

Revision 19

A

3

Affixin~ the

Dimensions in mm

spacing stickers

CHAPTER 14 Page 59

I

MAINTENANCE MANUAL BO 105

EUROCOPTER

1 2 3 4

5 6 7 8

Pointer Detent Rigging pin Heating pin

Temperature recorder Power supply Temperature control limer

7

8

~: ~

2

~l-+-+-I-I 11---5

4

Figure 14-28 Application of resin applicator 105-15181 W22

CHAPTER 14 Page60

Revision 19

_eurooopter 14 -19

NOTE

MAINTENANCE MANUAL 80 105

Restore protective coating and inspection marking in the balance weight areas - main rotor blade type 2 On main rotor blades, whose top coat ends at the erosion protective shell, apply protective coating just up to this top coat edge at the erosion protective shell. The erosion protective shell areas have to be kept free of paint in this case.

1. Mask off balance weight areas 1 and 2 (9,15 figure 14-5) La.w. figure 14-29 by using adhesive tape on the upper surface of the main rotor blade. Use suitable masking material to prevent paint from spraying on to adjacent blade surfaces. 2. Using abrasive cloth (320 grit or finer), sand top coat in masked area by hand. 3. Clean sanded area with PUR thinner (CM 413), then wipe area dry. 4. Apply coating of singl~layer lacquer (CM 427) and allow to dry at room temperature per manufacturer's instructions. 5. Polish edges of paint coat by using commercial polishing compound. Sand a beveling at the front edge (pressure edge) using abrasive cloth (320 grit or finer). 6. Mari< boundary of balance weight area 1 (9 figure 14-5) La.w. figure 14-29 on the lower surface of the main rotor blade by using a water-resistant feIt-tiP pen. On main rotor blades, where the protective coat has been applied just up to the top coat edge at the erosion protective shell (see note on top of this page), additionally marl< an approximately 2 cm wide area in front of the protective coating.

Revision 22

CHAPTER 14 Page 61

_eurocopter

MAINTENANCE MANUAL BO 105

75

Not to scale AII dimensions in mm

fri"'!"

&

& Top coat edge on the erosion protective shell

Coat marked areas on blade upper surface with protective coating (white paint, CM 427). On main rotor blades, whose top coat ends at the erosion protective shell, apply protective coating just up to this top coat edge at the erosion protective shell. The erosion protective shell areas have to be kept free of paint.

Mark balance weight area 1 on blade lower side (broken line area), using permanent marker. On main rotor blades, where the protective coating on the upper surface has been applied just up to the top coat edge of the erosion protective shell, additionally mark an approximately 2 cm wide area in front of the protective coating using a permanent marker. 3

Figure 14-29

CHAPTER 14 Page 62

Application of protective coating and inspection marking in the balance weight areas

Revision 22

_eurocopter 14 - 20

MAINTENANCE MANUAL 80 105

STORAGE, PACKAGING AND SHIPPING - MAIN ROTOR BLADE

1. Use original container for storage or shipping. 2. Store main rotor blades so that they are safe from damage. 3. Main rotor blades being returned for repair shall be shipped in sturdy containers, preferably in original container P/N 102074-44-S000410001WD. The blades must be stowed and secured in the container so that no damage is sustained during transport, even if the container is subjected to rough or careless handling. Cut-to-size foam cüshions are especially suitable for storage protection in the container. Each main rotor blade is wrapped separately in polythene sheeting. The containers must not be overloaded. Container Iids must be secured, e.g. by steel straps.

Revision 22

CHAPTER 14 Page 63

_eurocopter

MAINTENANCE MANUAL SO 105

BLANK PAGE

CHAPTER 14 Page 64

Revision 22

fleurocopter

MAINTENANCE MANUAL MBB - BO 105

21

F U S E LAG E

Table of Contents

Paragraph

Title

21 - 1

DESCRIPTION - FUSELAGE

3

21 - 2

REPAIR - FUSELAGE

3

21 - 3

INSPECTION FOR CONDITION - FUSELAGE

15

21 - 4

F o 1 d i n g

d o o r

25

21 - 5

Removal - folding door

25

21 - 6

Inspection and repair - folding door

25

21 - 7

Installation - folding door

25

21 - 7A

Removal - door handle (folding door)

21 - 78

Installation - door handle (folding door)

21 - 8

S 1 i d i n g

21 - 9

Removal - sliding door

27

21 - 10

Inspection and repair - sliding door

27

21 - 11

Installation - sliding door

27

21 - 11A

Removal - coor handle (sliding door)

21 - 11B

Installation - door handle (sliding door)

21 - 12

Re a r

21 - 13

Removal - rear door

29

21 - 14

Inspection and repair - rear door

29

21 - 15

Installation - rear door

30

21 - 16

s

33

21 - 17

Removal - spoiler

Revision 6

Paqe

d o o r

d o o r

poi 1 e r

* * 26A * *

26A

27

* * 29 * * 29 * * 29

33

BO 105 CHAPTER 21 Page 1

_eurocopter Paragraph

MAINTENANCE MANUAL M88 - 80 105

Title

Page

21 - 18

Inspection and repair - spoiler

33

21 - 19

Installation - spoiler

33

21 - 20

Wi n d o w s

35

21 -21

Cleaning - windows

35

21 - 22

Removal - upper windshield

35

21 - 23

Installation - upper windshield

36

21 - 24

Removal - lower windshield

38

21 - 25

Installation - lower windshield

39

21 - 26

Removal - cabin roof window

43

21 - 27

Installation - cabin roof window

43

21 - 28

Removal - folding door window

45

21 - 29

Installation - folding door window

45

21 - 30

Removal and installation - sliding door window

48

BO 105 CHAPTER 21 Page 2

Revision 6

EUROCOPTER

21 - 1

MAINTENANCE MANUAL 80105

DESCR1PT10N - FUSELAGE

The fuselage is a light-alloy, semi-monocoque construction, comprlslng airframe, folding doors, sliding doors, rear clamshell door, windows and floor panels.

21 - 2

REPA1R - FUSELAGE

1.

For fuselage material identification, refer to figure 21-1.

2.

Repair local damage according to FAA Publication, AC 43.13-1A, A1RCRAFT 1NSPECT10N AND REPA1R, REM 201 and S1-B0105-142. 1f damage is more extensive, refer to manufacturero

3.

Repair KEVLAR/EPOXY sandwich panels using standard approved methods for glass-fiber structures, whereby one ply of KEVLAR can be replaced by two plies of glass fiber WL 8.4548.6.

Revision 15

BO 105 CHAPTER 21 Page 3

* *

*

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8 7

Configuration BO 105

6 4

3 2

9 11

10

12 8

16 15 18 17

1 21

7

20 19

22 4

3 2

Configuration BO 105 S

15 17 22

21

19

20 18

200166

Figure 21-1 BO 105 CHAPTER 21 Page 4

Material identification - fuselage

(1 of 11)

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0.4

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Outer skin - 1 ply KEVLAR ATLAS 1/7

WL 5.2230.30

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21

Nose shel1 door (control linkage access)

Glass fabric EPOXY sandwich Core: Hard foam panel

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111

EUROCOPTER

MAINTENANCE MANUAL 80105

INSPECTION FOR CONDITION - FUSELAGE

21 - 3 1.

Wherever possible, inspect installed doors for condition in accordance with inspection criteria set forth in paras 21-6, 21-10 and 21-14.

2.

Visually inspect windows for cracks, crazing and other obstructions to visiono

3.

a.

Polish out scratches to max. 0.1 mm in depth using a flannel buffing wheel with polishing wax (CM 759) .

b.

Cracks, holes or other damage may be temporarily repaired by stop drilling, patching or other approved methods (see paragraph 21-2), but window must be replaced at earliest opportunity. Refer to para 21-20 for window replacement procedure.

Inspect fuselage skin, stringer and frames for cracks, dents, and corrosion. a.

If cracks and dents are visible, refer to'paragraph 21-2.

b.

Polish out corrosion not exceeding 10% of material thickness in depth and not exceeding 10% of component surface area using 400 grit abrasive cloth. Touch up surface protection in accordance with Chapter 02.

4.

Inspect drain holes (see figure 21-5) for obstruction. Clear clogged holes with a suitable tool or compressed airo

5.

Wherever possible with transmission struts installed, inspect main transmission mounts (3, figure 21-4) for mechanical damage, corrosion and loose rivets. Inspect the area around the main transmission mounts for cracks and loose rivets. a.

Repair cracks and loose rivets as outlined in paragraph 21-2.

b.

Polish out mechanical damage and corrosion, not exceeding 0.2 mm in depth with 400 grit polishing cloth. Touch up surface protection in accordance with Chapter 02.

6. Perform this step if the transmission supporting struts have been removed. Inspect spherical bearings (16, figure 21-4) and bushings (14) in the main transmission mounts (3) for play and evidence of corrosion. a.

Replace spherical bearings with axial play in excess of 1.0 mm or radial play in excess of 0.5 mm, and replace corroded spherical bearings. Refer to Chapter 02.

b.

Press in claw bushing with axial play not exceeding 0.2 mm using tool, P/N 105-21832 W1; otherwise replace according to Chapter 02.

Revision 6

BO 105 CHAPTER 21 Page 15

EUROCOPTER

MAINTENANCE MANUAL BO 105

7. Wherever possible with engines installed, inspect engine mounts (4) and attach fittings (6, 8 and 9) for mechanical damage and corrosion. Inspect the area around the attach fittings for cracks and loose rivets. a.

Polish out mechanical damage and corros ion on the engine mounts with 400 grit abrasive cloth. Refer to Chapter 61 for damage and repair limits.

b.

Polish out mechanical damage and corros ion not exceeding 0.2 mm depth on attach fittings (6, 8 and 9) with 400 grit abrasive cloth, and apply surface protection according to Chapter 02.

c.

Repair cracks and loose rivets according to paragraph 21-2.

8. Perform this step only if the engine has been removed. Inspect the bores of attach fittings (6, 8 and 9) for wear; if excessively worn boreholes have been bushed, also inspect bushing boreholes. If bores show signs of wear, check bore dimensions. a.

Maximum allowable diameter of bore in the aft attach fitting and in the atta eh fitting of the engine hinged support strut is 8.07 mm, and 10.07 mm for bore in the forward attach fitting.

b.

If the maximum diameter is exceeded, install bushing (refer to step 12. and 14.) or replace bushing (refer to step 13.).

9. Visually inspect tail boom connecting ring flange and adjacent fuselage areas (10) for cracks, other mechanical damage, corros ion and loose rivets. In particular inspect areas between the necked-down bolts, using a magnifying glass.

* * * * * *

a.

Repair cracks according to paragraph 21-2. If there are more than 10 loose rivets, replace these with solid rivets LN9198 DU or MS20470 DD of the appropriate length and diameter. It is recommended that all rivets in the ring flange be replaced at the same time.

b.

Polish out other mechanical damage and corros ion not exceeding 0.2 mm in depth with 400 grit abrasive cloth. Touch up surface protection in accordance with Chapter 02.

c.

If tail boom is removed, inspect bore areas of flange (10) for corrosion. 1)

Using 12 mm dia. spotface tool and 6 mm dia. pilot pin, remove corros ion to a depth of 0.1 mm below bare metal surface. The remaining wall thickness of the ring flange must be at least 5.4 mm (see fig. 21-4, section A-A) .

2)

Clean reworked area with tetrachloroethylene (CM 205), then brush-coat with chemical conversion material (CM 316) .

3)

Apply paint to match existing paint finish on tail boom. Keep front of ring flange free of paint.

BO 105 CHAPTER 21 Page 16

Revision 14

_eurocopter

MAINTENANCE MANUAL SO 105

10. Visually inspect landing gear fittings (12) and adjacent fuselage areas for deformation, corrosion, loose rivets, paint damage, and cracks (using magnifying glass). a.

Repair deformation, cracks and loose rivets.

b.

Polish out corrosíon to a depth of 0.2 mm with 400 grit abrasive cloth. Touch up surface protection in accordance with Chapter 02.

11. Iftail boom has been removed, inspectframe 2L forcracks. Stop-dril! any existing cracks and inspectthem for propagation at the next inspection. Repair cracks which have propagated. 12. If necessary, install bushings in attach fittings (6 and 8, figure 21-4) as follows: Special tool: Milling tool .

·105-20001 W2

a.

Position guide block (1, figure 21-2) over attach fitting (3) and insert centering pin (2).

b.

Press centering pin (2) up against original bore edge, secure guide block with setscrews (4), and remove . centering pino

C.

Rework attach fitting bore to 11.5 mm ± 0.1 mm diameter using roughing cutter, then to 12 - 0.005 mm diameter using finishing cutter. Ouring milling, apply coolant (CM 109) or equivalent.

d.

Remove guide block and deburr holes as necessary.

e.

Brush-coat bushing (4, figure 21-3) with corrosion preventive compound (CM 502) and press it into attach fitting (5) using the pressing-in device ofthe milling tool1 05-20001 W2 (figure 21-3). The bushing must be flush with the surface of the attach fitting.

f.

Check bore dimension of installed bushing. The required diameter is 8 + 0.015 mm for attach fitting (8, figure 21-4) and 10 + 0.015 mm for attach fitting (6). Hone to size and deburr if necessary.

13. If necessary, replace bushing as follows: Special tools: Pressing-out tool

Too 1 no. 33(105-20001 W4)

Milling tool

105-20001 W2

. a.

•

Refer toChapter 04

Orive bushing out with pressing-out tool, No. 33.

Revision 23

CHAPTER 21 Page 17

_euro 00 pter

MAINTENANCE MANUAL SO 105

b. Apply a brush coating of corrosion preventive compound (CM 502) to the bushing and install it in attach fitting using pressing- in device of milling tool1 05-20001 W2 (see figure 21-3). The bushing must be flush with attach fitting surface. c.

Check bore dimension of installed bushing. The required diameter is 8 + 0.015 mm for attach fitting (8, figure 21-4 and 10 + 0.015 mm for attach fitting (6) respeetively. Hone to size and deburr if necessary.

14. Install bushing in attach fitting (9, figure 21-4 as follows: Special tools:

Milling Tool 105-20001 W2 Milling cutter Cherry hand riveter

a. Using a milling cutter, cut a section (see cutout in figure 21-1 A) out of the sheet metal structure just large enough to allow milling tool1 05-20001 W2 to be mounted on the attach fitting. b. For milling tool mounting procedure and milling of hole, refer to step 12, sub-steps a. thru d. c.

Insert bushing per step 12, sub-step e.

d. . Check bushing for inner diameter of 8 + 0.015 mm. Hone to size and deburr as necessary.

Arewall - - " " - -

Attach fitting ---H----~:...-.--""'-

Figure 21-1 A CHAPTER 21 Page 18

Cutout in sheet metal structure Revision 6

_ eu rocopter

MAINTENANCE MANUAL MBB - BO 105

e.

Fabricate angle plate from sheet metal, taking account of the rivet spacing shown in figure 21-1B.

f.

Drill out existing rivets (2 off).

g.

Align angle plate over cutout and drill 3.6-rnrn-dia. holes in outboard and inboard legs of angle plate, using the existing rivet holes in the firewall and the specified edge distances respectively, as a guide.

h.

Deburr holes.

i.

Brushcoat mating faying surfaces of angle plate and sheet metal structure with silicone rubber (CM 619) and attach angle plateo

j.

Rivet angle plate in place using cherry hand riveter.

* * * * * * * * * * * *

* * * * * *

~A

5fCTION

A- A

•

1 0-

- -OI- - - -O1

-

L

r

~--,¡---

I

*

- - - -._._.J" - -\

--I011

1I

-t----2

11 11

11

I O 11

B

-A 5ECTION

,

B-B

1 2

Rivet (NAS 1738M-4-1) Sheet metal (3.7024.1. 0.4 mm thick)

;

200182

I

<:>

N

(~

t

-

Figure 21-1B

\ ~

27

&

Drill out existing rivets and transfer rivet hole pattern to angle plate

Dlmensions in mm

Patching the cutout

BO 105 CHAPTER 21

Revision 6

* * * * *

Page 19

* * * * * * * * * * * * * * * * * * * * * * * * * * *

_ eurocopter

MAINTENANCE MANUAL MBB - BO 105

A..., .

A-A

I

2

I

Central position

o 3 -~---3

Out of central position

200165

1 2 3 4

Guide block Centering pin Attach fitting Setscrews Figure 21-2

'-----'\,--- Wear depth

r---+----t-+--~

Attachment of milling tool for bore enlargement

-1----

1 2 3 4 5 6

Figure 21-3 BO 105 CHAPTER 21 Page 20

5

Hex nut Washer Stepped washer Bushing Attach fitting Hex bolt

Installation of bushing using pressing-in device of milling tool 105-20001 W2

Revision 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

4

Dlmension In mm

4

seCTION

A· A

DETAlL

A

11

DETAll

·~A

B

8 DETAll

E

11"11----'0 DETAll

_----9

e ./

\\+--'2

'3--DETAll

1

\ 6

& Bushing

is installed only if repaired according to para 21-3

3

&

Rework permissible on this side only

200172

Figure 21-4

Inspection areas - fuselage BO 105 CHAPTER 21

Page 21/22

2 3

4

&-5 6 &-7

8 9

D

Cabin frame attachment points Spherical bearing Main transmission mount Engine mount Bushing Engine attach fitting Bushing Attach fitting Attach fitting

10 11

12 13 14

15 16

Tailboom connecting flange Tail rotor drive shaft bearing bracket Landing gear fitting DU bushing (landing gear mount) Bushing Back-up disk Spherical bearing

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

200174

Figure 21-5

Location of drain ho1es

BO 105 CHAPTER 21

Page 23/24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 21 - 4

F e 1 d i n g

d e e r

Refer te paragraph 21-5 fer functienal check of jettison mechanism.

NOTE

21 - 5

Remeval - folding door

l.

Open felding door (1, figure 21-6).

2.

Remove safety wire from door jettison lever (7).

3.

Support felding deor to prevent if from falling and getting damaged; pull deor jettison lever and remove felding door.

21 - 6

Inspection and repair - folding door

l.

Inspect folding door for cracks, dents and other damage. Repair as necessary in accordance with paragraph 21-2.

2.

Inspect bulb seals (10, figure 21-6) and seals on window sliding vents for damage, deterioration and bond separation. Remove old adhesive from separated seals and clean the bonding surfaces with acetone (CM 203) . Bond rubber seals with adhesive (CM 673). Replace damaged seals.

3.

Inspect felding door windows in accordance with paragraph 21-3.

4.

Inspect deor latching mechanism (3) for proper operatien and freedom of movement. If there is evidence of binding, remove latching mechanism and inspect fer worn and dirty parts. Replace damaged parts.

5.

Inspect door hinges for evidence of damage and freedom of movement. Remove binding hinges, clean them with dry cleaning solvent (CM 202) and lubricate them with grease (CM 101). Replace damaged parts.

21 - 7

Installation - folding door

l.

Coat hinge bolts (4, figure 21-6) and pins of jettison mechanism with grease (CM 101) .

2.

Install door so that the hinge bolts (4) slide into the mating sleeves in the cabin structure.

3.

Push door jettison lever (7) up against the frame to lock thehinge bolts (4) in place.

BO 105 CHAPTER 21 Page 25

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

SECTION

A· A

10---·~

7----

6-----{f

200m

1

&-2

&-

Folding door may incorporate window 2, 8, or 9, depending on configuration Figure 21-6

BO 105 CHAPTER 21

Page 26

3 4 5 6 7

& 1~

10

Folding door Window Door latching mechanism Hinge bolts Window Cockpit frame Door jettison lever Window Window Bulb seal

Cockpit door

MAINTENANCE MANUAL 80 105

EUROCOPTER

21 - 7A

Removal - door handle (folding door)

1.

Remove screw (1, fig. 21-6A) and washer (2).

2.

Pull inher handle (3) off outer handle (S).

3.

Pull out outer handle (S).

s

6

Dlmenslon ·X· Locatlon 28 mm SlIdlng door 38 mm Foldlng door

200180

1 Screw 2 Washer

3 Inner handle

4 Folding door S Outer handle 6 Window

Figure 21-6A Removal and installation - door handle 21 - 7B

Installation - door handle (folding door)

1.

Before installing outer handle (S), check that it belongs to folding door (4) by measuring the length of its square shank (dimension "X" in fig. 21-6A). Only door handles with a 38-rnm-long shank may be installed in the folding door.

2.

Insert outer handle (S) through folding door (4) and fit inner handle (3) on the end of it in accordance with figure 21-6A.

3.

Brushcoat screw (1) with loctite (CM 676) and install handtight together with washer (2).

Revision 16

BO lOS CHAPTER 21 Page 26A

EUROCOPTER

4.

MAINTENANCE MANUAL BO 105

If the door lock is replaced, ensure that associated grub screw for securing the locking cylinder is of the correct length. Apply loctite (CM 651) to grub screw. Install grub screw to full extent, then back off 1/8 of a turno In this position, the grub screw must not protrude from the grip shaft. This would cause damage to the coller. AIso the locking barrel must be able to rotate.

BO 105 CHAPTER 21 Page 26B

Revision 16

EUROCOPTER

21 - 8

S lid i n g d o o r

21 - 9

Removal - sliding door

MAINTENANCE MANUAL BO 105

1.

Close sliding door (1, figure 21-7).

2.

Remove rubber stop (8) and, if installed, angle bracket (3) from door rails.

3.

Open sliding door and carefully slide it aft out of the door rails.

21 - 10

Inspection and repair - sliding door

1.

Inspect sliding door for cracks, dents and other damage. Repair as necessary in accordance with paragraph 21-2.

2.

Inspect sliding door windows in accordance with paragraph 21-3.

3.

Inspect door seals, door frame seals and seals on lower door rail for damage, deterioration and bond separation. Remove old adhesive from separated seals and clean the bonding surfaces with acetone (CM 203) . Bond rubber seals with adhesive (CM 673) and other seals with adhesive (CM 672). Replaced damaged seals.

4.

Inspect door latching mechanism for proper operation and freedom of movement. If there is evidence of binding, remove latching mechanism, clean it with dry cleaning solvent (CM 202) and coat it with grease (CM 101). Replace damaged parts.

5.

Check sliders (12, figure 21-7) for tight seat and inspect for condition. Replace if damaged. Tighten loose hardware and secure with Loctite (CM 651). If slider has to be replaced, secure hardware after installation with Loctite (CM 651).

21 - 11

Installation - sliding door

l.

Clean upper and lower door rails, uppei slider (11, figure 21-7) and lower sliders (12).

2.

position forward lower edge of slidir:g door in the aft end of lower door rail and then guide the upper slider (11) over upper door rail.

3.

Push sliding door forward. Close and lock.

4.

Check sliding door for proper fit to structure. It must butt against the cockpit door and fuselage. If necessary, adjust latch striker (14).

5.

Install rubber stop (8) and angle bracket (3).

6.

Rub talcum powder (CM 108) onto the coor seals and other seals.

Revision 16

BO 105 CHAPTER 21 Page 27

* * * *

EUROCOPTER

MAINTENANCE MANUAL

DETAlL

eo 105

B

~ ,

2 3 4

')

."ft:=.l .

,-"Jo ,

11

13

14 15 16

DETAlL

A

~iC!r---12

12

7

8

9

10

200170

Figure 21-7 BO 105 CHAPTER

Page 28

21

Sliding door

1 Sliding door Scre",¡ Angle bracket 4 Spacer 5 Washer 6 Nut 7 Door rail 8 Rubber stop 9 Washer 10 Scre'l'l 11 Upper slider 12 Lower slider 13 Plate 14 Latch striker 15 Screw 16 Washer 2 3

5 6

_eurocopter

MAINTENANCE MANUAL MSS - SO 105

21 - 11A Removal - door handle (sliding door)

* * * * * * * *

Removal is in accordance with paragraph 21-7A.

21 - 11B

Installation - door handle (sliding door)

*

* Installation is in accordance with paragraph 21-7B. Take note that only outer * handles with a square shank length of 28 mm may be installed (see figure *

*

21-6A) .

21 - 12

Re a r

d o o r

21 - 13

Removal - rear door

1.

Remove split pins (12, figure 21-8) and washers (11).

2.

Open and secure door (1).

3.

Withdraw bolt (10) and remove door.

21 - 14

Inspection and repair - rear door

1.

Inspect door for cracks, dents and other damage. R8pair as necessary in accordance with paragraph 21-2.

2.

Inspect rubber seals (7, figure 21-8) for damage, deterioration and bond separation. Remove residual adhesive from separated seals and clean the bonding surfaces with acetone (CM 203). Rebond seals with adhesive (CM 673). Replace damaged seals.

3.

Inspect latching mechanisms (3 and 5) for proper operation ahd freedom of movement. If there is evidence of binding, remove latching mechanisms, clean them with dry cleaning solvent (CM 202), and coat them with grease (CM 101).

4.

Inspect door struts (8) and netting (4) for damage. Replace if damaged.

5.

Inspect hinges (9) for cracks and mechanical damage. Replace if cracked or badly worn.

Revision 6

BO 105 CHAPTER 21 Page 29

MAINTENANCE MANUAL MBB - BO 105

21 - 15

Installation - rear door

1.

Clean bolts (10, figure 21-8) and coat with grease (CM 101).

2.

Support door on hinge fittings of fuselage and install bolts (10) and shim washer (11). Install split pins (12).

3.

Treat rubber seal with talkum powder.

4.

Close both doors and check for flush fit with fuselage. Open doors and rub talcum powder (CM 108) on the door seals. Close doors.

BO 105 CHAPTER 21 Page 30

Revision 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-H---1 8 ----J"-H----T/

---3 '---ff----- 4

/~\I}_-------

DETAlL

A

5

9

1 2 200171

3 4 5 6 7 8 9

10 11

12

Figure 21-8

Rear door Door lock Upper latch mechanism Netting Lower latch mechanism Placard Rubber seal Door struts Hinge, Bolt . Washer Split pin

Rear door BO 105 CHAPTER 21 Page 31/32

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL. MBB - BO 105

21 - 16

S poi 1 e r

21 - 17

Rernoval - spoiler

1.

Unscrew nuts (4, figure 21-9) frorn screws (6) and rernove screws.

2.

Detach spoiler (1) frorn angle brackets (3).

3.

Rernove attaching screws (2), angle brackets (3), plates (5) and wedge-shaped shirns (7) frorn the fuselage.

21 - 18

Inspection and repair - spoiler

1.

Inspect spoiler (1, figure 21-9) for cracks, dents and other darnage. Repair as necessary in accordance with paragraph 21-2.

2.

Inspect angle brackets (3), plates (5) and wedge-shaped shirns (7) for rnechanical darnage. Replace if badly worn.

3.

Visually inspect spoiler for paint darnage, touch up paint finish as necessary in accordance with Chapter 02.

21 - 19

Installation - spoiler

l.

Install angle brackets (3, figure 21-9) and plates (5) on the fuselage with screws (2); in addition, install the wedge-shaped shirns on the outer angle brackets.

2.

Fit spoiler (1) in angle bracket (3) and secure with screws (6).

3.

Align angle brackets (3) and tighten screws (2).

4.

Install nuts (4) tightly on screws (6).

BO 105 CHAPTER 21

Page 33

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

r J

-====...===,===;;7::::::::7 -----

~,

5~ I I 11

4 _-«t.,~~I..1:'~

3

I

-----i/l~~

200169

Additionally install wedgeshaped shims on outer angle bracket

Figure 21-9 BO 105 CHAPTER 21 Page 34

1 Spoiler 2 Screw 3 Angle bracket 4 Nut 5 Plate 6 Screw 7 Wedge-shaped shim

Spoiler - removal and installation

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 21 - 20

Wi n d o w

21 - 21

Cleaning - windows

CAUTION

S

o DO NOT USE GASOLINE, ALCOHOL, KEROSENE, BENZENE, XYLENE, TOLUENE, HEXANE, KETONES INCLUDING ACETONE, CARBON TETRACHLORIDE, FlRE EXTINGUISHER OR DEICING FLUIDS, LACQUER THINNERS, WINDOW CLEANING SPRAYS, OR OTHER UNAPPROVED SOLVENTS BECAUSE THEY WILL SOFTEN ACRYLIC PLASTIC ANO CAUSE CRAZING. o DO NOT WEAR RINGS OR OTHER RARD OBJECTS LlKELY TO CAUSE SCRATCHES DURING CLEANING.

1.

Apply cleaning agent (CM 721) with a sponge or chamois and remove the dirt.

2.

Rinse windows thoroughly with clear water and dry using either damp chamois, clean cotton flanell cloth, or soft facial-tissues. Do not rub the windows after they are dry.

3.

Apply a film of water repellent (CM 722) to the clean, dry windows.

4.

Grease, oil, or paint can be removed from the windows by rubbing lightly with a cotton flanell cloth saturated with cleaning agent (CM 222) .

5.

Remove electrostatic charge and resultant dust particles by dabbing the window with damp chamois.

21 - 22

Removal - upper windshield

1.

Remove folding door. Refer to paragraph 21-5.

2.

Remove battery access door.

3.

Remove interior panelling as necessary. Refer to Chapter 703.

4.

If necessary, remove windshield wiper converter. Refer to Chapter 800.

5.

Remove any components in the cockpit that obstruct the removal of the upper windshield (13, figure 21-10) .

6.

Remove door holder (16); keep sleeve (14) and washer (15) forreuse at assembly.

7.

If installed, remove fitting for rotor blade folding system.

BO 105 CHAPTER 21 Page 35

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. Remove hinge bolt (31) together with washers (33 and 34) and nut (35). 9. Drill out blind rivets (38).· 10. Detach bulb seal (32) as necessary. 11. Remove screws (1) with washers (2), screws (3) with washer (4) and nuts (S), screws (11) with washers (lO), and screws (22 and 37). 12. Detach windshield retainers (28 and 36) from upper windshield (13). 13. Separate the upper windshield (13) from the cabin structure using a suitable tool. 14. If necessary, remove filler strip (39) and keep for reuse at assembly.

Installation - upper windshield

21 - 23 l.

Remove aging sealant from the cabin structure, windshield retainers (28 and 36, figure 21-10), and packing strip (43). Clean bonding surfaces with dry cleaning solvent (CM 202) .

2.

Install new upper windshield (13) as follows: a.

Strip off protective covering from around the edges of the windshield (13) only as far as necessary for fitting and subsequent rework.

b.

Mount the windshield so that it has an all-round clearance of not more than 8 mm to the adjacent windshield panels.

c.

With a 3-mm-diameter drill, drill securing screw holes into windshield using hole pattern in cabin frame as a guide and then size drill hole diameters according to figure 21-10.

d.

Temporarily install upper windshield (13) with the windshield retainers and several of the attaching screws.

e.

Transfer outline of door mounting sleeves in cabin structure onto windshield edging (12) and cut out accordingly.

f.

Remove upper windshield (13) from cabin structure and deburr screw holes.

g.

If removed, install filler strip (39).

h.

Position upper windshield in place and secure it with its screws and retainers. Before installation, brush-coat retainers (28 and 36), contact surfaces on the cabin structure, and packing strip (43) with sealant (CM 636) (refer to sections A-B and G-H) , and brush-coat all screw heads with sealant (CM 662) .

BO 105 CHAPTER 21 Page 36

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 i.

Install folding door (refer to paragraph 21-7) .

j.

Trim excess material from windshield edging (12) so that there is clearance of 1 to 3 mm between the cabin structure and the folding door.

k.

Install fairing (6 or 7), according to configuration, on windshield edging (12) with screws. There must be no contact between fairing and folding door when the latter is opened. If there is contact, line the mounting side of the fairing with a layer of glass fabric sufficient to elirninate contacto

l.

Remove fairing (6 or 7) and brush-coat contact surface with adhesive (CM 601). Secure fairing to windshield edging with screws (9) and washers (8). Rernove excess adhesive.

m.

If necessary, determine bore diarneter for windshield wiper converter shaft and mark its location on the windshield panel. NOTE

o The bore diarneters for the single and dual windshield wiper configurations are 26 mm and 18 mm respectively. o Use a slow-running drilling tool for drilling the holes. Interrupt drilling repeatedly to prevent darnage to windshield by overheating.

n.

Drill hole for windshield wiper converter shaft in windshield using hole cutter of the appropriate size.

o.

Drill converter driveshaft seal mounting holes (6.2 mm dia) in the windshield to match hole pattern in associated washer.

p.

Fill upper windshield (13)-to-retainer (28 and 36) joints and packing strip (43)-to-cabin structure joints with sealant (CM 636).

q.

Finish rework area to match original paint finish.

r.

Clean bulb seal (32) with acetone (CM 203) and remove all traces of adhesive from its mounting surface on the cabin structure. Bond bulb seal with adhesive (CM 605) .

s.

Install components removed from the cabin in reverse order of the sequence, steps 1. thru 9., in paragraph 21-22. Brush-coat door holder (16) with sealant (CM 636) prior to installation.

t.

Peel off windshield protective covering and clean windshield as described in paragraph 21-21.

BO 105 CHAPTER 21 Page 37

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 21 - 24

Rernoval - lower windshield

l.

Remove folding door (refer to paragraph 21-5) .

2.

Remove battery access door.

3.

Remove interior panelling as necessary (refer to Chapter 703).

4.

Remove any components in the cockpit that obstruct the removal of the lower windshield (23, figure 21-10) .

5.

Remove door holder (16); keep sleeve (14) and washer (15) for reuse at assembly.

6.

If installed, rernove fitting for main rotor blade folding system.

7.

Remove hinge bolt (31) together with washers (33 and 34) and nut (35).

8.

Detach bulb seal (32) as necessary.

9.

Remove screws (19) with washers (20), screws (22), screws (24) with washers (25) and nuts (26), and screws (30).

10. Detach retainers (28 and 29) from lower windshield. 11. Separate Iower windshield (23) from cabin structure using suitable tool.

BO 105 CHAPTER 21 Page 38

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 21 - 25

Installation - lower windshield

l.

Remove old sealant from the cabin structure and retainer. Clean sealing surfaces with dry cleaning solvent (CM 202) .

2.

Install new lower windshield as follows: a.

Strip off protective covering from around the edges of the lower windshield only as far as necessary for fitting and subsequent rework.

b.

Mount the lower windshield (23, figure 21-10) so that there is a clearance of 2 mm between the windshield edging (27) and the floor, and a clearance not exceeding 8 mm between windshield and both the liner (41) and windshield (13).

c.

With a 3-mm-diameter drill, drill securing screw holes into windshield using hole pattern in cabin frame as a guide and then drill hole diameters according to figure 21-10.

d.

Temporarily install lower windshield (23) with the retainers (28 and 29) and several of the attaching screws.

e.

Transfer outline of door mounting sleeves onto the windshield edging (21) and cut out accordingly.

f.

Remove lower windshield (23) from cabin structure and deburr holes.

g.

Position lower windshield (23) in place and secure to cabin structure with the appropriate screws and retainers. Before installation, brush-coat the retainers (28 and 29) and mating surfaces on the cabin structure with sealant (CM 636), and brush-coat all screw heads with sealant (CM 662) .

h.

Install folding door (refer to paragraph 21-7) .

i.

Trim excess material from windshield edging (21) so that there is a clearance of 1 to 3 mm between the cabin structure and the cockpit door.

j.

Fill lower windshield (23) to retainer (28 and 29) joints and windshield edging (27 and 21) to cabin structure joints with sealant (CM 636) .

k.

Finish rework area to match original paint finish.

l.

Clean bulb seal (32) with acetone (CM 203) and remove residual adhesive from the cabin structure. Bond bulb seal with adhesive (CM 605).

BO 105 CHAPTER 21 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 m.

Reinstall components removed from the cabin in reverse order of the sequence, steps l. thru 7., in paragraph 21-24. Brush-coat door holder (16) with sealant (CM 636) prior to installation.

n.

Strip off remainder of windshield protective covering and clean windshield as described in paragraph 21-21.

BO 105 CHAPTER 21 Page 40

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1

2 3 4

5 6 7

8 9 10 11

12 13 14 15

16 17 18 19 20 21 22 23 24 25 26 27 28 29

30

31 32 33 34

35

36 37 38 39

40 41 42 43

44

13-----.. Screw Washer 40---... Screw Washer Nut Fairing Fairing Washer Screw Washer Screw Windshield edging 40 - - - ' Upper wind~hield Sleeve Washer SECTION A- B Door holder Screw Washer 40 Screw Washer Windshield edging Screw Lower windshield Screw Washer Nut Windshield edging Windshield retainer Windshield retainer Screw Hinge bolt Bulb seal Washer 39 Washer Nut Windshield retainer Screw Blind rivet SECTION G - H Filler strip Sealant (CM 636) Liner Sealant (CM 662) Packing strip U-profile (cabin structure)

44

[j"

'1

1

1 /

~---40

41--I'~""';"'''O~~~F2 1'" ,,,

32

,

" .._ ."

---~((~~~ ~

16

"~o

o

\\.

"'.1

I'-----23

SECTION

c· D

23

Bore dia. 4.3 mm

+---23

1+---24 42--"":

40 27--~

SECTION

'+-----12

E· F

- - I ' + - ; - f - - - - - - 13

Sore dla. 12.5 mm

15

....---38 32

---ti

.

...",,~16 ~

31---

I

~ Installed depending on configuration

¡

Sore dia. 4.3 mm

DETAlL 200163

Figure 21-10 Upper/lower windshield - removal and installation BO 105 CHAPTER 21

Page 41/42

A

30

29 24

26

23

22 27

21

r

1I 20 19

,~

<

~ 18

17

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 21 - 26

Removal - cabin roof window

l.

Remove interior panelling as necessary, refer to Chapter 703.

2.

Remove any components obstructing removal of the window.

3.

If necessary, remove OAT thermometer (5, figure 21-11) .

4.

Remove screws (11), washers (4), and nuts (3).

5.

Separate window from cabin roof using a suitable tool.

21 - 27

Installation - cabin roof window

1.

Remove old sealant from cabin roof and clean bonding surfaces with dry cleaning solvent (CM 202) .

2.

Install new window as follows: a.

Strip off window protective covering from the edges of the window only as far as required for fitting and subsequent rework.

b.

Mount window in cabin roof so that there is an all-round clearance of 2 mm between the window and cabin roof.

c.

Transfer hole pattern from the old window to the new window.

d.

Remove window and drill the securing screw holes at the marked locations using a 4.3-rnrn-diameter drill.

e.

Apply sealant (CM 636) to window mounting structure.

f.

Brush-coat heads of screws (11, figure 21-11) with sealant (CM 662). Position window on the supporting frame from within the cabin. Align screw holes of window and frame, and se cure with washers (4) and nuts (3).

g.

Apply a bead of sealant (CM 636) around the edge of the window at intersection with the cabin roof and the upper windshield edging (12). Smooth out sealant.

h.

Finish rework area to match original paint finish.

l.

Reinstall components removed from the cabin in reverse order of the sequence, steps 1. thru 3., in paragraph 21-26.

j.

Strip off remainder of window protective covering and clean window as described in paragraph 21-21.

BO 105 CHAPTER 21 Page 43

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

12

4~

6 5

3

200176

1 Cabin roof 2 Left window 3 Nut 4 Washer 5 OAT thermometer 6 Washer 7 Right window 8 Rubber washer 9 Washer 10 Shield 11 Screw 12 Upper windshield edging Figure 21-11

BO 105 CHAPTER 21

Page 44

Cabin roof windows - removal and installation

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

Removal - folding door window

21 - 28 l.

Remove folding door, refer to paragraph 21-5.

2.

Remove folding door window: a.

b.

Window (attached with screws) 1)

Remove attaching screws (5, figure 21-13) with washers (4 and 6) and nuts (7), and remove window (3) from folding door.

2)

Remove double-backed adhesive tape from folding door, and clean bonding surface with acetone (CM 203) .

Window (bonded with cement) 1)

Cut out the damaged window within the optical area using a compass saw, leaving a narrow edging of approx. 5 mm wide.

2)

Mask the areas of the folding door (4, fig. 21-12) adjacent to the window with thin wooden strips (5) to provide a heat shield.

3)

Cut a slit into the residual edging (2) at any point. CAUTION

21 - 29

WHEN HEATING THE RESIDUAL WINDOW EDGING, TARE CARE NOT TO DAMAGE THE ADJACENT LAMINATE (HEATRESISTANT TO MAX. 80 OC).

4)

Using a handblower (1), heat the window edging at the slit until it begins to soften, then grip the window edging with a pair of pliers and carefully peel it off (see fig. 21-12). By alternately heating and peeling, it is possible to remove the entire edging in a single operation.

5)

Remove old adhesive with acetone (CM 203) . Installation - folding door window

l.

Strip off protective covering from the edges of window (3, figure 21-13) as required to install the window.

2.

Position new window in folding door (1). If required, trim window edges so that there is an all-round clearance of 1 to 3 mm.

3.

Position window (3) in place, and back-drill screw holes (3.0 - 3.4 mm dia.) using holes in folding door as a guide.

4.

Remove window (3) and deburr holes.

BO 105 CHAPTER 21 Page 45

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

l· Handblower 2 Residual edging of window 3 Pliers 4 Folding door 5 Wooden strip

2

4 200179

Figure 21-12

Peeling off residual window edging

5.

Degrease bonding surfaces on folding door with acetone (CM 203).

6.

Roughen window faying surfaces with steel woo1 and clean with dry cleaning solvent (CM 202) .

7.

Install double-backed adhesive tape (2) on folding door, press down light1y, and pul1 away the tape backing.

8.

Position window (3) in folding door, pressing it 1ightly against the fo1ding door, and se cure with screws (5), washers (4 and 6), and nuts (7). Torque opposite screws alternate1y, working round the window several times.

9.

Using dry cleaning solvent (CM 202), clean window edging and folding door where paint is required (refer to figure 21-13) .

10. Apply a coat of primer (CM 423) to window edging and folding door, and restore original paint finish. 11. Remove remainder of protective covering from the window, and clean window according to paragraph 21-21. 12. Insta1l folding door, refer to paragraph 21-7.

BO 105 CHAPTER

Page 46

21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A 3

Apply lacquer to this area SECTION

3

A· B 2

r---6

--7

4

~ Clearance between edge of

window panel and folding door shall be 1-3 mm all round

Figure 21-13

5

1 Folding door 2 Double-backed adhesive tape 3 Window 4 Washer 5 Screw 6 Washer 7 Nut

Rernoval and installation - Folding door window, attached with screws BO 105 CHAPTER 21 Page 47

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Removal andOinstallation - sliding door window

21 - 30

The procedures for removing and installing the sliding door windows are similar to those for the folding door windows and will not be described separately here. Remove and install the sliding door window in accordance with paragraphs 21-28 and 21-29. Refer to paragraphs 21-9 and 21-11 for procedural steps to remove and install the sliding door.

BO 105 CHAPTER

Page 48

21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 22

C O WL 1 N G S

Table of Contents

Paragraph

Title

22 - 1

DESCRIPTION - COWLINGS

22 - 2

INSPECTION FOR CONDITION - COWLINGS

3

22 - 3

REPAIR - COWLINGS

4

22 - 4

Removal - cowlings

6

22 - 5

Insta11ation - cow1ings

7

Page

.

...

3

BO 105 CHAPTER 22 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 22 - 1

DESCRIPTION - COWLINGS

Depending on the configuration, the cowlings (fig. 22-2 and 22-3) are either two- or four-piece assemblies and cover main transmission, tandem hydraulic unit and engines. Access doors and covers are additionally installed which . allow minor maintenance work on the respective components. The cowlings are attached to the fuselage by quick release fasteners and snap rings. Depending on the configuration, the cowlings are lined in the engine compartment with fire protective mats made of ceramic material or asbestos. The fire protective mats are coating of fire retardant paint.

22 - 2

INSPECTION FOR CONDITION - COWLINGS

1. Visua11y inspect cowlings, access doors, covers and screens for cracks, deformation, damaged paint finish, and damage to laminated structure. Repair damaged parts in accordance with para 22-3 and REM 201. 2. If installed, inspect observation window (7, fig. 22-2) for damage, contamination and crazing. Clean contaminated window and replace if damaged or crazed; refer to para 22-3. 3. Inspect snap rings of quick release fasteners for damage and security. Replace broken or cracked snap fasteners in accordance with chapter 02. 4. Inspect quick release fasteners for damage and security. Inspect loose quick release fasteners for proper operation. Replace damaged quick release fasteners in accordance with chapter 02.

5. Inspect latches and hinges on access doors for proper operation and damage. a.

Replace damaged latches.

b.

Replace hinges if cracked or binding.

6. Inspect access door seals and bulb seals at mating surface to the tailboom for damage, porosity, and separation. Replace damaged seals and bond separated seals in accordance with para 22-3. 7. Inspect ejector assemblies for damage, and repair in accordance with para 22-3.

BO 105 CHAPTER 22 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. If hand holds are installed on the cowling¡ inspect them for security of attachment. Tighten loose hardware or replace loose rivets. Repair damaged cowlings in accordance with REM 201. 9. Depending on the configuration, inspect ceramic or asbestos mats for secure bonding and general condition. a.

Bond separated mats¡ refer to para 22-3, step 7.

b.

Replace damaged mats¡ refer to para 22-3, step 7.

c.

If fire retardant paint coating is damaged, touch up in accordance with para 22-3, step 8. or renew completely.

22 - 3

REPAIR - COWLINGS

1. Repair local damage in accordance with FAA Publication, FAA AC 43.l3-1A, AIRCRAFT INSPECTION AND REPAIR MANUAL and REM 201. If damage is more extensive, a decision on whether to replace or repair the affected cowling must be made according to the circumstances. 2. KEVLAR-EPOXY sandwich parts shall be repaired in accordance with the standard repair practices for fiberglass sandwich structures, with one layer of KEVLAR being replaceable with two layers of fiberglass WL 8.4548.6. 3. Replace quick release fasteners in accordance with Chapter 02. 4. Replace observation window as follows: a.

Remove screws.

b.

Detach observation window from cowling with suitable tool.

c.

Remove old adhesive with 80 grit abrasive paper, taking care not to abrade the laminate.

d.

Position observation window in place. If necessary, transfer the bore pattern from the cowling to the window.

e.

Clean bonding surfaces with acetone (CM 203) .

f.

Apply adhesive (CM 601) to the bonding surfaces, position observation window in place on the cowling, and secure with screws, washers and nuts. Remove excessive adhesive.

5. Bond access door seals and bulb seals as follows: a.

Remove old adhesive with 80 grit abrasive paper, taking care not to abrade the laminate.

b.

C1ean bonding surfaces with acetone (CM 203) .

BO 105 CHAPTER 22 Page 4

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Coat bonding surfaces with adhesive (CM 605) and press seals/bulb seals onto cowling.

6. Repair damage to ejector assemblies as follows: a.

Stop-drill cracks not exceeding 10 mm in length at ejector edges with a 3mm-drill. If more extensive cracks are evident replace ejector or repair.

b.

Restore dented or otherwise deformed surfaces to original contour using plastic hammer and suitable straightening tools.

7. Bond or replace fire protective mat (ceramic mat) as follows:

NOTE

Bond separated fire protective mat per steps a. thru c., replace fire protective mat per steps d. thru h.

a.

Remove old adhesive with 80 grit abrasive paper, taking care not to abrade the laminate.

b.

Clean bonding surfaces with acetone (CM 203) .

c.

Apply silicone rubber (CM 619) to cowling and around edges of the fire protective mato

d.

Prepare bonding area in accordance with steps a. and b.

e.

Apply adequate amount of silicone rubber (CM 619) to cowling and distribute evenly, using a wooden spatula.

f.

Apply silicone rubber (CM 619) to seamed edges of the fire protective mato

g.

position fire protective mat on engine cowling, apply pressure and put weight on mat, using sandbags.

h.

Apply fire retardant paint per step 8. to those cowling areas which are located in the hot zones and which are not covered with fire protective mats.

8. Touch up fire retardant paint coating as follows: a.

Remove fire retardant paint from damaged area: 1)

If damage is negligible, remove paint coating with 80 grit abrasive papero

2)

If damage is extensive, remove varnish finish with paint remover (CM 433), then soften up fire retardant paint coat with water and remove with brush or paint remover (CM 433).

BO 105 CHAPTER 22 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Clean repair area with acetone (CM 203) .

c.

App1y two coats of fire retardant paint and allow to dry between coats; for drying time refer to manufacturer's instructions.

d.

When dry, lightly abrade the fire retardant paint with220 grit abrasive papero

e.

Apply two top finish coats of two-component PUR finishing varnish (CM 432) and allow to dry between coats; for drying time refer to manufacturer's instructions.

9. Touch up external paint finish as follows: a.

Remove paint finish in damaged area with 220/230 grit abrasive paper, taking care not to abrade the laminate.

b.

Clean repair area with acetone (CM 203) .

c.

Apply two-component PUR topcoat to match existing paint finish of the helicopter. Refer to Chapter 02

22 - 4

Removal - cowlings

1. Remove two-piece cowling (fig. 22-3) as follows: a.

Open quick release fasteners of left and right cowlings.

b.

Carefully remove left and right cowlings.

2. Remove four-piece cowling (fig. 22-2) as follows: a.

Open quick release fasteners securing forward cowlings to cabin roof, firewall and to each other.

b.

Carefully remove both forward cowlings.

c.

Open quick release fasteners securing both aft cowlings to engine deck and firewall.

d.

Carefully remove both aft cowlings.

BO 105 CHAPTER 22 Page 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

22 - 5

Installation - cowlings

1. Install two-piece cowling (fig. 22-3) as follows: a.

Install left and right cowlings so that the aft firewall engages with the retainers on the cowlings.

b.

Close quick release fasteners.

2. Install four-piece cowling (fig. 22-2) as follows: a.

position both forward cowlings in place and secure to cabin roof, firewall, and each other with quick release fasteners.

b.

Position both aft cowlings in place and secure to firewall and engine deck with quick release fasteners.

3. The annular clearance between the ejector assemblies and exhaust stacks shall be approx. equal all the way round. A difference in annular clearance of not more than 10 mm is allowed at opposite points. If this limit is exceeded, loosen clamp of exhaust stack and turn exhaust stack in the appropriate direction to adjust for constant annular clearance.

-==-

I

60020;

Correct

Incorrect

Figure 22-1 Annular clearance for ejector ventilation BO 105 CHAPTER 22

Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS

~-2

7-----+.---::'ry 77'"'----4

A+-+-------- 5

unF----------6 600143

1 Ejector assembly, RH 2 Ejector assembly, LH -3 Air SCOOp for engine compartment forced ventilation 4 Aft access door S Forward access door 6 Quick release fastener with snap ring 7 Observation window

Figure 22-2 BO lOS CHAPTER 22 Page 8

Helicopters with S/N 321 and subsq. and those modified by SB 60-31

Four-piece cowling

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

7 --~-----:::~

~~--4

+-~"':::;'-'----5

600143.1

1 2

~-3

4 5 ~-6 7

Ejector assemb1y, RH Ejector assemb1y, LH Air scoop for engine compartment forced ventilation Aft access door Forward access door Quick release fastener with snap ring Observation window Figure 22-3

~

Helicopters with S/N 321 and subsq., and those modified by SB 60-31

~

Helicopters with S/N 301 and subsq., and those modified by SB 60-23

Two-piece cowling BO 105 CHAPTER 22 Page 9/10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

31

T A I L B O O M A S S E MB L Y

Table of Contents

Paragraph Title

Page

31 - 1

DESCRIPTION - TAIL BOOM ASSEMBLY

3

31 - 2

INSPECTION - TAIL BOOM ASSEMBLY

4

31 - 3

REPAIR - TAIL BOOM ASSEMBLY

6

31 - 4

Ta i 1 b o om

6

31 - 5

Removal - tail boom

6

31 - 6

Inspection and repair - tail boom

11

31 - 7

Installation - tail boom

12

31 - 8

Ver t i c a 1 s t a b i 1 i z e r

12

31 - 9

Removal - vertical stabilizer

12

31 - 10

Inspection and repair - vertical stabilizer

13

31 - 11

Installation - vertical stabilizer

14

31 - 12

H o r izo n t a l

14

31 - 13

Removal - horizontal stabilizer

14

31 - 14

Inspection and repair - horizontal stabilizer

14

31 - 15

Installation - horizontal stabilizer

17

31 - 16

F a i r i n g s

17

31 - 17

Removal - fairings

17

31 - 18

Inspection and repair - fairings

17

31 - 19

Installation - fairings

17

31 - 20

Ta i 1 s k i d

18

31 - 21

Removal - tail skid

18

31 - 22

Installation - tail skid

18

s t a b i 1 i z e r

BO 105 CHAPTER 31 Page 1/2

MAINTENANCE MANUAL

EUROCOPTER

eo 105

DESCRIPTION - TAIL BOOM ASSEMBLY

31 - 1

The tail boom assembly essentially consists of the following parts: -

tail boom horizontal stabilizers vertical stabilizers vertical fin

Mounted along the upper surface of the tail boom is the tail rotor drive shaft which is covered by fairings. These fairings are attached by springtype quick-release Camloc fasteners and can be removed for maintenance purposes.

.-+--4

15 1---5

14

7

~-8

9

300401

1 2

3 4 5

6

Drive shaft fairing Nose fairing Vertical fin Camloc fastener Vertical tail fairing Tail skid

7 Vertical stabilizer LH 8 Position light 9 End cap 10 Horizontal stabilizer 11 Angle bracket 12 Bearing bracket 13 Retaining washer 14 Stud 15 Vertical stabilizer RH 16 Electrical connector 17 Tail boom

See figure 31-7 for tail skid configurations Figure 31-1

Tail boom - assembly BO 105 CHAPTER 31 Page 3

EUROCOPTER

31-2

MAINTENANCE MANUAL 80105

INSPECTION - TAIL BOOM ASSEMBLY

1. Inspect tail boom skin for cracks, other mechanical damage, corrosion and loose or missing rivets. In particular, inspect skin on RH side of tail boom in area behind the ring flange. a.

Repair cracks and other mechanical damage in accordance with paragraph 31-3.

b. Polish out corrosion damage to a depth not exceeding 10% of skin thickness and 10% of surface area, using 400 grit polishing cloth. Touch up paint finish in accordance with Chapter 02. c.

Replace allloose or missing rivets.

2. Visually inspect drain holes for free passage. Clear blocked drain holes with suitable tool. 3.

Inspect horizontal stabilizer (10, fig. 31-1) and angle brackets (11) for secure attachment, and angle brackets (11) also for mechanical damage and corros ion. a. Tighten loose attaching screws. b.

4.

Polish out mechanical damage and corrosion to a depth not exceeding 0.2 mm with 400 grit polishing cloth. Touch up paint finish in accordance with Chapter 02.

Inspect vertical stabilizers (7) and (15) for general condition, secure attachment and presence of lockwires in attaching screws. a. Tighten loose attaching screws, taking care that each pair of rubber washers is compressed between 0.3 mm and 0.5 mm. b.

Replace all damaged or missing lockwires.

5. Visually inspect tail rotor gearbox attachment fitting. a.

If tail rotor gearbox is not removed: Remove maintenance cover in vertical fin and inspect tail rotor gearbox attachment fitting for loose rivets and cracks. 1) If cracks are evident, replace the tail rotor gearbox attachment fitting after first consulting with ECO. 2) If there are cracks in the tail rotor gearbox attachment .fitting, also remove the tail rotor gearbox (refer to Chapter 32-59) and inspect for cracks. 3) Replace loose rivets.

b.

If tail rotor gearbox has been removed: Inspect tail rotor gearbox attachment fitting for loose rivets and cracks. 1) If cracks are evident, replace the tail rotor gearbox attachment fitting after first consulting with ECO. 2) If there are cracks in the tail rotor gearbox attachment fitting, also inspect the tail rotor gearbox for cracks. 3) Replace loose rivets.

CHAPTER 31 Page4

Revision 18

_eurocopter 1ft EAOO

6.

MAINTENANCE MANUAL SO 105

CIImpeny

Inspect vertical fin. a.

Remove vertical fin fairing.

b. Visually inspect vertical fin for cracks in the intermediate gearbox attachment area. If cracks are found, contact the ECO Customer Service prior to next flight for advice on how to proceed. c;

Inspect outer and inner surfaces of skin and spar as follows: 1) Thoroughly clean outer and accessible inner surfaces of skin and spar with a brush and dry cleaning solvent (CM 202). Ifthere is severe contamination, it is recommended to remove the aft short driveshaft for thoroughly c1eaning of inner surface. 2) Visually inspect skin and spar outer surfaces, incfuding frame 11 L, and LH and RH framesheets for cracks, loose rivets and other anomalies (e.g., distortion). 3) Using a mirror and lamp, inspect inner surfaces of skin and spar wherever possible through the lightening holes for cracks, loose rivets and other anomalies (e.g., distortion). 4) Replace loose rivets. If cracks or other anomalies (e.g., distortion) are found, contact the ECO Customer Service prior to next flight for instructions on how to proceed.

d. Visually inspect vertical fin fairing attach brackets for cracks. Cracks not exceeding 10 mm in length are admissible on two attach brackets, provided the brackets are not adjacent to each other. Replace attach brackets with cracks exceeding specified length. e. 7.

8.

Install vertical fin fairing.

Inspect tail skid (see fig. 31-7) and attachment fittings for cracks, other mechanical damage, corrosion and security of installation. a.

Replace loose rivets in attachment fittings.

b.

Polish out mechanical damage and corrosion on tail skid and attachment fittings to a depth not exceeding 0.5 mm, using 400 grit polishing cloth. Touch up paint finish in accordance with Chapter 02.

c.

Torque loose attaching hardware. Secure nut (6) with split pin (7)onconfiguration 1.

d.

Replace tail skid if it shows signs of major damage, deformation, or cracks.

Remove drive shaft fairing (1 fig. 31-1) and nose fairing (2) and inspect as follows: a. Visually inspect upper surface of tail boom (17) in the area in front ofthe vertical fin (3) for cracks. If cracks are evident, proceed according to para 31-3. b.

Visually inspect protective edging of tail rotor drive shaft fairing and nose fairing for damage. Replace damaged or separated protective edging (adhesive tape CM 634).

c.

Inspect bearing brackets (12, figure31-1) and (30, figure31-3) oftail rotordriveshaftbearingsforcracks and security of attachment. Replace mounting bracket if cracked and replace loose rivets.

Revision 23

CHAPTER 31 Page5

I

Oeurocopter

MAINTENANCE MANUAL BO 105

... EAI:S CamplIny

9.

Check necked-down bolts (8, fig. 31-3) for specified torque value. If torque value of a necked-down bolt is less than specified, the necked-down bolt must be replaced.

10. hlspect flange ring (3) for cracks (especially near rivets), other mechanical damage, corrosion and loose rivets. a.

Repair rivets per para 21-2. Ifthere are more than 10 loose rivets, replace these with solid rivets LN 9198 DU or MS 20470 DD of the appropriate length and diameter. It is recommended that all rivets in the ring flange be replaced at the same time.

b. Polish out mechanical damage and corrosion to a depth not exceeding 0.2 mm with 400 grit polishing cloth. Touch up paint finish in accordance with Chapter 02.

31 - 3

REPAIR - TAIL BOOM ASSEMBLY

Local damage shall be repaired in accordance with standard practices. Repair of more extensive damage must be accomplished after consultation with the manufacturero

31 - 4

31 - 5

Tail boom

Removal - tail boom

Special tools:

Hoisting sling for tail boom Support for tail boom

117-30001 W3 117-30001 W1

1. Remove rear engine cowling, refer to Chapter 22. 2.

Remove vertical fin fairing (33, figure 31-3).

3.

Remove upper interior panelling at rear end of cargo compartment to the extent that control red (6) can be removed from torsion shaft (15).

4.

Remove control rod (6) from the torsion shaft (15) and from bellcrank (21) and pull control rod (6) aft out of tail boom (1).

5.

Remove bolts (25), nuts (23) and washer (24). Remove shims (32) and keep for reuse.

CAUTION

6.

TO PREVENT DAMAGE TO THE FORWARD DRIVE SHAFT (22), RECOMMENDED TO REMOVE IT AS DESCRIBED IN CHAPTER 32.

IT IS

Remove bolts (31), washers (28) and nuts (26) securing bearing (29) to bearing bracket (30).

7. Attach hoisting sling P/N 117-30001 W3 to tail boom as shown in figure 31-2. 8.

Remove necked-down bolts (8, figure 31-3) together with bushings (9) and nuts (10).

9. Separate tail boom from fuselage only to the extent that electrical connector (7) can be disconnected. 10. Place tail boom on support 117-30001 W1. CHAPTER 31 Page6

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

31110

1 Hoisting sling 117-30001 W3 2 Sling attachment points on tail skid

Figure 31-2

Attach points - hoisting sling

BO 105 CHAPTER 31

Page 7/8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1

62

3 4

5 6 7 8 9

10 11

12 13 14 15 16 17 18 19 20

6

21 22

23 24 25 26 27 28 29 30 31 32 33

6

Tail boom Tail rotor drive shaft Flange ring, tail boom Flange ring, tail boom mounting cone Locating pin Control rod Electrical connector Necked-down bolt Bushing Nut Bolt Nut Washer Split pin Torsion shaft Vertical fin Bolt Washer Nut Split pin Bellcrank Forward drive shaft Nut Washer Bolt Nut Split pin Washer Bearing Bearing bracket Bolt Shim Vertical fin fairing

11

I 5-7 Nm

2

3

n.

c.-rRefer to chapter 32 and IPC for tail rotor drive shaft configuration

I 6-8 Nm

<

24 23 \

I

I

6

~,

22

'"

31

32 16

I

DETAll

I 5-7 Nm

-_oc

O

/1----33

~ I

17

4 3 9 10

DETAll

6 ---.,.r SECTION

300402

Figure 31-3

2~

\,+----15

Tail boom removal and installation BO 105 CHAPTER 31 Page 9/10

c· o

G

F

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 31 - 6

Inspection and repair - tail boom

Special tool: spot facer, 12 mm in dia. with pilot, 6 mm in dia. 1.

2.

Inspect flange ring (1, figure 31-4) for corros ion at abutment areas with bushings (9, fig. 31-3). a.

Using spot facer, milI corroded surface to a depth of 0.1 mm below the bare metal surface. The remaining wall thickness of the flange ring must still be at least 5.4 mm (see figure 31-4) .

b.

Clean the reworked surface with tetrachloroethylene (CM 205) and then treat with chemical conversion material (CM 316) .

c.

Apply top coat matching the existing paint on the tail boom. Make sure that paint is not applied to the face of the flange.

Inspect chafe protection in guides for control rods for condition. Replace damaged chafe protection.

1

5.4

2

Flange ring Tail boom

2

200133.2

Rework permitted on this side only Figure 31-4

Dimensions in mm

Rework on flange ring BO 105 CHAPTER 31 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3. Inspect locating pins (5, figure 31-3) for condition. Replace if damaged. 4. Visually inspect inner surface of tail boom for condition, corrosion, loose rivets and damaged seals. 31 - 7

Installation - tail boom

1. Clean flange rings (3 and 4, figure 31-3) with dry cleaning solvent (CM 202) . 2. Using hoisting sling 117-30001 W3, position tail boom against flange ring (4). Connect electrical connector (7). 3. Align flange rings and install necked-down bolts (8), bushings (9) and

nuts (10). 4. Lubricate threads of bolts (11 and 17) with grease (CM 101) and install control rod (6) with them. Install and tighten nuts (12 and 19) and secure with split pins (14 and 20) . 5. Install bearing (29) on bearing bracket (30). Secure nuts (26) with split

pins (27). 6. If previously removed, install forward drive shaft. Refer to chapter 32.

7. Align tail rotor drive shaft (2), shims (32) and forward drive shaft (22), and install bolts (25), washers (24) and nuts (23). Apply locking compound (CM 620) to nuts. 8. Install vertical fin fairing (33).

9. Install engine cowlings, refer to chapter 22. 10. Install upper interior panelling at rear end of cargo compartment. 31 - 8

Ver t i c a 1 s t a b i 1 i z e r

31 - 9

Removal - vertical stabilizer

1. Remove position light (5, figure 31-6) as outlined in chapter 92. 2. Remove screws (7), washers (8) and rubber washers (9L. 3. Remove vertical stabilizer (2) from horizontal stabilizer (3).

BO 105 CHAPTER 31 Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 31 - 10 1.

Inspection and repair - vertical stabilizer

Inspect vertical stabilizer for erosion damage, impact damage and for damaged paint finish. If such a damage is evident, repair or replace vertical stabilizer. a.

b.

Touch up erosion damage and paint damage as follows: 1)

Abrade damaged area with abrasive cloth (220 grit or finer), clean with acetone (CM 20~) and degrease.

2)

Repair damaged area with UP putty (CM 303) and coat with zinc chromate primer (CM 417) and a topcoat matching the existing paint on the helicopter.

Repair damage to end cap (4 and 6, figure 31-6) as follows: 1)

Abrade damaged area with polishing cloth (80-120 grit) and clean with tetrachloroethylene (CM 205) .

2)

Cut glass fabric to size as shown in figure 31-5.

3)

Fit the prepared layers of fabric to end cap using epoxy resin (CM 616) and hardener (CM 617) in the ratio 5:1 by weight.

4)

After curing, grind off protruding portions of fabric using abrasive paper (60-80 grit).

5)

Clean the reworked area with tetrachloroethylene (CM 205), coat with UP putty (CM 303), zinc chromate primer (CM 417) and a topcoat matching the existing paint on the helicopter.

approx. 30 mm

approx. 30 mm

300393.1

Scarf joint

Figure 31-5

Overlap joint

Application of fabric layers

BO 105 CHAPTER 31 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

31 - 11

Installation - vertical stabilizer

1.

Install vertical stabilizer (2, figure 31-6) on horizontal stabilizer.

2.

Fill out gap between horizontal stabilizer (3) and angle bracket on vertical stabilizer (2) with rubber washers (9). See fig. 31-6 for position and quantity of rubber washers.

3.

Secure vertical stabilizer (2) with screws (7) and washers (8). Tighten screws (7) until rubber washers (9) have been compressed by 0.3-0.5 mm. Secure screws (7) in pairs with lockwire

4.

Install position light (S), refer to chapter 92.

31 - 12

H o r izo n t a l

s t a b i 1 i z e r

31 - 13

Removal - horizontal stabilizer

1.

Remove vertical stabilizer as outlined in paragraph 31-9.,

2.

Remove vertical fin fairing.

3.

Remove wiring of position lights from horizontal stabilizer.

4.

Remove screws (12 and 13, figure 31-6) and angle brackets (10, 11, 14 and 15) .

5.

Carefully remove horizontal stabilizer (3) from tail boom.

31 - 14

Inspection and repair - horizontal stabilizer

Inspect horizontal stabilizer for impact damage and damaged paint finish. 1.

Replace or repair horizontal stabilizer if impact damage is evident.

2.

Abrade damaged surface finish with polishing cloth (220 or finer), clean with acetone (CM 203) and coat with zinc chromate primer (CM 417) and with a top coat matching the existing paint on the helicopter as outlined in chapter 02.

BO 105 CHAPTER

Page 14

31

------

MBB MANUAL HELICOPTERS_ -----=::m MAINTENANCE MBB BO 105

4

1 Tail boom bilizer 2 Vertical statabilizer 3 Horizontal s 4 End cap, top l' ght 'tion ~ 5 Pos~ buttom 6 End cap, 7

Screw

~-----

'~

11

6

~10

)

Washer (elastomer 8 bber bracket, washer lower LHH 9 Ru 10 Ang lee bracket, upper L 11 Ang 1 12 Screw S rew upper RH 13 c 1 e bracket, lower RH 14 Ang bracket, 15 Angle

I

13

---11

DETAlL

12

8

B 1 4- S Nm

300403.1

Figure 31-6

I 7

3

, - horizontal stabilizer installat~~n, r Removal and t'cal stablllze and ver 1 BO 105 CHAPTER 31 Page 15/16

4-S Nm

7

A

10

DETAlL

5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 31 - 15

Installation - horizontal stabilizer

1.

Carefully insert horizontal stabilizer (3, figure 31-6) in tail boom (1).

2.

Install wiring of position lights (5).

3.

Install angle brackets (10, 11, 14 and 15) with screws (12 and 13) on tail boom and horizontal stabilizer.

4.

Install vertical stabilizer as outlined in paragraph 31-11.

5.

Instal1 vertical fin fairing.

31 - 16

Fa i r i n g s

31 - 17

Removal - fairings

1.

Open Camloc fasteners on nose fairing (2, figure 31-1) and remove nose fairing.

2.

Open Camloc fasteners on drive shaft fairing (1) and remove drive shaft fairing.

3.

Open Camloc fasteners on vertical tail fairing (5). Detach vertical tail fairing and disconnect electrical connector (16).

31 - 18

Inspection and repair - fairings

Inspect drive shaft fairing, nose fairing and vertical tail fairing for damaged or missing Camloc fasteners. 1.

Replace damaged Camloc fasteners or ejector springs as outlined in chapter 02.

2.

Replace missing Camloc fasteners or ejector springs as outlined in chapter 02.

31 - 19

Installation - fairings

1.

Plug in electrical connector (16, figure 31-1) and install vertical tail fairing (5) on vertical fin (3) with Camloc fasteners.

2.

Place drive shaft fairing (1) on tail boom and secure with Camloc fasteners.

3.

Install nose fairing (2) on drive shaft fairing (1) and vertical fin (3) with Camloc fasteners. BO 105 CHAPTER 31 Page 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 31 - 20

Ta i 1

31 - 21

Removal - tail skid

s

k i d

1.

Remove sealing compound from tail skid (1, figure 31-7) and doubler guards (2 and 3) .

2.

Extract plug (8) from tail skid.

3.

Remove screws (4) with nuts (6) and washers (5).

4.

Pull tail skid (1) out of doubler guards (2 and 3).

31 - 22

Installation - tail skid

1.

Insert tail skid (1) in doubler guards (2 and 3).

2.

Insert plug (8) in tail skid (1).

3.

Attach tail skid with screw (4), washer (5) and nut (6). Secure nut (6) with split pin (7) (only for configuration 1).

4.

Seal split lines (around entire circumference) between doubler guards (2 and 3) and tail skid (1) with sealing compound (CM 662) .

BO 105 CHAPTER 31 Page 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

4

5

8

3

2 -----., .....

~_ _5_6

DETAlL

1 5. 5 - 7 Nm I

A

Conliguratlon I

#'---7

AI)..--4

1 Tail skid Doubler guard (front) 3 Doubler guard (aft) 4 Screw 5 Washer 6 Nut 7 Split pin 8 Plug

2 15.5-7 Nm I

DETAlL

A

Configuratlon 11

2 300121

Figure 31-7

Tail skid BO 105 CHAPTER 31

Page 19/20

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32

TA1 L ROTOR DR 1 VE

Table of Contents

Paragraph

Title

32 - 1

DESCRIPTION - TAIL ROTOR DRIVE

5

32 - 2

TROUBLESHOOTING - TAIL ROTOR DRIVE

7

32 - 3

INSPECTION - TAIL ROTOR DRIVE

9

32 - 4

1 n s p e e t ion

(Configuration

Page

1 -

t a i 1 r o t o r d r i v e with laminated disc couplings)

9

- t a i 1 r o t o r d r i v e (Configuration 11 - with membrane couplings)

11

32 - 6

SHIMMING - DRIVESHAFTS . . . . . . . . . . .

13

32 - 7

S h i m m i n g - d r i ves h a f t s (Configuration 1 - with laminated disc couplings)

13

S h i m m i n g - d r i ves h a f t s (Configuration 11 - with membrane couplings)

15

32 - 9

on

17

32 - 10

DRIVESHAFTS - CONFIGURATION 1 (with laminated disc couplings)

19

32 - 11

F o r wa r d

19

32 - 12

Removal - forward short driveshaft

19

32 - 13

Disassembly - forward short driveshaft

20

32 - 14

Inspection and repair - forward short driveshaft

21

32 - 15

Assembly - forward short driveshaft

23

32 - 16

Installation - forward short driveshaft

24

32 - 5

32 - 8

1 n s p e e t ion

CHANGE

s h o r t

d r i ves h a f t

BO 105 CHAPTER 32 Page 1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Paragraph

Title

32 - 17

L o n g d r i ves h a f t

25

32 - 18

Rernoval - long driveshaft

25

32 - 19

Disassembly - long driveshaft

27

32 - 20

Inspection and repair - long driveshaft

28

32 - 21

Assembly - long driveshaft . .

29

32 - 22

Installation - long driveshaft

30

32 - 23

Co u P 1 i n g

31

32 - 24

Rernoval - coupling

31

32 - 25

Disassembly - coupling

31

32 - 26

Inspection and repair - coupling

32

32 - 27

Assembly - coupling

32

32 - 28

Installation - coupling

32

32 - 29

A f t s h o r t d r i ves h a f t i n ver t i c a 1 fin . . . .

33

32 - 30

Rernoval - aft short driveshaft in vertical fin

33

32 - 31

Disassembly - aft short driveshaft in vertical fin

34

32 - 32

Inspection and repair - aft short driveshaft in vertical fin . . . . . . . . . . . .

34

32 - 33

Assembly - aft short driveshaft in vertical fin

35

32 - 34

1nstallation - aft short driveshaft in vertical fin .

35

DR1VESHAFTS - CONFIGURATION 11 (with rnembrane couplings)

37

32 - 36

F o r wa r d

37

32 - 37

Rernoval - forward short driveshaft

37

32

Inspection and repair - forward short driveshaft

38

Installation - forwatd short driveshaft

38

32 - 35

38

32 - 39

BO 105 CHAPTER 32 Page 2

Page

s h o r t

d r i ves h a f t

MAINTENANCE MANUAL 80 105

EUROCOPTER

Paragraph

Title

32 - 40

Lo n g

32 - 41

Removal - long driveshaft

39

32 - 42

Disassembly - long driveshaft

40

32 - 43

Inspection and repair - long driveshaft

40

32 - 44

Assembly - long driveshaft

40

32 - 45

Installation - long driveshaft

40

32 - 46

Co u P 1 i n g

41

32 - 47

Removal - coupling

41

32 - 48

Inspection and repair - coupling

41

32 - 49

I~stallation

32 - 50

Af t s h o r t d r i ves h a f t ver t i c a 1 fin

Page d r i ves h a f t

39

- coupling

41 i n

41

32 - 51

Removal - aft short driveshaft in vertical fin

42

32 - 52

Inspection and repair - aft short driveshaft in vertical fin . .

42

32 - 53

Installation - aft short driveshaft in vertical fin

42

32 - 54

INTERMEDIATE GEARBOX

32 - 55

Removal - intermediate gearbox

32 - 56

Inspection and repair - intermediate gearbox

43

32 - 57

Installation - intermediate

54

32 - 58

TAIL ROTOR GEARBOX

55

32 - 59

Removal - tail rotor gearbox

55

32 - 60

Inspection and repair - tail rotor gearbox

57

32 - 61

Installation - tail rotor gearbox

64

Revision 11

* * * 42 * * 42

g2a~box

BO 105 CHAPTER 32 Page 3/4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 DESCRIPTION - TAIL ROTOR DRIVE

32 - 1 1. General

The tail rotor drive transrnits torque frorn the rnain rotor transrnission to the tail rotor. It consists of the forward short driveshaft (4, fig. 32-1), long driveshaft (6), interrnediate gearbox (9), aft short driveshaft (8) in the vertical fin, tail rotor gearbox (7), and either one or two coupling(s) (3), depending on the configuration. . The latter are either rnembrane or larninated disc couplings:

Conflguratlon with lamlnated dlsc coupllngs

3

5

4

3 8

Configuratlon wlth membrana coupllngs 1 2

4

5

(Bandix)

ÜIlHII----U·~ 300352.1

1

2 3 4

5

Tail rotor drive flange on rnain transrnission Rotor brake Coupling Forward short driveshaft Bearing Fig. 32-1

Long driveshaft Tail rotor gearbox 8 Aft short driveshaft in vertical fin 9 Interrnediate gearbox

6 7

Tail rotor drive schernatic BO 105 CHAPTER 32 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

2. Tail rotor driveshafts The forward short driveshaft, the long driveshaft positioned along the top of the tailboom and supported at four points by bearings, and the coupling(s) connect the tail rotor output flange on the main transmission to the tail rotor intermediate gearbox. Connection from the intermediate gearbox to the tail rotor gearbox is provided by the aft short driveshaft in the vertical fin. The flexible couplings compensate for length differences at driveshaft installation and absorb angular deflection during flight. 3. Intermediate gearbox The intermediate gearbox is installed at the junction of the tailboom and vertical fin. It changes the direction of drive upward from the tailboom to the vertical fin. 4. Tail rotor gearbox The tail rotor gearbox is located at the top of the tailboom vertical fin and provides 90-degree change in direction of drive between input driveshaft in vertical fin and output shaft to tail rotor.

BO 105 CHAPTER 32

Page 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 2

TROUBLESHOOTING - TAIL ROTOR DRlVE

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Pedal buzz

Loose driveshaft bearings on tailboorn

Check bearing supportto-mounting bracket attachment for presence of cotter pins. Retorque nuts to 6-8 Nm, as necessary, and install cotter pins

Driveshaft bearing play exceeds lirnits

Inspect bearings for radial play (maximum allowable 0.1 mm), roughness, and condition of rubber collars. Replace rubber collars if necessary (refer to para 32-17 or 32-40, as applicable)

Major darnage to shafts or couplings

Check shafts and couplings for major damage (e.g. deformation) and check for loase attaching hardware. Tighten or replace as necessary

Loose attachrnent of interrnediate gearbox or tail rotor gearbox

2

Traces of oil on input or output flanges of interrnediate gearbox or tail rotor gearbox

Leaking seals or damaged seal contact surfaces (tooling rnarks or wear) on input or output flanges

Table 32-1

Check attaching hardware for proper torque and signs of darnage. . Retorque or repair as necessary Replace seal in accordance with para 32-56 or para 32-60, as applicaole, and, if necessary, rework seal contact surface in accordance with REM 303 or 304, as applicable

Troubleshooting (1 af 2)

BO 105 CHAPTER 32 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

3

Traces of oil on edges of input or output covers of intermediate gearbox or tail rotor gearbox

Dar:naged O-ring in cover

Replace O-ring in accordance with para 32-56 or para 32-60 as applicable

4

Oil in area adjacent to oil drain plug, oil sight glass, and oil filler neck of intermediate gearbox or tail rotor gearbox

Damaged O-ring or packing

Replace O-ring or packing, as applicable

Table 32-1 Troubleshooting (2 of 2)

BO 105 CHAPTER 32 Page 8

EUROCOPTER

32 - 3

MAINTENANCE MANUAL 80 105

INSPECTION - TAIL ROTOR DRIVE

32 - 4

I n s p e c t ion - t a i 1 r o t o r d r i v e (Configuration I - with laminated disc couplings)

1. Inspect tail rotor driveshafts as follows: a.

b.

mnspect driveshafts for cracks, deformation, other mechanica1 damage and corrosion. 1)

Scrap deformed or cracked driveshafts.

2)

Polish out mechanical and corros ion damage on driveshafts, and final polish with 600 grit abrasive cloth. For damage and repair limits, refer to paras 32-14, 32-20 and 32-32. '

*

Inspect for proper condition of flange-to-driveshaft connecting rivets * and for rotational play between flange and driveshaft. * 1) Replace loose rivets and rivets without locking rings per para. 32-14. 2) Rotational play must not exeed 0.6 mm, otherwise replace shaft.

c.

d.

e.

Inspect visible areas of driveshaft flanges for mechanical damage. 1)

Polish out mechanical damage and final polish with 600 grit abrasive cloth. See fig. 32-4 for damage and repair limits.

2)

Coat reworked areas with corros ion preventive compound (CM 505) .

Inspect laminated disc assemblies for deformation and cracks. Use 8-power magnifying glass for crack inspection. 1)

Deformed discs are allowed, provided deformation do not exceed two gaps of max. 0.6 mm each between any two bolts of a disc assembly.

2)

Discard cracked or excessively deformed discs. Replace disc assembly if more than three discs are damaged.

Inspect visible parts of beveled washers for damage to silver plating. Even minor damage is cause for replacement.

Revision 16

BO 105 CHAPTER 32 Page 9

* * * * * *

EUROCOPTER

MAINTENANCE MANUAL BO 105

2. Inspect couplings as follows: a.

Inspect visible areas of coupling flanges (1, fig. 32-10) for mecha-nical damage. 1)

Polish out mechanical damage that is within damage and repair limits (refer to para 32-14), and final polish with 600 grit abrasive cloth.

2)

Coat reworked areas with corrosion preventive compound (CM 505) .

b.

Inspect disc assembly in accordance with step l.d.

c.

Inspect beveled washers in accordance with step 1.e.

3. Check that all attaching hardware is secured properly with cotter pins and lacquer marking. If hardware safetying is damaged or missing, check torque and secure hardware. 4. Inspect bearings (9, fig. 32-6) as a.

b.

follo~s:

Inspect bearings for roughness, radial play (max. allowable 0.1 mm), and corros ion . 1)

Replace bearings if roughness is evident, or radial play is in excess of 0.1 mm.

2)

Polish out minor corrosion damage on outer race with 400 grit abrasive cloth. If corrosion is suspected inside a bearing, replace bearing.

Inspect rubber collars for cracks and deformation. Replace damaged collars.

5. Inspect intermediate gearbox and tail rotor gearbox as follows: a.

Inspect intermediate gearbox and tail rotor gearbox for cracks. Replace if cracks are evident.

b.

Inspect intermediate gearbox and tail rotor gearbox for mechanical and corros ion damage. Acceptable damage limit is 0.2 mm in depth. If depth is exceeded, return gearbox to manufacturero Refer to Chapter 02-5 for rework criteria.

c.

Inspect magnetic plugs for metal deposits (refer to para 32-56) .

d.

Inspect intermediate gearbox and tail rotor gearbox for evidence of leakage in area adjacent to the seals. Replace leaking seals (refer to paras 32-56 and 32-60) .

e.

Inspect attaching hardware for proper torque load; retorque as necessary.

BO 105 CHAPTER 32 Page 10

EUROCOPTER

MAINTENANCE MANUAL 80 105

f.

Inspect intermediate gearbox and tail rotor gearbox for damaged surface protection; touch up as necessary (refer to Chapter 02) .

g.

Inspect oil sight glass of intermediate gearbox and tail rotor gearbox for damage, crazing, signs of leakage, and proper wire-locking; repair as necessary in accordance with para 32-56.

h.

Inspect oil level in oil sight glass of intermediate gearbox and tail rotor gearbox; if necessary, fill with oil (CM 103) to required level (middle of sight glass) .

Revision 16

BO 105 CHAPTER 32 Page 10AlB

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 I n s p e e t ion - t a i 1 r o t o r d r i v e (Configuration II - with membrane couplings)

32 - 5

l. Inspect driveshafts and coupling as follows: a.

Inspect tubular sections of driveshafts for cracks, distortion, other mechanical ~amage and damaged surface protection. 1)

Scrap any cracked or deformed driveshafts.

2)

Polish out mechanical damage and corrosion, and final polish with 600 grit abrasive cloth. For damage and repair limits, refer to paras 32-38 and 32-43.

3)

Touch up damaged surface protection in accordance with para 32-38 and Chapter 02.

b.

Inspect riveted Bendix shafts for condition of rivets. Replace loose rivets in accordance with para 32-14.

c.

Inspect visible areas of shaft and coupling flanges and membranes for cracks, other mechanical damage and damaged surface protection. For damage and repair limits, refer to para 32-38.

2. Inspect all attaching hardware for proper safetying (cotter pins and lacquer marking): If hardware safetying is damaged or missing, check torque and secure the attaching hardware. 3. Inspect bearings (8, fig. 32-14) as follows: a.

b.

Inspect bearings for roughness, radial play (max. allowable 0.1 mm), and corrosion. 1)

Replace bearings if roughness is evident, or radial play exceeds 0.1 mm.

2)

Polish out minor corros ion damage on outer race with 400 grit abrasive c10th. If corrosion is suspected inside a bearing, replace bearing.

Inspect rubber collars for cracks and deformation. Replace damaged collars.

BO 105 CHAPTER 32 Page 11

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

4. Inspect intermediate gearbox and tail rotor gearbox as follows: a.

Inspect intermediate gearbox and tail rotor gearbox for cracks; replace if cracks are evident.

b.

Inspect intermediate gearbox and tail rotor gearbox for mechanical and corrosion damage. Acceptable damage limit is 0.2 mm depth. If exceeded, return gearbox to manufacturero Refer to Chapter 02-5 for rework criteria.

c.

Inspect magnetic plugs for metal deposits (refer to para 32-56) .

d.

Inspect intermediate gearbox and tail rotor gearbox for evidence of leakage in area adjacent to seals. Replace leaking seals (refer to paras 32-56 and 32-60) .

e.

Check attaching hardware for proper torque load; retorque as necessary.

f.

Inspect intermediate gearbox and tail rotor gearbox for damaged surface protection; touch up as necessary (refer to Chapter 02).

g.

Inspect oil sight glass of intermediate gearbox and tail rotor gearbox for damage, crazing, signs of leakage, and proper wire-locking; repair as necessary in accordance with para 32-56.

h.

Inspect oil level in oil sight glass of intermediate gearbox and tail rotor gearbox; if necessary, fill with oil (CM 103) to required level (middle of sight glass) .

BO 105 CHAPTER 32 Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 6

SHIMMING - ORlVESHAFTS

32 - 7

S h i m m i n g - d r i ves h a f t s (Configuration 1 - with laminated disc couplings)

1. When driveshafts are installed, they may be found not to correspond in length to the distance between their respective mating flanges due to the existence of dimensional tolerances. These length differences must be compensated for by installing or removing shims at the shirnming locations indicated by SYIDbol~ in figs. 32-2, 32-6 and 32-11. 2. A maximum of two 0.8-mm-thick shims may be installed at each shimming location. For example, if more than four shims are required to compensate for the length difference arising from installation of the forward short driveshaft, additional shims must be installed at the other shimming locations in this drive section (refer to step 3. and figs. 32-2 and 32-6). If the length of the forward short driveshaft were to exceed the distance between its mating flanges, an appropriate number of shims would have to be removed. One 0.8-mm-thick shim can be substituted by two 0.4-mm-thick shims. 3. Tables 32-2 and 32-3 list the shim requirements for given length differences. Length differences of +3.0 mm to -3.0 mm ,and +1.5 mm to -1.5 mm require no shimming adjustments because the compression and tension loads in these sections are absorbed by the laminated disc couplings. SHIMMING

SHIMMING

Length difference in mm

Length difference in mm

from

to

+ -

- 3.0 - 3.8 - 4.6 - 5.4 -6.2 - 7.0 - 7.8 - 8.6 - 9.4

3.0 3.0 3.8 4.6 5.4 6.2 7.0 7.8 8.6

Shims 0.8 mm thick

-

1 2 3 4 5 6 7 8

Table 32-2 Orive section between main transmission and intermediate gearbox

Shimming at one location,-E at two locations -E at three locations at four locations

tl,

OO-

P

from

to

+ -

-

1.5 1.5 2.3 3.1 3.9

Shims 0.8 mm thick 1.5 2.3 3.1 3.9 4.7

-

1 2 3 4

Table 32-3 Orive section between intermediate gearbox and tail rotor geaibox

BOlOS CHAPTER 32 Page 13/14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 8

NOTE

S h i m m i n 9 - d r i ves h a f t s (Configuration 11 - with membrane couplings) o Listed below are the normal temperature ranges for installing the shafts and coupling. Operational environment temperature range

Installation environment temperature range

A

-100 to 50 OC

15 0 to 25 OC

B

-45 0 to -10 oC

-15 0 to -5 oc

o If installation is performed in ambient temperatures of between 15 oc and 25 oc (A) for subsequent operation in an environment where temperatures of between -45 oC and -10 oC prevail (B), a clearance of between 0.6 mm and 0.8 mm must be left between main transmission and intermediate gearbox (pre-stressed installation) befo re the flanges are connected. o When changing operational environments (high to low, or vice versa), the driveshaft between main transmission and intermediate gearbox must be reshimmed. 1. When driveshafts are installed, they may be found not to correspond in length to the distance between their respective mating flanges due to the existence of tolerances. These length variations must be cómpensated for by installing or removing shlms at the shimming locations indicated by symbol~ in figs. 32-13, 32-14 and 32-15. 2. A maximum of three 0.4-mm-thick shims may be installed at each shimming location. For example, if more than three shims are required to compensate for the length difference arising from installation of the forward short driveshaft, additional shims must be installed at the other shimming locations in this drive section (refer to step 3. and fig. 32-14). If the length of the forward short driveshaft exceeds the distance between its mating flanges, an appropriate number of shims have to be removed at the other shimming locations.

BO 105 CHAPTER 32 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3. TabIes 32-4 and 32-5 list the shim requirements for given Iength differences. SHIMMING

SHIMMING

Length difference in mm

Length difference in mm

from

from

O

0.2 0.6 1.0 1.4 1.8 2.2 2.6 3.0 3.4

to 0.2 0.6 1.0 1.4 1.8 2.2 2.6 3.0 3.4 3.8

Shims 0.4 mm thick

1

O- atIocations two

7

]

8

one Iocation

~

0.2 0.6 1.0 1.4

1_~1:..;;'4~1_~1.;..;:'8~

1_.... 1 ;...,:'8,....-1_.... 2~.2¡-

2.2

2.6

Shims 0.4 mm thick 1

2 3 4 5 6

at three Iocations

9

TabIe 32-4 Drive section between main transmission and intermediate gearbox

BO 105 CHAPTER 32 Page 16

rt~himming at

2 3 4 5 6

O 0.2 0.6 1.0

to

TabIe 32-5 Drive section between intermediate gearbox and tail rotor gearbox

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 32 - 9

01L CHANGE

Special tools: Oil drain hose assembly NOTE

1x56 134 519 (Tedeco p/N DB 75 A)

The oil change procedure for the intermediate gearbox and tail rotor gearbox is the same.

1. Remove bayonet-type plug (8, fig. 32-16) from filler neck on intermediate gearbox and, depending on configuration, either remove bayonet-type plug from, or open snap-cap on, oil filler neck (15, fig. 32-23) on tail rotor gearbox. 2. Remove magnetic plug from self-closing oil drain plug (14, fig. 32-16 of intermediate gearbox or 17, fig. 32-23 of tail·rotor gearbox, as applicable). To remove, press magnetic plug inward and turn counterclockwise to disengage bayonet pins. Inspect magnetic plug for metal particles in accordance with para 32-56. 3. Connect oil drain hose 1x56 134 519 to oil drain plug so that bayonet pins engage. Drain oil from gearbox and remove drain hose. 4. Prior to installation, clean magnetic plug and inspect O-ring for correct seating and condition. Replace O-ring if damaged. 5. Install magnetic plug by hand in oil drain plug. To install, press magnetic plug into oil drain plug and turn clockwise to engage bayonet pins. NOTE

Before servlclng the gearbox, agitate oil cans so that oil and additives are well mixed.

6. Service gearbox with oil through oil filler inlet (8, fig. 32-16 or 15, fig. 32-23, as applicable), until oil level is at center of sight glass. Gearbox capacities: Intermediate gearbox: Tail rotor gearbox:

approx. 0.6 liter approx. 0.4 liter

7. Reinstall plug in filler neck or close snap-cap, whichever applicable.

BO 105 CHAPTER 32 Page 17/18

_~~~er

MAINTENANCE MANUAL 80105

32 - 10

DRIVESHAFTS - CONFIGURATION I (with laminated disc couplings)

32 - 11

F o r w a r d s h o r t d r i ves h a f t

32 - 12

Removal - forward short driveshaft

a:

1

!I ~

'lJ,'

g

@

Shimming (refer to para 32-7)

1 2 3 4 5 6 7 8 9 10

1

111 Figure 32-2

Forward short driveshaft Shinis Bolt Washer Nut Coupling adapter Bolt Washer Nut Locking plate Coupling flange

Removal and installation - forward short driveshaft

1. Remove cowlings and fairings (e.g. engine cowlings, firewalls, tail rotor driveshaft fairing) as required. 2. Remove nuts (5, fig. 32-2), washers (4), and bolts (3) connecting forward short driveshaft to the coupling adapter (6) and coupling flange (11). 3. Remove forward short driveshaft (1). 4. Record number, thickness and position of shims (2) for reinstallation at originallocation if same driveshaft is to be re-installed.

Revision 24

CHAPTER 32 Page 19

I

MAINTENANCE MANUAL BO 105

32 - 13

Disassemble - forward short driveshaft

NOTE

Do not remove hex bolts (5, fig 32-3) unless damaged (refer to para 32-14).

1. Remove nut (2), washers (3) and beveled washers (4). 2. Remove coupling flange (1). 3.

Remove laminated disc assembly (5) and beveled washers (4). Take care not to alter the relative position of the individual discs in the stack.

1

Coupling flange

2

Nut

3

Washer

4

Beveled washer

5

Laminated disc assembly (12 discs)

6

Hex bolt

7

Forward short driveshaft

5

6

6 4

i: ~,o

o !Xl Figure 32-3

CHAPTER 32 Page 20

Disassembly and assembly - forward short driveshaft

Revision 24

_~..'ooI~ter 32 - 14 1.

2.

MAINTENANCE MANUAL 80105

INSPECTION ANO REPAIR - FORWARO SHORT ORIVESHAFT

Inspect forward short driveshaft for cracks, deformation, other mechanical damage and corrosion. a.

Discard cracked or deformed driveschaft.

b.

Polish out other mechanical damage and corrosion with 400 grit abrasive cloth. See fig. 32-4 for damage and repair Iimits.

Clean disc assembly (5, fig. 32-3) with dry cleaning solvent (CM202) and inspect for cracks, deformation and damaged coating. a. Discard damaged discs. b.

3.

If more than 3 discs are damaged, discard disc assembly.

Inspect hex bolts (6) for damage, and beveled washers (4) for damaged silver plating. a. Replace hex bolts in accordance with step 5. b. Replace beveled washers even if only slightly damaged.

4.

Inspect for loose rivets. Replace loose rivets, evidenced, for example, by frictional corrosion on rivet heads, in accordance with step

6. 5.

Replacing hex bolts (6). a. Remove hex bolt from disc coupling flange (1) or driveshaft (7) by hand, or if necessary, place forward short driveshaft (7) with attached disc coupling on suitable base and press out hex bolt. b.

Insert new hex bolts into coupling flange (1 ) orflange of driveshaft (7) by hand. If manual installation is not possible, heat coupling or flange of driveshaft to approx. 120°C, cool hex bolts to approx. -50°C and insertthem.

Revision 16

CHAPTER 32 Page 21

O~~pter

MAINTENANCE MANUAL SO 105

~I

~I

~",1 o

o al

TYPE OF DAMAGE

DAMAGE AND REPAIR L1MITS ZONE 1

I Mechanical

Depth: 0.4 mm Area: S x 4 mm2 Minimum spacing: 10 mm

& & &

Depth: 0.3S mm Length: axial: SO mm circumferential: 1Smm Minimum spacing: SO mm

-

0.1 mm in depth on 30 % of surface area

Max. allowable bore diameter is 6.10 mm. It may be exceeded by 0.01 mm on 1/4 of circumference. Max. allowable bore diameter is 8.01 mm. It may be exceeded by 0.01 mm on 1/4 of circumference Max. allowable damage in 10 mm wide area surrounding bore: Total cumulative local damage not to exceed SO % of surface area and 0.1 mm in depth.

Figure 32-4

CHAPTER 32 Page 22

..

ZONE3

0.03 in depth on total surface area

Corrosion

I

I

ZONE2 ~·:·:·:········l ~ :':':':':':'.

Forward short driveshaft and coupling flanges - damage and repair limits

Revision 24

MAINTENANCE MANUAL 80105 6.

Replacement of rivets.

• If one of a row of rivets running circumferentially is damaged, al50 replace diametrically opposite rivet.

NOTE

• If more than 1 rivet is affected, the entire row of rivets running circumferentially must be replaced. • Replace the rivets consecutively. a.

Drill out rivet with 3.6-mm-dia. dril!.

b.

Drill rivet hole to 4.0 mm dia., then ream to 4.05 - 4.2 mm diameter, using reamer.

c.

To provide a better support for the rivet heads, countersink the rivet hole to 8.0 +0.3 mm día., using spot facer.

d.

Deburr rivet holes at both ends without breaking the edges,and clean with compressed airo

e.

Install blind rivet NAS 1398 M5 A3, CR 4523-5-3 (CHERRY MAX).

32 - 15

ASSEMBLV - FORWARD SHORT DRIVESHAFT

1. Assemble the 12 discs of disc assembly (5, fig. 32-3) 50 that the discs of the disc assembly are stacked with the indexing edges of each successive disc offset 60° to preceding disc (see fig. 32-5).

/---

I

.""-". "

(

\

"

DETAlL

A

( ) Orientation of indexing round edges

Figure 32-5

Assembling the discs of the disc assembly CHAPTER 32 Page 23

O~~pter

MAINTENANCE MANUAL BO 105

2.

Fit one beveled washer (4, fig. 32-3) (flat side against flange) on each hex bolt (6) in driveshaft coupling flange.

3.

Fit disc assembly (5) on hex bolts (6) in driveshaft coupling flange.

4.

Install one beveled washer (4) (beveled side against the disc assembly) on each of the hex bolts (6) in driveshaft coupling flange.

5.

Install washer (3) and nuts (2) on hex bolts (6) and finger-tighten nuts (2).

6.

Install hex bolts (6) (heads aft) in coupling flange (1) and fit one beveled washer (4) (flat side against flange) on each of them.

7.

Insert hex bolts (6) of coupling flange (1) through the corresponding bores in the disc assembly (5).

8.

Fit one beveled washer (4) (beveled side against the disc assembly) on each of the hex bolts.

9.

Install washer (3) and nuts (2) on hex bolts and finger-tighten nuts.

10. Torque nuts (2) to 4 Nm, then back off and retorque to 2.5 Nm. 11. Mark nuts (2) with safetying lacquer (CM 620).

32 - 16

IN5TALLATION - FORWARD 5HORT DRIVE5HAFT

NOTE

During installation offorward short driveshaft (1 , fig. 32-2) pay attention to correct installation positioning. The forward short driveshaft must only installed as decribed below. If the driveshaft is incorrectly installed, its freedom of movement may be restricted in relation to the firewall.

1.

Make sure that the forward short driveshaft (1) is installed so that two coupling adapters (6) are fitted on the brake disc side and one coupling flange (11) is fitted on the long driveshaft side.

2.

Place forward short driveshaft (1) in installed position and perform shimming in accordance with para 32-7.

3. Apply a thin coat of corrosion preventive compound (CM 505) to all flange and shim contact surfaces. 4.

Secure forward short driveshaft (1) and, if installed, shims (2), using bolts (3), washers (4) and nuts (5) to: -

the both coupling adapters (6) at the brake disc side,

-

the long driveshaft together with the coupling attached to the forward short driveshaft.

5.

Mark nuts (5) with safetying lacquer (CM 620).

6.

Install cowlings and fairings.

CHAPTER 32 Page 24

Revision 24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 17

L o n g d r i ves h a f t

32 - 18

Removal - long driveshaft

1. If not previously removed, support free end of forward short driveshaft to prevent it from tipping. 2. Mask openings around bearing rnounting brackets (14, fig. 32-6) with adhesive tape. 3. Remove nuts (4), washers (3) and bolts (2) connecting long driveshaft to coupling flanges on forward short driveshaft and interrnediate gearbox. 4. Rernove cotter pins (13), nuts (12), washers (15) and bolts (11) connecting the four long driveshaft bearings to the rnounting brackets (10 and 14) . 5. Remove long driveshaft. 6. Record number, thickness and position of shirns (5) for reinstallation at original position if sarne long driveshaft is to be re-installed.

BO 105 CHAPTER 32 Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS

I

6-8 Nm

4

I 5

~

~ ',.~~,,~V"

r

I

I I

5

~, 4

3

_ _1

9

v 13 Mask wlth adhesiva tape

12

1

6-8 Nm

15 11

15 \

300357

BO lOS CHAPTER 32 Page 26

13

~ Shlmmlng (see para 32-7)

~

1 Long driveshaft 2 BoH 3 Washer 4 Nut S Shim 6 Locking p1ate 7 BoH Fig. 32-6

12

14

8 9

10 11

12 13

14 lS

Coupling Bearing Mounting bracket BoH Nut Cotter pin Mounting bracket Washer

Removal and instal1ation - long driveshaft and coupling

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 19

Disassembly - long driveshaft

Special tools: Press-in tool 1121-31502 W1 NOTE

Do not disassemble the long driveshaft unless it needs repairing. 'O

1------3

34 I

/.- ~

6-~

11

2

6 5--~ 4---~

I

[f-3

-+----2 5----~~

'O

[2-3 Nm

I4

_----JIII:!'

300013.3

Installation

Rernoval 1 2 3 4 Fig. 32-7

Driveshaft Press-in tool Spring pin Nut

5 Washer 6 Driveshaft flange 7 Bolt

Rernoval and installation - bolted driveshaft flange

BO 105 CHAPTER 32 Page 27

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1. Remove nuts (4, fig. 32-7), washers (5) and bolts (7) securing driveshaft flange (6) to long driveshaft (1). 2. Remove spring pins (3) as shown in fig. 32-7. 3. Remove driveshaft flange (6). 4. Remove bearings (9, fig. 32-6) from long driveshaft. Inspection and repair - long driveshaft

32 - 20

1. Inspect long driveshaft according to inspection criteria in para 32-14, and repair as necessary. In addition perform the following inspections and observe the following damage limits:

Zona A

Zona B

Fig. 32-8

BO 105 CHAPTER

Page 28

32

Long driveshaft - damage and repair limits

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

NOTE

Do not inspect in accordance with steps a. and b. unless the driveshaft flange has to be removed for repair work.

a.

Max. allowable bore diameter (Zone A, fig. 32-8) is 10.09 mm (lineream bores in assembled shaft and flange to common diameter); locally 10.24 mm dia. (polish out sharp nicks) .

b.

Inspect silver plating in Area B for damage. Only 4 damage areas of max. 8 mm2 each with at least 10 mm spacing are allowed.

2. Inspect driveshaft bearings for roughness, radial play (0.1 mm allowed) and corros ion; inspect rubber collars for misalignment and condition (cracks, deformation).

a.

Evidence of bearing roughness, excessive play and damage to rubber collar requires replacement of affected parts (refer to paras 32-19 and 32-21) .

b.

Polish out minor corrosion damage on bearing outer race with 400 grit abrasive cloth or finer. Suspicion of corros ion inside bearing requires bearing replacement.

32 - 21

Assembly - long driveshaft

Special tools: Press-in tool 1121-31502 W1 NOTE

The dimensions in fig. 32-9 are approximate bearing center-tocenter dimensions; actual dimensions are established when the long driveshaft is installed.

l--

80

32111

3135

-i

Dimensions in mm Fig. 32-9

Position of bearings on driveshaft prior to driveshaft installation BO 105 CHAPTER 32 Page 29

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 1. Install bearings (9, fig. 32-6) on long driveshaft (1) sothat they are spaced as shown in fig. 32-9. If bearings are installed together with spring rings (refer also to IPC), the latter shall face forward. 2. Install driveshaft flange (6, fig. 32-7) on end of long driveshaft (1) and align its boreholes with boreholes in driveshaft. 3. Install spring pins (3) as shown in fig. 32-7. 4. Install bolts (7), washers (5) and nuts (4).

32 - 22

Installation - long driveshaft

1. Place long driveshaft (1, fig. 32-6) in position and perform shirnming in accordance with para 32-7. 2. Apply thin coat of corrosion preventive compound (CM 505) to all flange and shim mating surfaces.

NOTE

Bearings (9) must be attached to the rear fa ce of mounting brackets (10 and 14) as shown in fig. 32-6.

3. Align lug bores of bearings (9) with respective mating bores in mounting brackets (10 and 14) and install bolts (11), washers (15) and nuts (12). 4. Tighten nuts (12) to specified torque and safety with cotter pins (13). 5. Secure long driveshaft (1) to flanges of coupling on intermediate gearbox and short forward driveshaft respectively with bolts (2), washers (3), nuts (4) and, if required, shims (5).

6. Mark nuts (4) with safetying lacquer (CM 620).

BO 105 CHAPTER 32 Page 30

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 23

NOTE

Co u P 1 i n 9

Paragraphs 32-24 through 32-28 provide for the coupling (8, fig. 32-6) on the These instructions are also applicable main transmission, in conjunction with

32 - 24

maintenance instructions intermediate gearbox. for the coupling on the fig. 32-2.

Removal - coupling

l. Remove nuts (4, fig. 32-6), washers (3) and bolts (2 and 7) connecting coupling (8) to long driveshaft and intermediate gearbox.

2. Remove coupling (8). 3. Record number, thickness and position of shims (S) for reinstallation at original position if same coupling is to be reinstalled. 4. Remove locking plate (6) from intermediate gearbox flange.

32 - 25

Disassembly - coupling

Disassemble coupling according to para 32-13, Disassembly forward short driveshaft, in conjunction with fig. 32-10.

3

2

4

5

4

6

~// 31/12

L.-1

/~ ,

./

".,

".,

I 2

Fig. 32-10

6

4

Coupling flange Nut Washer 4 Beveled washer S Disc assembly (12 discs) 6 Hex boH

1 2 3 4

3

Disassembly and assembly - coupling BO 105 CHAPTER 32 Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

32 - 26

Inspection and repair - coupling

Inspect and repair coupling according to para 32-14, Inspection and repair forward short driveshaft. 32 - 27

Assembly - coupling

Assemble coupling according to para 32-15, (Assembly - forward short driveshaft), in conjunction with fig. 32-10. Installation - coupling

32 - 28

1. Position coupling (8, fig. 32-6) in place, and perform shimming in accordance with para 32-7. 2. Apply a thin coat of corrosion preventive compound (CM 505) to all flange and shim mating surfaces. 3. Insert locking plate (6) in intermediate gearbox flange. 4. Connect coupling to long driveshaft flange and intermediate gearbox flange with bolts (2 and 7), washers (3), nuts (4) and, if required, shims (5). 5. Mark nuts (4) with safetying lacquer (CM 620).

BO 105 CHAPTER

Page 32

32

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

32 - 29

Af t

32 - 30

Removal - aft short driveshaft in vertical fin

S

h

O

r t

d r i ves h a f t

i n ver t i c a 1 fin

1. Remove nuts (5, fig. 32-11), washers (4) and bolts (3 and 6) connecting aft short driveshaft to intermediate gearbox flange and tail rotor gearbox flange. 2. Remove aft short driveshaft (1). 3. Record number, thickness and position of shims (2) for reinstallation at

original location if same driveshaft is to be reinstalled. 4. Remove locking plates (7) from intermediate gearbox flange and tail rotor

gearbox flange.

,

~4S'l

2

6-8 Nm

.........../ 6-8 Nm

I

I ~ Shlmmlng (refer to para 32-7)

1 2

Aft short driveshaft Shims

3

Bolt

4 Washer 5 Nut 300358

6 Bolt

7 Locking plate Fig. 32-11

Removal and installation - aft short driveshaft in vertical fin BO 105 CHAPTER 32

Page 33

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

32 - 31

Disassembly - aft short driveshaft in vertical fin

Disassemble aft short driveshaft in vertical fin according to para 32-13, Disassembly - forward short driveshaft, in conjunction with fig. 32-12. 3 2 4

5

I

6 300400

1 Coupling flange Nut 3 Washer 4 Beveled washer 5 Disc assembly (12 discs)

2

6 Hex bolt

7 Aft short driveshaft Fig. 32-12 Disassembly and assembly - aft short driveshaft in vertical fin

32 - 32

Inspection and repair - aft short driveshaft in vertical fin

Inspect and repair aft short driveshaft in vertical fin according to para 32-14, Inspection and repair - forward short driveshaft.

BO 105 CHAPTER 32

Page 34

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

32 - 33

Assembly- aft short driveshaft in vertical fin

Assemble aft short driveshaft in vertical fin according to para 32-15 (Assembly- forward short driveshaft), in conjunction with fig. 32-12. 32 - 34

Installation - aft short driveshaft in vertical fin,

Install aft short driveshaft in vertical fin according to para 32-16 (Installation - forward short driveshaft), in conjunction with fig. 32-11. NOTE

During this procedure, observe the required minimum· clearance to the vertical fin spar (5, fig. 32-11). If necessary, rework vertical fin spar.

BO 105 CHAPTER 32

Page 35/36

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 35

DRIVESHAFTS - CONFIGURATION 11 (with membrane couplings)

32 - 36

F o r wa r d

s h o r t

d r i ves h a f t

Removal - forward short driveshaft

. 32 - 37

CAUTION

HANDLE DRlVESHAFTS AND COUPLINGS WITH CARE. DAMAGE TO THE MEMBRANES WILL MAKE DRIVESHAFT OR COUPLING UNSERVICEABLE.

1. Removal cowlings and fairings (c.g., engine cowlings, firewalls, tail rotor driveshaft fairing) as required. 2. Remove nuts (5, fig. 32-13), washers (4) and bolts (3 and 6) connecting forward short driveshaft (1) to main transmission flange and long

driveshaft flange and remove forward short driveshaft. 2 2

4

300353

6


Shlmmlng (refer to para 32-8)

1 2

Forward short driveshaft Shim

3

BoH

4 Washer 5 Nut 6

BoH

7 Locking plate

Fig. 32-13

Removal and installation - forward short driveshaft BO 105 CHAPTER 32 Page 37

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3. Record number, thickness and position of any shims (2) for reinstallation at original location if same shaft is to be reinstalled. 4. Remove locking plate (7) from main transmission flange. Inspection and repair - forward short driveshaft

32 - 38

The inspection criteria for the forward short driveshaft are identical with those listed in chapter 11-55, with the exception of the following damage limits. NOTE

Letters which suffix the dash numbers of those part numbers listed be10w with an *) symbol have no meaning.

l. Permissible depth of damage (after rework) is 0.40 mm for: a.

Stee1 shafts, PIN 19E144-2*), 19E145-2*).

b.

Thick-wal1ed aluminum shafts, p/N 19E144-3*), 19E145-3*), 105-31503, 105-31504.

2. Permissib1e depth of damage (after rework) is 0.15 mm for thin-walled a1uminum shafts, p/N 19E144-1*), 19E145-1*), 105-31505, 105-31506. 32 - 39

Instal1ation - forward short driveshaft

l. Install locking plate (7) on main transmission f1ange. 2. App1y thin coat of corrosion preventive compound (CM 505) to all f1ange and shim contact surfaces. 3. Place forward short driveshaft (1, fig. 32-13) in position and perform shimming in accordance with para 32-8. 4. Connect ends of forward short driveshaft to main transmission flange and long driveshaft flange respectively with bolts (3 and 6), washers (4), nuts (5) and, if required, shims (2). 5. Mark nuts (5) with safetying lacquer (CM 620). 6. Install cow1ings and fairings.

BO 105 CHAPTER 32 Page 38

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 40

L o n g d r i ves h a f t

32 - 41

Removal - long driveshaft 4

.~

11 v

s

3

5 3

I 6-s'Nm 13 Mask with adhesiva tapa

12

\

300354

1 Long driveshaft BoU Washer 4 Shim 5 Nut 6 Coupling 7 BoU 8 Bearing 2 3

Fig. 32-14

12

13

6-S Nm

11 9

11

~


14

Shimming (refer to para 32-S)

~ BoU Mounting bracket 11 Washer 12 Nut 13 Cotter pin 14 Mounting bracket 15 Locking plate 9

10

Removal and installation - long driveshaft and coupling BO 105 CHAPTER 32 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1. If still in situ, support free end of forward short driveshaft to prevent it from tipping. 2. Mask openings adjacent to bearing mounting brackets (14, fig. 32-14) with adhesive tape. 3. Remove nuts (5), washers (3) and bolts (2) connecting long driveshaft to forward short driveshaft flange and flange of coupling on intermediate gearbox. 4. Remove cotter pins (13), nuts (12), washers (11) and bolts (9) connecting long driveshaft bearings to bearing mounting brackets (10 and 14) . 5. Remove long driveshaft. 6. Record number, thickness and position of shims (4) for reinstallation at original position if same long driveshaft is to be reinstalled. 32 - 42

Disassembly - long driveshaft

Disassemble long driveshaft according to para 32-19, using press-in tool p/N 105-31501 W2. 32 - 43

Inspection and repair - long driveshaft

Inspection and repair requirements correspond to those in para 32-20, except for the following damage limits which apply to Zone B (fig. 32-8): -

max. 0.2 mm, with minimum transition radius of 10 mm mino allowable outer diameter of 27.80 mm may be exceeded on max. 30% of damage area.

depth: area:

32 - 44

Assembly - long driveshaft

Assemble long driveshaft according to para 32-21, using press-in tool P/N 105-31501 W2. 32 - 45

Installation - long driveshaft

Install long driveshaft according to para 32-22, and perform shimming as described in para 32-8.

BO 105 CHAPTER

Page 40

32

EUROCOPTER

MAINTENANCE MANUAL 80105

32 - 46

Co u P 1 i n g

32 - 47

Removal - coupling

Remove coupling (6, fig. 32-14) according to para 32-37, in conjunction with fig. 32-14. 32 - 48

Inspection and repair - coupling

Inspect and repair coupling (6,fig. 32-14) according to para 32-38. 32 - 49

Installation - coupling

Install coupling (6, fig. 32-14) according to para 32-39, in conjunction with fig. 32-14. 32 - 50

Af t s h o r t d r i ves h a f t ver t i c a 1 fin

~

i n

Shlmmlng (refer to para 32-8)

6

1 2

3

4 5 6 Fig. 32-15

Bolt

Washer Shim Nut Aft short driveshaft Locking plate

Removal and installation - aft short driveshaft in vertical fin BO 105 CHAPTER 32 Page 41

EUROCOPTER

32 - 51

MAINTENANCE MANUAL BO 105

Removal - aft short driveshaft in vertical fin

Remove aft short driveshaft (5, fig. 32-15) according to para 32-37, in conjunction with fig. 32-15. Inspection and repair - aft short driveshaft in vertical fin

32 - 52

Inspect and repair aft short driveshaft (5, fig. 32-15) according to para 32-38. Installation - aft short driveshaft in vertical fin

32 - 53

Install aft short driveshaft (5, fig. 32-15) according to para 32-39, in conjunction with fig. 32-15. 32 - 54

INTERMEDIATE GEARBOX

32 - 55

Removal - interrnediate gearbox

*--

* NOTE

*--

Interrnediate gearboxes intended for shipment shall be preserved per Chapter 02.

l. Disengage quick release fasteners of vertical fin fairing and raise latter approx. 15 cm from installed position, then disconnect electrical connector on frame 11L. 2. Detach control rod (16,fig. 32-16) from lever (15) and remove control rod (9) (refer to Chapter 42). NOTE

When removing aft short driveshaft (5) and coupling (1), hold on to the associated locking plates (3) to prevent them from falling and perhaps getting lost.

3. Disconnect coupling (1) and aft short driveshaft (5) from interrnediate gearbox (4) input and output drive flanges respectively, and support aft short driveshaft to prevent it from tipping. If same gearbox is to be reinstalled and its connecting flanges have not been removed, record number and position of shims (2) for reassembly at original locations. 4. Remove locking plates (3) from gearbox input and output drive flanges. 5. Remove screw (7) and washers (6) and remove interrnediate gearbox. 6. If the intermediate gearbox is being replaced, remove bellcrank and plates per Chapter 42-26, or remove yaw brake per Chapter 42-28A.

BO 105 CHAPTER 32 Page 42

Revision 13

EUROCOPTER

32 - 56

MAINTENANCE MANUAL 80 105

Inspection and repair - intermediate gearbox

Special tools: Drift 1x56 131 407 Puller 1x56 136 393 Assembly/disassembly fixture 105-31501 W5} Puller 105-31501 W6 See NOTE at beginning 1x56 136 288 of step 5. Fixture 1x56 112 756 Drift 1x56 122 209 Puller Counter support 1x56 122 232 Pusher screws 1x56 131 399 1x56 131 400 Drawing-off plate Assembly device 1x56 134 517 1x56 150 111 Guide bolts 1. Inspect intermediate gearbox housing for cracks, mechanical damage, corrosion, and damaged surface protection. a.

Replace gearbox if cracks are evident.

b.

Mechanical and corrosion damage is acceptable to a depth of 0.2 mm. If damage limit is exceeded, return gearbox to manufacturero Refer to Chapter 02-5 for rework criteria.

c.

Touch up damaged surface protection according to chapter 02.

2. Inspect magnetic plug for metal deposits. a.

Press magnetic plug (14, fig. 32-16) inwards, turn it counter-clock wise and withdraw it.

b.

Determine nature of any deposits found on the plug in accordance with Table 32-6, and take appropriate action.

c.

Clean magnetic plug and inspect O-ring for correct seating and condition. Replace O-ring as required.

d.

Insert magnetic plug into oil drain plug and, pressing it inwards, turn it clockwise until bayonet pins engage.

Revision 11

BO 105 CHAPTER 32 Page 43

MAINTENANCE MANUAL BO 105

EUROCOPTER

-1---- 5

2----..---... 3--,:-:-\

4---f-

INPUT

12

~ c,"

-lJ/"~

"'---14~

3-5 Nm

13

I

-H----15

3-5 Nm

I

32113-0\

1 2 3 4 5

Coupling Shims Locking pIate Intermediate gearbox Aft short driveshaft in vertical fin

6 Washer Screw Oil filler knob Control rod 10 Cotter pin 11 Nut 7 8 9

12 13

14

* 15 * 16

Fig. 32-16

BO 105 CHAPTER 32 Page 44

Washer BoU Oil drain plug with magnetic plug Be11crank or yaw brake Control rod

Removal and installation - intermediate gearbox

Revision 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

METAL PARTICLES

FIG. 32-17

PROBABLE CAUSE

1. Limited accumulation of fine fuzz (normal wear)

Detail A/B

None

2. Massive accumulation of fine fuzz

Detail C

Carefully inspect fuzz for presence of flakes by spreading fuzz evenly on smooth surface or on palm of hand. If there are no flakes, drain oil, flush gearbox and fill with clean oil. Reinspect magnetic plug after 10 flight hours and repair in accordance with REM 303 or 304, as applicable,if there are any signs of fuzz or flakes.

3. Flakes, usually

Detail D

Gear failure

Remove gearbox according to para 32-55 or 32-59, as applicable, and repair according to REM 303 or 304, as applicable

Detail E

Gear failure

Refer to step 3.

Detail F

Bearing failure

Refer to step 3.

Detail G 6. Several very thin flakes, shiny on one side, present in fuzz accumulation

Bearing failure

Refer to step 3.

still exhibiting a smooth or scored and scratched machined surface, with signs of fracturing on opposite surface 4. Smooth flakes

CORRECTIVE ACTION

with scratches (scores) 5. Several very thin flakes, shiny on one side

Table 32-6

Magnetic plug inspection BO 105 CHAPTER 32 Page 45

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A

DETAlL

D

DETAlL

DETAlL

DETAlL

B

E

DETAlLe

DETAlL

F

G

100285

Fig. 32-17 BO 105 CHAPTER 32 Page 46

Identification of metal deposits on magnetic plug

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3. Inspect intermediate gearbox for leakage in area adjacent to seals, and replace leaking seals according to step 5., as necessary.

4. Inspect oil sight glass for damage, crazing, discoloration, leakage and intact lockwiring. a.

If lockwire is missing or damaged, check torque of sight glass (29-31 Nm) and secure with lockwire.

b.

If there is evidence of leakage, replace sealing ring in accordance with step c.

c.

If oil sight glass is damaged, crazed or discolored, replace as follows: 1)

Drain oil according to para 32-9.

2)

Remove lockwire.

3)

Unscrew and remove oil sight glass together with sealing ringo

4)

Clean oil sight glass using an appropriate cornmercial cleansing agent.

S)

Screw new or cleaned oil sight glass into gearbox, together with new sealing ring, and torque to 29-31 Nm.

6)

Secure oil sight glass with lockwire.

7)

Fill gearbox with oil according to para 32-9.

5. Replacement of seals. NOTE ------

o Seals can be replaced using tools P/N 10S-31S01 WS/W6 or 1xS6 136 288. Note that it is not necessary to remove the gearbox when replacing the output seal using tools, P/N 10S-31S01 WS and W6. However, replacement of the input seal requires removal of the gearbox, which allows alternative use of tool, P/N 1xS6 136 288. Refer to REM 304 for tool description. o

The following steps describe replacement of seals with gearbox removed, using tools, P/N 10S-31S01 WS and W6.

BO lOS CHAPTER 32 Page 47

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

& I 35-45 Nm I 2 - - - - - - - 3-------_ la-10Nm

I

4 ---

5 ----#!;'<

& &

OUTPUT

6

Wlth vent hole

"\.r---

Wlthout vent hole

a

------9 ------10

~-----11

17

I

\ a-lO Nm

f - - - - - - - - - 12

16 9 5

~----13

4 15

1 Locking plate 2 Screw 3 O-ring

4 Hex screws 14

6 3

2

I 35-45 Nm 300328.1

& Fig. 32-18

BO 105 CHAPTER 32 Page 48

INPUT

5 Washer 6 Flange 7 Shim

8 Cover 9 Seal 10 O-ring 11 Centering ring 12 Oil filler cap 13 Intermediate gearbox 14 Oil drain plug with magnetic plug 15 Spring ring 16 Cover 17 O-ring

Replacement of seals - intermediate gearbox

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 a.

Removal of seals NOTE

Procedural steps 1) thru 9) below apply to both input and output seals.

1) Remove bellcrank (15, fig. 32-16) and its mounting support, then fit assembly device, P/N 1x56 134 517 to intermediate gearbox. 2) Drain oil according to para 32-9. 3) Bolt disassembly fixture, P/N 105-31501 W5, to flange (6, fig. 32-18) so that the keys of the socket wrench (1, tig. 32-19) engage the corresponding slots in screw (2, fig. 32-18). 4) While holding flange (6) with handle of disassembly fixture (2, fig. 32-19), insert square drive of wrench in corresponding square hole in socket wrench (1) and loosen screw (2, fig. 32-18). 5) Remove bolts attaching disassembly fixture to flange (6) and unscrew and remove screw (2) by hand. Discard O-ring (3). 6) Unscrew spindle (1, fig. 32-20) of puller, P/N 105-31501 W6, by hand, until it bottoms, then bolt puller to flange (6, fig. 32-18) . 7) Insert square drive of wrench in corresponding square hole of spindle (1, fig. 32-20) and, holding puller steady, pull flange off pinion shaft by screwing in the spindle. Remove shim (7, fig. 32-18). 8) Remove flange (6) from puller by removing the connecting bolts. 9) Remove hex screws (4) and washers (5). 10) Input seal only: a)

Install jackscrews 1x56 131 399 through both threaded bores in the flange of cover (16) to pull cover evenly from housing. Discard O-ring (17).

b)

Remove spring ring (15), position puller, P/N 1x56 122 209, against seal (9), thread counter support, P/N 1x56 122 232, onto puller, and brace it against edges of the cover. Remove seal.

11) Output seal only: a)

Remove cover (8) and centering ring (11) and discatd O-ring (10) .

b)

Place cover on drawing-off plate, P/N 1x56 131 400, and press seal (9) from cover using drift, P/N 1x56 131 407. BO 105 CHAPTER 32 Page 49

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

I I

! .......,

"'--'"

2---f-

I 2---+-

I

300360

1 Socket wrench 2 Handle

Fig. 32-19 Application of Assembly/Disassembly fixture, p/N 105-31501 W5

BO 105 CHAPTER

Page 50

32

1 Spindle 2 Handle

Fig. 32-20 Application of Puller p/N 105-31501 W6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Installation of seals NOTE

1)

Procedural steps 1) and step 2) apply to input and output seals respectively. Step 3) and subsequent apply equally to both seals. Input seal installation a)

Apply a thin coat of silicone grease (CM 104) to outer diameter of seal (2, fig. 32-21) and, using drift (1) P/N 1x56 112 756, press seal, lip first, into cover (3) (refer to fig. 32-21).

""""-_ _

-r5~~-2

'--::::::::::;;~"--""7r-3

1

Drift

2 Seal 3 Cover Fig. 32-21

Pressing seal into cover

b)

Insert spring ring (15, fig. 32-18) in mating annular groove (next to seal) of cover.

e)

Lubricate O-ring (17) with silicone grease (CM 104) and insert in mating annular groove of cover.

d)

Screw two guide bolts, P/N 1x56 150 111, in diametrically opposite holes in cover mating surface on gearbox casing. BO 105 CHAPTER 32 Page 51

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2)

e)

Slide cover (16) over guide bolts until it contacts the gearbox casing. Install hex screws (4) with washers (5) in the free bores, and progressively torque hex screws,alternating diarnetrically, until cover is seated tightly against gearbox casing. Take care not to dislodge and darnage O-ring (17) in the process.

f)

Rernove guide bolts, install rernaining hex screws (4) and washers (5) and tighten diarnetrically opposite bores in incrernents to required torque value.

g)

Proceed according to step 3).

Output seal installation. a)

Apply a thin coat of silicone grease (CM 104) to outer diarneter of seal (9, fig. 32-18) and, using drift, P/N 1x56 112 756, press seal, lip first, into cover (8) (refer to fig. 32-21).

b)

Lubricate O-ring (10, fig. 32-18) with silicone grease (CM 104) and install in rnating annular groove in cover.

c)

Push centering ring (11), with its tangs facing outboard, into bearing bushing until seated.

d)

Locate cover (8) on centering ring and press in until seated against gearbox casing.

e)

Install hex screws (4) and washers (5) and tighten progressively to specified torque, alternating diarnetrically. Lockwire oil filler cap (12) to nearest hex screw (4) in cover (8).

f)

Proceed according to step 3).

3)

Input and output seal installation. a)

Thinly coat shirn (7) with silicone grease (CM 104), installon pinion shaft, and slide up against inner race of roller bearing. Take care to install the correct shirns on the input and output ends (refer to IPC).

CAUTION

o THE SHIMS MUST SEAT AGAINST BEARING INNER RACE OTHERWISE THEY MAY SLIP INTO THE SHAFT GROOVE ANO BECOME DAMAGED WHEN THE FLANGE IS INSTALLED. o FLANGE (6) MUST BE INSTALLED USING PULLER 1x56 136 393. DO NOT DRIVE THE FLANGE IN PLACE, e.g. WITH A HAMMER. THIS MAY CAUSE DAMAGE.

BO 105 CHAPTER 32 Page 52

MAINTENANCE MANUAL BO 105

EUROCOPTER

b)

Install flange (6) on plnlon shaft with puller 1x56 136 393 (refer to fig. 32-22).

1 Flange 2 Puller Fig. 32-22

Flange installation

e)

Lubrieate new O-ring (3, fig. 32-18) with silieone grease (CM 104) and install in O-ring groove of serew (2). Depending on the seal removed, install screw (2) with vent hole in output gear shaft or serew (2) without vent hole in input gear shaft by hand.

d)

Bolt assembly fixture, P/N 105-31501 W5, to flange (6) so that keys of soeket wreneh (1, fig. 32-19) in fixture handle fit into the eorresponding slots in serew (2, fig. 32-18).

e)

While holding flange (6) with handle of assembly fixture (2, fig. 32-19), insert square drive of wreneh in eorresponding square hole of soeket wrench (1) and tighten serew (2, fig. 32-18) to 35 Nm.

BO 105 CHAPTER 32 Page 53

EUROCOPTER

* *

f)

Insert locking plate (1) in groove of flange (6). Check that teeth of locking plate exactly engage with teeth of screw (2). If they do not,retighten screw until exact engagement is obtained. However, do not exceed max. torque load of 45 Nm. Screw (2) must not protrude from the drive flange. Using a cord, provisionally attach locking plate to flange until aft short driveshaft or coupling is installed.

g)

Seal split lines, screw heads etc., in accordance with chapter 02.

h)

Service gearbox with oil according to para 32-9.

i)

Install intermediate gearbox according to para 32-57.

j)

Perform ground run and check for leakage.

32 - 57

* * * * * * * * * * * * * * *

MAINTENANCE MANUAL 80 105

Installation - intermediate gearbox

1.

Install intermediate gearbox (4, fig. 32-16) to vertical fin with washers (6) and hex screws (7).

2.

Lightly coat flange and, if applicable, shim contact surfaces with corrosion preventive compound (CM 505). Insert locking plates (3) in input and output drive flanges, and install coupling (1) and aft short driveshaft (5) on input and output drive flanges respectively, together with any installed shims (2) (refer to para 32-10 or para 32-35, as applicable).

3.

If previously removed, install plates and bellcrank per Chapter 42-28 or install yaw brake per Chapter 42-28C.

4.

Install control rods (9 and 16) per Chapter 42-36.

5.

Check gearbox oil level and service with oil as required (refer to para 32-9) .

6.

Connect electrical cables and install vertical fin fairing.

7.

Inspect intermediate gearbox as follows: a.

Intermediate gearbox removed only temporarily and not preserved - Perform ground run (without load) for 10 minutes and check for leakage.

b.

Preserved intermediate gearbox - Perform ground run (without load) for 10 minutes and check for leakage. - After completing ground run, remove magnetic plug and check for metal deposits. If metal deposits are present, proceed according to Table 32-6.

BO 105 CHAPTER 32 Page 54

Revision 13

EUROCOPTER

32 - 58 32 - 59

MAINTENANCE MANUAL 80105

TAIL ROTOR GEARBOX Removal - tail rotor gearbox

NOTE

• The tail rotor shaft with attached sliding sleeve, pitch links and bellcrank need not be removed from the gearbox unless required for repair purposes. Refer to Chapter 33 for removal and installation procedures. • Tail rotor gearboxes intended for shipment shall be preserved per Chapter 02.

1. Remove cover at top of vertical fin together with vertical fin fairing. 2. Remove tail rotor, refer to Chapter 33.

3. Remove control rod (22, fig. 32-23). When removing the aft short driveshaft (1), hold on to the associated locking plates (3) to prevent it from falling and perhaps getting los!:

NOTE

4. Remove aft short driveshaft (1) in accordance with para 32-30 or 32-51, as applicable, or only detach it from gearbox drive flange and support it as near as possible in its normal operating position, using adhesive tape or similar. Record the number of existing shims (2) so that they can be reinstalled in the same position should the same gearbox be reinstalled without the drive flange having been removed since gearbox removal. Remove locking plates (3) from tail rotor gearbox input drive flange and from output drive f1ange of intermediate gearbox. 5. Remove anti-eollision Iight (11) as follows: a.

Remove clamp (12).

b.

Pulllens together with lamp socket upwards out of retainer (13).

c.

Disconnect electrical connections.

d.

Remove electrical cable from gearbox casing.

NOTE

If shims (5) are installed, they must be removed without replacement.

6. Remove nuts (7), washers (6) and bolts (10). Remove nut (7) and either washer (6) or spring washer (23) together with washer (24) from studs (4). 7.

If spring washers (23) are installed, measure their height "H" (see Detail A, fig. 32-23). If their height is less than specified, replace spring washers with new ones.

Revision 18

CHAPTER 32 Page 55

I

EUROCOPTER

MAINTENANCE MANUAL BO 105

I ~ 10

23

~U4,

í~

~7

~_ .

&

Tail rotor gearbox, double-webbed

1-------11

6 ~,

F~;;;__----12 ~,

5

J, 8

.J'l5oO~,.------13 S .....-4jj¡)

14&

"'-15

~. ___

&6-~'\ 7--../ 6------'

DETAlL

23

A

"H"· 2.9 mm minimum

I

Tail rotor gearbox, single-webbed

13 - 5 Nm I

~ ~I

I

~I

20

g & &

&

22

Omit from installation

19

21

1 Aft short driveshaft 2 Shim Only with modified oil filler neck 3 Locking plate 4 Stud &5 Shim Washer (6) on studs replaced by spring &6 Washer washer (23) and washer (24) in 7 Nut accordance with ASB-B01 05-30-1 02. 8 Fitting (vertical fin) 9 Tail rotor gearbox 10 Bolt 11 Anti-collision Iight 12 Clamp 13 Retainer 14 Polyethylene foam insert

&

Figure 32-23

CHAPTER 32 Page 56

15 Oil filler cap 16 Tail rotor shaft with assembled sliding sleeve, pitch Iinks and bellcrank 17 Oil drain plug with magnetic plug 18 Bolt 19 Washer 20 Nut 21 Cotter pin 22 Control rod 23 Spring washer 24 Washer

I

Removal and installation - tail rotor gearbox

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 32 - 60

Inspection and repair - tail rotor gearbox

Special tools: 105-31501 W7 Alignrnent device Assembly/Disassembly fixture 105-31501 WS Puller 105-31501 W6J See NOTE at beginning Fixture 1xS6 136 288 of step 6. 1xS6 131 400 Drawing-off plate 1xS6 131 407 Drift 1xS6 112 756 Drift 1xS6 136 393 Puller 1xS6 131 399 Pusher screws 1xS6 122 209 Puller 1xS6 122 232 Counter support 1xS6 136 418 Drift 1x56 103 766 Drift 1x56 150 111 Guide bolts 1. Inspect tail rotor gearbox housing for cracks, other mechanical damage, corrosion and damagedsurface protection. a.

Replace gearbox if cracks are evident.

b.

Mechanical and corrosion damage is acceptable to a depth of 0.2 mm. If damage limit is exceeded, return gearbox to manufacturero Refer to Chapter 02-5 for rework criteria.

c.

Touch up damaged surface protection according to chapter 02.

2. Inspect magnetic plug (17, fig. 32-23) for metal deposits according to para 32-56, step 2. 3. Inspect tail rotor gearbox for oil leaks in area adjacent to seals, and replace leaking seals accordingto step 6., as necessary. 4. Inspect oil level sight glass according to para 32-56, step 4. 5. If required by Chapter 101 (Inspections), or if deformation of tailboom is suspected, check for alignment of tail rotor gearbox with intermediate gearbox as follows: a.

Remove aft short driveshaft (l,fig. 32-23) according to para 32-29 or 32-50, depending on shaft type.

b.

Slide ring (3, fig. 32-24) and sleeve (6) of alignment device outward to end stops. Install alignment device between tail rotor gearbox and intermediate gearbox according to figure 32-24. Alternately tighten nuts of bolted connections (1) progressively to specified torque.

BO 105 CHAPTER 32 Page 57

- - - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

!---7

2--""'"+-1

L.

300293

L--.J

I

~

3

4

Bolted connection Flange (intermediate gearbox) 3 Ring 4 Tube

1

2

Fig. 32-24

5

6

5 6 7

Tube Sleeve Flange (tail rotor gearbox)

Alignment device, P/N 105-31501 W7

c.

Slide ring (3) and sleeve (6) inward froro their respective end stops. Correct tail rotor gearbox-to-intermediate gearbox alignment is indicated by the ease with which ring (3) and sleeve (6) can be slid into and over tubes (5) and (4) respectively, before making contact with the ends of the tubes. If the ring and sleeve cannot be slid int%ver the tubes, or become jarnmed in the process, gearbox-togearbox alignment is out of perrnissible tolerance. In this case, consult MEB for suitable corrective action.

d.

Remove alignment device.

e.

Install aft short driveshaft (1, fig. 32-23). Refer to para 32-29 or 32-50, depending on shaft type.

BO 105 CHAPTER 32 Page 58

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 6. Replacement of seals. NOTE

a.

o

The input seal can be replaced with the gearbox installed on the helicopter, using tools, P/N 105-31501 W5 and W6. If the gearbox is removed from the helicopter, tool, P/N 1x56 136 288, may also be used as an alternative. Refer to REM 303 for tool description.

o

The following steps describe seal replacement with gearbox installed, using tools, P/N 105-31501 W5/W6.

Input seal removal. 1) Remove aft short driveshaft (1, fig. 32-23) according to para 32-29 or 32-50, depending on shaft type. 2) Drain oil from gearbox according to para 32-9. 3) Bolt assembly fixture, P/N 105-31501 W5, to input drive flange (4, fig. 32-25) so that the keys of the socket wrench fit into the corresponding slots in screw (1). 4) While holding input drive flange (4) with handle of disassembly fixture (fig. 32-19), insert square drive of wrench into corresponding square hole in socket wrench (1) and loosen screw (1, fig. 32-25). 5) Remove bolts attaching-disassembly fixture to input drive flange (4) and unscrew and remove screw (1) by hand. Discard O-ring (3). 6) Unscrew spindle (1, fig. 32-20) of puller, P/N 105-31501 W6, by hand until it bottoms, then bolt puller to input drive flange (4, fig. 32-25) . 7) Insert square drive of wrench in corresponding square hole of spindle (1, fig. 32-20) and, holding puller steady, pull input drive flange off pinion shaft by screwing in the spindle. Remove shim (5, fig. 32-25). 8) Remove input drive flange (4) from puller by removing the connecting bolts. 9) Remove hex screws (8) and washers (9). 10) Remove cover (6) and centering ring (12) and discard O-ring (11). 11) Place cover (6) on drawing-off plate, P/N 1x56 131 400, and press seal (10) from cover using drift, P/N 1x56 131 407.

BO 105 CHAPTER 32 Page 59

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Input seal installation. 1) Apply a thin coat of silicone grease (CM 104) to outer diarneter of seal (10, fig. 32-25) and, using drift, p/N 1x56 112 756, press seal into cover (6) so that lip of seal faces toward drift (see fig. 32-21). 2) Lubricate new O-ring (11, fig. 32-25) with silicone grease (CM 104) and insert in rnating annular groove of cover. 3) With its keys facing outboard, press centering ring (12) into bearing bushing until seated. 4) Locate cover (6) on centering ring (take oil drain plug position into account) and press in until seated. Install hex screws (8) with washers (9) and tighten progressively to specified torque, alternating diarnetrically. 5) Lockwire oil drain plug (7) to nearest hex screw (8) in cover (6). 6) Thinly coat shirn (5) and slide it along input shaft until it contacts the inner race of tapered roller bearing.

CAUTION

o THE SHIM MUST SEAT AGAINST BEARING INNER RACE OTHERWISE IT MAY SLIP INTO THE SHAFT GROOVE ANO BECOME DAMAGED WHEN THE FLANGE IS INSTALLED. o THE FLANGE (4) MUST BE INSTALLED USING PULLER 1x56 136 393. DO NOT DRIVE THE FLANGE IN PLACE, e.g. WITH A HAMMER. THIS MAY CAUSE DAMAGE.

7) Install input drive flange (4) on input shaft using puller, p/N 1x56 136 393 (see fig. 32-22). 8) Lubricate new O-ring (3, fig. 32-25) with silicone grease (CM 104) and install in rnating annular groove of screw (1). Install screw in input shaft and tighten by hand. 9) Bolt the assembly fixture, p/N 105-31501 W5, to input drive flange (4) so that keys of socket wrench fit into corresponding slots of screw (1). 10) While holding input drive flange (4) with handle of assembly fixture (2, fig. 32-19), insert square drive of wrench in corresponding square hole of socket wrench (1) and tighten screw (1, fig. 32-25) to 35 Nrn.

BO 105 CHAPTER 32 Page 60

EUROCOPTER

MAINTENANCE MANUAL BO 105

Tail rotor gearbox, single-webbed

I

OUTPUT

TaH rotor gearbox, double-webbed

I

',~ 5

-

~

~,

/JO '-. :.

11

~

- 0,. Il

~ "--

3

10 9

8

I 8-10 Nm I 7

2

I 35-45 Nm

Figure 32-25

1 2 3 4 5 6 7

Screw Locking plate O-ring Input drive flange Shim Cover Oil drain plug with magnetic drain plug 8 Hex screw 9 Washer 10 Seal

11 12 13 14 15 16 17 18 19 20 21

O-ring Centering ring OH filler cap Bearing outer race O-ring Seal Cover Countersunk screw Pawl Washer Hex screw

Partial disassembly of tail rotor gearbox for replacement of seals

11) Insert locking plate (2) in groove of input drive flange (4). Check that teeth of locking plate exactly engage with teeth of screw (1). If they do not, advance screw until exact engagement is obtained. However, do not exceed a torque load of 45 Nm. Screw (1) must not protrude from the drive flange. Using a cord, provisionally attach locking plate to flange until driveshaft is installed. 12) Seal split lines, screw heads etc., in accordance with Chapter 02. Revision 18

CHAPTER 32 Page 61

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 13) Service gearbox with oil according to para 32-9. 14) Install aft short driveshaft (1, fig. 32-23) according to para 32-39 or 32-50, depending on driveshaft type. 15) Ground run helicopter to inspect for oil leaks. c.

Output seal removal. 1) Remove tail rotor shaft in accordance with Chapter 33. 2) Remove hex screws (21, fig. 32-25) and washers (20). 3) Install jackscrews 1x56 131 399 through both threaded bores in flange of cover (17) to pull cover evenly from housing. Discard O-ring (15). 4} Remove countersunk screws (18) from inner face of cover and remove pawl (19). 5) Position puller, p/N 1xS6 122 209, on outer race (14) of roller bearing, thread counter support, p/N 1x56 122 232, onto puller and brace against cover mating surface ongearbox casing. Extract bearing outer race. 6) Press seal (16) from cover with drift, p/N 1x56 136 418.

d.

Output seal installation. 1) Apply thin coat of silicone grease (CM 104) to outer diameter of seal (16, fig. 32-25) and, using drift, P/N 1x56 131 407, press seal into cover (17) with lip of seal facing toward drift (see fig. 32-21). 2) Press outer race (14, fig. 32-25) of roller bearing into cover (17) using drift, P/N 1xS6 103 766. Install pawls (19) with countersunk screws (18) as shown in fig. 32-26, and stake countersunk screws with center puncher (see fig. 32-26). 3) Lubricate new O-ring (15, fig. 32-25) with silicone grease (CM 104) and install in mating annular groove of cover (17). 4) Screw two guide bolts, P/N 1xS6 150 111, into diametrically opposite threaded holes in the cover mating surface on gearbox casing. S} Locate cover (17) on guide bolts and slide it up against the gearbox casing. Install hex screws (21) with washers (20) in free threaded bores, and alternately tighten diametrically opposite screws, by increments, until cover is seated on the gearbox casing. When tightening the screws, take care not to press O-ring (lS) from its annular groove. This will damage the O-ringo 6) Remove guide bolts and install remaining hex screws (21) and washers (20). Alternately tighten diametrically opposite screws by increments to specified torque.

BO 105 CHAPTER 32 Page 62

_eurocopter 8ll

MAINTENANCE MANUAL 80 105

EAllS Campany

7)

Lockwire bellcrank-to-gearbox pivot pin to hex screw (21) nearest to it in gearbox cover (17).

8)

Seal split lines, screw heads etc., according to Chapter 02.

9)

Install tail rotor shaft according to Chapter 33.

10) Ground run helicopter to inspect gearbox for oil leaks.

VIEW

A

Figure 32-28

CHAPTER 32 Page 63

o

euroc::opter 8t\

32 - 61

MAINTENANCE MANUAL 80 105

EADS C!lmpMy

Installation -tail rotor gearbox

NOTE

• The tail rotor gearbox must be positioned level on its mounting surface in the vertical fin to prevent it from being distorted when the hex nuts (7, figure 32-23) are tightened. • Following repair work on the tail boom, or if damage is suspected, check for alignment of tail rotor gearbox with intermediate gearbox according to para. 32-60, using alignment device P/N 105-31501 W7. • Only spring washers which have a height "H" of at least 2.9 mm shall be reused (see DETAlLA).

1. Attach tail rotor gearbox to fitting (8) on vertical fin using bolts (10, figure 32-23) and assocíated washers (6) and nut (7). Depending on the type of attachment, install either washer (6) or washer (24) together with spring washer (23) on studs (4) and secure with nuts (7). Tighten nuts just enough to seat the gearbox on the fitting. 2.

Check that the gearbox rests flush against its mounting bracket. If a gap exists at any point between them, remove the gearbox and remove the cause of the gap (e. g. paint coating too thick and unevenly applied). If the gap cannot be removed, do not install tail rotor gearbox and inform ECD Customer Service of this condition.

-

Alternating diametrically, progressively tighten nuts (7) by increments of 5 Nm, until specified torque is obtained. After that check all nuts (7) all-around for cracks. If necessary, use a mirror and a torcho Replace nuts with cracks by new ones. Repeat check for cracks. 4.

Install aft short driveshaft (1) according to para. 32-29 or 32-50, depending on driveshaft type.

5.

Install control rod (22) and secure attaching hardware with cotter pins.

6.

Install tail rotor and blade assembly according to Chapter 33.

7.

Install anti-collision light (11) as follows:

-

a. Thread electrical cable into socket retainer (13). b.

Connect electrical wiring to socket.

c.

Secure socket and lens to retainer (13) with clamp (12).

d.

Perform functional test.

8.

Check gearbox oil level and service with oil as required according to para. 32-9.

9.

Install vertical fin fairing and cover on vertical fin.

CHAPTER 32 Page 64

Revision 25

EUROCOPTER

MAINTENANCE MANUAL 80105

10. Inspect tail rotor gearbox as follows: a.

*

Tail rotor gearbox removed only temporarily and not preserved - perform ground run (without load) for 10 minutes and check for leakage.

b.

Preserved tail rotor gearbox

* * * *

* *

*

- perform ground run (without load) for 10 minutes and check for leakage.

* * * * *

- after completing ground run, remove magnetic plug and check for metal deposits. If metal deposits are present, proceed according to * Table 32-6. *

Revision 13

BO 105 CHAPTER 32 Page 65/66

MAINTENANCE MANUAL 80105

33 TAIL ROTOR Table of Contents

Paragraph Title

Page

33 - 1

DESCRIPTION - TAIL ROTOR .......................................•.......

3

33 - 2

TROUBLESHOOTING - TAIL ROTOR

.

4

33 - 3

BALANCING - TAIL ROTOR ......................•.........................

5

33 - 4

INSPECTION - TAIL ROTOR ..............................•.............•...

6

33 - 5

Pitch Iinks .•.........................................................•.....

10

33 - 6

Removal - pitch links

.

10

33 - 7

Inspection and repair - pitch links

.

10

33 - 8

Installation - pitch links

.

11

33 - 9

Bellcrank ..................................................••..............

13

33 - 10

Removal - bellcrank

.

13

33 - 11

Inspection and repair - bellcrank

.

13

33 - 12

Installation - bellcrank

.

14

33 - 13

Tail rotor head ...............................................•.............

15

33 - 14

Removal - tail rotor head

.

15

33 - 15

Disassembly - tail rotor head

.

21

33 - 16

Inspection and repair - tail rotor head

.

21

33 - 17

Assembly - tail rotor head

.

24B

33 - 18

Installation - tail rotor head

.

25

Revision 24

CHAPTER 33 Page 1

MAINTENANCE MANUAL BO 105

Paragraph Title

Page

33 -19

Tail rotor shaft .....................................................•.......

33 - 20

Removal - tail rotor shaft

33 - 21

~

31

.

31

Inspection and repair - tail rotor shaft

.

34

33 - 22

Installation - tail rotor shaft

.

43

33 - 23

Sliding sleeve ........•....................................................

46

33 - 24

Removal - sliding sleeve

.

46

33 - 25

Disassembly - sliding sleeve

.

46

33 - 26

Inspection and repair - sliding sleeve

.

48

33 - 27

Assembly - sliding sleeve

.

54

33 - 28

Installation - sliding sleeve

.

56

CHAPTER 33 Page2

Revision 24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 33 - 1

DESCRIPTION - TAIL ROTOR

The tail rotor counteracts main rotor torque and controls the heading of the helicopter. Power is transmitted through the main rotor transmission to the tail rotor via the drive shafts, the intermediate gearbox and the tail rotor gearbox. Directional control inputs are made by operating the control pedals in the cockpit. This movement is transmitted through push rods to the tail rotor pitch assembly. The tail rotor (figure 33-1) consists of the tail rotor blades (10), tail rotor head (5), tail rotor shaft (4), and the pitch control assembly consisting of the pitch links (2), sliding sleeve (3) and bellcrank (1). 10--~~-

3 6-....,..,~'q

4

2

1 2

3 4

5 6 7

8 9 33/32.1

10

Figure 33-1

Bellcrank Pitch links Sliding sleeve Tail rotor shaft Tail rotor head Blade mounting fork Control lever Laminated strap pack Inner sleeve Tail rotor blade

Tail rotor BO 105 CHAPTER 33 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 33 - 2

TROUBLESHOOTING - TAIL ROTOR

NO. TROUBLE SYMPTOM 1

High frequency vibration of the tail rotor (felt in the pedals as a buzzing sensation)

PROBABLE CAUSE

CORRECTIVE ACTION

Tail rotor out of balance

Balance tail rotor (refer to paragraph 33-3)

Tail rotor head is not properly centered in the forked end of the tail rotor shaft

Check installation position and correct as necessary (refer to paragraph 33-18)

Defective tail rotor bearings

Check bearings according to paras 33-4, 33-7, 33-11, 33-16 and 33-26, and replace if necessary

Table 33-1

BO 105 CHAPTER 33 Page 4

Troubleshooting

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 33 - 3

BALANCING - TAIL ROTOR HEAD Whenever balancing of the "tail rotor" is referred to be1ow, tail rotor shall be understood to mean the assembled tail rotor head (5, fig. 33-1) and blades (10).

NOTE

1.

The tail rotor must be balanced whenever components of the tail rotor head (6 to 9, figure 33-1) or one or both rotor blades have been replaced or repaired. Minor repair work, such as polishing out corros ion marks or touching up paint damage, does not require the tail rotor head to be balanced.

2.

Balancing procedures. a.

The tail rotor must always be statically balanced. Use of the Marvel balancing kit (refer to Chapter 107-1) is preferable. Alternatively, static balancing can be performed in accordance with Chapter 107-2, using the balance rig.

b.

Rotor inbalance can be further reducedby performing dynamic balancing according to chapter 107-3. However, static balance of the rotor must be achieved first.

BO 105 CHAPTER 33 Page 5

EUROCOPTER

33-4

INSPECTION - TAIL ROTOR

CAUTION

I I

MAINTENANCE MANUAL 80105

IF ANY DAMAGE IS FOUND TO HAVE BEEN CAUSED BY CONTACT WITH AN OBSTACLE, THE SPECIAL INSPECTION PER CHAPTER 101, PARAGRAPH 101-13.1, STEP 3, SHALL BE ADDITIONALLY PERFORMED.

1. Inspect pitch links (2, fig. 33-1). Where possible, inspect installed pitch links for mechanical damage, corrosion, cracks (visual inspection), damaged surface protection and bearing play per paragraph 33-7. If the permissible bearing play is exceeded, remove bolts (4, fig. 33-3) and inspect them for cracks per paragraph 33-16, step 7. 2.

Inspect bellcrank (1). Where possible, inspect installed bellcrank for mechanical damage, corrosion, damaged surface protection and bearing play per paragraph 33-11.

3. Check flapping hinge operation.

4.

5.

a.

If taíl rotor head is moved about the flapping axis, the spherical bearing inner races (7, fig. 33-8) and close-tolerance bolt (4) must follow the same motion. The spherical bearing outer races (5) must not rotate in sympathy.

b.

If this is not the case, remove tail rotor head according to para. 33-14 and inspect spherical bearings for roughness, f1anged bushings (6) for elongated bores, and close-tolerance bolt (4) for damaged shank. Replace damaged parts.

Inspect tail rotor head (5, fig. 33-1). Where possible, inspect installed tail rotor head for cracks, mechanical damage, corrosion and damaged surface protection. a.

If cracks are suspected, dye-penetrant inspect affected parts according to MIL-STD-6866. Discard any cracked parts.

b.

Repair other mechanical damage and corros ion according to REM 301 or REM 308, as applicable.

c.

Touch up damaged surface protection on aluminum alloy blade mounting forks in accordance with Chapter02.

Inspect tail rotor shaft (31, fig. 33-5). a.

Detach outboard boot (45) from sliding sleeve (26). Before inspecting for scores, clean sliding surface with dry cleaning solvent (CM 201, 202 or CM 217). Where possible, visually inspect taíl rotor shaft in installed position for cracks and other mechanical damage and for excessive scoring of the sliding surface for sliding sleeve slide bearing. Replace tail rotor shaftwith cracks. If cracks are suspected, orthe extent of any damage found is believed to exceed the damage Iimits defined in para. 33-21, remove the driveshaft and inspect it thoroughly according to para. 33-21.

b.

Inspect spherical bearings for play. If radial play exceeds 0.1 mm, replace both spherical bearings according to para. 33-21, even if only one of them exhibits excessive play. If a spherical bearing is found to exhibit excessive play, accomplish additional action described in para. 33-21, step . 1.c.

CHAPTER 33 Page6

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Inspect steel plug (53) for tight fit and condition. Remove loose or corroded plug and replace with plastic plugs according to para 33-21. Inspect plastic plug (53) for tight fit and damage, and inspect sealing compound around plug edges for damage. Replace damaged plug according to para 33-21 and renew damaged sealant.

6.

Where possible, inspect installed sliding sleeve (26, figure 33-5) for cracks, deformation, mechanical damage, corrosion and damaged surface protection. Inspect boots for damage and security. a.

Replace cracked or deformed parts according to paragraph 33-23.

b.

If cracks are suspected, or it is believed that the extent of damage found exceeds the damage limits defined in para 33-26, remove sliding sleeve and inspect it thoroughly according to para 33-26.

c.

Polish out minor damage and final polish with 400 grit abrasive cloth. See para 33-26 for damage limits.

d.

Touch up damaged surface protection according to chapter 02.

e.

Replace damaged boot or retighten loose boot. Install outer boot (45) to dimensions shown in fig. 33-17.

7.

Inspect all attaching hardware for proper locking. If locking devices are missing, check for specified torque, correcting as necessary, and install locking devices.

8.

Check tail rotor shaft for play. Special tool: Runout check device

105-31702 W24

a.

Remove tail rotor head and pitch links (refer to paragraphs 33-14 and 33-6) .

b.

Unscrew and remove star knob (4, figure 33-2) from indicator support of runout check device 105-31702 W24 and remove swive1 arm (2) with attached dial indicator (3).

c.

Back off two adjacent screws on the tail rotor gearbox output drive cover and use these to attach the dial indicator support (1) to the gearbox.

d.

Reinstall assembled dial indicator and swivel arm on indicator support so that the dial indicator finger is positioned vertically on the shaft and is depressed approx. 2 mm, then secure in this position by tightening the star knob.

BO 105 CHAPTER 33 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

.-----3

4

6

3-----+

Indicator support Swivel arm 3 Dial indicator 4 Star knob

1 2

33/12

Figure 33-2 e.

+ O 250 - 10 rran This dimension must be maintained when using a locally fabricated runout check device

Application of runout check device 105-31702 W24

Measure tail rotor shaft playas follows: 1)

Adjust dial indicator to show zero, then pull tail rotor shaft upward at its forked end with a force of approx. 30 N and note radial displacement on dial indicator. A max. of 0.3 mm displacement is permissible.

2)

If the limit of play is exceeded, remove tail rotor shaft according to para 33-20, and inspect bearing surfaces (zones 2 and 4, fig. 33-12) for condition and dimensional accuracy. Damage and repair limits and rework measures for the tail rotor shaft and the hollow shaft are given in fig. 33-12 and REM 303 respectively.

3)

If there is play in the hollow shaft bearing seat, repair the tail rotor gearbox according to REM 303 .

BO 105 CHAPTER 33 Page 8

EUROCOPTER

9.

MAINTENANCE MANUAL SO 105

f.

Deleted

g.

Remove runout check device and retighten both attaching bolts to specified torque load.

* * * * * * * * * * * * * * * * * * *

Check ball bearing of sliding sleeve for roughness, notches and play. To do so, remove bellcrank (refer to paragraph 33-10), detach boot and rotate sliding sleeve by hand. Discard bearing if roughness, notches or play is evident (refer to paragraphs 33-25 and 33-27) .

10. Inspect tail rotor blades according to chapter 34. For inspection interva1s and scope of inspection refer to chapter 101.

Revision 16

60 105 CHAPTER 33 Page 9

MAINTENANCE MANUAL 80105

EUROCOPTER

33 - 5 33 - 6

PIT eH L INKS Removal • pitch Iinks

1. Remove attaching hardware (14, 15, 27, 28 and 29, figure 33-5). 2. Remove stop ring (13) and pitch link (30) with teflon washer (42). if installed.

33 - 7

Inspection and repair. pitch Iinks

Special tools: Milling tool Milling cutter Milling tool retainer Staking tool Staking tool

105-31821 W4 105-13141 W3 105-40001 W1 105-31821 W5 105-13141 W4

1. Inspect pitch links for cracks, deformation, mechanical damage, corrosion and damaged surface protection. a.

Discard pitch links showing cracks and deformation.

b.

Polish out mechanical and corrosíon damage with polishing cloth 400. Damage tolerance limits: A depth of 0.25 mm before and 0.30 mm after repair on max. 30% of area.

c.

Touch up damaged surface protection with chemical conversion material (CM 316) and coating lacquer (CM 402) in acordance wíth Chapter 02.

lA. Check pitch links for legibility of P/N. If P/N is iIIegible, apply"P/N 105-31821" with wipe-proof paint. Check for correct correlation of P/N to the pitch links by measuring the totallength of the pitch Iinks or the distance from center-to-<:enter of their spherical bearings. Correlation is correct if the total length = 250.5 ± 0.5 mm or the distance from center-to-<:enter of the spherícal bearings = 216 ± 0.5 mm.

I

2. Check bearings for excessive play, corrosion and binding. Permissible play: radial 0.1 mm or axial DA mm, whichever occurs first. Replace bearing accordance to step 3., if any of these conditions are found. 3. Replacement of bearings. a.

Removal of bearings 1) Mili off outward staked portion of outer raee of bearing with milling tool 105-31821 W40r 105-13141 W3 and press out bearing (refer to Chapter 02).

CHAPTER 33 Page 10

Revision 16

_eurocopter 2}

b.

MAINTENANCE MANUAL M88 - 80 105

Inspect bore for mechanical and corrosion damage. Polish out any damage with polishing cloth 600. The maximum permissible bore diameters are 23.02 mm and 17.47mm, as applicable. The diameter may be exceeded by 0.02 mm on one quarter of the circumference. If these limitsare exceeded, replace pitch link.

Installation of bearings Install bearings according to Chapter 02 using staking tool retainer 105-40001 W1 together with either staking tool 105-31821 WS or staking tool 105-13141 W4.

33 - 8 CAUTION

Installation - pitch links TAKE CARE TO INSTALL PITCH LINKS WITH THE CORRECT DIMENSIONS i.e. THE PITCH LINKS TO BE INSTALLED MUST HAVE AN ASSEMBLY LENGTH (i.e., CENTER-TO-CENTER OF BEARINGS) OF 216 mm AND A TOTAL LENGTH OF 250 TO 251 mm.

1.

Brush-coat bolts (4 and 11, figure 33-3) with corrosion preventive compound (CM 505) .

2.

Fit pitch link (2) on bolt (11), followed by stop ring (9) with concave side facing the bearing in pitch link. Install castle nut and tighten to specified torque then secure with split pino If the split pin cannot be inserted at the specified torque, use a different castle nut. NOTE

3.

The"Teflon washers (3, fig. 33-3) should always be installed, even if they were not present at removal. They prevent the pitch link ends from chafing on the clevis lugs of the sliding sleeve.

Insert other end of pitch link (2) between the clevis lugs of the sliding sleeve together with Teflon washer (3). Insert bolt (4) through the aligned bores and install castle nut (S). Tighten castle nut to specified torque and safety with split pin (6). If the split pin cannot be inserted at the specified torque, use a different castle nut.

BO 105 CHAPTER 33 Page 11

fleurocopter

DETAlL

A

9~3

8

\::l~I:~--7

"

-

.'\

" 11--~

MAINTENANCE MANUAL MBB - 80 105

8 9

-1

5-8 Nm

,..............--- 3

5---~

2

+----10

I

/ ..... 13-SNm

I

~-4

2 ------'Ilo,;?----:¡W, E300408

SECTION

1 Sliding sleeve 2 Pitch link 3 Teflon washer 4

BoU

5 CasUe nut 6 Cotter pin Figure 33-3 BO 105 CHAPTER 33 Page 12

A· B

7 8 9 10

Cotter pin CasUe nut Stop ring Pitch control lever

11

BoU

Pitch link installation

Revision 8

Gteurocopter 33 - 9

Be 1 1 c r a n k

33 - 10

Removal - bellcrank

MAINTENANCE MANUAL MBB - 80 105

1.

Remove vertical fin fairing.

2.

Depending on configuration, either remove lockwire and screws (33, figure 33-5) and remove bolt (32) with or without O-ring (54), as applicable, or remove split pin (36), nut (37) and stop ring (35).

3.

Remove attaching hardware (40, 15 and 41) and remove bellcrank (34) with attached control rod (38).

4.

Remove attaching hardware (49, 50, 51 and 39) and detach control rod (38) from bellcrank (34); securefree end of control rod.

*

Inspection and repair - bellcrank

33 - 11

Special tools: Milling Staking Staking Staking Staking 1.

tool tool retainer tool tool tool

105-31781 105-40001 105-45361 105-31781 105-42121

W2 W1 W3 W6 W6

Inspect bellcrank for cracks, deformation, other mechanical damage, corros ion and damaged surface protection. a.

Discard bellcrank if cracks and deformation are evident.

b.

Polish out mechanical and corrosion damage with polishing cloth 400. Damage tolerance limits: A depth of 0.45 mm before and 0.50 mm after repair on max. 30% of area.

c.

Touch up damaged surface protection with chemical conversion material (CM 316) and coating lacquer (CM 402) in accordance with Chapter 02.

2.

Check spherical bearing for excessive play, corros ion and binding. Permissible play: radial 0.1 mm. Replace bearing according to step 4., if any of these conditions existo

3.

Check ball bearings for condition and unrestricted movement. Replace bearings exhibiting roughness, notches, corrosion or evidence of corrosion accordingto step 4.

3A. Inspect bolt (32) for cracks, mechanical damage and corrosion. Replace cracked bolt. Polish out mechanical damage and corrosion, using 400 grit abrasive cloth. Only for bolt with O-ring:

* *

3B. Inspect O-ring (54) for damage, and replace as necessary.

Revision 8

* *

* BO 105 CHAPTER 33 Page 13

EUROCOPTER

4.

MAINTENANCE MANUAL 80105

Replacement of bearings a. Removal of bearings 1) Place bellcrank on base plate of milling tool P/N 105-31781 W2 so that the pilot pin of the appropriate bearing support fits in the bore of the bearing to be removed (refer to Chapter 02). 2) Mili off staked lip of bearing outer race or bushing with the appropriate cutters. 3) Press out bearing or bearing together with bushing, whichever is applicable. 4) Inspect bore for mechanical damage and corrosion. Polish out damage with polishing cloth 600 if necessary. The maximum permissible bore diameters are 35.025 mm, 23.826 mm and 22.021 mm respectively. They may be exceeded by 0.02 mm on one quarter of the bore circumference. Replace bellcrank if aboye limits are exceeded. b. Installation of bearings Install bearings, as described in Chapter 02, with staking tool retainer 105-40001 W1 together with either staking tool 105-45361 W3 or staking tool 105-31781 W6 or 105-42121 W6.

33 - 12

Installation - Bellcrank

1. Brush-coat bolt (39, fig. 33-5), pivot pin (43) and, depending on sliding sleeve configuration, either bolt (32) and screw (33) or mounting stud (44) with corrosion preventive compound (CM 505). If bolt (32) with O-ring (54) is installed, insert bolt (32) dry.

1 2.

Install control rod (38) on bellcrank (34) (see fig. 33-5).

3. Install bellcrank (34). a. Configuration 1: With the sliding sleeve pushed to the extreme outboard position, install bellcrank on pivot pin (43) of tail rotor transmission and then position it for attachment with bolt (32) to the mating surface on the sliding sleeve. Install bolt (32) with or without Q-ring (54), as applicable, and secure with screws (33). Tighten screws totorquevalues shown in figure 33-5, and safetywith lockwire.lnstallwasher (41) and nut (15) on pivot pin (43) and tighten nut to torque loads shown in fiigure 33-5. Install split pin (40). b. Configuration 11: Position bellcrank on pivot pin (43) and mounting stud (44). Install stop ring (35) and nut (37) on mounting stud (44). Tighten nut and secure with split pin (36). Install washer (41) and nut (15) on pivot pin (43). Tighten nut and secure with split pin (40). See figure 33-5 for torque loads. 4.

Install vertical fin fairing.

CHAPTER 33 Page 14

Revision 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 33 - 13

Ta i 1

r o t o r

h e a d

33 - 14

Removal - tail rotor head

l.

Remove tail rotor blades and pitch links (refer to paragraphs 34-3 and 33-6) .

2.

Using a felt-tip pen, color-code head of close-tolerance bolt (21, figure 33-5) to side of inner sleeve (22) on which it is seated, and mark its position relative to the tail rotor shaft, so that the bolt can be relocated in the same position when tail rotor head is reinstalled; inserting the bolt from the opposite side will result in an out-of-balance condition.

3.

Remove attaching hardware (24, 23 and 21), detach tail rotor head.

4.

Using a felt-tip pen, color-code bushing flange, bearing outer race, and face of inner race on the outboard side of each of the fork arms of the tail rotor shaft (use a different color for each side). This enables their original positions and, consequently, original dimension A (see fig. 33-8) to be restored when the tail rotor head is reinstalled. Figure 33-4 shows in exaggerated form examples of possible asymmetrical spherical bearing installation. The dimensions of outer and inner races are identical in all four cases.

NOTE

Cases 2 and 4 illustrate the change in the extent of projection of the inner race from the outer race when the inner race is rotated so that the inboard face of the inner race is repositioned to the outboard side.

33/6

6

symmetry deviation

Case 1

Case 2

Case 3

Case 4

Spherical bearing inner and outer races are symmetrical (ideal condition)

Spherical bearing inner race is not symmetrical

Spherical bearing outer race is not syrmnetrical

Spherical bearing inner and outer races are not syrmnetrical

Figure 33-4

Examples of asymmetrical installation of spherical bearings

BO 105 CHAPTER 33 Page 15/16

MAINTENANCE MANUAL MBB - BO 105

Configuration I

VIEW

Blade rnounting fork Nut Split pin Split pin Washer Tail rotor blade Close-tolerance bolt with balance washers Bolt Bolt Washer Control lever Bolt Stop ring on control lever Split pin Nut Weight Split pin Split pin Nut Larninated strap pack Close-tolerance bolt Inner sleeve Nut Split pin Tail rotor transrnission sliding sleeve

1 2 3

4 5 6 7 8

9

10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25 26

I

27 28 29 30

31

1~~32

33 34

35 36 37 38 39

40 41 42 43

44 45 46

47 48

49 1)0

51 52

53 154

Split pin Nut Bolt Pitch link Tail rotor shaft Bolt Screw Bellcrank Stop ring on bellcrank Split pin Nut Control rod Bolt Split pin Washer Teflon washer Pivot pin Mounting stud Outboard boot Inboard boot Nut Washer Split pin Nut Washer Angle Plug O-ring

A

'~;<~~---34

\\ 41

\\

\\

¡\

Is-aNm

49 f-- 40~ 15 ~ ~rso -1 39

Configuration 11

3-S Nm

1. . . .

.... 51 ~38

A'"

25

30

~ Bolt without O-ring

1~'v'---31

~ Bolt with O-ring 53

I 5-8 Nm

E300279

Figure 33-5

Revision 8

(1 of 2)

Tail rotor BO 105 CHAPTER 33 Page 17/18

~15 _ _...J

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

6---tt-

6--11=6-H-

~

Conflguratlon I

Conflguratlon 11

~

Conflguratlon 11I

~

5----,

I .~::.-----

11

-10

-""\. '"

19

1

5-S Nm I 15

I

23

-7-'~:'f~ 1-; \ ~") --

',1

t(~J

\"~......

_....14 13

......

/''1-.. ,/1

oV' -..:.

,

-<)'

.

,

Nm

" ',""

I

I

I

15 --, 5-SNm

3.5-5 I /24 ~

~, I

16

2

I

.....

13 ..",af--14

N L-. ~Q"1s 1& I

-n,-X~~

~

I

<).

17

~

~ For specified torque, refer to paragraph

(

" ", ..

5

33-17

~ ~

•

Make sure that the different weight types are installed on the applicable blade rnounting fork/rotor blade installation (refer to IPC) ~ Washer (48) is installed only on the tail rotor configuration with blade rnounting forks rnanufactured frorn titaniurn

300419

~

For specified torque, refer to paragraph 33-18

~ For appropriate configuration refer to IPC

Figure 33-5

(2 of 2)

Tail rotor BO 105 CHAPTER 33

Page 19/20

MAINTENANCE MANUAL MBB - BO 105

33 - 15

Disassembly - tail rotor head

1.

Inspect tail rotor head for play between inner sleeve and blade rnounting forks according to paragraph 33-16, step 1., prior to its disassembly.

2.

Mark installation location of blade rnounting forks relative to inner sleeve.

3.

Rernoveattaching hardware (3, 2 and 8, figure 33-5) and pull blade rnounting fork (1) and larninated strap pack (20) in that order frorn inner sleeve (22).

4.

Rernove hardware (18, 19, 10, 9 and, if installed, 48 and 52) to disconnect control lever (11) frorn blade rnounting fork (1) only if required for repairing control lever or blade rnounting fork.

5.

Rernove balance weights (16) frorn control lever (11) only if required for repair work. Prior to rernoval record the installation position of the balance weights.

Inspection and repair - tail rotor head

33 - 16 1.

Check blade rnounting forks for play with respect to inner sleeve. a.

Clamp inner sleeve (2, figure 33-6) and attached blade mounting forks (3) in a soft-jawed vise.

b.

Position dial gauge (1) on 1st measuring point and take reading while manually moving blade mounting fork up and down. Rotate blade rnounting fork 90° by hand and take another reading. Repeat above procedure at 2nd measuring point. If play exceeds 0.2 mm, repair tail rotor head in accordance with REM 301 or REM 308.

Revision 9

BO 105 CHAPTER 33 Page 21

* *

MAINTENANCE MANUAL MBB - BO 105

1. Measuring polnt

3

-

-t--.

2. Measuring polnt

.....1---

-t-.

65-.......r

-+t-+--ft---

-~

33/7.1

1 Dial gauge 2 Inner sleeve 3 Blade rnounting fork Figure 33-6 Measuring the play between blade rnounting fork and inner sleeve 2.

Inspect alurninurn alloy blade rnounting fork for cracks. Crack inspection of the blade rnounting fork does not require prior rernoval of the control lever.

NOTE

a.

Visually inspect zone I, figure 33-7 for cracks. Discard blade rnounting fork if there is evidence of cracks.

BO 105 CHAPTER 33 Page 22

EUROCOPTER

NOTE

MAINTENANCE MANUAL 80 105

To avoid damaging the Teflon lining of the bearing bushings, clean the blade mounting fork with MEK solvent (CM 217) only.

b.

Mask sliding surfaces of bearing bushing with masking tape (CM 609) .

c.

Clean blade mounting fork with MEK solvent (CM 217). NOTE

Inspect Zone 2 for cracks only when the blade mounting fork has been removed from the inner sleeve. For removal and inspection schedules, refer to chapter 101, Intermediate Inspections.

d.

Inspect blademounting fork for cracks in zones 2 and 3 in figure 33-7, using dye penetrant method per MIL-STD-6866. For this purpose, the flanged bushings need not be removed. Discard blade mounting fork if cracks are evident.

e.

Clean blade mounting fork again with MEK (CM 217) and remove the masking tape.

Zone 1

Zone 2

~

~1§}1~

Zone 3 (:::;::::;::::::::::::::;::::1

33/31

Figure 33-7

Inspection for cracks - aluminum alloy blade mounting fork

BO 105 CHAPTER 33 Page 23

MAINTENANCE MANUAL BO 105

EUROCOPTER

3.

* 4. * * * 5.

* *

Inspect individual components of tail rotor head for cracks, deformation, mechanical damage, corros ion and wear. a.

Replace cracked or deformed parts.

b.

If mechanical damage and signs of corros ion are detected, inspect affected part in accordance with REM 301 or REM 308 and perform the instructions described therein.

c.

Perform dimensional check of all flanged and bearing bushings in accordance with REM 301 or REM 308.

d.

Restore damaged surface protection according to Chapter 02.

Inspect close-tolerance bolt (21, figure 33-5) according to paragraph 33-21. Inspect close-tolerance bolt (8, figure 33-5): a.

Close-tolerance bolt without solid film lubricant coat (gas nitrided) 1)

Inspect bolt shank for mechanical damage, corros ion, wear and deformation. a)

Eliminate minor mechanical damage and fretting corros ion using polishing cloth 600.

b)

Check dimension of shank diameter. The minimurn perrnissible shank diameter is 11.98 mm.

e)

Replace close-tolerance bolt if deforrned.

i) Visually inspect thread of the close-tolerance bolt for damage. Eliminate minor thread damage. Thread damage is perrnissible on 30% of the thread, provided the threaded section can be easily screwed in by hand. .

* *

* * * * * * * * * * * * *

b.

Close-tolerance bolt coated with solid film lubricant (P/N 105-317391.12) . 1)

*

*

* BO 105 CHAPTER 33 Page 24

Inspect bolt shank for deformation, mechanical damage and condition of solid film lubricant coat. a)

Replace deformed bolt.

b)

Polish out mechanical damage such as individual scores, nicks and scratches that extend through the solid film lubricant coat and penetrate the base metal, using 400 grit abrasive cloth.

e)

The solid film lubricant coat may be worn down to the base metal on the entire coated surface. Polish out scores, nicks and scratches in the solid film lubricant coat, using 400 grit abrasive cloth. The diameter of the bolt shank shall not be less than 11.97 mm.

Revision 12

e

eurocopter

MAINTENANCE MANUAL BO 105

2) Visually inspect thread of the c1oSErtolerance bolt for damage. Eliminate minor thread damage. Thread damage is permissible on 30 % of the thread, provided the threaded section can be easily screwed in by hand. 6. Inspect close-tolerance bolt (7, figure 33-5):

a Close-tolerance bolt without solid film lubricant coat (nickel-platad). 1) Visually inspect bolt shank for mechanical damage, chipped or peeling nickel plating ánd deformation: a) Using polishing cloth 400/600, remove mechanical damage to bolt shank which impairs the ease of installation of close-tolerance bolt. Ensure that the nickel plating is not removed down to the base material. b) Replace c1ose-tolerance bolt if nickel plating is chipped or peeling, or if bolt is deformad. 2) Visually inspect thread of close-tolerance bolt for damage. Eliminate minor thread damage. Thread damage is permissible on 30 % of the thread, providad the threadad section can be easily screwad in by hand. b. Close-tolerance bolt coatad with solid film lubricant (P/N 105-317391.11). 1) Inspeet bolt shank for deformation, mechanical damage and condition of salid film lubricant coat. a) Replace deformad bolt. b) Polish out mechanical damage such as individual scores, nicks and scratches that extend through the solid film lubricant coat and penetrate the base metal, using 400 grit abrasive cloth. c) The solid film lubricant coat may be worn down to the base metal on the entire coatad surface. Polish out scores, nicks and scratches in the solid film lubricant coat, using 400 grit abrasive cloth. The diameter of the bolt shank shall not be less than 11. 97 mm. 2) Visually inspect thread of close-tolerance bolt for damage. Eliminate minor thread damage. Thread damage is permissible on 30 % of the thread, providad the threaded section can be easily screwed in by hand. 7. Inspect bolt (29, figure 33-5): Inspect for cracks only if requirad per paragraph 33-4, step 1.

NOTE

a Inspect bolt shank for cracks, deformation, mechanical damage, corrosion and wear. Crack inspect per dye penetrant MIL-8TD-6866 or magnetic particle MIL-8TD-1949 method. 1) Replace cracked or deformad bolt. 2) Remove minor mechanical damage and corrosion with 600 grit abrasive cloth. 3) Dimensionally check diameter of shank. The minimum allowable shank diameter is 7.90 mm. b. Visually inspect bolt threads for damage. Remove minorthread damage. Thread damage is permissible on 30 % of the thread area, providad the bolt can be screwed in easily by hand. Revision 20

CHAPTER 33 Page24A

EUROCOPTER

33 - 17

MAINTENANCE MANUAL BO 105

Assembly - tail rotor head

Special tool: Guide sleeve NOTE

117-31713 W1

Take care to use the balance weights and control levers assigned to the particular tail rotor blades (refer to IPC).

1.

If previously removed, reinstall control lever (11, figure 33-5). Coat attaching bolts (9) with corrosion preventive compound (CM 505). Install control lever (11) on blademounting fork (1) with bolts (9), washers (10) and, depending on the configuration, washers (48) and angles (52). Tighten nuts (19) to specified torque load and safety with split pins (18) .

2.

If previously removed, reinstall balance weights (16) on control lever to the position recorded at disassembly and secure with split pins (17).

3.

Apply a thin coat of corrosion preventive compound (CM 508) to visible laminates of laminated strap pack (20).

4.

Install laminated strap pack (20) in inner sleeve (22) so that bores in laminated strap pack align with bores in inner sleeve.

5.

Insert close-tolerance bolt (21) together with guide sleeve 117-31713 W1 to rigidly fix the assembly.

6.

Slide blade mounting fork (1) over inner sleeve (22). The pitch link connecting bolt on the control lever must be located in the extension of the flapping hinge axis (refer to figure 33-5) .

* 7. If a bolt (8) without a solid film lubricant coat is installed, lightly coat bolt shank with grease (CM 101, CM 102 or CM 120), corrosion preven* tive compound (CM 505) or lubricant (CM 146) . Do not lubricate new bolt coated with solid film lubricant. Apply lubricant (CM 146) to previously installed bolt coated with solid film lubricant. Install bolt in position shown in fig. 33-5. Fit nut (2) and tighten until it is seated, then back off or advance it to nearest split pin holeo Do not exceed max. torque load of 8 Nm. Safety nut with split pin (3).

*

*

* *

8.

Remove close-tolerance bolt (21) and unscrew guide sleeve 117-31713 W1.

BO 105 CHAPTER 33 Page 24B

Revision 12

O~~er 33 - 18

MAINTENANCE MANUAL BO 105

Installation - tail rotor head

Special tools:

Measuring device for tail rotor shaft fork Pressing-in and pushing-out tool Guide sleeve

105-31702 W23 105-31702 W4 117-31713 W1

NOTE

If the center of gravities of the tail rotor drive shaft and of the tail rotor head do not align, there is the possibility of vibration. Object of the adjustment of the distance between the spherical bearings is to minimize vibrations. The bushings (2, figure 33-8) of the tail rotor head are not adjustable, so the distance of the spherical bearings is adjusted by the means of addition or removal of shims (8). The inner dimension of the tail rotor shaft fork (distance "A", figure 33-8) is influenced by these shims. The target of this procedure is to match the measure "A" and the outer dimension of the tail rotor head (distance "B") (B-A $; 0.05 mm).

NOTE

Adjustment of the distance of the spherícal bearings is only necessary, if: - vibrations are to be reduced, - parts are not installed in exactly the same position again, - parts of the tail rotor or of the tail rotor drive shaft have been replaced. The checking of distances "A" and "B" is strongly recommended.

1. Press the spherical bearing outer rings fully into the tail rotor shaft fork, using pressing-in tool1 05-31702 W4 (see paragraph 33-21). 2.

Install measuring device 105-31702 W23 as follows: a.

Disassemble measuring device.

b.

Screw measuring washer (5, figure 33-9) on locating bolt (1) fully, then unscrew by 1/4 turno

c.

Installlocating bolt (1) to the spherical bearings of the tail rotor shaft fork. Doing so, install measuring flange (2), adjustable sleeve (4) and measuring flange (3).

d.

Install measuring washer (5) on knurled nut (6) fully, then unscrew by 1/4 turno

e.

Install knurled nut (6) to the locating bolt (1) fingertight, so that a possible bearing play and a possible play between spherical bearing and measuring device is no longer noticeable.

f.

Turn both measuring washers (5) until they seat fully to the outer face of the tail rotor shaft fork (7).

g. Turn adjustable sleeve (4) until measuring flanges (2,3) seat fully against spherical bearing.

Revision 24

CHAPTER 33 Page 25

_eurocopter lIIl

MAINTENANCE MANUAL SO 105

EACS ComplIIly

3

8

8 A

1 2 3 4

Inner sleeve Bushing Forked end of tail rotor shaft Close-tolerance bolt

Figure 33-8

NOTE

3.

5 6 7 8

Spherical bearing outer race Bushing Spherical bearing inner race Shims

Adjustment of distance between sperical bearings

After the adjustment procedure distance "A" must be equal or at best 0.05 mm less than distance "B". The difference of "X1" and "X2" ("y 1" and "Y2" respectively) must be 0.025 mm or less.

Determine location and number of shims (S, figure 33-8) as follows: a.

Determine distance "B" (see figure 33-S) with a micrometer gauge or a slip caliper with a dial gauge.

b.

Determine distance "A" with a micrometer gauge or a slip caliper with a dial gauge. If the measuring device 105-31702 W23 is installed, the distance "A" can be measured from outer surface to surface of the measuring flanges (2, 3, figure 33-9).

c.

Determine distances "X1" and "X2" (figure33-S). The distance is measured from outer surface oftail rotor shaft fork (3) to the inner race (7) of the spherical bearing. If measuring device 105-31702 W23 is installed, the distances 'Y1" and "Y2" are to be determined (see figure 33-9). Both measuring flanges (2, 3) as well as both measuring washers (5) have the same thickness. They are therefore subtracted automatically during the calculation of eccentricity.

d. Subtract distance "A" from distance "B". The residual value must be between Omm and 0.05 mm.

B - A = O~~.05 mm (= Residual Value AB) If the residual value is negative, remove spherical bearings (see paragraph 33-21), remove shims and install spherical bearing (see paragraph 33-21). Continue with step a. CHAPTER 33 Page 26

Revision 24

MAINTENANCE MANUAL BO 105

A 4

3

5

~7 3 Measuring flange 4 Adjustable sleeve

1 Locating bolt 2 Measuring flange Figure 33-9

e.

5 Measuring washer 6 Knurled nut 7 Forked end of tail rotor shaft

Application of measuring device 105-31702 W23

Subtract distance "X2" from "X1" (use the greater distance as "X1") or "Y2"from "Y1". The residual value must be between Omm and 0.025 mm.

Xl - X2 = O~~.025 mm (= Residual Value X1X2) f.

If both values are within the limits, continue with step 5, else calculate the necessary shims as follows: 1) Divide "Residual Value AB" by 2 (value "AB").

AB

= Residual Value AB 2

2) Divide "Residual Value X1X2" by 2 (value "X1X2").

X1X2

= Residual Value X1X2 2

3)

Determine the number of shims on "X1" side:

NXI

= AB + X1X2 0.025 mm

The value in front of the dot is equal to the number of 0.025 mm thick shims. For each two 0.025 mm thick shims use one 0.05 mm thick shim. Revision 24

CHAPTER 33 Page 27

MAINTENANCE MANUAL BO 105

4) Determine the number of shims on "X2" side:

= AB -

NX2

X1X2

0.025 mm

The value in front of the dot is equal to the number of 0.025 mm thick shims. For each two 0.025 mm thick shims use one 0.05 mm thick shim. 5) Press out the spherical bearings (see paragraph 33-21) and add or remove shims according to the calculations for "NX1" and "NX2". Press in spherical bearing (see paragraph 33-21). 6) Repeat step 3. (a. to f.) until the values are within the tolerance range. If the tolerance range cannot be fullfiled, turn sperical bearings inside out. If this still does not work, install new sperical bearings.

4.

Example: The way to determine the number of shims is to be explained with the following example. The values are assumed as follows: a.

Distance "A" Distance "X1"

b.

Subtract distance "A" from distance "B":

Residual Value AB c.

94.84 mm 30.30 mm

=B

= 95.29 mm

- 94.84 mm

95.29 mm 30.28 mm

= OA5 mm >-

0.05 mm

Subtract distance "X2" from distance "X1 ":

Residual Value X1X2 d.

- A

Distance "B" Distance "X2"

= Xl

- X2

= 30.30 mm -

30.28 mm

= 0.02 mm

Divide "Residual Value AB" and "Residual Value X1X2" by 2:

AB

= ResidualialueAB = OA5 mm = 0.225 mm 2

X1X2

= Residual V;lue X1X2 = 0.02 mm = 0.01 mm 2

e.

Determine number of shims (for 0.025 mm thick shims):

NX1

= AB + X1X2 = 0.225 mm + 0.01 mm = 0.235 mm = 9 4

NX2

= AB -

0.025 mm

X1X2 0.025 mm

0.025 mm

= 0.225 mm

- 0.01 mm 0.025 mm

0.025 mm

.

= 0.215 mm = 8 6 0.025 mm

.

The calculation shows thatforthe "X1" side a number of nine 0.025 mm thick shims (orfourO.05 mm thick shims and one 0.025 mm thick shim) and for the "X2" side eight 0.025 mm thick shims (or four 0.05 mm thick shims). f.

The values afier the dot are:

NX1 : OA

*

0.025 mm

=

0.010 mm

NX2 : 0.6

*

0.025 mm

=

0.015 mm

The sum of the values afier the dot is 0.025 mm and therefore within the tolerance range. g. Afier inserting the shims, the distances "A", "B", "X1 ", and "X2" have to be measured again and the calculation has to be repeated with the new values. CHAPTER 33 Page 28

Revision 24

MAINTENANCE MANUAL BO 105 5.

Install tail rotor head to the tail rotor shaft fork as follows: a.

Install tail rotor blades (refer to paragraph 34-5).

b.

Check if static balancing of the tail rotor head is necessary (refer to paragraph 33-3).

c.

Install guide sleeve 117-31713 W1 to the c1ose-tolerance bolt (21, figure 33-5).

d. Treat close-tolerance bolt (21) prior installation as follows: 1) Nickel-plated or gas-nitrided close-tolerance bolt: Apply a thin layer of grease (CM 101, CM 102 or CM 120) or corrosion preventive compound (CM 505) or lubricant (CM 146) onto close-tolerance bolt. 2) Close-tolerance bolt coated with solid film lubricant: a) Do not lubricate a new close-tolerance bolt coated with solid film lubricant. b) Close-tolerance bolt which was previously installed: if solid film is damaged, inspect close-tolerance bolt in accordance with paragraph 33-21, -

apply a thin layer of lubricant (CM 146).

e.

Position tail rotor head and install close-tolerance bolt (21) according to its markings.

f.

Remove guide sleeve 117-31713 W1 and install nut (23) hand tight.

g. Torque nut (23) to 10 Nm and align with pin hole to insert split pino The maximum torque value of 16 Nm must not be exceeded. h. Check flapping hinge function (refer to paragraph 33-4, step 3.).

i.

Secure nut (23) with split pin (24)

j.

Install pitch links (refer to paragraph 33-8).

k.

Balance tail rotor dynamically (r~fer to chapter 107-3).

Revision 24

CHAPTER 33 Page 29

Oeurocopter lIIl EAl:S

MAINTENANCE MANUAL BO 105

Compeny

BLANK PAGE

CHAPTER 33 Page30

MAl NTENANCE MANUAL 80 105

33 - 19 Tail rotor shaft 33 - 20

Removal - tail rotor shaft 1x56 134519 1x56 122 276 1x56 131 404 1x56 131 405 117-31706 W1

Oil drain hose assy Puller Socket wrench Socket wrench Pushing-out device

Special tools:

1. Remove pitch links, bellcrank and assembled tail rotor head and blades (refer to paragraphs 33-6, 33-10 and 33-14, respectively). 2. Drain oil from tail rotor gearbox (refer to paragraph 32-9). 3. Disconnect boot from tail rotor gearbox. 4. Remove screws (9, figure 33-10) and washers (8) and detach cobr (6). Discard O-ring (7). 5. Remove locking plate (2) with puller 1x56 122 276. 6. Remove screw (5, LH thread) from tail rotor shaft (4) with socket wrench 1x56 131 405. Discard O-ring (3). 7. Unsrew shaft nut (1) from hollow shaft (10) with socket wrench 1x56 131 404.

175 - 85 Nm

1 70

- 80

Nm

l- 1 - - , ;x~~~~~~~

!~=t!ml!~~

l- 5---l4---WkYr-¡ 6----+

o} a: ~

;, I 8 - 10 Nm ~Io

r-

7=~~

1 2 3 4 5 6 7 8 9 10

Shaft nut Locking plate O-ring Tail rotor shaft Screw Cover O-ring Washer Screw Hollow shaft

8

9---Wn"~7'

o ID

Figure 33-10 Revision 24

Tail rotor shaft removal and installation CHAPTER 33 Page 31

_~.!a!~Pter 8.

Press tail rotor shaft from hollow shaft with pushing-out device 117-31706 W1 (1 and 2, figure 33-11). a.

Unscre spindle (1) of pushing-out device until it abuts.

b.

Screw bell-shaped body (2) on threaded end of hollow shaft (5) until finge of bell-shaped body is seated against gearbox housing (4). If the bores in the seated flange do not align with the bores in the gearbox housing, back off gell-shaped body just enough to obtain bore alignment.

CAUTION

9.

MAINTENANCE MANUAL BO 105

DO NOT TIGHTEN SCREWS (3) AS LONG AS THE BELL-SHAPED BODY IS NOT SEATED SOLlDLY AGAINST THE GEARBOX HOUSING. THIS MAY CAUSE DAMAGE TO THE BALL BEARING AND BUSHING.

c.

Install screws (3) in mating bores of bell-shaped bodyflange and gearbox housing so that approximately three fu 11 threads are engaged.

d.

Rotate tail rotor shaft (6) clockwise (viewed from forked end) until the bell seats tightly againstthe gearbox housing. Finger-tighten screws (3).

e.

Press tail rotor shaft from hollow shaft by screwing in the spindle (1).

Detach boots from sliding sleeve and tail rotor shaft. Pull sliding sleeve and boots carefully offtail rotor shaft.

10. Inspect zones 2 and 4 (fig. 33-12) on tail rotor shaft for silver residues. If such residues are found, evaluate hollow shaft (5, fig. 33-11) according to REM 303 and repair as necessary.

CHAPTER 33 Page 32

Revision 24

_~er

MAINTENANCE MANUAL 80105

2

1 2 3 4 5 6

Figure 33-11

Revision 24

3

4

5

6

Spindle Bell-shaped body Screw Gearbox housing Hollow shaft Tail rotor shaft

Pushing out tail rotor shaft with tool 117-31706 W1

CHAPTER 33 Page 33

O~~pter 33 - 21

Inspection and repair - tail rotor shaft

Special tools:

1.

MAINTENANCE MANUAL BO 10S

Press-in tool Hoisting tool Pushing-out tool Measuring device

105-31702 W4 105-31702 W22 105-31702 W14 105-31803 W2

Inspect tail rotor shaft: a.

Inspect tail rotor shaft for mechanical damage and corrosion. Remove damage with polishing cloth 400/600. For damage tolerance Iimits, referto figure 33-12. If damage exceeds the permissible damage Iimits, send taíl rotor shaft to ECO or authorized service station for repair.

b. Visully inspect tail rotor shaft for cracks. If cracks are suspected, perform dye penetrant inspection per ASTM- E-1417. Oiscard taíl rotor shaft if cracks existo

•

c.

Inspect spherical bearings in taíl rotor shaft fork for play, corrosion and roughness. Max. permissible play: radial 0.1 mm. Ifany such condition is found, replace both bearings in accordance with step 2, even ifany one ofthe bearings is affected. If the spherical bearings have to be replaced, accomplish the following additional steps: 1) Visually inspect tail rotor gearbox mounting bracket on vertical fin for loose rivets and cracks, and also adjacent areas for cracks. 2) Inspect tail rotor gearbox attaching hars ware for proper torque (refer to Chapter 32-61). 3) Visually inspect tail rotor gearbox housing for cracks and oilleakage in areas adjacent to mounting bolts and flange ribs.

d.

Inspect plug in bore oftail rotor shaft for damage, security and proper sealing. Replace plug if damged or loose in accordance with step 4.

e.

Inspect close-tolerance bolt (21, figure 33-5): 1) Gas- nitrided close-tolerance bolt (P/N 105-31702.16)

•

a) Inspect bolt shank for cracks, deformation, mechanical damage and corrosion. Crack inspect per dye penetrant ASTM-E-1417 or magnetic particle ASTM-E-1444 method. - remove corrosion with 400/600 git abrasive cloth. - discard bolt if any of the other conditions are found. b) Inspect threads of close-tolerance bolt for damage. Minor damage to threads which does not adversely affect the installation of bolt is permissible. Oiscard bolt if thread flanks are deformed or broken.

CHAPTER 33 Page 34

Revision 24

O~~ter

MAl NTENANCE MANUAL SO 105

2) Nickel-plated close-tolerance bolt (P/N 105-31702.14) a) Inspect bolt shank for deformation, mechanical damage, broken or delaminated nickel plating and with magnifying glass for cracks. - Discard close-tolerance bolt if cracked or deformed. Discard or send to ECD for repair if nickel plating is broken, delaminated or worn. - Minor mechanical damage to the bolt shank which does not adversely affect installation of bolt (Le., must be insertable by hand) is permissible and requires no rework. - More severe mechanical damage adversely affecting installation shall be removed with polishing cloth 400. However, take care not to remove nickel plating down to the base metal. b) Inspect bolt for thread damage. Minor damage to threads which does not adversely affect the installation of bolt is permissible. Discard bolt if thread flanks are deformed or broken. 3) Close-tolerance bolt coated with solid film lubricant (P/N 105-31700.16 or P/N 105-31700.18) a) Inspect bolt shank for deformation, mechanical damage, condition of solid film lubricant coat and with magnifying glass for cracks. - Discard close-tolerance bolt if cracked or deformed. - Mechanical damage such as individual scores, nicks and scratches which extend through the solid film lubricant coat and penetrate the base metal shall be polished out using 400 grit abrasive cloth. - The solid film lubricant coat may be worn down to the base metal of the bolt on the entire coated surface. Polish out scores, nicks and scratches in the solid film lubricant coat using 400 grit abrasive cloth. The diameter of the bolt shank shall not be less than 12.655 mm. b) Inspect thread of close-tolerance bolt for damage. - Minor damage to threads which does not adversely affect the installation of bolt is permissible. Discard bolt if thread flanks are deformed or broken.

Revision 24

CHAPTER 33 Page 35

o !:lJa!~ter

MAINTENANCE MANUAL BO 105

2

3 4

5

6

NOTE

If the inspection of the tail rotor shaft reveals silver residues in zone 2 and 4, inspect holiow shaft (5, figure 33-11) according to REM 303, and repair as necessary.

Zone 1

Polish out longitudinal seores and corrosion on spline flanks down to a max. depth of 0.2 mm. Damge to root of spline is not permíssible.

Zone2

Polish out mechanical damage and corrosíon. Min. permissible diameter: 34.99 mm. Rework is permissible on 100% of zone surface. Polish out silver resides with polishing cloth (600).

Zone3

Polish out local mechanical damage down to a max. depth of 0.2 mm.

Figure 33-12

CHAPTER 33 Page 36

Tail rotor shaft - damage and repair limits (1 of 2)

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

Zone 4

Polish out mechanical damage and corrosion. Min. permissible diameter: 44.99 mm. Corros ion damage is permissible at three locations on circumference, each covering an area of not more than 50 mm2 . Damage areas must be at least 35 mm aparto Polish out silver residues with polishing cloth 600.

Zone 5

Polish out local mechanical damage down to a max. depth of 0.2 mm.

Zone 6

Polish out longitudinal seo res and corros ion on spline flanks down to a max. depth of 0.2 mm. Material removal caused by wear is permissible down to a max. depth of 0.1 mm and a max. width of 20 mm and does not require rework. Damage to root of spline is not permissible.

Zone 7

Polish out local mechanical damage down to a max. depth of 0.2 mm.

Zone 8

Polish out longitudinal scores and corrosion down to a max. depth of 0.1 mm. Min.permissible diameter: 50.6 mm. Local dents are permissible and require no rework.

Zone 9

Polish out local mechanical damage down to a max. depth of 0.2 mm. Make sure that any rework on the outboard faces of the fork arms does not affect their relative symmetry. Symmetry is a prerequisite for obtaining the accurate measurements required to center the tail rotor head in the forked end of the tail rotor shaft according to para 33-18.

Figure 33-12 2.

(2 of 2) Damage and repair limits - tail rotor shaft

Replacement of spherical bearings a.

Remove spherical bearing (4, figure 33-13): 1)

From inboard side of fork arm (6), insert boH (3) of tool 105-31702 W4 through the spherical bearing (4).

2)

Place bell-shaped body (2) on bolt (3), then install and tighten nut (1) until spherical bearing is pressed from the bushing (Sr.

3)

Inspect bushing bore for mechanical and corrosion Polish out damage with polishing cloth 400/600. For max. permissible bore diameter, refer to step If the max. permissible bore diameter is exceeded one quarter of the circumference, replace bushing step 3.

damage. 3.b. on more than according to

BO 105 CHAPTER 33 Page 37

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~-------2 ~J-4~r------- 3 "~¡..¿j-------- 4

'+--6

300351.1

1

~3

Tool 105-31702 W4

2 4 5 6

Figure 33-13 b.

Nut Bell-shaped body Bolt Spherical bearing Bushing Fork arm of tail rotor shaft

Removal of spherical bearings with tool p/N 105-31702 W4

Install spherical bearing (1, figure 33-14) as follows: 1)

Measure inner diameter of installed bushing (2) in accordance with step 3.

2)

Degrease faying surfaces of spherical bearing and bushing with methyl ethyl ketone (CM 217).

3)

Position spherical bearing (1) on mating bore on outboard side of fork arm (3).

4)

Insert bolt (6) of tool p/N 105-31702 W4 through spherical bearing froro outboard side of fork armo

5)

Place washer (4) of tool on bolt as shown in figure 33-14, then fit nut (5) on bolt and tighten nut until spherical bearing is pressed in to full extent. Remove tool.

BO 105 CHAPTER 33 Page 38

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

2 3 4

5

6

:":'30':":03~Sl-:""o1.A~

Figure 33-14

0

_ _

•

- -

o

1 Spherical bearing 2 Bushing 3 Fork arm of tail rotor shaft 4 Washer Tool 5 Nut 105-31702 W4J 6 Bolt

Installation of spherical bearings with tool p/N 105-31702 W4

6)

Check that face of spherical bearing inner race protrudes from bushing flange on inboard side of fork armo If this is not the case, rotate inner race so that the outboard face is positioned inboard.

7)

Check bearing breakaway torque as follows: a)

NOTE

8)

Insert bolt of measuring device p/N 105-31803 W2 from inboard face of fork arm through bearing bore and install associated nut with flange leading. Torque nut to 8 Nm.

The torque wrench of measuring device p/N 105-31803 W2 can be used for cw and ccw rotation.

b)

Insert torque wrench through the opposite fork arm and into the bolt of the measuring device.

e)

Set wrench to 350 Ncm and determine breakaway torque of bearing by turning grip of torque wrench.

d)

If the indication is above 350 Ncm, install a bearing with a lower friction coefficient.

Color-code bearing according to paragraph 33-14, step 4. BO 105 CHAPTER 33 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3.

Replacement of bushings a.

Remove bushing (6, figure 33-15) as follows: 1)

Remove spherical bearing according to step 2.

2)

Insert drift (4) of tool P/N 105-31702 W14 from inboard face of fork arm through bushing (6).

3)

Install bell-shaped body (3) and washer (2) and nut (1) on drift and tighten nut until bushing is pressed from tail rotor shaft fork.

íf'f't":r------1 ~~~~:__---2

R+-------3

6

5 4

I 300089

--$: Tool 105-31702

Figure 33-15 4)

W14~

1 Nut 2 Washer 3 Bell-shaped body 4 Drift 5 Fork arm of tail rotor shaft 6 Bushing

Removal of bushing with tool P/N 105-31702 W14

Inspect bore in fork arm of tail rotor shaft for mechanical damage and corrosion. Remove damage with 400/600 grit abrasive cloth. The max. permissible bore diameter is 28.02 mm. It must not be exceeded by more than 0.01 mm on one quarter of the circumference. If limits are exceeded, return tail rotor shaft to MBB or an authorized repair facility.

BO 105 CHAPTER 33 Page 40

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Install bushing (2, figure 33-16) as follows: 1)

Degrease bushing and mating bore in fork arm of tail rotor shaft with methyl ethyl ketone (CM 217).

2)

Chill bushing to approx. -50 oC.

3)

Heat fork arm of tail rotor shaft (1) to approx. 80 oC.

4)

Manually press bushing into fork arm bore as far as possible.

5)

From outboard side of fork arm, insert drift (3) of tool p/N 105-31702 W14 through bushing.

6)

Install bell-shaped body (4), washer (5), and nut (6) on end of drift (3) and tighten nut(6) until the flange of the bushing is seated on the fork armo

7)

Measure bore diameter of installed bushing. a)

The diameter of bushing bore must be 25.40 - 0.01 mm.

b)

If the bore diameter is smaller than speeified, hone bushing to speeified diameter using tool p/N 105-31702 W22 and a hand-drill.

e)

If the bore diameter exeeeds the speeified value, replaee bushing.

101--

3

~---"'I"l't"-------2

,,"+---+------4 ~~;:;;~~:....-._+_----5

l...bd;j------j-----6

Tool 105-31702

Figure 33-16

Wl~

1 Fork arm of tail rotor shaft 2 Bushing 3 Drift 4 Bell-shaped body 5 Washer 6 Nut

Installation of bushing with tool 105-31702 W14 BO 105 CHAPTER 33 Page 41

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 4.

Replace sealing plug as follows: a.

Remove sealing compound (2, figure 33-17) with suitable tool made of wood or plastic.

b.

Using tool, press shaft sealing plug (1) out of tail rotor shaft (3).

c.

Clean plug seating surface in shaft with acetone (CM 203) .

d.

Install new plastic sealing plug in tail rotor shaft. For installation position, refer to figure 33-17.

e.

Seal split line of plug and shaft bore around entire circumference with a fillet of sealing compound (CM 662) .

158 - 160

1"

,_ 60 - 65

33/33

Dimensions in mm

Figure 33-17

BO 105 CHAPTER 33 Page 42

1 2 3

Plastic sealing plug Sealing compound Tail rotor shaft

Installation position of sealing plug and outer boot on tail rotor shaft

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Installation - tail rotor shaft

33 - 22

Special tools: Mounting device Socket wrench Socket wrench Puller 1.

Install sliding sleeve on tail rotor shaft as follows: a.

b.

Slide outer boot with new clamp on tail rotor shaft and secure as follows: 1)

Install boot on tail rotor shaft as shown in figure 33-17.

2)

Tighten clamp screw and apply safetying lacquer (CM 621) to screw head and clamp lock.

Apply grease (CM 101) to inner splines of sliding sleeve. CAUTION

2.

105-31702 W19 1xS6 131 404 1xS6 131 405 1xS6 122 276

IF SLIDING SLEEVE IS IMPROPERLY INSTALLED ON THE TAIL ROTOR SHAFT, THE CONTROL FUNCTION OF THE TAIL ROTOR WILL BE IMPAlRED.

c.

Position sliding sleeve on tail rotor shaft such that the matchmark on the sliding sleeve (on front face of splined end) aligns with matchmark on splines of tail rotor shaft.

d.

Fasten outer boot to sliding sleeve.

e.

Slide inner boot on tail rotor shaft and fasten to sliding sleeve.

Install tail rotor shaft (6, figure 33-18) in tail rotor transmission with mounting device p/N 105-31702 W19: a.

Unscrew bell-shaped body (4) of tool from spindle (3).

b.

Screw spindle (3) into threaded bore of tail rotor shaft (6).

c.

Slide splined setting sleeve (1) over splined section of spindle (3) and onto splined section oí tail rotor shaft (6).

d.

Tighten nut (2) and remove splined setting sleeve (1).

BO 105 CHAPTER 33 Page 43

- - - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 e.

Ciean faying surfaces of taii rotor shaft (6) and hoiiow shaft (5) with acetone (CM 203) . CAUTION

THE TAIL ROTOR SHAFT MUST BE COOLED PRIOR TO INSTALLATION IN THE HOLLOW SHAFT. FAILURE TO DO THIS CAN RESULT IN THE DESTRUCTION OF THE SILVER PLATING ON THE HOLLOW SHAFT BORE.

f.

Cooi gearbox end of taii rotor shaft together with attached tooi to approx. -50 oC, using dry ice. Keep dry ice away from rubber boot.

g.

Heat hoiiow shaft (5) in taii rotor transmission to max. 80 oC with a heater fan.

h.

Insert taii rotor shaft into hoiiow shaft as far as possibie by hand, then screw beii-shaped body (4) on spindie (3) and puii taii rotor shaft into hoiiow shaft untii it abuts.

~.

Unscrew spindie (3) from taii rotor shaft (6) and remove tooi.

3.

Instaii shaft nut (1, figure 33-10) on hoiiow shaft (10) with socket wrench 1xS6. 131 404. For torque vaiue refer to figure 33-10.

4.

Appiy a thin film of siiicone compound (CM 104) to new O-ring (3) and fit O-ring on screw (5).

5.

Instail screw (5, LH thread) in taii rotor shaft (4) with socket wrench 1xS6 131 405. For torque vaiue, refer to figure 33-10.

6.

Position iocking piate (2) on screw (5) with puiier 1xS6 122 276 and press it inward so that tabs of iocking piate engage behind shaft nut (1).

7.

Attach cover (6) to taii rotor gearbox housing as foiiows: a.

Appiy a thin coat of siiicone compound (CM 104) to new O-ring (7) and instaii O-ring in cover.

b.

Appiy a thin coat of corrosion preventive compound (CM 505) to seating surfaces on cover and secure cover with washers (8) and screws (9) to gearbox housing. For torque vaiue, refer to figure 33-10.

c.

Seai spiit lines between screws (9) and cover (6) and between cover and transmission housing with PUR topcoat (CM 437) or sealing compound (CM 662) .

d.

Mark screws with thread seaiant (CM 620) .

BO 105 CHAPTER 33 Page 44

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. Fasten inboard boot (46, figure 33-5) to gearbox housing cover, taking care that one vent hole is facing down. 9. Replenish tail rotor gearbox with oil (refer to paragraph 32-9) . 10. Install tail rotor head, bellcrank, pitch links and tail rotor blades (refer to paragraphs 33-18, 33-12, 33-8 and 34-5, respectively). 2

3

Tool

r ¡~

105-31702 W19--l Figure 33-18

4

Splined setting sleeve Nut Spindle Bell-shaped body

5

6

7

5 Hollow shaft 6 Tail rotor shaft 7 Tail rotor transmission

Instal1ation of tail rotor shaft with tool p/N 105-31702 W19 BO 105 CHAPTER 33 Page 45

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 33 - 23

S 1 i d i n g

s 1 e e v e

33 - 24

Removal - sliding sleeve

Refer to paragraph 33-20 (Removal-tail rotor shaft) for removal procedure. 33 - 25

Disassembly - sliding sleeve

Special tools: Extractor or extractor Socket wrench Support plate Receptacle

1.

105-31763 W2 (applicability: all configurations) 105-31762 W2 (applicability: only sliding sleeve with short inner splines) 105-31762 W3 tool no. 17 refer to Chapter 04 or 105-31765 W1 tool no. 32 refer to Chapter 04 or 105-31762 W4

Clamp receptacle tool no. 32 or P/N 105-31762 W4 (1, figure 33-19) in a soft-jawed vise, and place inner sleeve (2) in the receptacle.

;------2

I

I

I

I L

--lI

1 2 Tool r 3 105-31763 W2---l 4 Figure 33-19 BO 105 CHAPTER 33 Page 46

Receptacle . Sliding sleeve Bell-shaped body Support with screw

Clamping of sliding sleeve and app1ication of extractor P/N 105-31763 W2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

3.

Remove unthreaded locking plate (1, figure 33-20) with screwdriver. Remove threaded locking plate with either extractor p/N 105-31762 W2 or extractor p/N 105-31763 W2 as follows: a.

Screw bell-shaped body (3, figure 33-19) onto the locking plateo

b.

Press out locking plate by screwing in screw of support (4).

Unscrew Shurlock nut (2, figure 33-20) with socket wrench p/N 105-31762 W3.

2 138-40 Nm

I

~~ 5 6

Grease

7~

8

9

--j

3-5 Nm

10

6

33115

Figure 33-20 4.

1 Locking plate 2 Shurlock nut 3 Spacer 6- 4 Spacer 5 Outer ring 6 Lub fitting 7 Cover 6 - 8 Washer 9 Screw 10 Sliding sleeve On configuration I only (see fig. 33-5, 1 of 2)

Sectional view - sliding sleeve

Remove lockwire and remove screws (9) and, if configuration I, washers (8) •

5.

Detach outer ring (5).

6.

Remove spacer (4) from configuration l.

7.

Position support plate, tool no. 17 or p/N 105-31765 W1 (1, figure 33-21) on sliding sleeve (6).

8.

Place two-point puller (5) on spacer (4) and pull ball bearing (3) off sliding sleeve, along with spacer (2).

9.

Remove cover (7, figure 33-20) froro sliding sleeve (10).

BO 105 CHAPTER 33 Page 47

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~~--+--+---2

::::::11''--+----4

'-----5 ~-------6

300315

1

Support plate Spacer 3 BaH bearing 4 Spacer 5 Two-point puller 6 Sliding sleeve

2

Figure 33-21

Removal of grooved ball bearing

Inspection and repair - sliding sleeve

33 - 26

Special tool: P~shing-out

device

105-31762 W1

l.

Inspect ball bearing for roughness, chatter marks, play and corrosion. If any of these conditions are present, discard bearing.

2.

Visually inspect slide bearing in sliding sleeve for wear. If wear is evident, recognizable by pale surface, replace bearing using tool pushing-out device P/N 105-31762 W1, as follows: a.

Remove spring ring (6, figure 33-22).

b.

Place sliding sleeve (4) on support (1) of pushing-out device 105-31762 W1.

c.

Place thrust pie ce (3) on slide bearing (5) and press out with plunger (2) using a press.

d.

Inspect bearing seat for mechanical damage and corrosion. Polish out damage with polishing cloth 400, as necessary. The maximum permissible diameter of bearing seat is 57.20 mm. It may be exceeded by 0.02 mm on one quarter of the circumference.

BO 105 CHAPTER 33 Page 48

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

V

1/

v

V 300104

r

Tool 105-31762 W~

Support Plunger 3 Thrust piece

1 2

Figure 33-22

3.

1/

I

V V

I

4 Sliding sleeve 5 SEde bearing 6 Spring ring

Replacement - sleeved bearing, using pushing-out device p/N 105-31762 W1

e.

Chill slide bearing to approximately -50 oC.

f.

Heat sliding sleeve (4) to approximately 80 oC and press slide bearing (5) in sliding sleeve until it abuts. Use thrust piece (3) if necessary.

g.

Insert spring ring (6).

Inspect sliding sleeve for cracks, other mechanical damage, corrosion and damaged surface protection. a.

Discard sliding sleeve if cracks existo

BO 105 CHAPTER 33 Page 49

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

4.

5.

b.

Polish out damage that is within the permissible damage lirnits defined in figure 33-23, and final polish with 400 grit abrasive cloth.

c.

Touch up damaged surface protection withzinc chromate primer (CM 401) and two-component PUR topcoat (CM 412) in accordance with Chapter 02.

Inspect outer ring for cracks, other mechanical damage, corrosion and damaged surface protection. a.

Discard outer ring if cracks existo

b.

Polish out damage that is within the permissible lirnits defined in fig. 33-24, and final polish with 400 grit abrasive cloth. If outer ring is made of aluminum, use a non-ferrous abrasive cloth only.

c.

Touch up damaged surface protection with zinc chromate primer (CM 401) and two-component PUR top-coat (CM 412) in accordance with Chapter 02.

Inspect cover for cracks, other mechanical damage, corrosion and damaged surface protection. a.

Discard cover if cracks existo

b.

Polish out damage that is within the permissible lirnits defined in fig. 33-25, and final polish with 400 grit abrasive cloth. If cover is made of aluminum, use a non-ferrous abrasive cloth only.

c.

Touch up damaged surface protection with zinc chromate primer (CM 401) and two-component PUR top-coat (CM 412) in accordance with Chapter 02.

BO 105 CHAPTER 33 Page 50

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Sleeved bearing

300313

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS Zone 1

Zone 2

Zone 3

I!

~

L8

~

Mechanical and corros ion

Depth: 0.5 mm Area: max. 30%

Depth: 0.05 mm Area: max. 30% Individual damage max. 5 %

j:7:0l

Depth: 0.3 mm Area: max. 30%

~

Local mechanical damage and corrosion is permissible down to a depth of 0.2 mm on the entire spline flank and requires no rework. Wear is permissible down to a depth of 0.1 mm and a max. width of 10 mm on all spline flanks and requires no rework.

ffi

Damage to threads is permissible down to a depth of 0.5 mm without rework, provided nut can be unscrewed by hand. Damage down to 0.5 mm which adversely affects the installation requires removal of burrs.

~

Polish out mechanical damage and corrosion with polishing cloth 400. The maximum bore diameter is 7.94 mm. It may be exceeded by 0.05 mm on 10% of the circumference. Figure 33-23

Damage and repair limits - sliding sleeve

BO 105 CHAPTER 33 Page 51

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Configuration 1

Configuration 11

300314.1

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS Zone 1

O Mechanical and corrosion

Depth: 0.5 mm Area: max. 30%

Zone 2

¡.•.:. . :.J

Depth: 0.05 mm Area: max. 30% Individual damage max. 10%

Zone 3 ~

== -

Depth: O. 05 mm Area: max. 30% Individual damage max. 10%

~

Po1ish out mechanical damage and corros ion with non-ferrous abrasive cloth 400. The maximum bore diameter is 11.2 mm. It may be exceeded by 0.01 mm on one quarter of the circumference.

~

Mechanical damage and corros ion is not permissible on the inboard end (1/3) of mounting bolt. Damage on the outboard end (2/3) may be removed with 400 grit abrasive cloth. Allowable minimum diameter is 11.0 mm. Figure 33-24

BO 105 CHAPTER 33 Page 52

Damage and repair limits - outer ring

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

Configuration I

Configuration 11

Zone 2 Contact surface to Tail-Rotor-Gear

300406

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS Zone 1 Zone 2

ftiitittiii~ Mechanical and corros ion Figure 33-25

Depth: 0.3 mm Area: max. 50%

Depth: 0.05 mm Area: max. 50%

Damage and repair limits - cover

BO 105 CHAPTER 33 Page 53

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 33 - 27

Assembly - sliding sleeve

Special tools: Socket wrench

CAUTION l.

105-31762 W3

USE BALL BEARINGS ONLY IN PAIRS WITH IDENTICAL SERIAL NUMBERS.

Apply grease (CM 101) to lubrication groove (3, figure 33-26) and bearing seat.

Configuration 1

Configuration Il

2

Outer ring 2 Bal! bearing 3 Lubrication groove 4 Spacer 1

Figure 33-26

BO 105 CHAPTER 33 Page 54

~ Configuration I only

Deep groove ball bearing installation

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2.

Pack deep groove ball bearings (2) with grease (CM 101) .

3.

Assemble ball bearings (2) for installation with arrows point to point (see figure 33-26).

4.

Coat spacer (4, figure 33-26, configuration I) with grease (CM 101) and place in outer ring (1).

~-16 /-1---2

6- 1

2

=r--r---3

3 4

6-5

1\

9~-----+-l

6

~~~45~

------41/

8-+------'

6

13 •

5 Nm

7

8

I

9

Spacer Outer ring Deep groove ball bearing Cover Washer Screw Sliding sleeve Stop collar Spacer

~~-----7

6 Figure 33-27

CAUTION

5.

On configuration I only (see fig. 33-5, 1 of 2)

Sliding sleeve assembly

PRESS AGAINST BEARING OUTER RACE ONLY.

Press deep groove ball bearings (3, figure 33-27) in outer ring (2) until fully seated.

BO 105 CHAPTER 33 Page 55

EUROCOPTER

6.

MAINTENANCE MANUAL 80 105

Heat sliding sleeve outer ring (2) with installed deep groove ball bearings (3) to approximately 80 oC.

7. Coatcover (4) and spacer(9) with grease (CM 101). Position coveron sliding sleeve (7) and spaceron stop collar (8). APPLY PRESSURE TO BEARING INNER RACE ONLy.

CAUTION 8.

Press outer ring (2) with installed bearings onto sliding sleeve (7) until fully seated (see figure 33-27).

9.

Fasten cover (4) with screws (6) and washers (5, configuration I only). See figure 33-27 for torque values. Lockwire screws.

10. Insert spacer (3, figure 33-20). 11. Tighten Shurlock nut (2) with socket wrerich 105-31762 W3. 12. Install locking plate (1). AFTER PACKING SLlDING SLEEVE WITH GREASE, REMOVE EXCESSIVE GREASE. GREASE CAN DESTROY THE BOOT.

CAUTION

13. Pack sliding sleeve with grease as follows: a.

Inject grease (CM 101) through lubrication fitting (6) until it emerges from coverand outer ring flange (see figure 33-20).

b. Turn outer ring and inject more grease to ensure equal distribution of grease over entire surface. c.

Detach the inboard boot from the outer ring of the sliding sleeve and push it towards the tail rotorgearbox, then remove excessive grease from both sides of the sliding sleeve .

d.

Reattach inboard boot to outer ring of sliding sleeve.

14. Check ball bearing for unrestricted rotation. Hold sliding sleeve and apply gentle axial force to outer ringo There must be no perceptible bearing play. Turn outer ringo No notches shall be felt. Replace bearings if play or notches are evident.

33 - 28

Installation - sliding sleeve

Refer to paragraph 33-22, Installation - Tail Rotor Shaft.

CHAPTER 33 Page 56

Revision 18

cteurocopter

MAINTENANCE MANUAL SO 105

on EAOO Company

34 TAIL ROTOR BLADE Table of Contents

Paragraph Title

Page

34-1

DESCRIPTION - TAIL ROTOR BLADE

.

34-1A

DESCRIPTION - TAIL ROTOR BLADE

.

34-2

INSPECTION - TAIL ROTOR BLADE

.

7

34-3

REPAIR - TAIL ROTOR BLADE

.

19

34-4

REMOVAL - TAIL ROTOR BLADE

.

23

34-5

INSTALLATION - TAIL ROTOR BLADE

.

24

34-6

STORAGE, PACKAGING AND SHIPPING - TAIL ROTOR BLADE

.

25

Revision 25

3

3A.

CHAPTER 34 Page 1

_e.

urocopter

MAINTENANCE MANUAL BO 105

11ft EAm QlmpIny

BLANK PAGE

CHAPTER 34 Page 2

Revision 21

-eurocopter

MAINTENANCE MANUAL SO 105

un EADS Campeny

•

34-1

DESCRIPTION - TAIL ROTOR BLADE

•

Pre S8 80105-30-112.

EFFECTIVITY

The tail rotor blade is manufaetured from glassfiber-reinforeed plasties (GRP). The blade spar (2, fig. 34-1) is made up of numerous glass fiber strands impregnated with epoxy resin and formed into ribbons (or rovings). These rovings run spanwise from the blade tip to the blade rool, where they loop around the two bushings (6, fig. 34-2 or 34-3 or 34-4 or 34-5), and return to the blade tip again. Alead rod (1, fig. 34-1) is embedded in • the leading edge of the spar. The rest of the blade body is made of a PVC hard-foam eore (3, fig. 34-1). The entire rotor blade, exeept for fitting surfaee (5, fig. 34-2 or 34-3 or 34-4 or 34-5), is eovered by a fiberglass • eloth skin. A steel erosion strip (2, fig. 34-2 or 34-3 or 34-4 or 34-5) made from sheet metal is bonded to the blade nose, • and a neek shell (9) and a nose shell (4), made from resin-impregnated eomposites, are bonded to the blade rool. The eover band (3) provides proteetion against erosiono On blade eonfigurations 11 and IV (see table 34-1), a PU foil (1, fig. 34-3 or 34-5), whieh also provides proteetion against erosion, is bonded to the forward outboard area of both the thrust and camber side of the blade. On blade eonfigurations I and 111 (see table 34-1), an aluminum plate (1, fig. 34-2 or 34-4) is bonded and partially riveted to the blade, instead of the PU foil.

On blade eonfigurations I to IV, the tip of the blade is fitted with a stainless steel end cap (13, fig. 34-2 or 34-3 or 34-4 or 34-5). An identifieation plate (7, fig. 34-2 or 34-3 or 34-4 or 34-5) is installed on the thrust side • of the blade, with a part number (8) stamped on the blade surfaee below il. The tail rotor blade is attaehed to the blade mounting fork of the tail rotor by two hex bolts whieh fit through two steel bushings (6) resin-bonded in the blade rool. The various blade eonfigurations are speeified in table 34-1 and shown in figs. 34-2, 34-3, 34-4, 34-5. Eaeh eonfiguration has variants with a 0 0 eoning angle and a 1 0 eoning angle, respeetively. Otherwise, both variants are identical and therefore are inspeeted and repaired to the same eriteria.

Configuration

Figure Related part numbers (old) 34-2

105-31754, 105-31756, 105-317565, 105-31757, 105-31758

11

34-3

105-31754 CTI-MOD "A", 105-31756 CTI-MOD "A", 105-31757 CTI-MOD "A"

111

34-4

105-31754 modified aeeording to DSK2-01179, 105-31756 modified aeeording to DSK2-01179

IV

34-5

105-31791, 105-317915, 105-31793, 105-31964, 105-31966, 105-319675, 105-31968, 105-31970, 105-31980

______________ 1 Table 34-1 Tail rotor blade - eonfiguration

1 a:

;:¡ ~ I

2

3

I

I

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············l········································

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Figure 34-1 Revision 25

Lead rod Roving area Core

Tail rotor blade - eross seetion CHAPTER 34 Page 3

-eurocopter

MAINTENANCE MANUAL SO 105

. . en EAffi l:'.ompany

34 - 1A

DESCRIPTION - TAIL ROTOR BLADE

EFFECTIVITY

Post SB B010S-30-112 for all BO 10S helieopters exeept BO 10S CBS-SKLH and BO 10S CB-3.

The tail rotor blade is manufaetured with prepreg. The blade spar (2, fig. 34-1) is made up by unidireetional prepreg (prepreg rovings). These rovings run spanwise from the blade tip to the blade root, where they loop around the two bushings (6, fig. 34-SA), and return to the blade tip again. Alead rod (1, fig. 34-1) is embedded in the leading edge of the spar. The rest of the blade body is made of a PVC hard-foam eore (3, fig. 34-1). The entire rotor blade, exeept for fitting surfaee (S, fig. 34-SA), is eovered by a FVW-prepreg skin. A niekel erosion strip (2, fig. 34-SA) made from sheet metal is bonded to the blade nose, and a neek shell (9) and a nose shell (4), made from prepreg, are bonded to the blade rool. The eover band (3) provides proteetion against erosion. An identifieation plate (7, fig. 34-SA) is installed on the thrust side of the blade, with a part number (8) stamped on the blade surfaee below it. The tail rotor blade is attaehed to the blade mounting fork of the tail rotor by two hex bolts whieh fit through two steel bushings (6) in the blade rool. The various blade eonfigurations are speeified in table 34-1 A and shown in fig. 34-SA. Tail rotor blades with a 0 0 eoning angle (P/N 1OS-3180S) and tail rotor blades with a 1 0 eoning angle (P/N 1OS-3181 O) can be installed on the helieopter. Both variants are identieal and therefore are inspeeted and repaired to the same eriteria.

Configuration V

Figure Related part numbers (new) 34-SA 10S-3180S, 10S-31810 Table 34-1 A Tail rotor blade - eonfiguration

-.

CHAPTER 34 Page 3A

Revision 2S

CDeurocopter en

MAINTENANCE MANUAL BO 105

EA06 O:lmpeoy

BLANK PAGE

Revision 25

CHAPTER 34 Page 38

Aeurocopter ~

•

811

MAINTENANCE MANUAL 80105

EAOS Compe!1y

~.,

Pre SB B0105-30-112.

EFFECTIVITY

o ID

1 2 3 4 5 6 7

8

Aluminum plate Erosion protection Cover tape Nose shell Fitting surface Bushings Identification plate

9

10 11 12 13

Figure 34-2

•

EFFECTIVITY

1

1

Part number Neck shell Blade skin Trailing edge Rivet End cap

Tail rotor blade - configuration I

Pre SB B0105-30-112.

2

3

- - - - - - - - - -

4

5

,le

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\~ (\7 9

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Figure 34-3 CHAPTER 34 Page 4

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10

11 1 PU foil 2 Erosion protection 3 Cover tape 4 Nose shell 5 Fitting surface 6 Bushings 7 Identification plate

6

8 9 10 11 12 13

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Part number Neck shell Blade skin Trailing edge Rivet End cap

Tail rotor blade - configuration 11 Revision 25

-

Oeurocopter

MAINTENANCE MANUAL BO 105

en EADS Company

Pre SB B0105-30-112.

EFFECTIVITY 1

2

~

3

5

::lt::===============::¡:::================¡ I

10

11

1 2 3 4 5

6 7

8

Aluminum plate Erosion protection Cover tape Nose shell Fitting surface Bushings ldentification plate

9 10 11 12 13

Figure 34-4

EFFECTIVITY

;f:~

Part number Neck shell Blade skin Trailing edge Rivet End cap

Tail rotor blade - configuration 111

•

Pre SB B0105-30-112.

3

4

5

l::=::::::=:::=====~~==========1 ~\ I 11

1 2 3 4 5 6 7

PU foil Erosion protection Cover tape Nose shell Fitting surface Bushings Identification plate

Figure 34-5 Revision 25

•

\

j;-----

12

4

8 9 10 11 12 13

7

10 Part number Neck shell Blade skin Trailing edge Rívet End cap

Tail rotor blade - configuration IV CHAPTER 34 Page 5

Aeurocopter ~

I

lIIl

MAINTENANCE MANUAL BO 105

EA!X\ Compeny

EFFECTIVITY

-

Post S8 80105-30-112 for all 80 105 helicopters except 80 105 C8S-5 KLH and 80 105 C8-3.

2

3

4

,....----\,-----r-__ -kmd~ 0::

1

----------------------------------

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1

8 10

11

9

2 Erosion protection

7 Identification plate

3 Cover tape 4 Nose shell 5 Fitting surface 6 8ushings

9 Neck shell

8 Part number

10 81ade skin 11

Trailing edge

Figure 34-5A Tail rotor blade - configuration V

CHAPTER 34 Page 6

Revision 25

ClDeurocopter lII1

MAINTENANCE MANUAL BO 105

EAOS Comp6ny

34 - 2

INSPECTION - TAIL ROTOR BLADE

WARNING

• BLAOES WITH OAMAGEO SKIN, OAMAGEO TRAILlNG EOGE, OR OAMAGE EXCEEOING THE ACCEPTABLE L1MITS, SHALL BE REPAIREO BY ECO OR BY A REPAIR FACILlTY AUTHORIZEO BY ECO.

• IF ANY OAMAGE IS FOUNO TO HAVE BEEN CAUSEO BY CONTACT WITH AN OBSTACLE, THE SPECIAL INSPECTION PER CHAPTER 101, PARAGRAPH 101-13.1, STEP 3. SHALL AOOITIONALLY BE PERFORMEO.

NOTE

• The inspections apply equally to blades with or without a coning angle. • Oifferences in the inspection criteria between tail rotor blades are given in the inspection steps. • AII inspections shall be performed on both sides of the blades.

1.

Clean tail rotor blade with dry c1eaning solvent (CM 202) or degreasing agent (CM 209), then wipe dry.

2.

Inspect blade body (Le. blade skin) for erosion damage, impact damage, delamination, and cracks. a.

Erosion damage to the blade body is acceptable only if it is restricted to the paint finish. To prevent the damage from spreading, it is recommended to touch up the damaged paint finish (see para. 34-3, item 2).

b.

Impact damage to the blade body is unacceptable.

c.

Oelamination (separation of blade skin from core) is unacceptable.

WARNING

d.

CRACKS IN THE BLAOE BOOY ARE UNACCEPTABLE. CRACKS MAY LEAO TO THE OESTRUCTION OF THE BLAOE ANO POSSIBLY TO THE LOSS OF THE ENTIRE TAIL ROTOR.

Cracks in the paint finish are acceptable only if cracks along the edges of the metal plates do not extend into the blade body, and if no debonding of the metal plate edges has been caused in the area of the cracks (see fig. 34--6). If there is doubt in this respect, consult ECO or an authorized repair facility.

3.

Inspect markings (7, 8, fig. 34-2 or 34-3 or 34-4 or 34-5 or 34-5A) for legibility.

•

If markings are difficult to read, use a water-resistant felt-tip pen for touching up. 4.

Inspect cover tape (3, fig. 34-2 or 34-3 or 34-4 or 34-5 or 34-5A) for impact damage and separation. If the cover tape is damaged (e.g. from impact damage, or there is separation), replace it (see para. 34-3, item 3.). In that case, inspect the nose shell underneath (4) before attaching a new covertape, see item 6.

Revision 24

CHAPTER 34 Page 7

•

MAINTENANCE MANUAL BO 105

•

Pre S8 80105-30-112 .

EFFECTIVITY

----........

/ '. .

.

"\

2

3

-

7

Dimensions in mm

6

5

Debonding

1--+-,...

><

E

Permissible cracks in the paint Impermissible cracks in the paint

1 Cover tape 2 Erosion protection 3 Aluminum plate

Figure 34-6

4 5 6 7

End cap Blade skin Trailing edge Bushings

(1 of 3) Examples of acceptable and unacceptable damage - tail rotor blade, configurations and 111

1

CHAPTER 34 Page 8

Revision 25

Oeurocopter lIIl

.

•

Pre SB B0105-30-112.

EFFECTIVITY

/'

MAINTENANCE MANUAL SO 105

EAOO Company

.------.......-

"\

2

3

7

Dimensions in mm a:: 0

1

6

NI

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~ No delaminations admissible

~",1

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& &

5

/-

I l

Delaminations admissible Permissible cracks in the paint

/

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x

ro

E

Impermissible cracks in the paint

1 Cover tape 2 Erosion protection 3 PU foil 4 End cap

5 6 7

Blade skin Trailing edge Bushings

Figure 34-6

(2 of 3) Examples of acceptable and unacceptable damage - tail rotor blade, configurations 11 and IV

Revision 25

CHAPTER 34 Page 9

Gteurocopter

MAINTENANCE MANUAL SO 105

""EA06~

I

EFFECTIVITY

& &

Post SB B0105-30-112 for all BO 105 helicopters except BO 105 CBS-5 KLH and BO 105 CB-3.

Permissible cracks in the paint Permissible cracks in the paint

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ID

1 2 3 4

Blade skin Erosion protection Covere tape Nose shell

Figure 34-6 (3 of 3) Examples of acceptable and unacceptable damage - tail rotor blade, configuration V

CHAPTER 34 Page 10

Revision 25

Oeurocopter lIIl

5.

MAINTENANCE MANUAL 80 105

EADS Campany

Inspect neck shell (9, fig. 34-2 or 34-3 or 34-4 or 34-5 or 34-5A) for erosion damage, debonding, and • cracks along bonding joints. a.

Erosion damage to the neck shell is acceptable only if the damage does not extend through to material underneath.

b.

Debonds and cracks running alongside bonding joints and extending into the bonding joints are unacceptable.

6.

Inspect nose shell (4, fig. 34-2 or 34-3 or 34-4 or 34-5 or 34-5A), only if cover tape (3) has been removed • due to damage (see item 4.), according to the inspection of the neck shell (see item 5.).

7.

Inspect erosion protection (2, fig. 34-2 or 34-3 or 34-4 or 34-5 or 34-5A) for erosion damage, impact dam- • age, debonds, and cracks. a.

Erosion damage to the erosion protection is acceptable only if the damage does not extend through to material underneath.

CAUTION

IF THE EROSION PROTECTION HAS IMPACT DAMAGE, THE REST OF THE BLADE BODY SHALL BE INSPECTED THOROUGHLY FOR DAMAGE ON BOTH SIDES UP TO THE BLADE TRAILlNG EDGE (11). NO DAMAGE OF ANY KIND IS ACCEPTABLE (E.G. CRACKS, CHIPPING, DEBONDS OR DEFORMATION).

b.

Impact damage to the erosion protection is acceptable only if the damage does not extend through the erosion protection.

c.

To test tor debonds, use tapping hammer (see Chapo 04, tool no. 37) or a coin weighing approx. 10 g, and tap entire surface on both sides of the parto A good bond sounds light and hard, whereas a debond sounds dull and emits no resonance. Debonding of the erosion protection is acceptable only within the Iimits given in figure 34-7.

NOTE

d.

The debonding criteria tor the erosion protection are governed by the size of the cover tape (3) used (see para. 34-3, item 3.).

Cracks in the erosion protection are unacceptable.

Revision 24

CHAPTER 34 Page 11

•

eurocopter

MAINTENANCE MANUAL SO 105

, . en EAOS Compeny

•

EFFECTIVITY

Pre S8 80105-30-112.

Dimensions in mm

125

Leg area

125

AREA 1 Area atthe beginning of the erosion protection

D

AREA2

~ Nose area r--------------- f-------------Delaminations admissible Delaminations admissible without limitations

*

without limitations

AREA3

AREA4

11I

D

Warning area

Leg area

---------- -------------No delamination admissible

* Delaminations admissible with limitations

Area 4 The total delamination in this area must not exceed 1 cm2 (per erosion protection side)

Figure 34-7

(1 of 5) Delamination criteria for the erosion protection - tail rotor blade of configuration I or 11 with short cover tape

.CHAPTER 34 Page 12

Revision 25

Aeurocopter un ~

MAINTENANCE MANUAL BO 105

EA.OS Q:lmpeny

•

Pre SB B0105-30-112.

EFFECTIVITY

Dimensions in mm Cover tape ends here

125

Leg area

125

125

55


AREA2 AREA1 AREA3 AREA4 Area at the beginning and the end of the Nose area Leg area Warning area erosion protection ---------- -------------~-------------- .... Delaminations admissible Delaminations admissible No delamination * Delaminations admissible without limitations without limitations admissible with limitations

O

*

~ -------------

11I

D

Area 4 The total delamination in this area must not exceed 1 cm2 (per erosion protection side)

Figure 34-7

(2 of 5) Delamination criteria for the erosion protection - tail rotor blade of configuration I or 11 with long cover tape

Revision 25

----------------~ ... _..~..

CHAPTER 34 Page 13

,"."._-,---------

tIb eurocopter

MAINTENANCE MANUAL SO 105

. . , . 8IlEAOO~

•

Pre SS S0105-30-112.

EFFECTIVITY

Dimensions in mm

125

Leg area

... ...

125

AREA 1 Area atthe beginning of the erosion protection

D

1--------------Delaminations admissible without limitations

*

CO

N

AREA2

~

Nose area

-------------

AREA3

B

Warning area

AREA4

D -------------Leg area

----------- * Delaminations admissible

Delaminations admissible No delamination without limitations admissible

with Iimitations

-

Area 4 The total delamination in this area must not exceed 1 cm2 (per erosion protection side)

Figure 34-7

(3 of 5) Delamination criteria for the erosion protection - tail rotor blade of configuration 111 or IV with short cover tape

-. CHAPTER 34 Page 14

Revision 25

/,,.-,

eeurocopter " . 80 EAOO

MAINTENANCE MANUAL 80 105

CJmpeoy

•

Pre SB B0105-30-112.

EFFECTIVITY

Dimensions in mm Cover tape ends here

125

Leg area

AREA 1 AREA2 Area at the beginning Nose area and the end of the erosion protection

D

--------------Delaminations admissible without limitations

*

~

AREA3 •

Warning area

------------- ----------

Delaminations admissible No delamination admissible without limitations

AREA4

D -------------Leg area

* Delaminations admissible with limitations

Area 4 The total delamination in this area must not exceed 1 cm2 (per erosion protection side)

Figure 34-7

(4 of 5) Delamination criteria for the erosion protection - tail rotor blade of configuration 111 or IV with long cover tape

Revision 25

CHAPTER 34 Page 15

4'eurocopter

MAINTENANCE MANUAL BO 105

, . 811 EAOS Oompeny

I

Post SB B0105-30-112 for all BO 105 helicopters except BO 105 CBS-5 KLH and BO 105 CB-3.

EFFECTIVITY

Dimensions in mm

8

125 (j)

......

......

55

co

LO N

......

LO N

ZONE 1 [ ] Area at the beginning and the end of the erosion protection

ZONE 2

ZONE 3

Delaminations admissible without limitations

Delaminations admissible No delamination admissible without limitations

ZONE4

~ Nosearea ~ Warning area ~ Leg area ---------------- -------------- ----------- --------------

*

Delaminations admissible with limitations *

Zone 4 The total delamination in this area must not exceed 1 cm 2 per erosion protection side)

Figure 34-7

(5 of 5) Delamination criteria for the erosion protection - tail rotor blade of configuration V

CHAPTER 34 Page 16

Revision 25

O~~Pter EFFECTIVITY 8.

MAINTENANCE MANUAL 80105

Perform step 8. only on tail rotor blades of configuration I or 111 (see fig. 34-2 or 34-4).

Inspect camber and thrust face plates (1) for erosion damage, impact damage and debonds. a.

Erosion damage to the camber and thrust face plates is acceptable only if the damage does not extend through them to the material underneath.

b.

Impact damage to the camber and thrust face plates is acceptable only if the damage does not extend through them to the material underneath.

c.

To test for debonds, tap-test the entire surface of the respective parts (see item 7.c.). Oebonds on the camber and thrust face plates are acceptable only if: debonding along the entire diagonal edge of the plates does not exceed 10 mm in width (see fig. 34-6 (1 of 2)). debonding elsewhere under the plates does not exceed 200 mm2 on each plate (see fig. 34-6 (1 of 2)).

EFFECTIVITY 9.

Perform step 9. only on tail rotor blades of configuration 1I or IV (see fig. 34-3 or 34-5).

Inspect PU foil (1) on camber and thrust sides of blade for erosion damage, impact damage, debonds, and for cracks in paint finish in area of PU foil. a.

Erosion damage to PU foil on camber and thrust sides of blade is acceptable only if it does not extend through to the material underneath.

b.

Impact damage to the PU foil on the camber and thrust sides ofthe blade is acceptable only ifthe damage does not extend through to the material underneath.

c.

No bond separations are allowed underthe PU foils on the camber and thrust sides ofthe blade in an area extending 10 mm from their edges. Oebonding elsewhere is acceptable if it does not exceed 200 mm 2 on each PU foil (see fig. 34-6 (2 of 2)).

d.

Cracks in the paintfinish inthe areaofthe PU foil are acceptable. The damaged paint coat can betouched up per para. 34-3, item 2.

10. Inspect bonding joints for erosiono Erosion of adhesive butt joints between installed parts (erosion protection, end cap, aluminum plates, PU-foil) and between installed parts and the blade body are acceptable so long as the installed parts have no debonds at their edges. To prevent damage from spreading, it is recommended to fill eroded bonding joints (see para. 34-3, item 1.). 11. Inspect rivet (12, fig. 34-2 or 34-3 or 34-4 or 34-5) for looseness, and for corrosion if paint has been removed. Loase or corroded rivets shall be replaced by ECO or an authorized repair facility.

Revision 24

CHAPTER 34 Page 17

MAINTENANCE MANUAL 80 105

12. Inspect end cap (13, fig. 34-2 or 34-3 or 34-4 or 34-S) for erosion damage, impact damage, and debonds. a.

Erosion damage to the end cap is acceptable only if the damage does not extend through to the material underneath.

b.

Impact damage to the end cap is acceptable only if the damage does not extend through to the material underneath.

c.

To testfor debonding, tap-test along the edges ofthe part (see item 7.c.). Debonding of the end cap is acceptable only if: -

the individual debond is not longer than 10 mm chordwise (see fig. 34-6).

-

the space between adjacent debonds is not less than SO mm (see fig. 34-6).

WARNING

•

IMPACT DAMAGE AND CRACKS ARE NOT ACCEPTABLE ON THE BLADE TRAILlNG EDGE. THEYCAN LEADTOTHEDESTRUCTION OFTHE BLADEANDPOSSIBLYTO THE LOSS OF THE ENTIRE TAIL ROTOR.

13. Inspect blade trailing edge (11, fig. 34-2 or 34-3 or 34-4 or 34-S or 34-SA) for impact damage, cracks, chipping, debonds, and deformation. No damage whatsoever is acceptable on the blade trailing edge.

NOTE •

•

Perform steps 14. and 1S. only with the tail rotor blade removed.

14. Inspect bushings (6, fig. 34-2 or 34-3 or 34-4 or 34-S or 34-SA) for mechanical damage, corrosion, wear, and intact bonding. a.

Polish out mechanical damage and corrosion, using 400/600 grit abrasive cloth. The maximum allowable bore diameter is 12.02 mm.lt may be exceeded by 0.02 mm on one quarterofthebore circumference (see fig.34-8).

b.

If wear is evident, measure diameter of bore. For allowable diameter, see item a.

c.

Debonding of the bushings is not allowed.

1S. Check dimensions of fitting surfaces (S, fig. 34-2 or 34-3 or 34-4 or 34-S or 34-SA). If the damage limits given in fig. 34-8 are exceeded, have the tail rotor blade repaired by ECD or by an authorized repair facility.

CHAPTER 34 Page 18

Revision 24

MAINTENANCE MANUAL 80105

Dimensions in mm

4 SECTION N 'l'+...........,/H----¡'

A- A

~~-3

g-

ij"//1---4

~I

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1

2

3

1 2 3 4

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Tail rotor blade Fitting surface Bushings Circular area

Dimension X for the length of the bushings (3) as well as for the distance between the fitting surfaces (2) within the circular areas (4) must not fall below 20.96 mm. Dimension Y in case of a step at the edge of the circular area must not exceed 0.1 to 0.3 mm • The maximum permissible diameter Z of the bushings (3) is 12.02 mm. It may be exceeded on one quarter of the circumference by 0.02 mm.

Figure 34-8

Revision 24

Fitting surfaces and bushings - damage limits

CHAPTER 34 Page 18A

O~~er

MAINTENANCE MANUAL 80105

BLANK PAGE

CHAPTER 34

Page 188

MAINTENANCE MANUAL BO 105

34 - 3

REPAIR - TAIL ROTOR BLADE

1. Filling eroded butt joints. a.

Degrease butt joints with acetone (CM 203).

b.

Fill butt joints with adhesive (CM 602) and mask with adhesive tape (CM 603).

c.

Allow adhesive to cure, then peel off adhesive tape and remove excessive adhesive by hand, using 180 grit abrasive cloth.

d. Applytop coat and warning orfluorescent paint (see step 2.). 2. Touching up damaged paint finish. WARNING

• WHEN SANDING THE PAINT FINISH, DO NOT DAMAGE THE BLADE SKIN AND BLADE TRAILlNG EDGE. SUCH DAMAGE MAY LEAD TO DESTRUCTION OF THE BLADE AND POSSIBLY TO LOSS OF THE ENTIRE TAIL ROTOR. • THE TAIL ROTOR BLADE IS SENSITIVE TO PRESSURE AND CONSEQUENTLY MAY BECOME IRREPARABLY DAMAGED IF IT IS NOT HANDLED WITH PROPER CARE. PRESSURE MAY DAMAGE THE SKIN/CORE BOND OR THE COREo • TAKE CARE THAT THE WEIGHT OF THE BLADE FOLLOWING REPAIR OF DAMAGE TO ITS PAINT COAT IS NOT MORE THAN - 10 GRAMS ON CONFIGURATIONS I TO IV - 6 GRAMS ON CONFIGURATION V ABOVE ITS WEIGHT AT DELlVERY (SEE HISTORICAL RECORD).

I

• THE BLADE SKIN AND THE BLADE TRAILlNG EDGE MAY BE REPAIRED ONLY ONCE IN THE SAME PLACE.

NOTE

When removing the protective finish, take care not to damage the identification plate because it bears the necessary identifying data.

a.

Clean tail rotor blade with either dry cleaning solvent (CM 202), degreasing agent (CM 220) or acetone (CM 203).

b.

Using masking tape (CM 609), mask off identification plate (7, fig. 34-2 or 34-3 or34-4 or 34-50r 34-5A) and areas not to be painted.

c.

Using 220 grit or finer abrasive cloth, sand paint coat in affected areas by hand, while taking care not to expose the blade skin. This is ensured if the color of the paint does not change while sanding. To ensure that the blade contour does not change, it is necessary to leave a strip of paint 1-2 mm wide on the trailing edge.

d.

Clean sanded area with thinner (CM 413).

Revision 24

CHAPTER 34 Page 19

I

_~~pter

MAINTENANCE MANUAL SO 105

e.

Prepare a mixture oftwo-component wash primer (CM 472), hardener (CM 459) and thinner (CM 436) to manufacturer's instructions, and apply to the bare metal surfaces.

f.

Allow wash primer tocure at room temperature and then wet sand it with 400 grit wet sand papero

g.

Clean sanded area with thinner (CM 413).

h.

Prepare a mixture of PUR topcoat (CM 405), hardener (CM 420) and thinner (CM 413) to manufacturer's instructions and apply ta treated area.

i.

Allow paint finish to cure per manufacturer's instructions.

NOTE

Fluorescent paint (CM 406) or (CM 428) or warning paint (CM 491) hitherto used for repairing the damaged surface protection on the blade tip are not suitable for repairing the damaged surface protection. Instead ofthese consumables, laquer (CM 482) can be used for repairing damaged surface protections.

j.

Touching up damaged warning paint. Prepare a mixture of lacquer (CM 482), hardener (CM 483) and thinner (CM 484) to manufacturer's instructions and apply to treated area.

k.

Allow laquer to cure per manufacturer's instructions.

CHAPTER 34 Page 20

Revision 24

_~~ter 3.

MAINTENANCE MANUAL SO 105

Replacing the cover tape

NOTE

• Using a longer cover tape (220 x 60 mm) instead of the formerly used, short cover tape (162 x 60 mm), results in revised debonding criteria for the erosion protection (see para. 34-2, item 7.c.). In the event of cover tape replacement, the cover tapes of both tail rotor blades must be replaced. • In case paint damage needs to be repaired close to the cover tape at the same time, the cover tape is fitted to the tail rotor blade after touching up the paint.

a.

Step a. deleted.

b.

Using hot-air blower, heat cover tape to max. 50°C and then peel it from blade.

c.

Remove residual adhesive with acetone (CM 203).

d.

Clean new bonding areas on rotor blade with acetone (CM 203).

•

e. Allow cleaned areas to air dry for at least 10 minutes. f.

Coat bonding area for cover tape with Promotor 86 (CM 750) and allow to air dry for at least 30-60 minutes.

g.

Applya mark representing the center of the nose area on the non-adhesive side of the cover tape.

h.

Pull center protective backing from rear side'of cover tape.

i.

Align marking on cover tape with the center of the nose area of the tail rotor blade.

j.

Beginning at the nose, apply the cover tape by working out all blisters towards the edges of the tape.

k.

Remove remaining protective backing and apply the rest of the cover tape by working out all blisters towards the edges of the tape.

1.

If any blisters are left underthe covertape, they can be removed by pricking them with a pin and pressing down the cover tape.

Revision 24

CHAPTER 34 Page 21

MAINTENANCE MANUAL 80105

BLANK PAGE

CHAPTER 34 Page 22

_~~Pter 34 - 4

MAINTENANCE MANUAL SO 105

REMOVAL - TAIL ROTOR BLADE

1.

Identify tail rotor blades and close-tolerance bolts with their respective installed positions, so that rebalancing is not required if the same unchanged parts are reused in their original installed positions.

2.

Remove split pins (6, fig. 34-9), nuts (7) and washers (3) from close tolerance bolts (4).

3.

Remove close-tolerance bolts (4) and detach tail rotor blade (1).

1----'1+-

Direction of rotation

--.::>.---- 2

3 5

4

a:

",1

'"~ 1

J:

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o

o m

1

2 3 4

Tail rotor blade Bushings Washer Close-tolerance bolt

Figure 34-9 Revision 24

5 6 7

Blade mounting fork Split pin Nut

Removal and installation - tail rotor blade CHAPTER 34 Page 23

-eurocopter WanEAOOea34-5

MAINTENANCE MANUAL BO 105

-

INSTALLATION - TAIL ROTOR BLADE

NOTE

CAUTION

If the previously installed blade and attaching hardware (including balance washers) are reinstalled unchanged to their original positions on the same tail rotor, the tail rotor need not be rebalanced, provided it was properly balanced prior to their removal. • DURING INSTALLATION ONLY TAIL ROTOR BLADES WITH THE SAME P/N MAY BE PAIRED. • ENSURE CORRECT MATCHING OF TAIL ROTOR BLADE TO TAIL ROTOR HEAD AND CONTROL LEVER (REFER TO IPC).

I

• THE WEIGHT DIFFERENCE OF THE ROTOR BLADES MUST NOT EXCEED 10g. BALANCING IS NOT POSSIBLE ABOVE THIS L1MIT. 1. Coat shank of close-tolerance bolt (4, fig. 34-9), provided it is not coated with solid film lubricant, and balance weights with either grease (CM 101, CM 102 or CM 103), corrosion preventive compound (CM 505), or lubricant (CM 146). 2.

If a new bolt coated with solid film lubricant is installed, remove all grease from the mating bushing bores in the blade mounting fork and blade (2) with dry c1eaning solvent (CM 202), then dry install bolt. Apply lubricant (CM 146) to previously installed bolt coated with solid film lubricant.

3.

Install tail rotor blade (1) in blade mounting fork (5), and observe proper installation position.

4.

Insert c1ose-tolerance bolts (4) with washers (3), then install nuts (7) and tighten them to specified torque. Secure nuts with split pins (6).

5.

Balance tail rotor according to chapter 107.

-

CHAPTER 34 Page 24

Revision 25

O~~opter 34 - 6

MAINTENANCE MANUAL 80105

STORAGE, PACKAGING AND SHIPPING - TAIL ROTOR BLADE

1. Keep original container for storage or shipping. 2. Store tail rotor blades so that they are safe from damage. 3. Tail rotor blades shall be packed in pairs in a wooden container (see fig. 34-10) or in a plastic container. • Container cover must be secured, e.g. by a steel strap. 4. Tail rotor blades being returned for repair shall be shipped only in sturdy containers, preferably in wooden container B 411.01/73 or in plastic container 102153-410004WD. The blades must be stowed and secured in the container so that no damage is sustained during transport, even if the container is subject to rough or careless handling.

~----1

;-i-':--:-':~-¡':'¡-----2

1-----4

1 2 3 4

Figure 34-10 Revision 24

Cover Foam pad - upper part Foam pad - lower part Wooden box

Container B 411.01/73 CHAPTER 34 Page 25

I

_~~pter

MAINTENANCE MANUAL SO 105

BLANKPAGE

CHAPTER 34 Page 26

cteurocopter 41

MAINTENANCE MANUAL MBB - 80 105

MA 1 N

ROT OR

C O N T ROL S

Table of Contents

Page

Paragraph

Title

41 - 1

DESCRIPTION - MAIN ROTOR CONTROLS

5

41 - 2

RIGGING - MAIN ROTOR CONTROLS . .

9

41 - 3

INSPECTION - MAIN ROTOR CONTROLS

9

41 - 4

Removal - cyclic stick lock

14

41 - 5

Installation - cyclic stick lock

15

41 - 6

Removal - cyclicstick boot

15

41 - 7

Installation - cyclic stick boot

15

41 - S

Removal - cyclic stick RH and longitudinal control link

15

41 - 9

Inspection and repair - cyclic stick RH and longitudinal control link . . . . . . . . .

21

41 - 10

Installation - cyclic stick RH and longitudinal control link

25

41 - 11

Removal - lateral control lever (RH)

27

41 - 12

Inspection and repair - lateral control lever and bearing support . . . . . . . . . . . .

28

41 - 13

Installation - lateral control lever (RH)

31

41 - 14

Removal - lateral control lever (LH)

33

41 - 15

Installation - lateral control lever (LH)

33

41 - 16

Removal - connecting part . . . . . . .

35

41 - 17

Inspection and repair - connecting part

35

41 - 18

Installation - connecting part

35

41 - 19

Removal - bellcrank . . . . . .

36

BO 105 CHAPTER 41 Page 1

_eurocopter

MAINTENANCE MANUAL MBB - BO 105.

Page

Paragraph

Title

41 - 20

Removal - bellcrank

36

41 - 21

Inspection and repair - bellcrank

39

41 - 22

Installation - bellcrank

42

41 - 23

Installation - bellcrank

42

41 - 24

Removal - lateral control bellcrank

42

41 - 25

Inspection and repair - lateral control bellcrank

47

41 - 26

Installation - lateral control bellcrank

51

41 - 27

L o n g i t ti d 1 n a 1 t r i rn s y s t e m

51

/

1 a ter a 1

41 - 28

Removal - longitudinal trirn systern

51

41 - 29

Removal - lateral trirn system .

52

41 - 30

Disassembly - longitudinal/lateral trirnmer

55

41 - 31

Inspection and repair - longitudinal/lateral trirnmer

55

41 - 32

Assembly - longitudinal/lateral trirnmer

55

41 - 33

Installation - longitudinal trim systern

63

41 - 34

Installation - lateral trirn system

63

41 - 35

Removal - longitudinal trirnmer bellcrank

65

41 - 36

Rernoval - lateral trirnmer bellcrank

65

41 - 37

Inspection and repair longitudinal and lateral trirnmer bellcranks

68

41 - 38

Installation - lateral trirnmer bellcrank

71

41 - 39

Installation - longitudinal trirnmer bellcrank

71

* 41 - 40

Col 1 e c t i v e p i t c h

72

* 41 - 41

Removal - collective pitch stick RH/LH

72

Installation - collective pitch stick RH/LH

73

41 - 42

s tic k

B0 105

CHAPTER 41 Page 2

Revision 8

EUROCOPTER

MAINTENANCE MANUAL 80105

Paragraph

Title

41 - 43

Removal - pitch brake

75

41 - 44

Installation - pitch brake

75

41 - 45

Removal - pitch protector RH/LH

75

41 - 46

Installation - pitch protector RH/LH

75

41 - 47

Removal - cover, cyclic stick LH

77

41 - 48

Installation - cover, cyclic stick LH

77

41 - 49

Removal - cover, collective pitch stick LH

78

41 - 50

Installation - cover, collective pitch stick LH

78

41 - 51

Removal - pitch shaft lever

79

41 - 52

Inspection and repair - pitch shaft lever

79

41 - 53

Installation - pitch shaft lever

83

41 - 54

Removal - pitch shaft

83

41

Inspection and repair - pitch shaft

84

41 - 56

Installation - pitch shaft

86

41 - 57

Be 1 1 c r a n k s

41 - 58

Removal - bellcranks

86

41 - 59

Disassembly - bellcranks

89

41 - 60

Inspection and repair - bellcranks

90

41 - 61

Assembly - bellcranks

93

41 - 62

Installation - bellcranks

93

41 - 63

Removal - pitch stick stop

93

41 - 64

Installation - pitch stick stop

93

41 - 65

Mi x i n g

95

55

Page

(pitch, lateral and longitudinal)

1 e ver

a s s e mb 1 Y

.

86

BO 105 CHAPTER 41 Page 3

MAINTENANCE MANUAL BO 105

Paragraph Title

Paga

41 -66

Removal - mixing lever assembly

.

41 - 67

Disassembly - mixing lever assembly

.

95 95

41-68

Inspection and repair - mixing lever assembly

.

97

41- 69

Assembly - mixing lever assembly

.

125

Installation - mixing lever assembly

.

126

41-71

Swashplate .••••..•.•..•••.••...••..•..•••.•.•..•..••.•.••••.••.•.••.•••.••

127

41-72

Inspection and repair - swashplate

.

128

41-73

Inspection of bearings - swashplate

.

129

41-74

Lubrication - swashplate

.

130

41 -75

Replacement of boot - swashplate

.

130

41-76

Control rods and Iinks ....•.•.•••••...••.••••••••••••..•.....••••••••••••••

133

41-77

Removal - control rods in non-boosted section of the controls

.

133

41-78

Removal - control rods and links inthe boosted section of the controls

.

134

41-79

Disassembly - control rods

.

135

41 -80

Inspection and repair - control rods and Iinks

.

136A

41-81

Assembly control rods

.

143

41-82

Installation - control rods in the non-boosted section of the controls

.

145

41-83

Installation - control rods and Iinks in the boosted section of the controls

.

145

• 41-70

CHAPTER 41

Page4

Revision 22

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 1

DESCRIPTION - MAIN ROTOR CONTROLS

The main rotor control system (figure 41-1) comprises the collective and the cyclic blade pitch angle control systems. All bladepitch changes are initiated by the pilot through movements of the cyclic stick and the collective pitch stick. The cyclic stick can be locked in place with the cyclic stick lock assy. The collective pitch stick can be locked in place with the collective pitch stick lock assy. with dual controls, the copilot's cyclic stick is mechanically linked to the pilot's cyclic stick via a control linkage. The copilot's collective stick is mechanically linked to the pilot's colléctive stick via a pitch shaft. The control inputs are transferred via the mixing lever assembly, the swashplate and the rotating pitch links by a series of bellcranks and control rods to the four main rotor blades installed on the main rotor head. The control forces from the pilot or copilot are augmented by a dual hydraulic system. The longitudinal and lateral trirnmers are provided to artificially increase the force required by the pilot to make inputs on the cyclic stick.The control forces on the cyclic stick can be trirnmed to zero with the trirnming system by either the pilot or the copilot once a stable flight condition has been obtained. This is effected by a four-way switch on the cyclic stick which causes a longitudinal and a lateral trim actuator to move the trirnmers via bellcranks until the pilotor copilot stops actuating the four-way switch. The maximum control input s are limited by mechanical stops. The control forces can be adjusted by means of a pitch brake which acts on the pitch shaft.

BO 105 CHAPTER 41 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-1 2 3

4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25 26 27

28 29 30

Lateral control rod Lateral trimmer Lever, lateral trimmer Servo motor (lateral) Cyclic stick LH Servo motor (longitudinal) Longitudinal control rod Cyclic stick RH Cyclic stick lock Longitudinal trimmer Lever, longitudinal trimmer Bellcrank Control rod between hydraulic unit and mixing lever assembly Mixing lever assembly Control link between swashplate mixing lever assembly and swashplate Swashplate Control rod (rotating) between swashplate and main rotor head Control rod between hydraulic unit and bellcrank Bellcrank Collective control rod Longitudinal control rod Support bracket (control rods) Lateral control rod Pitch shaft Pitch stick LH Bellcrank Longitudinal control rod Longitudinal control rod-copilot Pitch stick RH Lateral control bellcrank

-'

e

o

15

i

l al

12 ------~~I'-----__:_''-'-t 11

, I "" --:/.!.I--.,:.,' ¡.;/~

..,,:.'..L....., / : /

I

10 ------r-/-+H~---..,.:-...,

19

20 21

4----~'-'-':--~

3

22

-----....;...,,..;...,,-~~

2-------~~

23

----

24

---- --.:;-;'-

25 28

30 400001.1

Figure 41-1

'.

Main rotor controls BO 105 CHAPTER 41 Page 7/8

29

27

26

cteurocopter 41 - 2

MAINTENANCE MANUAL MBB - BO 105

RIGGING - MAIN ROTOR CONTROLS

For rigging of main rotor controls refer to chapter 102. NOTE

The assembly length, dimension X, can be determined exactly by using alignment gauge, P!N 105-41482 L1, in conjunction with supplementary kit, P/N 105-41482 12.

Rigging is required in the following cases: - If it is not certain that dimension X (center-to-center of spherical bearings) of the new replacement control rod is exactly equa1 to the corresponding length of the removed control rod. - If it is not certain that dimension X of a removed control rod was accurately determined prior to its disassembly. - If it is not certain that the control setting has remained unchanged following replacement of parts or complete disassembly. - Following certain maintenance measures. 41 - 3

INSPECTION - MAIN ROTOR CONTROLS

l.

Check main rotor controls for freedom of movement.

2.

Check main rotor controls for play. If play is encountered, localize and eliminate.

3.

Inspect control elements in non-boosted section as follows: a.

Inspect cyclic stick (5, 8, figure 41-1), collective pitch stick (25, 29) and cyclic stick lock assy (9) for mechanical damage and security of installation. 1)

Polish out mechanical damage and corros ion with suitable tools and final polish with polishing cloth 400.

2)

Touch up damaged surface protection with two-component zinc chromate primer (CM 456) and two-component PUR topcoat (CM 426) as outlined in chapter 02.

b.

Inspect boots (46, figure 41-3 and 29, figure 41-4) for cracks, porosity and secure installation. Replace damaged boots as described in paragraphs 41-6 and 41-7.

c.

Check whether cyclic stick lock attaching hardware (fig. 41-2) is secured by split pino If split pin is missing, tighten nut (3) until cyclic stick lock is free of play and can be turned smoothly.

Revision 8

BO 105 CHAPTER 41 Page 9

* * *

faeurocopter

NOTE d.

e.

f.

MAINTENANCE MANUAL MBB - BO 105

Open the nose access door to inspect per step d. and step e. Inspect bellcrank (12, figure 41-1), bellcrank (26), lateral control bellcrank (30), longitudinal trimmer lever (11) and lateral trimmer lever (3) for mechanical damage and corrosion. 1)

Remove mechanical damage and corros ion with a suitable tool and final polish with polishing cloth 400. For damage and repair limits, refer to figures 41-16, 41-20 and 41-29.

2)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

Inspect control rods (1, 7, 18, 20, 21, 23, 27 und 28 figure 41-1) for general condition and rod end bearings for corros ion, binding and play. 1)

Discard bent control rods.

2)

Po1ish out scratches, nicks, chafe marks and traces of corros ion on control rod tubes. Refer to figure 41-78 for damage and repair limits.

3)

Touch up or renew damaged surface protection with two-component zinc chromate primer (CM 456) and two-component PUR topcoat (CM 426) in accordance with chapter 02.

4)

If spherical bearings are binding, corroded or have radial play in excess of 0.1 mm, replace bearings together with rod ends.

5)

Inspect sealing on rod ends of the control rods (5, figure 41-82). If sealing is missing or damaged, inspect control rods in accordance with paragraph 41-80.

Inspect all Qther parts for general condition and attaching hardware for security of installation and presence of locking devices.

BO 105 CHAPTER 41 Page 10

EUROCOPTER

4.

MAINTENANCE MANUAL 80105

Inspect control elements in boosted section as follows: a.

Inspect mixing lever (14, figure 41-1) for condition and for security and proper locking of attaching hardware. 1) If locking devices are missing, check attaching hardware for specified torque and installlocking devices.

2) Polish out mechanical damage and corros ion with polishing cloth 400. For damage and repair Iimits, referto paragraph 41-68. If the damage cannot be removed in the installed position, remove mixing lever assy as required in accordance with paragraph 41-66. Inspect and repair mixing lever assembly in accordance with paragraph 41-68. 3) Touch up damaged surface protection with single-component zinc chromate primer (CM 401) followed by two--eomponent PUR topcoat (CM 426) in accordance with Chapter 02. 4) Check grooved ball bearings for play and rough running. This requires disconnection of control rods from mixing lever assy. If bearing is damaged, remove affected lever and replace bearing in accordance with paragraph

41-68. b.

Inspect control rods (13 and 17, figure 41-1) and controllinks (15) for condition and inspect installed spherical bearings for play, signs of corrosion and binding.

1) Inspect tubes of controls rods (13 and 17) for condition. Oiscard bent control rods. Polish out scratches, nicks, chafe marks and corrosion on control rod tubes according to the damage and repair limits shown in fig. 41-80. In the case of rotating control rods P/N 105-13121 (distinguished by a tube 0.0. of 20 mm), also visually inspect reinforcement sleeves on control rod ends for cracks. Replace cracked control rods. 2) Inspect controllinks (15) for condition. Oiscard bent controllinks, and polish out scratches, nicks and corrosion according tothe damage and repair limits shown in fig. 41-78.

3) Touch up damaged surface protection, using two--eomponent zinc chromate primer (CM 456) followed by two--eomponent PUR topcoat (CM 426) in accordance with Chapter 02. 4) If radial play exceeds 0.1 mm or axial play exceeds 0.4 mm (whichever occurs first), orthere is binding or evidence of corrosion, replace assembled rod end and spherical bearing of control rod (13, figure 41-1). In the case of control link (15), replace spherica.1 bearing per Chapter 02. 5) If in the case of control rod (17) radial play exceeds 0.2 mm or axial play exceeds 0.4 mm (whichever occurs first), or there is binding or evidence of corrosion, remove either the assembled rod end and spherical bearing or only the spherical bearing per Chapter 02. 6) Inspect sealing on rod ends of control rods for condition. If sealing is damaged or missing, inspect control rods in accordance with paragraph 41-80.

Revision 18

CHAPTER 41 Page 11

I

MAINTENANCE MANUAL 80105

EUROCOPTER

NOTE

Item c. only applies, if the bolts (3, fig. 41-83) connecting upper end of rotating pitch control rods are not secured by tabwashers (i.e. configuration 1, fig. 41-83). c.

Inspect upper bolts (3) connecting rotating pitch control rods (l) to control levers on the main rotor head for secure fit in the control 1evers. 1)

If secure fit is assured but locking compound has not been applied, mark relative position of bolt head, washer and control lever, using sealing, locking and retaining compound ,CM 620) .

2)

If locking compound has been applied, but is damaged, or if bolt is loose, proceed as follows: a)

Remove affected pitch control rod in accordance with paragraph 41-78.

b)

Inspect bolt and bushing in control lever for mechanical damage, corrosion and weal. Replace damaged bolt. Polish out mechanical damage and corrosion on bushings, using polishing cloth 400. If bushings show wear, check bushing dimensions. For damage and rework lirnits, refer to REM 106.

* * * * *

* * *

e)

Inspect spherical bearing in upper rod end of the control rod for radial play (perrnissible: 0.2 mm) and axial play (permissible: 0.4 mm), rnechanical damage and corrosion. Replace damaged bearing in accordance with chapter 02 or replace ussembled rod end and bearing, depending on the configuration.

d)

Install pitch control rod in accordance with paragraph 41-83 and mark relative position of bolt head, washer and control lever, using sealing, locking and retaining compcund CM 620) .

* * *

d.

Inspect swashplate. 1)

BO 105 CHAPTER 41 Page 12

Visually inspect swashplate (16, figure 41-1) for general condition and visually inspect bearing forks of control ring (8, figure 41-72) and bearing ring (6) for cracks using a magnifying glass (at least 6 fold magnification) . a)

lf cracks exist on bearing forks, replace control ~ing and bearing ringo For disassembly of swashplate refer to REM 403.

b)

Polish out mechanical damage and corros ion on bearing ring (6) and control ring (8), except for their bearing forks, down to a depth of max. 0.5 mm using polishing cloth 400. Darnage to forks of bearing ring and control ring is not perrnissible.

Revision 10

EUROCOPTER

c) 2)

MAINTENANCE MANUAL BO 105

Touch up damaged surface protection with two-component PUR topcoat (CM 426) in accordance with chapter 02.

Inspect boot (5) for tears, porosity and security. a)

If the boot is torn or porous, replace per paragraph 41-75.

b)

For clamps with turnbuckle screws only: Check that safety lacquer on turnbuckle screws is intacto If clamp is loose or safety lacquer is cracked, reattach clamp per paragraph 41-75.

c)

4)

Revision 13

* *

For clamps with worm-type screw only: * Tighten loose clamp by turning worm-type screw. Torque value: *

*

O. 7 - O. 8 Nm •

3)

*

*

Inspect lubricant identification placard on bearing ring (6) for proper attachment and legibility. If the placard is beginning to separate or to become illegible, replace as follows: a)

Remove old placard.

b)

Clean bonding surface on bearing ring with dry cleaning solvent (CM 202) or acetone (CM 203) .

c)

Bond a new placard in place and coat with single-layer lacquer (CM 421) .

Inspect lockwires for intactness. If lockwires are loose or broken, check torque of respective screws and renew lockwires. For specified torque value, see figure 41-73.

BO 105 CHAPTER 41 Page 13

*

EUROCOPTER

41 - 4

MAINTENANCE MANUAL 80 105

Removal - eyelie stiek loek

1.

Remove split pin (1, figure 41-2). Unserew nut (3) and remove bolt (6) and washers (4 and 5) .

2.

Diseonneet spring (2) from retaining strap (7), and remove retaining strap and spring. 9

3

400630.1

Split pin Spring Nut 4 Washer 5 Washer 6 Bolt 7 Retaining strap 8 Leather sheath 9 Plaeard 1 2 3

I

Figure 41-2 BO 105 CHAPTER 41 Page 14

Cyelie stiek loek

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 5

Installation - cyclic stick lock

1.

Install cyclic stick lock as shown in figure 41-2.

2.

Tighten nut (3) and secure with split pin (1).

3.

Check cyclic stick lock for function. It rnust be free frorn play and must turn easily.

41 - 6

Removal - cyclic stick boot

Identify screws and washers for re-installation (screws are of different length).

NOTE 1.

Remove screws and washers (47 thru washers (30 thru 33, figure 41-4).

2.

Detach mounting frame (45, figure 41-3) with boot (46) or mounting frame (28, figure 41-4) with boot (29).

41 - 7

NOTE

51, figure 41-3) or screws and

Installation - cyclic stick boot

Insert screws and washers according to the markings.

l.

Install boot (46, figure 41-3) with rnounting frame (45) or boot (29, figure 41-4) with mounting frame (28).

2.

Attach boot and mounting frame with screws and washers (47 thru figure 41-3) or screws and washers. (30 thru 33, figure 41-4).

41 - 8 l.

51,

Removal - cyclic stick RH/LH and longitudinal control link

Cyclic stick RH a.

Remove boot (46, figure 41-3) as described in paragraph 41-6.

b.

Remove nose access door.

BO 105 CHAPTER 41 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Disconnect connector (42), unscrew clamp and remove cable from airframe.

d.

Remove hardware (2 thru 5) attaching longitudinal trirnmer (55) to cyclic stick (1).

e.

Remove hardware (6 thru 9) attaching lateral trirnmer (54) to cyclic stick (1).

f.

Remove hardware (la thru 13) attaching longitudinal control rod (53) to cyclic stick (1).

g.

Remove hardware (14 thru 18) attaching fork rod (19) to cyclic stick (1) .

2.

h.

Remove hardware (26 thru 31) attaching lateral control lever (41) to cyclic stick (1).

i.

Detach cyclic stick.

Cyclic stick LH a.

Disconnect connector (15, figure 41-4) .

b.

Unscrew tightening handle (1).

c.

Turn upper part of cyclic stick (2) around and detach.

WARNING

d.

IF THE ENTIRE CYCLIC STICK ASSEMBLY (LH) IS TO BE REMOVED, PROCEED ACCORDING TO STEP d. IF THE CYCLIC STICK IS TO BE REMOVED BUT NOT REINSTALLED, YOU MUST INSTALL THE COVER IN ACCORDANCE WITH PARAGRAPH 41-48.

Remove longitudinal control link (4) as follows: 1)

Remove boot (29, figure 41-4) as described in paragraph 41-6.

2)

Remove nose access door.

3)

Remove longitudinal control rod (35) from longitudinal control link (4); see figure 41-4.

4)

Remove hardware (9 thru 14) attaching longitudinal control link (4) to lateral control lever (16) and detach longitudinal control link.

80 105 CHAPTER 41 Page 16

_e;~~~;r 2 3 4 5 6

7 8 9

10 11

12 13 14 15 16 17 18 19 20

21 22 23 24

25 26 27 28

29 30

31 32 33 34 35

36 37 38

39 40

41 42 43

44 45 46 47

48 49

50 51

MAINTENANCE MANUAL MBB - BO 105

Split pin Nut Washer Bolt Nut Split pin Washer Bolt Bolt Washer Split pin 30 110-15 Nm Nut 29 Bolt Sleeve Washer Nut Split pin Fork rod Split pin Nut Washer Bolt 32---...,......... Nut Split pin Bolt Shim Sleeve Washer Nut Split pin Bearing support Washer Nut Spli t pin Lateral control lock stop 33---UJ1'1 Washer 15-7Nm 134---~~ Nut Split pin Bolt Lateral control lever 37 -----1((1» Electrical connector 1 5 - 7 Nm 13S----iII!lIIiI Bolt E400724.1 Washer 39~ Mounting frame Boot Screw Washer 52 Lateral control rod Screw 53 Longitudinal control rod Washer 54 Lateral tt'immer Screw 55 Longitudinal trirnrner

I

Figure 41-3

. Revision 8

Removal - cyclic stick RH and bearing support with lateral control lever BO 105 CHAPTER 41 Page 17/18

31 3-SNm

42 ---r.~'<::V'

1. . . .

lJ'

1

3 - 5Nm

,.....

--7

~-4S

/1---

46

MAINTENANCE MANUAL MBB - 80 105

1 2 3

4 5 6 7

8

9 10 11

12 13 14 15 16 17 18 19 20 21 22 23

24 25 26 27 28

29 30

31 32

33 34 35 36

37 38 39

40

Tightening handle Cyclic stick LH Sleeve Longitudinal control link Bolt Washer Nut Split pin Bolt Shim Sleeve Washer Nut Split pin Electrical connector Lateral control lever Bolt Bearing support Bolt Washer Washer Nut Split pin Bolt Washer Split pin Nut Mounting trame Boot Screw Washer Screw Washer Connecting part Longitudinal control rod Control rod Bolt Washer Nut Split pin

~A 1----2 Detail

A

--..;;;;;=;;:;;-'l}-----3

18-..... '~"

9

5

¡¡;¡¡trj~-27

\--26

I 5-7 Nm I :r--..--28

25

-29

I 5-7 Nm I 22

---;::=':::-1 ::=3~

E400n5

Figure 41-4

Revision 8

Removal - cyclic stick LH, longitudinal control link and lateral control lever with bearin~ rupport BO 105 CHAPTER 41 Page 19/20

40

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Inspection and repair - cyclic stick RH and longitudinal control link

41 - 9

Special tools: Mounting tool Assembly tool Pushing-out tool l.

117-400001 W1 117-46300 W1 W-Nr. 20 (117-46300 W2) refer to chapter 04

Inspect RH cyclic stick (1, fig. 41-3) as follows: a.

b.

Inspect cyclic stick for cracks, other mechanical damage, corrosion and damaged surface protection. 1)

Replace if cracked.

2)

Polish out damage that is within the damage and repair limits shown in fig. 41-6.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and single layer lacquer (CM 402) in accordance with chapter 02.

Inspect bushings (1, figure 41-6) for mechanica1 damage and corrosion. 1)

Polish out damage with polishing cloth 400. For permissible diameter refer to figure 41-6.

2)

Replace bushings in accordance with step 3. if bore diameter exceeds limito

c.

Inspect flange bushing (2) as described in step b.

d.

Inspect grooved ball bearing (4) for play, roughness and binding. Replace bearing in accordance with step 4. if any of these defects are evident.

e.

Inspect spherical bearings (3) for play, roughness and binding. 1)

If any of these defects are evident, replace bearing with claw bushing in accordance with chapter 02, using tool no. 20, (117-46300 W2) and tool 117-46300 W1.

2)

Inspect bore in RH cyclic stick for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible bore diameter is 28.02 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference.

2.

Inspect longitudinal control link (4, fig. 41-4) according to step la. thru Id.

3.

Replace bushing or flanged bushing as follows: a.

Press out bushing or flanged bushing with tool 117-400001 W1 as shown in figure 41-7. BO 105 CHAPTER 41 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

4.

b.

Inspect bore for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible diameter of bore is 9.02 mm. It may be exceeded by 0.02 mm on 1/4 of bore circumference.

c.

Apply corrosion preventive paste (CM 510) to bore.

d.

Chill bushing to approximately -50 oC and press in bushing with tool 117-400001 W1 as shown in figure 41-7.

e.

Check size of bushing bore. If necessary, hone to specified diameter of 6 ± 0.006 and deburr.

Replace grooved ball bearings as follows: a.

Remove bearings as shown in figure 41-5.

b.

Inspect bore for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible diameter of bore is 28.02 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference.

c.

Apply corrosion preventive paste (CM 510) to bore.

d.

Install bearings as shown in figure 41-5.

2

3

4

400632.A

1 Retaining ring 2 Washer 3 Grooved ball bearing Figure 41-5 BO 105 CHAPTER 41 Page 22

4 Retaining ring 5 Sleeve 6 Grooved ball bearing

Remova1 and installation - grooved ball bearings

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1--

4

4

·.-.:::::!lH-----3

2 ~---3

2

400633

1 2

TYPE OF DAMAGE

Bushing Flange bushing

3 4

Spherical bearing Ball bearing

DAMAGE AND REPAIR LIMITS

Mechanical

0.5 mm depth on 50% of surface are a

-

Corrosion

1.0 mm depth after repair on 50% of surface area

0.6 mm depth after repair on 50% of surface are a

ZONE 2

ZONE 1 ~~'::::::':':':1

~~:::·::::::::::l

0.3 mm depth on 50% of surface area

Max.permissible bore diameter:

&

6.02 mm

It may be exceeded by 0.02 mm on one quarter of the bore circumference. Figure 41-6

Cyclic stick RH and longitudinal control link - damage and repair limits BO 105 CHAPTER 41

Page 23

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

PRESSING OUT

1 Knurled head screw 2 Support 3 Wedge 4 Gauge block 5 Mandrel

5

3

2

PRESSING IN

5

400655

4

Step 1

Figure 41-7 BO 105 CHAPTER 41

Page 24

2

3

Step 2

Removal and installation of bushings with mounting tool 117-400001 W1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 10 1.

Installation - cyclic stick RH and longitudinal control link

Installation - cyclic stick RH a.

Apply grease (CM 101) to bolt (26, figure 41-3) . NOTE

For correct installation of cyclic stick the shims (27) must be installed as shown in figure 41-3.

b.

Position cyclic stick (1) on lateral control lever (41). Install attaching hardware (26 thru 31), tighten nut (30) and secure with split pin (31).

c.

Install longitudinal control rod (53). Tighten nut (13) and secure with split pin(12).

d.

Position lateral trirnmer (54) on cyclic stick (1). Install attaching hardware (6 thru 9), tighten nut (6) and secure with split pin (7).

e.

Position longitudinal trirnmer (55) on cyclic stick (1). Install attaching hardware (2 thru 5), tighten nut (3) and secure with split pin (2).

f.

Install fork rod (19). Tighten nut (17) and secure with split pin (l8) .

2.

g.

Connect electrical connector (42) and fasten to airframe with clamp.

h.

Check cyclic stick for freedom of movement.

i.

Check for presence of foreign objects.

j.

Install boot (46) as described in paragraph 41-7.

k.

Close the nose access door.

Installation - longitudinal control link and cyclic stick LH a.

If installed, remove cyclic stick cover, refer to paragraph 41-48.

b.

Apply grease (CM 101) to bolt (9, figure 41-4) . NOTE

c.

For correct installation of cyclic stick the shim (10) must be installed as shown in figure 41-4.

Position longitudinal control link (4) on lateral control lever (16). Install attaching hardware (9 thru 14), tighten nut (13) and secure with split pin (14).

BO 105 CHAPTER 41 Page 25/26

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

Install longitudinal control rod (35). Tighten nut (7) and secure with split pin (8).

e.

Install boot (29) as described in paragraph 41-7.

f.

Insert cyclic stick (2), tighten tightening handle (1) and secure with lockwire.

g.

Connect electrical connector (15).

h.

Check cyclic stick for freedorn of rnovernent.

i.

Check for presence of foreign objects.

j.

Close the nose access door. Rernoval - lateral control lever (RH)

41 - 11

l.

Rernove boot as described in paragraph 41-6.

2.

Rernove nose access door.

5

8

1 15 - 25 Nm I

3

2

~t-

1

6

7

400632.2

Split pin Nut Washer 4 Bearing support

1 2 3

Figure 41-8

Lateral control lever 6 Bushing 7 Bushing

5

8

BoH

Rernoval and installation - bearing support on lateral control lever BO 105 CHAPTER 41 Page 27

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3.

Remove cyclic stick as described in paragraph 41-8.

4.

Remove attaching hardware (20 thru 23, figure 41-3) and detach lateral control rod (52).

5.

Remove attaching hardware (33 thru 35 and 37 thru 39) and detach lateral control lever {41) together with bolts (43) and washers (44).

6.

Remove fork rod (19).

7.

Remove bearing support from lateral control lever as shown in figure 41-8.

41 - 12

Inspection and repair - lateral control lever and bearing support

Special tool: Mounting tool 117-400001 W1 l.

Inspection of lateral control lever (figure 41-9) a.

b.

c.

Inspect lateral control lever for cracks, other mechanical damage, corrosion and damaged surface protection. 1)

If cracks are evident, replace lateral control lever.

2)

Polish out mechanical damage and corrosion with polishing cloth 400. For damage and repair limits refer to figure 41-9.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

Inspect bolt (8, figure 41-8) for mechanical damage, corros ion and damaged threads. 1)

Polish out minor damage with polishing cloth 400. For mino permissible diameter see figure 41-9.

2)

Damage to threads is permissible on 30% of thread area, provided the mating nut can be screwed on by hand.

3)

If damage is more extensive, replace bolt as described in step d.

Inspect bushings (6 and 7, figure 41-8) for mechanical damage and corrosion. 1)

Polish out damage with polishing cloth 400. For max. permissible diameter see figure 41-9.

2)

If necessary, replace bushings as described in paragraph 41-9.

BO 105 CHAPTER 41 Page 28

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400632.4

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1 ZONE 2

-

f:Im

Mechanical

0.5 mm depth en 50% ef area

0.3 mm depth en 30% ef are a

Cerresien

1.0 mm depth after repair en 50% ef area

0.6 mm depth after repair en 50% ef area

i

'.

Max. permissible bore diameters:

& &

6.02 mm

They may be exceeded by 0.02 mm on one quarter of the bore circumference.

12.02 mm

Min. permissible diameters:

&

14.98 mm

&

19.99 mm

Figure 41-9

They may be 0.02 mm less on one quarter of the bore circumference.

RH/LH lateral control lever - damage and repair limits BO 105 CHAPTER 41 Page 29

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB' - BO 105

400717

TYPE OF DAMAGE

Mechanical

Corros ion

DAMAGE AND REPAIR LIMITS ZONE 1 ZONE 2

-

0.5 mm depth after repair on 60% of area

0.5 mm depth after repair on 30% of area

1.0 mm depth after repair on 60% of area

1.0 mm depth after repair on 90% of area

Max. permissib1e bore diameters:

&

28.02 mm

&

32.01 mm

They may be exceeded by 0.01 mm on one quarter of the bore circumference.

Figure 41-10

BO 105 CHAPTER 41 Page 30

Bearing support - damage and repair 1imits

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

2.

Replace bolt (8, figure 41-8) as follows: 1)

Chill bolt to approx. -50 oC and press out.

2)

Inspect bore for mechanical damage and corrosion. Polish out damage with polishing cloth 400. Max. perrnissible diameter is 19.98 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference.

3)

Chill bolt to approx. -50 oC and press home.

Inspection of bearing support (figure 41-10). a.

Inspect bearing support for mechanical damage, corros ion and damaged surface protection. 1)

Replace if a crack is evident.

2)

Polish out mechanical damage and corros ion with polishing cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

b.

Inspect grooved ball bearings for play, roughness, binding and corrosion. If any of these defects are detected, replace bearings as described in step C.

c.

Replace grooved ball bearings (3 and 7, figure 41-11). 1)

Remove bearings as shown in figure 41-11.

2)

Inspect bearing mating bores in bearing support (5) for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible bore diameters are 28.02 mm and 32.02 mm respectively. They may be exceeded by 0.01 mm on one quarter of the bore circumference.

3)

Apply a coat of corrosion preventive paste (CM 510) to bearing mating bores.

4)

Install bearings as shown in figure 41-11.

BO 105 CHAPTER 41 Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

7 6

4

3

400632

1 2 3 4

Retaining ring Washer Grooved ball bearing Retaining ring

Figure 41-11

41 - 13

5 Bearing support 6 Sleeve 7 Grooved ball bearing

Removal and installation - Grooved ball bearings

Installation - lateral control lever (RH)

l.

Install bearing support as shown in figure 41-8.

2.

Install fork rod (19, figure 41-3). Secure nut (24) with split pin (25) after rigging the main rotor controls.

BO 105 CHAPTER

Page 32

41

MAINTENANCE MANUAL MBB - 80 105

3.

Position lateral control lever (41) and secure with attaching hardware (43, 44, 33, 34, 37, and 38). Tighten nuts (34 and 38) and secure with split pins (35 and 39) .

4.

Insert lateral control rod (52) and secure with attaching hardware (21 thru 23). Tighten nut(21) and secure with split pin (20).

5.

Install cyclic stick (1) as described in paragraph 41-10.

41 - 14

Removal - lateral control lever (LH)

1.

Remove cyclic stick boot as described in paragraph 41-6.

2.

Remove cyclic stick as described in paragraph 41-8.

3.

Remove attaching hardware (6 thru 9, figure 41-12).

4.

Remove connecting part (11).

5.

Remove attaching hardware (19 thru 23, figure 41-4) and detach lateral control lever (16).

6.

Remove bearing support (4, figure 41-8) from lateral control lever (5)

7.

For inspection and repair of bearing support (4) and lateral control lever (5) refer to chapter 41-12.

41 - 15 1.

Installation - lateral control lever (LH)

Install bearing support on lateral control lever as shown in figure 41-8.

2.. Position lateral control lever (16, figure 41-4) and secure with attaching hardware (19 thru 22) . 3.

Interpose connecting part (11, figure 41-12) and secure with attaching hardware (6 thru 8).

4.

Tighten all nuts and secure with split pins.

5.

Install cyclic stick as described in paragraph 41-10.

BO 105 ·CHAPTER 41 Page 33

fteurocopter

MAINTENANCE MANUAL MBB - BO 105

..-1 D400560.1

1 2 3 4 5 6 7 8

Control rod Bo1t Washer Nut Split pin Bolt Washer Nut Figure 41-12

BO 105 CHAPTER 41 Page 34

13

3-5 Nm

114 - - - J l l I ; J l 15

9 Split pin 10 Lateral control link 11 Connecting part 12 Bolt 13 Washer 14 Nut 15 Split pin 16 Lateral control bellcrank

17 18 19 20 21 22 23

Flanged bushing Bushing Bolt Washer Nut Split pin Control rod

Rernoval and installation - connecting part

Revision 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 41 - 16

Removal - connecting part

Remove connecting part as shown in figure 41-12. 41 -

17

Inspection and repair - connecting part

Special tool: Mounting tool 117-400001 W1 1.

Inspect connecting part (figure 41-13) for cracks, other mechanical damage, corros ion and damaged surface protection. a.

Replace if a crack is evident.

b.

Polish out damage that is within permissible damage and repair limits stated in figure 41-13 and final polish with polishing cloth 400.

c.

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

2.

Inspect bushing and flanged bushing for mechanical damage and corrosion. Polish out damage with polishing cloth 400. For permissible bore diameter see figure 41-13. If diameter is exceeded, replace bushings as described in paragraph 41-9.

3.

Inspect bearing for play (permissible radial play is 0.1 mm), corrosion and roughness. If any such defect is evident, replace bearing in accordance with Chapter 02.

41 - 18

Installation - connecting part

1.

Install connecting part as shown in figure 41-12.

2.

Tighten all nuts and secure with split pins.

3.

Inspect for freedom of movement and presence of foreign objects.

BO 105 CHAPTER 41 Page 35

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF OAMAGE

Mechanical and corrosion

OAMAGE ANO REPAIR LIMITS ZONE 1 ZONE 2

•

:-:: ::_. e._ [ITl] : ..:: :::.:~

0.4 mm depth after repair on 50% of area

0.2 mm depth after repair on 30% of area

Max. permissible bore diameter:

&

6.02 mm

It may be exceeded by 0.01 mm on one quarter of the bore circurnference.

Figure 41-13

41 - 19

Connecting part - damage and repair limits

Removal - bellcrank (12, figure 41-1)

Remove bel1crank as shown in figure 41 - 20

41-14.

Rernoval - be11crank (26, figure 41-1)

Remove be11crank as shown in figure 41-15.

BO 105 CHAPTER 41 Page 36

cteuracopter

MAINTENANCE MANUAL MBB - BO 105

115-17 Nm

I

~~l--14

. . . . 13-5Nm

1----12

400718

7

1 Bellcrank 2 Control rod 3 Bolt 4 Washer 5 Nut 6 Split pin 7 Control rod

Figure 41-14

Revision 8

8 BoU 9 Washer 10 Nut 11 Split pin 12 BoU 13 Washer 14 Washer

15 16 17

18 19 20

Washer Washer Nut Split pin Bushing Flanged bushing

Removal and installation - bellcrank

BO 105 CHAPTER 41 Page 37

fteurocopter

MAINTENANCE MANUAL MBB - BO 105

3

'---17

25

7

....

IJ·s"m

--.,f'l\o.'\

1:=1

12

6~24

'/~l/~

~

25

~

11~1

10 . . . . 13-5Nm

400719

20~

/ /

21~

S

23-/-1 I

22 115-17 Nm

1 2 3 4 5 6

Bellcrank Control rod Bolt Washer Nut Split pin 7 Control rod 8 Bolt

Figure 41-15 BO 105 CHAPTER 41 Page 38

9 Washer 10 Nut 11 Split pin 12 Control rod 13 Bolt 14 Washer 15 Nut 16 Split pin

15

I

I

17

18 19 20 21 22 23 24 25

3-5Nm

1. . . .

Bolt Washer Washer Washer Washer Nut Split pin Bushing Flanged bushing

Removal and installation - bellcrank

Revision 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Inspection and repair - bellcrank

41 - 21

Special tool: Mounting tool 117-400001 W1 1.

Bellcrank (1, figure 41-14). a.

2.

Inspect for cracks, other mechanical damage, corros ion and damaged surface protection. 1)

Replace if a crack is evident.

2)

Polish out damage that is within permissible damage and repair limits stated in figure 41-16 and final polish with polishing cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

b.

Inspect bushings for mechanical damage and corrosion. Polish out damage with polishing cloth 400. For permissible bore diameter see figure 41-16. If diameter is exceeded, replace bushings as described in paragraph 41-9.

c.

Inspect flanged bushings (20, fig. 41-14) in accordance with step b.

d.

Inspect grooved ball bearing for play, roughness, binding and corrosion. If any of these defects are present, replace bearing according to step 3.

Bellcrank (1, figure 41-15) Inspect bellcrank in accordance with step l.

BO 105 CHAPTER 41 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1 ZONE 2

O Mechanical and cerresien

0.2 mm depth after

0.4 mm depth after

repair en 30% ef area

repair en 50% ef area

Max. permissible bere diameter:

&

6.02 mm

It may be exceeded by 0.01 mm en ene quarter ef the bere circumference. Figure 41-16

BO 105 CHAPTER 41 Page 40

Bellcranks - damage and repair limits

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3.

Replace grooved ball bearings as follows: a.

Remove bearings as shown in figure 41-17, using mounting tool 117-400001 Wl.

b.

Inspect bearing mating bore of bellcrank for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible diameter is 22.02 mm. It may be exceeded by 0.01 mm on one quarter of the bore circumference.

c.

Apply a coat of corros ion preventive paste (CM 510) to the bore surface.

d.

Install bearings as shown in figure 41-17, using mounting tool 117-400001 W1.

2

U:,~.---5

400121

1 2 3 4

Bellcrank Bellcrank Grooved ball bearing Sleeve

Figure 41-17

5 6 7 8

Retaining ring Grooved ball bearing Washer Retaining ring

Replacement - grooved ball bearings

BO 105 CHAPTER 41 Page 41

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

41 - 22

Installation - bellcrank (12, figure 41-1)

l.

Install bellcrank as shown in figure 41-14.

2.

Tighten all nuts and secure with split pins.

3.

Inspect for freedom of movement and presence of foreign objects.

41 - 23

Installation - bellcrank (26, figure 41-1)

l.

Install bellcrank as shown in figure 41-15.

2.

Tighten all nuts and secure with split pins.

3.

Inspect for freedom of movement and presence of foreign objects.

41 - 24

Removal - lateral control bellcrank

l.

Remove nose access door and cover on the cabin floor.

2.

Remove lateral control bellcrank as shown in figure 41-18.

3.

Disassemble lateral control bellcrank as shown in figure 41-19.

80 105 CHAPTER

Page 42

41

eeurocopter

MAINTENANCE MANUAL 80 105

21

2------"~

16

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

• ~

Nut Tabwasher Split pin Nut Washer Bolt Washer Shaft Washer Nut Split pin Bellcrank Bearing ring Distance sleeve Bolt Bellcrank Bolt Washer Nut Split pin Control rod Bolt Washer Nut Split pin Control rod Connecting part

15

•

14

®---18

~1913-5Nm I

13

'--20

&27 8

9

&

Configuration 1 Single control system

&

Configuration 11 Dual control system

10 1 5- 7Nm '---=11

12

23

1 3 - 5Nm

Figure 41-18

Revision 20

Removal and installation - lateral control bellcrank

CHAPTER 41 Page43144

•

25

124~r-

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

14---N~~

13---1

~:f.A-----

2

}------3

.------4 ~~

)------- 5

10 --~:=.._._::;;..""I

I

5-7 Nm

I

I

2 Nm

I

'Cl..:7..#'-------11

't'~----12 400702

1 Sleeve 2 Grooved ball bearing 3 Washer 4 Retaining ring 5 Distance sleeve Figure 41-19

6 7 8 9

10

Washer Split pin Nut Bolt Bellcrank

11

12 13 14

Tabwasher Nut Shaft Grooved ball bearing

Disassembly - lateral control bellcrank BO 105 CHAPTER 41 Page 45/46

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 41 - 25

Inspection and repair - lateral control bellcrank

Special tool: Mounting tool 117-400001 W1 1.

Inspect bellcrank (figure 41-20) . a.

2.

Inspect bellcrank for cracks, other mechanical damage and corrosion. 1)

Replace if a crack is evident.

2)

Polish out damage within permissible limits stated in figure 41-20 and final polish with polishing cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

b.

Inspect splines for condition and corrosion. If deformation or damage is detected, replace bellcrank. Polish out corros ion using polishing cloth 400.

c.

Inspect bushing for mechanical damage and corrosion. Polish out damage with polishing cloth 400. For the max. permissible diameter see figure 41-20. If diameter is exceeded, replace bushing as described in paragraph 41-9.

d.

Inspect flanged bushing as described in step c.

e.

Inspect grooved ball bearings (2 and 14, figure 41-19). 1)

Inspect bearings for play, roughness and binding.

2)

If any of these defects are evident, replace bearings.

Inspect shaft (figure 41-21). a.

b.

Inspect shaft for cracks, other mechanical damage and corrosion. 1)

Replace if a crack is evident.

2)

Polish out damage within permissible limits stated in figure 41-21 and final polish with polishing cloth 400.

Inspect splines for condition and corrosion. If deformation or damage is detected, replace shaft.

BO 105 CHAPTER 41 Page 47

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3.

Inspect sleeve (figure 41-22) for cracks, other mechanical damage and corrosion. a.

Replace if a crack is evident.

b.

Polish out damage within permissible limits stated in figure 41-22 and final polish with polishing cloth 400.

c.

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

O Mechanical and corrasían

0.4 mm depth after repaír an 50% af area

0.2 mm depth after repair an 30% af area

Max. permissible bore diameter:

&

6.02 mm

It may be exceeded by 0.01 mm on one quarter of the bore circumference. Figure 41-20

BO 105 CHAPTER 41 Page 48

Bellcrank - damage and repair limits

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400103

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

Mechanical and cerresien

0.2 mm depth after repair en 50% ef area

Figure 41-21

-

ZONE 2

The mino diameter ef 30.02 mm may be 0.02 mm 1ess en 30% ef area

Shaft - damage and repair limits

BO 105 CHAPTER 41

Page 49

- - - - - - - - - - - , . - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400104

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS

-

ZONE 1

Mechanical and corrosíon

ZONE 2

1;1

0.4 mm depth after repair on 50% of area

0.6 mm depth after repair on 50% of are a

Max. permissible diameter:

&

42.02 mm

It may be exceeded by 0.01 mm on one quarter of the bare circumference. Figure 41-22

BO 105 CHAPTER 41

Page 50

Sleeve - damage and repair limits

MAINTENANCE MANUAL BO 105

EUROCOPTER

41 - 26

Installation - lateral control bellcrank

1.

Apply a coat of corros ion preventive paste (CM 510) to the bore surface of sleeve (1, figure 41-19).

2.

Assemble lateral control bellcrank as shown in figure 41-19.

3.

Tighten nut (8) and secure with split pin (7).

4.

Secure nut (12) with tabwasher (11).

5.

Install lateral control bellcrank as shown in figure 41-18. Bellcranks (12 and 16) must be offset 90° to each other.

6.

Tighten all nuts and secure with split pins.

7.

Secure nut (1) with tabwasher (2).

8.

Check for freedom of movement and presence of foreign objects.

41 - 27

L o n g i t u d i n a 1

/ 1 a ter a 1

tri m s y s t e m

41 - 28

Removal - longitudinal trim system

NOTE

If both the longitudinal and the lateral trim systems are removed, identify the longitudinal and lateral trirnmers with their respective trim actuators.

1.

Remove nose door.

2.

Remove longitudinal trirnmer (1, figure 41-23) by removing hardware (2 thru 4 and 6 thru 9) attaching it to bellcrank (5) and RH cyclic stick respectively.

3.

Remove longitudinal trim actuator (10) by disconnecting its electrical connector and by removing attaching hardware (19 thru 22) from bellcrank (5) and attaching hardware (11 thru 14, 16 and 17) together with bonding jumper (15) from fuselage.

Revision 14

* * *

BO 105 CHAPTER 41 Page 51

EUROCOPTER

41 - 29

MAINTENANCE MANUAL BO 105

Removal - lateral trim system

1.

Remove nose door. _

2.

Remove lateral trirnmer (23, figure 41-23) by removing hardware (26 thru 28 and 33 thru 36) attaching it to bellcrank (25) and RH cyclic stick respectively.

3.

Remove lateral trim actuator (24) by disconnecting its electrical connector and by removing attaching hardware (29 thru 32) from bellcrank (25) and attaching hardware (37 thru 40, 42 and 43) together with jumper (4) from fuselage.

BO 105 CHAPTER 41 Page 52

MAINTENANCE MANUAL MBB - BO 105

I 3-SNm

!....

3S 33

34

. . . . 1 3-SNm

I

37----Il;:¡l

38

----C!~

39--~ 40-~~~

41~

9

. . . . .

/7"."-A----._ _

7

11

6

8 3-SNm

42 @ I.----~S-.7-N-m-¡ 44 @ 43~

l~oIl\\rI~~--12 1. . . .

10

~~--13

~-+--14

31

D400639.2 ~~::..--16 L..-.._ _

32

30

ce"........----lS

I 3-SNm

17 I'--S.-7-N-m-

1....

CE----18

Lateral trimrnel

Longitudinal trimmer

1 2 3 4 5 6 7 8

Longitudinal trirnmer Washer Split pin Nut Bellcrank Bolt Washer Nut

Figure 41-23

9 Split pin la Longitudinal trim actuator 11 Bolt 12 Washer 13 Rubber washer 14 Washer 15 Bonding jumper 16 Washer

17 18 19 20 21 22

Nut Split pin Bolt Washer Nut Split pin

Rernoval and installation - longitudinal/lateral trirnmer BO 105 CHAPTER 41

F.evision 8

Page 53/5-4

23 24 25 26 27 28 29 30

Lateral trirnmer Lateral trirn actuator Bellcrank Washer Nut Split pin Bolt Washer

31 32 33 34 35 36 37 38

Nut Split pin Bolt Washer Nut Spli t pin BoH Washer

39 40 41 42 43 44

Rubber washer Washer Bonding jurnper Washer Split pin Nut

MAINTENANCE MANUAL 80 105

EUROCOPTER

41 - 30

Disassembly - longitudinal/lateral trirnrner

NOTE

Distinguish between configuration I and configuration II; refer to fig. 41-24.

1.

Remove lockwire (6, fig. 41-25) and retaining ring (2 or 18, fig. 41-24).

2.

Remove trim rod assembly (4 or 19) from spring case (1 or 14).

41 - 31

Inspection and repair - longitudinal/lateral trimmer

1.

Clean trim rod assembly (4 or 19, fig. 41-24) and spring case (1 or 14), using cleaning agent (CM 201 or CM 202) .

2.

Inspect spring case for mechanical and corros ion damage. Visually inspect weld on bolt for cracks.

3.

a.

Replace spring case if weld is cracked.

b.

Polish out mechanical and corros ion damage, using 400 grit abrasive cloth. Touch up surface protection per chapter 02, using coating lacquer (CM 402) .

Inspect compression spring for wear. The compression spring can be reused if the specified wear limit of 3 mm is not exceeded (see fig. 41-24, Detail A). If wear limit is exceeded, replace compression spring as follows: a.

Disassemble trim rod assembly (4 or 19) as shown in fig. 41-24.

b.

Replace damaged compression spring with new one.

c.

Assemble trim rod assembly (4 or 19) as shown in fig. 41-24 and install nut (12 or 24) finger-tight.

d.

Adjust break-out force after final assembly, refer to para 41-32.

41 - 32

Assembly - longitudinal/lateral trimmer

1.

Apply grease (CM 140) to inner surface of spring case (1 or 14, fig. 41-24) .

2.

Insert trim rod assembly (4 or 19) into spring case.

3.

Install retaining ring (2 or 18) .

4.

Check break-out force values of longitudinal/lateral trimmer. Longitudinal trimmer

19.5 - 20.5

N

Lateral trimmer

15.5 - 16.5

N

Revision 10

*

* *

BO 105 CHAPTER 41 Page 55

MAINTENANCE MANUAL 80 105

EUROCOPTER

5.

If these values are not reached, re-adjust spring as follows: a.

Configuration 1 1) . Remove lrim rod assembly (4, fig. 41-24) from spring case (1). 2)

If the break-out force is too high, reduce the thickness of the laminum washers (8) by the same amount on both sides of the spring. If the break-out force is too low, replace installed laminum washers (8) with thicker washers on both sides.

3) NOTE

b.

Insert trim rod assembly (4) into spring case (1). With follow-up trim system inslalled (refer to chapter 847), an axial play of 0.5 mm must be left.

4)

Tighten nut (4, fig. 41-25) as necessary to remove axial play between trim rod and spring.

5)

Secure retaining ring (13) with lockwire (6) and nut (4) with split pin (5).

6)

For installation of longitudinal/lateral trimmer refer to paras 41-33 and 41-34.

7)

Check break-out force in helicopter in accordance with chapter 102, Rigging of Main Rotor Controls.

Configuration 11 1)

NOTE

If the break-out force is too low: - Tighten nut (8, fig. 41-25) until the required break-out force is obtained. With follow-up trim system installed (refer to chapter 847), an axial play of 0.5 mm must be left. - Tighten nut (10) until there is no more axial play between trim rod and sprinCj'. If the break-out force is too high: - Loosen nut (10) several turns. Loosen nut (8) until required break-out force is obtained. - Tighten nut (10) until there is no more axial play between trim rod and spring.

BO 105 CHAPTER 41 Page 56

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2)

Tighten nut (11) and secure with tabwasher (12).

3)

Secure nut (10) with split pin (9).

4)

Secure retaining ring (13, fig. 41-25) with lockwire (15)

5)

Install longitudinal/lateral trirnmer; refer to paras 41-33 and 41-34.

6)

Check break-out force in helicopter in accordance with chapter 102, Rigging of Main Rotor Controls.

BO 105 CHAPTER 41 Page 57

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1

2 3

4 5

6 7 8

9 10 11 12 13

14 15 16 17 18 19 20 21

22 23 24 25

26

BO 105 CHAPTER 41 Page 58

Spring case Retaining ring Retaining ring Trim rod assembly Trim rod Washer Bushing Laminum washer Washer Compression spring Sleeve Nut Split pin Spring case Nut Tabwasher Nut Retaining ring Trim rod assembly Trim rod Washer Bushing Sleeve Nut Split pin Compression spring

MAINTENANCE MANUAL MBB - BO 105 Configuration 1

Configuration 11 20

24 23 /'

.,

"

. /'

22

/

'

./ ///

//'

-

//

./

/' I II 26 21 22

21

DETAlL

E400753

Figure 41-24

Revision 8

Disassembly and assembly - longitudinal/lateral trirnmer BO 105 CHAPTER 41 Page 59/60

I~

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Configuration 1

14

I

16

DETAlL

2

A

16

3

DETAlL

4

5

B

13 -"""'"""":~~~~-15

7

Configuration Ir

B

9

14

J 400033.2

12

1

2 3 4

5 6 7 8

Laminum washer Compression spring Laminum washer Nut Split pin Lockwire Sleeve Nut

Figure 41-25

9

10 11

12 13 14

15 16

11

10

Split pin Nut Nut Tabwasher Retaining ring Trim rod Lockwire Washer

Adjustment of break-out force - longitudinal/lateral trimmer BO 105 CHAPTER 41 Page 61/62

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 41 - 33

Installation - longitudinal trim system

NOTE

o Ensure main rotor controls are rigged prior to installation of longitudinal trirnmer and trim actuator. Refer to chapter 102. o Do not confuse longitudinal trirnmer and trim actuator with lateral trirnmer and trim actuator.

Installation of longitudinal trirnmer and trim actuator. l.

Together with bonding jumper (15, figure 41-23), mount longitudinal trim actuator (10) to airframe using attaching hardware (11 thru 14, 16and 17). Then secure fork head to bellcrank (5) with attaching hardware (19 thru 21) .

2.

Connect electrical connector to longitudinal trim actuator.

3.

Move lateral trim actuator to 263.6 - 264.2 mm setting by actuating the four-way switch on the cyclik stick grip. Refer to figure 41-26.

4.

Arrest cyclic stick with cyclic stick lock.

5.

Connect longitudinal trirnmer (1) to bellcrank (5) and secure with nut (4) and washer (2). Adjust fork head to required length and attach to cyclic stick using attaching hardware (6 thru 8).

6.

Check trim actuator for freedom of movement by moving the four-way switch on the cyclic stick grip fore and aft.

7.

Secure fork head of longitudinal trimmer.

8.

Tighten nuts (4, 8, 17 and 21) and secure with split pins.

41 - 34

Installation - lateral trim system

NOTE

o Ensure main rotor controls are rigged prior to installation of lateral trimmer and trim actuator. Refer to chapter 102. o Do not confuse lateral trimmer and trim actuator with longitudinal trirnmer and trim actuator.

Installation of lateral trirnmer and trim actuator. l.

Together with bonding jumper (41, figure 41-23), mount lateral trim actuator (24) to airframe using attaching hardware (37 thru 40 and 42 thru 44). Connect fork head to bellcrank (25) with attaching hardware (29 thru 31) .

BO 105 CHAPTER 41 Page 63

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

263.6 - 264.2 mm 273.7 • 274.3 mm

41/26

Figure 41-26

Zero position dimension - longitudinal-lateral trim actuator

2.

Connect electrical connector to lateral trim actuator.

3.

Move lateral trim actuator to 273.7-274.3 mm setting by actuating the four-way switch on the cyclic stick grip. Refer to figure 41-26.

4.

Arrest cyclic stick with cyclic stick lock.

5.

Connect lateral trirnmer (23, figure 41-23) to bellcrank (25) and secure with nut (27) and washer (26). Adjust fork head to required length and attach to cyclic stick using attaching hardware (33 thru 35) . .

6.

Check trim actuator for freedom of movement by actuating the four-way switch on the cyclic stick to the right and to the left.

7.

Secure fork head of lateral trirnmer.

8.

Tighten nuts (27, 31 and 44) and secure with split pins.

BO 105 CHAPTER

Page 64

41

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

41 - 35

Removal -

longitudinal trirnmer bellcrank

1.

Open nose access door.

2.

Remove attaching hardware (2 thru 4, 5 thru 8 and 9 thru 13, figure 41-27) .

3.

Detach bellcrank (1).

41 - 36

Removal -

lateral trirnmer bellcrank

1.

Open nose access door.

2.

Remove attach¡ng hardware (2 thru 4, 5 thru 8 and 9 thru 13, figure 41-28) .

3.

Detach bellcrank (1).

BO 105 CHAPTER 41

Page 65

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

113-SNm

_ _- - 1 0

I 4--~J

I 7-9Nm 11

...._---11

1~'

'--

13

,-----11

~~--lS

400638 - 01

1 Bellcrank 2 Washer 3 Split pin 4 Nut 5 BoH 6 Washer 7 Nut

Figure 41-27 BO 105 CHAPTER 41 Page 66

8 9

10 11

12 13

14 15

Split pin Washer Nut Split pin Washer BoH Longitudinal trimmer Trim actuator

Removal and installation - longitudinal trimmer bellcrank

Revision 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~I r---

11

7-9 Nm

3

112 ---H-4~'

~--15

]----10

t----9 7

8

[3-5 Nm

11

400639.A-Ol

1 Bellcrank 2 Washer 3 Nut 4 Split pin 5 BaH 6 Washer 7 Split pin

Figure 41-28

Revisian 3

8 9

10 11

12 13

14 15

Nut BaH Washer Washer Nut Split pin Lateral trirruner Trim actuatar

Remaval and installatian - lateral trirruner bellcrank BO 105 CHAPTER 41 Page 67

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 37

Inspection and repair - longitudinal and lateral trimmer bellcranks

Special tools: Assembly tool Pushing-out tool 1.

117-46300 W1 tool no. 20 (117-46300 W2)

Inspect bellcrank (figure 41-27 and 41-28) for cracks, deformation, other mechanical damage, corrosion and damaged surface protection. a.

Replace if a crack is evident.

b.

Polish out damage within perrnissible limits stated in figure 41-29 and final polish with polishing cloth 400.

c.

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

2.

Inspect grooved ball bearings for play, roughness, binding and corrosion. If any of these defects are evident, replace bearings in accordance with step 4.

3.

Inspect spherical bearings these defects are present, in accordance with chapter bly tool (117-46300 W1) to

4.

Replace grooved ball bearings as follows:

for play, roughness and corrosion. If any of replace bearings together with claw bushings 02. Use tool no. 20 (117-46300 W2) and assemreplace spherical bearings and claw bushings.

a.

Remove bearings as shown in figure 41-30.

b.

Inspect bearing bore in bellcrank for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible diameter is 22.02 mm. It may be exceeded by 0.01 mm on one quarter of the bore circumference.

c.

Apply a coat of corrosion preventive paste (CM 510) to bearing bore in bellcrank.

d.

Install bearings as shown in figure 41-30.

BO 105 CHAPTER 41 Page 68

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - . . , . . MAINTENANCE MANUAL MBB - BO lOS

400705

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

~ Mechanical and cerresien

0.3 mm depth after repair en 30% ef area

Figure 41-29

0.5 mm depth after repair en 50% ef area

Longitudinal and lateral trirnrner bellcranks damage and repair limits BO 105 CHAPTER 41 Page 69

-~-----------MBB

HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400706

1 2 3 4 5

Washer Retaining ring Washer Grooved ball bearing Retaining ring

E'igure 41-30 80 105 CHAPTER

Page 70

41

6 7 8 9

Bellcrank Sleeve Grooved ball bearing Washer

Removal and installation - grooved ball bearings

MAINTENANCE MANUAL MBB - BO 105

41 - 38

Installation - lateral trirnmer bellcrank

l.

Install bellcrank as shown in figure 41-28.

2.

Tighten nuts (3, 8 and 12) and secure with split pins.

3.

Inspect for freedom of movement and presence of foreign objects.

4.

Close nose access door.

41 - 39

Installation - longitudinal trirnmer bellcrank

l.

Install bellcrank as shown in figure 41-27.

2.

Tighten nuts (4, 7 and 10) and secure with split pins.

3.

Inspect for freedom of movement and presence of foreign objects.

4.

Close nose access door.

Revision 8

BO 105 CHAPTER 4:1. Page 71

MAINTENANCE MANUAL MBB - BO 105

41 - 40

Col 1 e c t i v e p i t c h s t i c k

41 - 41

Removal - collective pitch stick RH/LH

WARNING

IN5TALL COVER IN ACCORDANCE WITH PARAGRAPH 41-50 IF LEFT COLLECTIVE PITCH 5TICK 15 NOT REIN5TALLED.

1.

Disengage locking device from collective pitch stick.

2.

Disconnect electrical connector and blank off open ends.

3.

Remove screws (6, figure 41-31) with washers (7), detach mounting frame (8) and boot (9).

4.

Unscrew and remove screw (3) together with spacer sleeve (5) from clamp (4) .

5.

5traighten tabs of lock washer (11), detach tightening handle (2), and remove collective pitch stick.

80 105 CHAPTER 41 Page 72

Revision 8

_eurocopter 41 - 42 l.

MAINTENANCE MANUAL M88 - 80 105

Installation - collective pitch stick RH/LH

If installed, remove cover of LH collective pitch stick per paragraph 41-49.

*

*

lA. Measure length of cutout in p1ates (12) (see Detail A, fig. 41-31). If cutout is longer than 16 mm, replace plateo

* *

2.

Insert collective pitch stick (1) in shaft (10).

*

NOTE

*

Steps 3. and 4. shall be accomplished only if plates (12) were removed.

3.

position plates (12) on shaft (10) and provisionally attach with bolts (13), washers (14) and nuts (15).

4.

Check left collective pitch stick for free movement between left seat and left door and right collective pitch stick for free movement between center console and right door, by moving the respective sticks up and down. Secure plates (12) in existing position with nuts (15) if collective pitch stick can move freely, otherwise shift p1ates to a position allowing free stick movement and tighten attaching nuts.

5.

Tighten handle (2) and secure with lock washer (11).

6.

Check collective pitch stick for freedom of movement.

7.

Inspect for presence of foreign objects.

8.

Attach boot (9) and mounting frame (8) to floor with screws (6) and washers (7).

9.

Secure clamp (4) to floor with spacer sleeve (5) and screw (3).

10. Remove blanks and reconnect electrical connector. 11. Engage locking device with collective pitch stick.

Revision 8

80 105 CHAPTER 41 Page 73

MAINTENANCE MANUAL MBB - BO 105

I

DETAlL

A

CQ{,6 m~j0-12

7-9 Nm

I

YV--11

2

Dimenslons In mm

1 Collective pitch stick 2 Tightening handle 3 Screw 4 Clamp 5 Spacer sleeve 6 Screw 7 Washer 8 Mounting frame 9 Boot 10 Shaft 11 Lock washer 12 Plate 13 BoU 14 Washer 15 Nut

9

......--r---:;>""t-10

Retainer is mounted on RH collective pitch only Figure 41-31 80 105 CHAPTER 41 Page 74

Removal and installation - collective pitch stick (RH and LH)

Revision 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 43

Removal - pitch brake

1.

Remove boot.

2.

Remove split pin (15, figure 41-36) and unscrew and remove nut (14) and cylinder nut (16).

3.

Remove friction handle (1), cylinder nut (2) and spring (3) from brake levers (17 and 18).

4.

Remove split pin (5) and unscrew and remove nut (4) and washer (6).

5.

Remove bolt (9) and washer (8) from brake box (7).

6.

Remove split pin (22), unscrew and remove nut (21) and washer (20), and remove bolt (19) from brake lever.

7.

Remove brake levers (17 and 18) and spring (3) from pitch shaft (30).

41 - 44

Installation - pitch brake

1.

Position brake levers (17 and 18) on pitch shaft.

2.

Install bolt (19) and washer (20). Tighten nut (21) and secure with split pin (22).

3.

Position brake lever (17) on brake box (7) and secure with attaching hardware (4 thru 9). Tighten nut (4) and secure with split pin (5).

4.

Install spring (3) between brake levers (17 and 18).

5.

Install friction handle (1) as shown in figure 41-36, hand-tighten nut (14) and secure with split pin (15).

6.

Adjust friction force of pitch stick in accordance with chapter 102.

7.

Inspect for presence of foreign objects.

8.

Install boot.

41 - 45

Removal - pitch protector RH/LH

Remove pitch protector as shown in figure 41-32. 41 - 46

Installation - pitch protector RH/LH

Install pitch protector as shown in figure 41-32.

BO 105 CHAPTER 41 Page 75

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A

12

~---10

=+t---

11 DETAlL

B \\n--- 2

13----~

14 - - - - - J ! ! I " l

15

1 2 3 4 5 6 7 8 9

10 11

12 13

14 15 16

pitch protector RH Pitch protector LH Screw Washer Screw Washer Base p1ate Screw Washer Screw Washer Pitch locking device Screw Clamp Spacer sleeve Screw Figure 41-32

BO 105 CHAPTER 41 Page 76

400129

Removal and installation - pitch protector RH/LH

HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

41 - 47

Removal - cover, cyclic stick LH

1.

Remove screws (2, figure 41-33) with washers (3).

2.

Detach cover (1).

3.

Install cyclic stick LH in accordance with paragraph 41-10.

41 - 48

Installation - cover, cyclic stick LH

1.

Remove cyclic stick LH in accordance with paragraph 41-8.

2.

Position cover (1, figure 41-33) and attach with screws (2) and washers (3) •

2

2

_--1---.. .

'-J-..~

__ 3

1 400708

Figure 41-33

Cover

2 Screw 3 Washer

Removal and installation - cover, cyclic stick LH BO 105 CHAPTER 41 Page 77

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

41 - 49

Removal - cover, collective pitch stick LH

l.

Remove screws (2, figure 41-34) and detach cover (1).

2.

Install collective pitch stick in accordance with paragraph 41-42.

41 - 50

Installation - cover, collective pitch stick LH

l.

Remove collective pitch stick in accordance with paragraph 41-41.

2.

Position cover (1, figure 41-34) and attach with screws (2).

2

------r-...-

400709

Figure 41-34

BO 105 CHAPTER 41

Page 78

1 Cover 2 Screw

Removal and installation - cover, collective pitch stick LH

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 51

Removal - pitch shaft lever

1.

Remove nose access door.

2.

Remove copilot seat and left seat rail in accordance withchapter 701.

3.

Remove left floor plate of the cable duct.

4.

Disconnect control rod (48, figure 41-36) from pitch shaft lever (26).

5.

Remove lockwire and screw (24).

6.

Remove split pin (28) and remove washer (29) and bolt (27).

7.

Remove tightening cap (25) and pull lever (26) from pitch shaft.

41 - 52

Inspection and repair - pitch shaft lever

Special tool: Mounting tool 117-400001 W1 l.

2.

3.

Inspect pitch shaft lever (figure 41-35) for cracks, other mechanical damage, corros ion and damaged surface protection. a.

Replace if a crack is evident.

b.

Polish out damage that is within permissible damage and repair 1imits stated in figure 41-35 and final polish with polishing cloth 400.

c.

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

Inspect bushing for mechanical damage and corrosion. Polish out damage . with polishing cloth 400. For permissible bore diameter see figure 41-35. If diameter is exceeded, replace bushing as described in paragraph 41-9. Inspect flanged bushing as described in step 2.

BO 105 CHAPTER 41 Page 79

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400110.1

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 2 ZONE 1

BIlfrmtl

Mechanical and corros ion

0.5 mm depth after repair on 50% of area

0.2 mm depth after repair on 30% of are a

Max. permissible bore diameter:

&

6,02 mm

It may be exceeded by 0.01 mm on one quarter of the bore circumference

Figure 41-35 BO 105 CHAPTER 41 Page 80

Pitch shaft lever - damage and repair limits

MAINTENANCE MANUAL MBB - BO 105 1

2 3

4 5 6

7 8

9

10 11 12 13

14

15 16 17 18

19 20 21 22 23

24 25 26 27

28 29 30

31 32 33

34 35

36 37 38 39

40 41

42 43 44 45

46 47 48 49

50 51

Friction handle Cylinder nut Spring Nut Split pin Washer Brake box t'lasher Bolt Screw Tab washer t'lasher Nut Nut Split pin Cylinder nut Brake lever Br ake lever bolt t'lasher Nut Split pin Bearing Screw Tightening cap Pitch shaft lever Bolt Split pin Washer Pitch shaft Retaining ring Bearing support t'lasher Screw t'lasher Screw Cover Split pin Nut Washer Bushing Retaining ring Washer Screw t'lasher Nut Split pin Control rod Flanged bushing Bushing Brake liner

Figure 41-36

Revision 8

4

I 5-6 Nm I 24

3 2 6

48

25

26

23 3-5Nm

E400722

1 ....

45

29 35

37

~"13-'Nm I 3-5 Nm

32 41

Removal and installation - pitch shaft and pitch brake BO 105 CHAPTER 41 Page 81/82

I

I

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

41 - 53

Installation - pitch shaft lever

1.

Insert pitch shaft lever (26, figure 41-36) into pitch shaft and install tightening cap (25).

2.

Insert bolt (27), washer (29) and secure with split pin (28).

3.

Tighten screw (24) and secure with lockwire.

4.

Connect control rod (48) with attaching hardware (44 thru 46). Tighten nut (46) and secure with split pin (47).

5.

Inspect for freedom of movement and presenee of foreign objeets.

6.

Install left floor plate of the cable dueto

7.

Install left seat rail and copilot seat in aeeordanee with ehapter 701.

8.

Close nose aceess door.

41 - 54

Removal - piteh shaft

l.

Open nose aeeess door.

2.

Open aeeess eover on the left outer side of the helieopter.

3.

Remove eopílot seat, left seat raíl and lap belt attaeh fitting, refer to ehapter 701.

4.

Remove left floor plate of the cable dueto

5.

Diseonnect control rod (48, figure 41-36) from pitch shaft lever (26).

6.

Remove piteh stiek RH/LH in aeeordanee with paragraph 41-41.

7.

Remove pitch brake in aeeordanee with paragraph 41-43.

8.

Remove pitch shaft lever (26) in aeeordanee with paragraph 41-51.

9.

Remove split pin (38) and remove nut (39) and washer (40).

10. Remove serews (36) and washers (35) and remove cover (37). 11. Remove retaining ring (42), bushing (41) and washer (43). 12. Remove screws (34) and washers (33) and detaeh bearing support (32). 13. Remove piteh shaft (30) with retaining ring (31) from bearing (23).

80 105

41 Page 83

CHAPTER

EUROCOPTER

41 - 55 •

MAINTENANCE MANUAL BO 10S

Inspection and repair - pitch shaft

1. Pitch shaft (figure 41-37) with bonded brake Iiner: a.

Inspect pitch shaft for mechanical damage and corrosíon. Visually inspect welds for cracks. 1) Replace if a crack is evident.

2) Polish out damage within permissible limits set forth in figure 41-37 and final polish with polishing cloth 400. 3) Touch up or renew damaged surface protection with two-component wash primer (CM 423) followed by coating lacquer (CM 402) in accordance with Chapter 02. b.

Inspect bearing (23, figure 41-36) for play, roughness and binding.lf any such defectexists, replace bearing.

c.

Inspect brake liner for wear and debonding. If any such defect exists, replace brake Iiner.

d.

Replace brake liner as follows: 1) Heat brake liner with hot air and remove from pitch shaft.

2) Remove adhesive residues with toluene (CM 219). 3) Heat new brake liner to approx. 120 oC. 4) Coat pitch shaft with two-component adhesive (CM 601). 5) Install brake liner on pitch shaft and press firmly in place with hose strap. 6) After allowing to dry, remove hose strap and rework brake liner to a diameter of 49.8 - 0.3 mm. 2. Pitch shaft without bonded brake liner: a.

Inspect pitch shaft (figure 41-37) tor mechanical damage and corrosíon. Visually inspect welds for cracks. 1) Replace if a crack is evident.

2) Polish out damage within permissible limits set forth in figure 41-37 and final polish with polishing c10th 400. 3) Touch up or renew damaged surface protection with two-component wash primer (CM 423) followed by coating lacquer (CM 402) in accordance with Chapter 02. b.

Inspect bearing (23, figure 41-36) for play, roughness and binding. If any such defect exists, replace bearing.

c.

Inspect braking surface forwear. The minimum allowable diameter is 44.8 mm.lfthere is excessive wear, replace the pitch shaft.

CHAPTER 41 Page 84

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF DAMAGE

DAMAGE AND REPAlR LlMlTS ZONE 1 ZONE 2

11] 0.4 mm depth after repair en 50% ef area

Mechanical and cerresien

0.2 mm depth after repair en 30% ef area

Min. permissible diameter:

&

24.96 mm

Figure 41-37

Pitch shaft - damage and repair limits BO 105 CHAPTER 4J. Page 85

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 56

Installatien - pitch shaft

1.

Insert piteh shaft (30, figure 41-36) in bearing (23).

2.

Install bearing suppert (32) en ether end ef pitch shaft and attach te meunting surface with washers (33) and serews (34). Tighten screws.

3.

Install washer (43), retaining ring (42) and bushing (41) en pitch shaft.

4.

Pesitien cever (37) en pitch shaft (30) and secure te bearing suppert with washers (35) and screws (36). Tighten screws.

5.

Install washer (40) and nut (39) en end ef piteh shaft and tighten nut and secure with split pin (38).

6.

Install pitch shaft lever (26) in accerdanee with paragraph 41-53.

7.

Install pitch brake in aceerdance with paragraph 41-44.

8.

Install pitch stick RH/LH in accerdance with paragraph 41-42.

9.

Inspect fer freedem ef mevement and presence ef fereign ebjeets.

10. Install left fleer plate ef the cable dueto 11. Install left seat rail, cepilet seat and lap belt attach fitting, refer te chapter 701. 12. Close nose access doer. 41 - 57

Be 1 1 c r a n k s

41 - 58

Removal - bellcranks

(pitch, lateral and longitudinal)

1.

Remove cepilot seat, left seat rail and lap belt attaeh fitting, refer to chapter 701.

2.

Remove bench seat, refer to chapter 800.

3.

Remove left floor plate ef the cable duct.

4.

Remove control rods (9 and 17, figure 41-38).

5.

Bend locking piate (12) epen and detach with screws (11).

6.

Remove split pin (1) and remove nut (2), washer (3) and belt (4).

7.

Remove bellcrank (10, 18 or 19) from cable duct.

BO 105 CHAPTER 41 Page 86

MAINTENANCE MANUAL MBB - BO 105

1~'"t---9

'-"'---9

11---' 12----l~

........ -_.:... ... ...

~

- ,,: .

4

....

4 3-5Nm 115--~ I-

. . . . , 3-5Nm

I 2 115-17 Nm

115-17 Nm

~,----I-

19

5

'----18

I

Bellcrank - Lateral control '-----10

13 9

17

Bellcrank - longitudinal control 15-7 Nm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Spli t pin Nut vlasher Bolt Bolt Washer Nut Spli t pin Control rod Bellcrank-longitudinal control Screw Locking plate Bol t vlasher Nut Split pin Control rod Bellcrank-lateral control Bellcrank-pitch control

I

'3~

1. . .

15

....13·5 Nm

2

I

1 15 - 17

Nm

I

Bellcrank - pitch control

Figure 41-38

Revision 8

Removal and installation - bellcranks BO 105 CHAPTER 41 Page 87/88

I

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

41 - 59

Disassembly - bellcranks

1.

Straighten tabs of lock washer (9, figure 41-39) and remove keyed nut (10), lock washer (9) and spacer bushing (8).

2.

Remove retaining ring (7) and washer (6).

3. 4.

Remove lever axle (1) from bellcrank (4) . • Remove spacer tube (3) with bearing (2) from bellcrank.

5.

Press bearing (5) from bellcrank.

4

5

6

8

7

9

10

I

3-5 Nm

I

r I I

i I 1._------------------------------------.

m

I I

s

.J

400674.2

2

1 2 3 4

Lever axle Bearing Spacer tube Bellcrank

5 Bearing 6 Washer 7 Retaining ring

Figure 41-39

3

8 Spacer bushing 9 Lock washer 10 Keyed nut

Disassembly - bellcrank BO 105 CHAPTER 41

Page 89

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 60

Inspection and repair - bellcranks

Special tool: Mounting tool 117-400001 W1 1.

Inspect be1lcrank (figure 41-40). a~

2.

1)

Polish out damage that is within permissible damage and repair limits stated in figure 41-40 and final polish with polishing cloth 400.

2)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

b.

Inspect bearing seat in bellcrank for mechanical damage and corrosion. Polish out damage with polishing c10th 400. For max. permissible diameter, refer to figure 41-40.

c.

Inspect bushing for mechanical damage and corrosion. Polish out damage with polishing cloth 400. For max. permissible diameter, refer to figure 41-40. If necessary, replace bushings as described in paragraph 41-9.

d.

Inspect flanged bushings as described in step c.

Inspect lever axle (figure 41-41) a.

3.

Inspect be1lcrank for mechanical damage and corrosion. Visually inspect welds for cracks. If crack is suspected, perform penetrant inspection per MIL-STD-6866.

Inspect lever axle for mechanical damage and corrosion. Visually inspect weld for cracks. If crack is suspected, perform penetrant inspection per MIL-STD-6866. 1)

Replace if crack is evident.

2)

Polish out dómage within permissible limits stated in figure 41-41 and final polish with polishing cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) in accordance with chapter 02.

4)

Minor damage to the thread is permissible, provided the ease of installation is not impaired.

5)

Replace lever axle if thread is deformed or broken.

Inspect bearing (5, figure 41-39) for play, roughness and binding. If any such defects are evident, replace bearing.

80 105 CHAPTER 41 Page 90

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400715.1

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1 ZONE 2

[11) Mechanical and corros ion

0.4 mm depth after repair on 50% of area

0.2 mm depth after repair on 30% of area

Max. permissible bore diameters: 6.02 mm

&

They may be exceeded by 0.01 mm on one quarter of the bore circumference.

32.02 mm

Figure 41-40

Bellcrank - damage and repair limits BO 105 CHAPTER 41

Page 91

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400676

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS

-

ZONE 1

Mechanical and cerresien

~

-

ZONE 2

0 .2 mm depth after repair en 50% ef area

The mino permissible diameter ef 15.45 mm may be 0.02 mm less en 30% ef area

ZONE 3

fWd1 0.2 mm depth after repair en 30% ef area

The max. permissible bore diameter is 8.02 mm. It may be exceeded by 0.02 mm one one quarter of the bore circumference.

Figure 41-41

BO 105 CHAPTER 41

Page 92

Lever axle - damage and repair limits

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 61

1.

Assembly - bellcranks

Apply corros ion preventive cornpound (CM SOS) to bore in bellcrank (4, figure 41-39).

2 .. Assemble bellcrank assy as shown in figure 41-39.

3.

Tighten keyed nut (10).

41 - 62

Installation - bellcranks

1.

Secure bellcrank (10, 18 or 19, figure 41-38) in position with attaching hardware (1 thru 4 and 11, 12).

2.

Tighten nut (2) and screw (11) and secure nut (2) with split pin (1).

3.

Connect control rods (9 and 17). Tighten nuts (7 and 15) and secure with split pins (8 and 16) .

4.

Inspect for freedorn of rnovernent and presence of foreign objects.

S.

Install left floor plate of cable duct.

6.

Install bench seat in accordance with chapter 800.

7.

Install left seat rails, copilot seat and lap belt attach fitting, refer to Chapter 701.

41 - 63

Rernoval - pitch stick stop

1.

Rernove lockwire.

2.

Rernove screws (1, figure 41-42), washers (2) and plates (3).

3.

Rernove guard (6) and stop (4) halves frorn pitch stick (5).

41 - 64

Installation - pitch stick stop

1.

position guard (6, figure 41-42) and stop (4) halves on pitch stick (5).

2.

Install plates (3), washers (2) and screws (1).

3.

Adjust collective pitch control in accordance with chapter 102 and tighten screws (1).

BO 105 CHAPTER 41 Page 93

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

5-----\

15-7 Nm

6

400716

1 2 3 4 5 6 Figure 41-42 BO 105 CHAPTER 41 Page 94

Screw Washer Plate Stop Pitch stick Guard

Removal and installation - pitch stick stop

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 65

M i x i n g 1 e ver

a s s e mb 1 Y

41 - 66

Removal - mixing lever assembly

Special tool: Clamping shoe

1x56 150 123 or 117-12010 W66

1.

Remove fairing, as required.

2.

To prevent swashplate from dropping when removing the control rods, install clamping shoe 1x56 150 123 on main rotor mast between sliding sleeve and transmission flange.

3.

Remove control rods connected between mixing lever assy and swashplate and between mixing lever assy and tandem hydraulic unit.

4.

Disconnect control levers (9 and 12, figure 41-70) by removing split pins (1), nuts (11) and guard washers (10).

5.

Remove guard washers (8).

6.

Remove bearing block (24) from flange on main transmissionhousing.

7.

Remove housings (6) with installed ball bearings from both sides of control fork (16) and detach washers (7) from studs of sliding sleeve (17) .

8.

Remove control fork (16) together with bearing support (23) and bearing block (24).

41 - 67

Disassembly - mixing lever assembly

1.

Detach bearing support (23, figure 41-70) from control fork (16).

2.

Detach bearing support (23) from bearing block (24).

BO 105 CHAPTER 41 Page 95/96

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

41 - 68

Inspection and repair - mixing lever assembly

Special tools: Staking tool Staking tool retainer Staking tool Milling tool Pressing-in tool Pressing-in tool Milling tool Pressing-in tool Pressing-in tool Mounting tool Mounting tool Pushing-out tool Pushing-out tool Pushing-out tool Support Puller 1.

refer refer refer refer refer refer refer

to to to to to to to

chapter chapter chapter chapter chapter chapter chapter

04 04 04 04 04 04 04

Inspection of control levers (9, 12, figure 41-70): a.

b.

c. 2.

105-31821 WS 105-40001 W1 105-42121 W2 (105-42121 W6) 105-42121 W3 105-42121 W4 105-42121 WS 105-42123 W3 105-42124 W1 105-42124 W3 Tool no. 4 (105-42121 W7), Tool no. 5 (105-42122 W2), Tool no. 6 (105-42124 W4), (105-42123 W4), Tool no. 7 Tool no. 8 (105-42122 W1), Tool no. 9, Tool no. 10,

Inspect control levers for cracks, other mechanical damage and corrosion. 1)

Discard control lever if cracks are evident.

2)

Polish out mechanical damage and corrosion with polishing cloth 400. For damage and rework limits refer to figure 41-43.

3)

Touch up or renew damaged surface protection with one-component zinc chromate primer (CM 401) and two-component pur topcoat (CM 426) in accordance with chapter 02.

Inspect flanged bushings (29 and 30, figure 41-70) for wear, mechanical damage and corrosion. 1)

Polish out mechanical damage and corros ion in flanged bushing bore with polishing cloth 400. For max. permissible diameter refer to figure 41-43.

2)

If tolerance limits are exceeded, replace flanged bushings in accordance with step 7.

Check bearings for play, roughness and corrosion. If indications of damage are evident, replace bearings in accordance with step 8.

Inspection of bearing support (23, figure 41-70): a.

Inspect bearing support as indicated above for control levers.

BO 105 CHAPTER 41

Page 97

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

b.

For damage and rework limits refer to figure 41-46.

c.

Replace flanged bushings in accordance with step 14.

d.

Replace bearings in accordance with step 13.

Inspection of control fork (16, figure 41-70): a.

b.

4.

Inspect control fork as indicated above for control levers. 1)

For damage and rework limits refer to figure 41-44.

2)

Replace flanged bushings, if necessary, in accordance with step 7. or9.

3)

Replace bearings, if necessary, in accordance with step 12.

Inspect bolts (27) for mechanical damage and corrosion. 1)

If deformation is evident, replace bolts in accordance with step 10. or 11.

2)

Polish out mechanical damage and corros ion with polishing cloth 400.

3)

Dimensionally check bolt shank diameter. For permissible shank diameter refer to figure 41-44.

4)

Remove mi~or thread damage. Darnage to thread is permissible on 30% of thread area provided the mating nut can be easily screwed on by hand.

5)

Inspect identification plate for secure installation. If plate is loose, rebond with adhesive (CM 601) .

Inspection of bearing block (24, figure 41-70): a.

b.

Inspect bearing block for cracks, other mechanical damage and corrosion. 1)

Discard bearing block if cracks are evident.

2)

Polish out mechanical damage and corrosion with polishing c10th 400. For damage and rework limíts refer to figure 41-45.

3)

Touch up or renew damaged surface protection with one-component zinc chromate primer (CM 401) and two-component PUR topcoat (CM 426) in accordance with chapter 02.

Inspect bearings for play, roughness and corrosíon. In the case of damage and excessive play replace bearings in accordance with step 15. Axial play of 0.2 mm and radial play of 0.2 mm are permissible.

BO 105 CHAPTER 41

Page 98

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

41128.1

TYPE OF DAMAGE

Mechanical and corros ion

DAMAGE AND REPAIR LIMITS ZONE 2 ZONE 1

-

fIlIE

~

0.2 mm depth on 30% of area

0.3 mm depth on 50% ofarea

0.2 mm depth on 30% of area

O. 1 mm depth prior to and 0.2 mm depth after repair on 30% of area

0.1 mm depth prior to and 0.2 mm depth after repair on 30% of area

O. 1 mm depth prior to and 0.2 mm depth after repair on 30% of area

ZONE 3

Max. permissible bore diameters: 8.02 mm

They may be exceeded by 0.01 mm on one quarter of the bore circumference.

9.53 mm Figure 41-43

Control lever - damage and repair limits BO 105 CHAPTER 41 Page 99

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

.,_-- Innsr sida Zona 3

41/29.1

TYPE OF DAMAGE

Mechanica1

Corros ion

DAMAGE AND REPAlR LlMlTS ZONE 1 ZONE 2

-

ZONE 3

ZONE 4

~

[[Q

0.2 mm depth on 30% of area

0.2 mm depth on 50% of are a

0.3 mm depth on 30% of area

0.1 mm depth on 30% of are a

O. 1 mm depth prior to and 0.2 mm depth after repair on 30% of area

0.1 mm depth prior to and 0.2 mm depth after repair on 50% of area

0.2 mm depth prior to and 0.3 mm depth after repair on 30% of area

0.05 mm depth prior to and 0.1 mm depth after repair on 30% of area

Max. permissible bore diameters: 8.02 mm 15.02 mm

They may be exceeded by 0.01 mm on one quarter of the bore circumference.

32.02 mm Min. permissible shaft diameter of bolts is 14.97 mm. 50% original contact surface must be maintained in an area of 4 mm around bore. Figure 41-44 BO 105 CHAPTER 41 Page 100

Control fork - damage and repair limits

e

eurocopter

TYPE OF DAMAGE

MAINTENANCE MANUAL BO 105

OAMAGE ANO REPAIR L1MITS ZONE 1

Mechanical

0.2 mm depth on 40% of area

Corrosion

0.1 mm depth prior to an 0.2 mm depth after repair en 40% of area

&

ZONE3

0.2 mm depth on 30%of area

0.1 mm depth on 30% of area

0.1 mm depth prior to an 0.2 mm depth after repair on 30% of area

0.05 mm depth prior to and 0.1 mm depth after repair on 30% of area

50% original contact area must be maintained in an area of 4 mm around bore.

Figure 41-45

Revision 22

-

ZONE2

Bearing block - damage and repair Iimits

CHAPTER 41 Page 101

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1 ZONE 2

ZONE 3

~~}}}I

~

-

Mechanical

0.1 mm depth on 30% of are a

0 .2 mm depth on 50% of area

0.2 mm depth on 50% of area

Corros ion

0.05 mm depth prior to and 0.1 mm depth after repair on 30% of area

0.1 mm depth prior to and 0.2 mm depth after repair on 50% of area

O. 1 mm depth prior to and 0.2 mm depth after repair on 50% of area

~

The max. permissible diameter of bushing bore is 8.0 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference.

~

50% original contact surface must be maintained in an area of 4 mm around bore. Figure 41-46

BO 105 CHAPTER 41 Page 102

Bearing support

- damage and repair tolerance limits

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5.

Inspect close-tolerance bolts (4, 13 and 18, figure 41-70) for mechanical damage, corrosion, wear, thread damage and deformation. a.

Polish out minor mechanical damage and corros ion with polishing cloth 400.

b.

Inspect bolts for serviceable limits. Minimum permissible shaft diameter is: 9.50 mm for bolt (4) 14.98 mm for bolt (13) 7.98 mm for bolt (18)

c.

Remove minor thread damage. Damage to thread is permissible on 30% of thread area provided mating nut can be screwed on easily by hand.

d.

Discard close-tolerance bolts if deformation is evident.

6.

Inspect guard washers for condition. Replace washers if damaged.

7.

Replace flanged bushing of control levers as follows: NOTE

a.

For replacement of flanged bushings in head with a clearance of 20.65 mm, use For replacement of flanged bushings in head with a clearance of 15.00 mm, use

control lever fork tool 105-42121 W4. control lever fork tool 105-42121 WS.

Press out flanged bushing with tool 105-42121 W4: 1)

Screw gauge block (4, figure 41~48) in intermediate ring (3) and insert ring in fork head of control lever (6).

2)

Install pusher (1). Hold intermediate ring and turn pusher until the gauge block with intermediate ring comes to rest free of play in the control 1ever fork head.

3)

Position control lever on support (5) and press out flanged bushing (2) with pusher (1).

4)

Inspect bore in control lever for mechanical damage and corrosion. Polish out damage with polishing cloth 400. Max. permissible diameter is 14.02 mm. It may be exceeded by 0.02 mm on one quarter of the bore circurnference.

BO 105 CHAPTER 41 Page 103

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

b.

c.

d.

e.

Press in flanged bushing with tool 105-42121 W4: 1)

Apply corrosion preventive compound (CM 505) to bore in control lever.

2)

Deburr flanged bushing, chill to approximately -50 oC and press in with tool 105-42121 W4 (see figure 41-49).

3)

Dimensionally inspect bore. If necessary, hone to specified diameter of 9.52 ± 0.005 mm and deburr.

Press back flanged bushing to specified dimension with tool 105-42121 W4: 1)

Screw gauge block (1, figure 41-50) in intermediate ring (2) and install ring in fork head of control lever.

2)

Insert pusher (3), hold intermediate ring and turn pusher until gauge block with intermediate ring comes to rest free of play in control lever fork head.

3)

Press flanged bushing (4) back with pusher (3) until it abuts against the gauge block.

Press out flanged bushing with tool 105-42121 W5. 1)

Press out flanged bushing, see figure 41-51.

2)

Inspect bore in control lever for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible diameter is 11.02 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference.

Press in flanged bushing with tool 105-42121 W5: 1)

Apply corros ion preventive compound (CM 505) to bore in control lever.

2)

Deburr flanged bushing, chill to approximately -50 oC and press in with tool 105-42121 W5 (see figure 41-52).

3)

Dimensionally inspect bore. If necessary, hone to specified diameter of 8.0 + 0.015 mm and deburr.

f.

Press back flanged bushing to specified dimension with tool 105-42121 W5: 1)

BO 105 CHAPTER

Page 104

41

Screw gauge block (1, figure 41-53) in intermediate ring (2) and insert in control lever (5).

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

8.

2)

Install pusher (4), hold intermediate ring and turn pusher until the gauge block with intermediate ring comes to rest in the control lever fork without play.

3)

Press flanged bushing (3) back with pusher (4) until it abuts the gauge block (1).

Replace ball bearings (32, figure 41-70) of control lever as follows: a.

Position control lever (3, figure 41-54) on support (4) and cut off staked edge of bushing (2) with tool 105-42121 W3 (1).

b.

Press out bushing with bearing using tool no. 4 (105-42121 W7) . Discard bushing with bearing.

c.

Inspect bore in control lever for rnechanical darnage and corrosion. Polish out darnage with polishing cloth 400. The rnax. permissible diameter is 36.03 mm. It rnay be exceeded by 0.02 mm on one quarter of the bore circurnference.

d.

Install bushing in control lever: 1)

Apply corros ion preventive compound (CM 505) to bore in control lever.

2)

Deburr bushing and chill to approximately -50 oC and press in with tool no. 4 (105-42121 W7) .

3)

Dimensionally inspect bore. If necessary, hone to specified diameter of 32 + 0,003 mm and deburr. - 0.013

e.

f.

Install ball bearing in control lever: 1)

Apply corros ion preventive compound (CM 505) to bushing.

2)

Deburr chamfered edge at contact surface of ball bearing outer race with honing stone.

3)

Press in ball bearing with tool no. 4 (105-42121 W7) .

Staking of ball bearing in control lever: 1)

Stake bearing with staking tool retainer 105-40001 W1 and with staking tool 105-42121 W6 as shown in figure 41-47.

2)

Apply required force by gradually increasing within 5 seconds to 80-85 kN.

BO 105 CHAPTER 41

Page 105

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3

--------~

'.

+---------- 2

41/32.1

1 2

Staking too1 holder Staking tool Figure 41-47

BO 105 CHAPTER 41 Page 106

3 4

BaH bearing Control lever

Staking of ball bearing wíth tool 105-40001 W1 and 105-42121 W6

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

2---+:~

41133

1 2 3

41133.A

Pusher Flanged bushing Interrnediate ring

Figure 41-48

Gauge block Support 6 Control lever

4 5

Pressing-out of flanged bushing with tool 105-42121 W4

1 2

Plunger Flanged bushing Figure 41-49

3 Support 4 Control lever

Pressing-in of flanged bushing with tool 105-42121 W4

3

2

'----5 41133.8

Gauge block Interrnediate ring 3 Pusher

1 2

Figure 41-50

4 Flanged bushing Control lever

5

Pressing-back of flanged bushing with tool 105-42121 W4 BO 105 CHAPTER 41 Page 107.

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

r+---2 41134

41133.(

1 Control lever 2 Support Figure 41-51

3 Flanged bushing 4 Plunger

Pressing-out of flanged bushing with tool 10S-42121 W5

1 Support 2 Flanged bushing Figure 41-52

3 Plunger 4 Control lever

Pressing-in of flanged bushing with tool 105-42121 WS 1 Cutter 2 Bushing 3 Control lever 4 Support

4

3 -~rz:;zrt""i7-r.,... 2-~'>..'"

41134.A

4

- f!:~¡ ¡ ~:¡;¡I I :I I I I:I I I I :l l li l:l l l l l1 1 1 1 1 1 1

41135

1 Gauge block 2 Intermediate ring 3 Flanged bushing Figure 41-53

BO lOS CHAPTER 41 Page 108

4 Pusher 5 Control lever

Pressing-back of flanged bushing with tool 10S-42121 W5

Figure 41-54

Cutting off flanged edge of bushing with tool 105-42121 W3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 9.

Replace flanged bushings of control fork as follows: a.

Replace flanged bushings (5, figure 41-55) in accordance with step 7.

b.

Rernove flanged bushings (2) as follows: 1)

position control fork (3) on tube section (4) of tool no. 5 (105-42122 W2) and cut off flange of flanged bushing (5) with cutter (1).

2)

Heat fork lever in the area adjacent to flanged bushings and press out both flanged bushings with rnandrel tool no. 5 (105-42122 W2) .

3)

Inspect bore in control fork for rnechanical darnage and corrosion. Polish out darnage with polishing cloth 400. The rnax. permissible diarneter is 18.02 mm. It rnay be exceeded by 0.02 mm on one quarter of the bore circurnference. Rework bore to a diarneter of 18.2 + 0.02 mm for installation of an oversize bushing.

__- - 2

5

I

41136.1

Figure 41-55

1

Itmr:tL

4

Cutter Flanged bushing 3 Control fork 4 Tube section 5 Flanged bushing

1 2

Rernoval of flanged bushings with tool No. 5 (105-42122 W2) BO 105 CHAPTER 41 Page 109

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Install flanged bushings: 1)

Apply corrosion preventive compound (CM 505) to bore in control fork.

2)

Deburr flanged bushing (2, figure 41-56), chill to approximately -50 oC and press in with mandrel (1) of tool no. 5 (105-42122 W2).

3)

Dimensionally inspect bore. If necessary, hone to specified diameter of 15 + 0.018 mm and deburr.

Ft----2

-J 41137.1

! 'l=:rr·-

/ / / / / / /

1/ / / / / / / /

Mandrel Flanged bushing Control fork 4 Tube section

1

2 3

Figure 41-56 BO 105 CHAPTER 41 Page 110

Pressing-in of flanged bushings with tool no. 5 (105-42122 W2)

-------------MBBHELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 10. Replace bolt (27, figure 41-70) of control fork (applicable to installation of bolts frórn inside into borehole of control fork. For installation of bolts frorn outside into borehole of control fork see step 11.). a.

Heat up control fork to approxirnately 70-80 oc.

b.

Position control fork on support, tool no. 9 and press out bolt.

c.

Inspect bore in control fork for rnechanical darnage and corrosion. Polish out darnage with polishing cloth 400. The rnax. perrnissible diarneter is 14.99 mm. The specified perrnissible diarneter rnay be exceeded by 0.02 mm on one quarter of the bore circurnference.

d.

Apply corros ion preventive cornpound (CM 505) to bore in control fork.

e.

Chill bolt (4, figure 41-57) to approxirnately -50 oC.

f.

Heat up control fork (5) to approxirnately 70-80 oC.

g.

Insert bolt frorn inside into bore of control fork. Position tube section (3) of tool no. 10 and washer (2) on bolt. Tighten hex nut (1) to pull bolt into bore until it abuts.

I'::;;~r---

2

¡----3

-;----5

41138

Figure 41-57

1 Hex nut M12x1.5 2 Washer 3 Tube section 4 Bolt 5 Control fork

Installation of bolt in control fork with tool no. 10 BO 105 CHAPTER 41 Page 111

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11. Replace bolt (27, figure 41-70) of control fork (applicable to installation of bolts frorn outside into borehole of control fork). a.

Rernove rollpin (1, figure 41-58) with drift (3.8 mm diarneter) .

b.

Heat control fork to approx. 70-80 oC.

c.

Position control fork on support (tool no. 9) and pull out bolt.

d.

Inspect bore in control Polish out darnaged area perrnissible diarneter is one quarter of the bore

e.

Apply corros ion preventive cornpound (CM 505) to bore in control fork.

f.

Chill bolt (2) to approx. -50 oC.

fork for rnechanical and corros ion darnage. with polishing c10th 400. The rnax. 20.02 mm. It rnay be exceeded by 0.02 mm on circurnference.

:!:t---7

........

5

¡~r: Contact surface

•••••

f

.

I .L.---~

400203.1

1 Rollpin Bolt 3 Control fork 4 Tube

2

Figure 41-58 BO 105 CHAPTER 41 Page 112

.",

I

~.--L.5 Washer 6 Hex head nut M12x1.5 7 Tube

Rernoval and installation of bolt in control fork

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

oc.

g.

Heat up control fork (3) to approx. 70-80

h.

Insert bolt from outside into bore of control fork. Position tube (7) and press bolt into bore until it abuts.

i.

Drill hole through control fork into bolt (3.8 mm diarneter spiral drill) .

j.

Install rollpin (1) and stake at both ends with 8 mm diameter steel ball.

k.

Pack cavity of rollpin with adhesive (CM 601) and seal off.

12. Replace ball bearing in bearing housing of control fork: a.

Press ball bearing (3, figure 41-59) with drift (1) tool no. 8 (105-42122 W1) from bearing housing (2).

b.

Inspect bearing housing for mechanical damage and corrosion. Polish out damage with polishing cloth 400. Max. permissible inner diameter of bearing housing: 27.995 mm. Min. permissible outer diameter of bearing housing: 32.0 mm.

c.

Press ball bearing (3) in bearing housing (2) with support (4) tool no. 8 (105-42122 W1) .

d.

Check ball bearing for proper running.

"41139.1 1 2

Drift Bearing housing

Figure 41-59

BaH bearing 4 Support

3

Removal and installation of ball bearing with tool No. 8 (105-42122 W1) BO 105 CHAPTER 41 Page 113

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

4

3----... 5---..p.",-"\ 2-----""""t--'

1 2 3 4 5

41140.1

Figure 41-60

Socket BaH bearing Flanged bushing Thrust piece Bearing support

Pressing-out of ball bearing with tool no. 6 (105-42124 W4)

13. Replace ball bearing (28, figure 41-70) of bearing support: a.

Press out ball bearing (2, figure 41-60) with tool no. 6 (105-42124 W4).

b.

Inspect bore of flanged bushing (3) for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible diameter is 32.02 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference. Replace flanged bushing if bore diameter is exceeded as follows: 1)

Press out flanged bushing with socket (1, figure 41-61) and thrust piece (4).

2)

Inspect bore in bearing support (2) for mechanical damage and corrosion. Polish out damage area with polishing cloth 400. The max. permissible diameter is 35.03 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference. r--4

r

I

l..

-+----'''''V

I

I

I I 2

3

41141.1

Figure 41-61 BO 105 CHAPTER

Page 114

41

1 2 3 4

Socket Bearing support Flanged bushing Thrust piece

Pressing out flanged bushing with tool no. 6 (105-42124 W4)

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

c.

Install flanged bushing with tool 105-42124 W1: 1)

Apply corrosion preventive compound (CM 505) to bore of rocker support.

2)

Place bearing support bolt (2).

3)

Insert guide bolt (3) in spring bolt.

4)

Deburr flanged bushing (5) and chill to approximately -50 oC.

5)

Slide flanged bushing over guide bolt and press into bore of bearing block with drift (4).

(6, figure 41-62) with bore on spring

..:::::

3

:~~

m.+:;~;~ii------

4

-------~~.

¡¡....------s

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

41142

1 Support 2 Spring bolt 3 Guide bolt Figure 41-62

4

Drift

5 Flanged bushing 6 Bearing support

Pressing-in of flanged bushing with tool 105-42124 W1 BO 105 CHAPTER 41

Page 115

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

Install ball bearing in flanged bushing with tool 105-42124 W1: 1)

Apply corros ion preventive compound (CM 505) to bore of flanged bushing.

2)

Place bearing support (5, figure 41-63) with flanged bushing (4) on spring bolt (6).

3)

Insert guide bolt (2) in spring bolt.

4)

Deburr chamfered edge at outer race of ball bearing (3) with honing stone.

5)

Slide ball bearing (3) and drift (1) over guide bolt and press bearing into flanged bushing with drift.

6)

Check ball bearing for proper running.

2--------ti~~

W'liA------ 3

4-------::::::::::m-""'fa

41143

1 Drift 2 Guide bolt 3 BaH bearing

4 Flanged bushing Bearing support Spring bolt Support

5 6 7

Figure 41-63 BO 105 CHAPTER 41 Page 116

Pressing-in of ball bearing with tool 105-42124 W1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 14. Replace flanged bushing (34, figure 41-70) of bearing support (23). a.

Insert adjustable spacer ring (4, figure 41-64) between flanged bushings of bearing support and adjust so that it abuts the fork arm inner surfaces.

b.

Place bearing support (2) on support (5) and press flanged bushings (3) from fork arms with plunger (1).

c.

Inspect bore in bearing support for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible diameter is 12.02 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference.

41144

1

2 3

Plunger Bearing support Flanged bushing

Figure 41-64

4 Adjustable spacer ring Support

5

Pressing-out of flanged bushing with tool 105-42124 W3

BO 105 CHAPTER 41 Page 117

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

Apply corrosion preventive compound (CM 505) to bore in bearing support.

e.

Deburr flange bushing and chill to approximately -50 oC.

f.

Press in flanged bushing (see figure 41-65).

g.

Measure distance between flanged bushings. Required distance: 12.7 + 0.03 mm. Rework if necessary.

h.

Inspect bore for dimensional accuracy, rework if necessary (e.g. with honing tool) . Diameter: 8.0 - 0.003 - 0.012

---~-

::::'::::::'~';:::;':':';::.;':':t:.:.:

.•".I.·...·:·:·.·a·~· :.',--.~•••••••••~. ~-

4----1-

5--~

3

41145

Installation of first flanged bushing

Support Flanged bushing Bearing support 4 Plunger

1 2 3

Figure 41-65

BO 105 CHAPTER 41 Page 118

Instal1ation of second flanged bushing

5

6 7

Plunger with threaded end Thrust plate Flanged bushing

Pressing-in of flanged bushings with tool 105-42124 W3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

15. Replace spherical bearing (33, figure 41-70) of bearing block (24). a.

Place bearing block (3, figure 41-66) with spherical bearing (2) in support (4) of tool no. 105-42123 W3 and cut off flanged portion of spherical bearing using cutter (1).

3

4

41146

Figure 41-66 b.

Cutter Spherical bearing Bearing block 4 Support

1

2 3

Cutting-off of staked portion of bearing with tool 105-42123 W3

Position bearing block (3, figure 41-67) on support (4) and press out spherical bearing (2) with the drift (1).

+----4 41146.\

1 Drift 2 Spherical bearing 3 Bearing block 4 Support

Figure 41-67 Pressing-out of spherical bearing with tool No. 7 (105-42123 W4) BO 105 CHAPTER 41

Page 119

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Inspect bores in bearing block for mechanical damage and corrosion. Polish out damage with polishing cloth 400. The max. permissible diameter is 17.48 mm. It may be exceeded by 0.02 mm on one quarter of the bore circurnference.

d.

Install spherical bearing in bearing block with tool 105-42123 W2: 1)

Apply corros ion preventive compound (CM 505) to the bore.

2)

Deburr edge of spherical bearing outer ringo

3)

position bearing block (4, figure 41-68) with bore over guide pin (2) on support (5).

4)

Slide spherical bearing over guide pin and press into bore of bearing block with flat side of drift (1).

" .........- 4

Drift Guide pin Spherical bearing 4 Bearing block 5 Support

1

2 3

41147

Figure 41-68

BO 105 CHAPTER 41 Page 120

Pressing-in of spherical bearing with tool 105-42123 W2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 e.

Stake spherical bearing in bearing bracket: 1)

Stake spherical bearing with staking tool retainer 105-40001 W1 and with staking tool 105-31821 W5 as shown in figure 41-69. Apply the required force approximately within 5 seconds by gradually increasing up to max. 54.5 kN.

2)

Measure breakaway torque of spherical bearing in circurnferential direction. Max. permissible breakaway torque must not exceed 100 Ncm.

~----2

3

41148

Figure 41-69

4

Staking tool retainer 2 Staking tool 3 Spherical bearing 4 Bearing bracket 1

Staking of spherical bearing with tool 105-40001 W1 and 105-31821 W5 BO 105 CHAPTER 41 Page 121/122

tteurooopter

MAINTENANCE MANUAL 80 105

,1

4 1 2 3

4 5 6 7 8 9 10

11 12 13

14 15

16 17 18 19 20

21 22 23

24 25 26 27

28 29

30 31 32 33 34 35

Split pin Nut Washer Close--tolerance bolt Screw Bearing housing with ball bearing Washer Guard washer Control lever, longitudinal Guard washer Nut Control lever, lateral Close--tolerance bolt Shim Washer Control fork Sliding sleeve Close--tolerance bolt Washer Nut Split pin Bolt Bearing support Bearing block Screw Washer Bolt Ball bearing Flanged bushing Flanged bushing Flanged bushing Ball bearing Special bearing Flanged bushing Washer

~-11116-22Nm I \+----10 ---"<:---

29 ' - - - 19 '----21 " ' - - - - 20

30----;~

'---19

11

22-...=;;:,.........?:~.

10

116-22 Nm 1 28--~

~---19

20 15,5-7,5

'----21

This washer is only required for bearing support configuration with flanged bushing and floating bushing. (See IPC for applicable PIN)

Figure 41-70 Mixing lever assembly - exploded view Revision 22

29

' - - - 20 1 4-6 Nm '-----21

~-4'.--33

&

12

CHAPTER 41 Page 123/124

Nml

I

14--6 Nm I

_eurooopter 41 - 69

MAINTENANCE MANUAL 80 105

Assembly - mixing lever assembly

1. Apply corrosion preventive compound (CM 505) to screws and close-tolerance bolts. 2.

Jnstall screws (25, figure 41-70) and washers (26) prior to assembly of bearing support (23) and bearing block (24).

3. Assemble bearing support (23) and bracket (24). 4. Assemble control fork (16) and bearing support (23). a. Measure and record inner dimension "A" of bearing support (figure 41-70A), while lightly pressing both bearing inner races outwards to remove any existing bearing play. b. Measure and record outer dimension "S" of control fork (figure 41-70A). c.

Determine required thickness of shim: A -2 S +0,000 -0,030

mm

d. Grind new shim (14, figure 41-70, original thickness = 2mm) or removed shim (itthickerthan required) to required thickness. Jt is recommended to use a flat grinder or equivalent. e. Install control fork in bearing support with a shim on both sides. 5. Tighten nuts to torque and secure with split pino

& 1 2 3

Required thickness of shim = A - S +0.000 mm 2 -0.030 . (grind shim to size)

Control fork Shim Searing support

Figure 41-70A Assembly of control fork and bearing support Revision 22

CHAPTER 41 Page 125

_eurocopter 41 - 70

MAINTENANCE MANUAL 80 105

Installation - mixing lever assembly

NOTE

Step 1. is only required if support tube, control fork, ball bearing, bearing housing or washer have been replaced. If this is not the case, begin with step 2.

1. Determine thickness of washers (7, figure 41-70) as follows: a.

Install bearing housing (6) with ball bearing in control fork arms and install screws handtight.

b. Measure distance A (figure 41-71) between faces of ball bearing inner races. c.

Measure distance B between studs on slidíng sleeve of swashplate.

d.

Determine thickness of washer: A

2B

e. If available washers are too thick, reduce to the specified dimension by polishing or similar process. 2. Apply corrosion preventive compound (CM 505) to screws and closetolerance bolts.

3. Position assembled control fork (16, figure 41-70), bearing support (23) and bearing block (24) on sliding sleeve (17). 4.

Install washer (7) with chamfered side towards sliding sleeve.

5. Install bearing housings (6) with ball bearings in control fork and secure with screws (5).

'm--+----3

1 2 3 4

Bearing housing Deep grove ball bearing Sliding sleeve Control fork

Figure 41-71

Determination of thickness of washers interposed between sliding sleeve and control fork

CHAPTER 41 Page 126

Revision 22

eeurocopter

MAINTENANCE MANUAL 80 105

6. Install bearing block (24) to flange of main transmission with washers (26) and screws (25).

NOTE

For position of guard washers relative to controllever, see IPC.

7. Slide guard washers (8), controllevers (9, 12) and guard washers (10) onto shank of bolts (27) of control fork and fasten with nuts (11). 8. Tighten nuts (11) and screws (5) and secure nuts with split pins (1) and screws with lockwire. 9.

Install control rods at mixing lever assembly. Tighten nut to maximum torque value. If split pin cannot be inserted, back off nut as appropriate. However, tightening torque must not be less then specified value. If necessary, use a new nut.

10. Inspect main rotor controls for freedom of movemEmt, control forces and rigging, refer to chapter 102. 11. Install fairings.

Revision 22

CHAPTER 41 Page 126A

_eurocopter

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 41 Page 1268

Revision 22

-------

41 - 71

-----=-==M:

MEB MANUAL HELICOPTERS_ BO 105 MAINTENANCE MEB

S wa s h p 1 a t e

----

12

2

9 3

7 --~

6 5 4

41114.2

1

. rotor head Maln

2 34

s~a~hPl~~~er assy Mlxln~ Rotatlng co ntrol rod

5 6

Boot Bearing ring

Figure 41-72

7 Control link 8 Control ring 9 Fork link sleeve 10 Shaft Inner sea 1 retainer Control lever

i~

Swashplate and adjacent assemblies BO 105 CHAPTER 41 Page 127

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2 3

9

4

I

3-5 Nm

5

6 7 8

1 2 3 4 5

Swashplate bearing Bearing ring BoH Screw Control ring Figure 41-73

41 - 72

6 7 8 9

Cardan ring BaH bearing Sliding sleeve Balance weight

Swashplate

Inspection and repair - swashplate

1.

The inspection for condition of the installed swashplate is described in paragraph 41-3, INSPECTION - MAIN ROTOR CONTROL.

2.

Repair swashplate as described in REM 403.

BO 105 CHAPTER 41 Page 128

I

- - - - - ' - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 73

Inspection of bearings - swashplate

Special tool: Spring scale Connection pin CAUTION

O - 100 N (cornmercial item) tool no. 27 (105-14102 W2), refer to chapter 04

BEFORE THE ROTATING PITCH CONTROL RODS ARE REMOVED, THE INNER SLEEVES AND ATTACHED ROTOR BLADES MUST BE SECURED AGAINST TWISTING OR PITCHING IN ORDER TO PREVENT THE TENSION-TORSION STRAPS FROM BEING EXCESSIVELY TWISTED AND CONSEQUENTLY DAMAGED.

l.

To prevent inner sleeves (10, figure 41-72) of main rotor head from twisting, move swashplate along sliding sleeve until rigging pin, tool no. 27 (105-14102 W2) or similar wooden pin can be inserted through rigging hole of control lever (12) and into hole in shaft seal retainer (11) onrotor armo

2.

Remove rotating control rods (4) from bearing ring (6) of swashplate (2).

3.

Remove fork link (9) of driving link assembly from bearing ring (6). Retain shims, if installed, for later re-installation. Swing fork link (4) upwards and secure against dropping.

4.

Remove clamp of boot (5) from bearing ring (6) and turn boot up.

5.

Inspect swashplate bearings (1, figure 41-73) for rolling friction as follows: a.

Attach a string to receptacle of fork link of driving link assembly on bearing ring (2) and wind string round bearing ring approximately 1 1/2 times.

b.

Attach a string to spring scale, then rotate bearing ring (2) relative to the stationary control ring (5) by slowly and evenly pulling on spring scale. The maximum permissible value for the force measured during one revolution of the bearing ring, not the breakaway force, is 60 N. The force fluctuation during one revolution of the bearing ring must not exceed 15 N.

c.

If, during the rolling friction test, one of the values specified in step b. is exceeded or if the bearing sticks at any point, remove and inspect the swashplate bearing as described in REM 403.

6.

Attach boot (5, figure 41-72) to bearing ring (6) with clamp as described in paragraph 41-75.

7.

Connect fork link (9) of driving link assembly to bearing ring (6) in accordance with para 13-23.

8.

Install rotating control rods (4, figure 41-72) on bearing ring (6). Torque-tighten nuts and secure with split pins. BO 105 CHAPTER 41 Page 129

cteurocopter 41 - 74

MAINTENANCE MANUAL SO 10S

Lubricatlon - swashplate

Lubricate swashplate bearings (1, figure 41-73) with grease (CM 101) through grease nipple(s) of bearing ring (2) until grease emerges from bearing seals. Gradually rotate bearing ring one full revolution, repeating this lubrication procedure at eight evenly distributed positions on bearing ring (5). Remove excess grease. CAUTION

41 - 75

MAKE SHURE THAT GREASE NIPPLE BALL IS STILL ON ITS PROPER LOCATION AFTER LUBRICATION

Replacement of boot - swashplate

CAUTION

CLAMPS WHICH HAVE NOT BEEN FASTENED CORRECTLY, I.E. TORQUE OF SECURING SCREW TOO HIGH OR TOO LOW, MAY DETACH AND CAUSE DAMAGE TO THE HELlCOPTER

1. Remove clamps and cable straps from boot (5, figure 41-72). 2. Remove and discard damaged boot. 3. Place a new split boot around rotor mast and bearing ring (6) and fit the slide-in sections of the boot into one another. 4. Secure boot: a. Secure lower collar of boot to bearing ring with clamp as described in step c. b. Secure upper collar of boot to rotor mast with clamp as described in step c. The clearance between upper edge of collar and upper edge of rotor mast flange shall be approximately 83 to 87 mm, as shown in figure 41-74. c.

Fit clamps. NOTE

The turnbuckle screws must be torqued to 0.5 Nm respective worm-type screws must be torqued to 0.7-0.8 Nm. Clamps may snap iftorque is higher, or work loose if torque is lower. Also refer to CAUTION.

1) For clamps with turnbuckle screw only: a) Coat thread of turnbuckle screw with sealant (CM 624) and screw it ¡nto turnbuckle. Torque to 0.5Nm. b) Coat screw head and screw thread on turnbuckle with sealant (CM 623).

CHAPTER 41 Page 130

Revision 21

MAINTENANCE MANUAL 80 105

EUROCOPTER

2)

For clamps with worm-type screw only: a)

*

Insert end of clamp into worm-type screw and turn screw to tighten the clamp. Torque value: 0.7 - 0.8 Nm.

*

*

* * d. Lace each of the two boot folds with two interlocked cable straps. * Install the cable straps in such a way that their joints are opposite * one another and at an angle of 90° to the split line of the boot. e.

After the boot has been installed, reinspect clamps for correct position and secure installation.

BO 105

Revision 13

CHAPTER 41 Page 130 AIB

* *

* *

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

E

E

~

,----+-----el:::::---;-L,.:;t----2

400730

1 Clamp 2 Cable straps 3 Clamp

Figure 41-74

Installation dimensions of boot - swashplate

BO 105 CHAPTER 41 Page 131/132

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

41 - 76

Con t rol

41 - 77

Removal - control rods in non-boosted section of the controls

1.

2.

3.

r o d s

a n d

1 i n k s

Removal control rods (1, 7, 27 and 28, figure 41-1) a.

Remove nose access door.

b.

Remove rubber rope from control rods.

c.

Remove attaching parts of the control rods to be removed and detach control rods.

Removal control rods (20, 21 and 23) a.

Remove copilot seat, left seat rails and lap belt attach fitting, refer to chapter 701.

b.

Remove bench seat, refer to chapter 800.

c.

Remove left floor plate of the cable duct.

d.

Remove attaching parts of the control rods to be removed and detach control rods.

Removal control rod (18) a.

Remove copilot seat, left seat rails and lap belt attach fitting, refer to chapter 701.

b.

Remove bench seat, refer to chapter 800.

c.

Remove left floor plate of the cable duct.

d.

Remove left cargo compartment panelling, as necessary, refer to chapter 703.

e.

Remove left engine cowling, refer to chapter 22.

f.

Remove attaching parts of the control rod to be removed and detach control rod.

BO 105 CHAPTER 41 Page 133

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 41 - 78

l.

Removal - control rods and links in the boosted section of the controls

Removal control rods (13, figure 41-1) Special tool:

2.

a.

Remove left engine cowlings, refer to chapter 22.

b.

Install lockring 1xS6 150 123 on the main rotor mast between support tube and transmission flange. This will prevent the swashplate from dropping when the control rods are removed.

c.

Remove attaching hardware of the control rods to be removed and detach control rod.

Removal control rods (17) Special tools: Connection pin Lock ring a.

tool no. 27 (105-14102 W2) 1xS6 150 123

refer to chapter 04

Install lock ring 1xS6 150 123 on the main rotor mast between support tube and transmission flange. This will prevent the swashplate from dropping when the control rods are removed.

CAUTION

3.

lock ring 1xS6 150 123

BEFORE THE ROTATING PITCH CONTROL RODS ARE REMOVED, THE INNER SLEEVES AND ATTACHED ROTOR BLADES MUST BE SECURED AGAINST TWISTING OR PITCHING IN ORDER TO PREVENT THE TENSION-TORSION STRAPS FROM BEING EXCESSIVELY TWISTED AND CONSEQUENTLY DAMAGED.

b.

If the main rotor blades are to remain installed during removal of the control rods, they must be secured against pitching by means of connection pin tool no. 27 (105-14102 W2) .

c.

Remove attaching parts of the control rod to be removed and detach control rod.

Removal control links (15) a.

Remove attaching hardware of the control link to be removed.

b.

Detach control link.

BO 105 CHAPTER 41 Page 134

EUROCOPTER

41 -79

MAINTENANCE MANUAL BO 105

Disassembly - control rods

Special tools: Alignment gauge Supplementary Kit Adjustment gauge NOTE

105-41482 L1 105-41482 L2 105-13101 W3

o This paragraph 41~79 applies only to control rods with removable rod ends. o To avoid the need to carry out a flight controls rigging check, it is recommended that before disassembling the control rods the installed dimension 'X', refer to figure 41-75, be measured. For this purpose use alignment gauge 105-41482 L1 for those control rods having spherical bearings with an internal diameter of 6.0 mm. With spherical bearings having an internal diameter of 8.0 mm and 9.52 mm use, in addition, supplementary kit 105-41482 L2.

1.

Prior to disassembling the rotating control rods, check for legibility of the P/Ns markedon both rod ends. Ifthe PIN is no longer legible, use the P/N of the rotating control rod to find the P/N of the associated rod ends in the IPC. Apply P/N with wipe-proof paint.

lA. Establish control rod assembled dimension 'X' . 2.

Remove any control rod sealant from the rod ends.

3.

Remove locking wire, then loosen nut (3, figure 41-75) and unscrew the rod ends (1 and 6) from the control rod tube (5), noting the right- and left-hand threads.

4.

Remove serrated washer (4) and nut from rod ends.

Revision 16

BO 105 CHAPTER 41 Page 135

* * * * * *

EUROCOPTER

MAINTENANCE MANUAL 80105

I 1..... - - - - - - - "X" - - - - - -.... .,~i

I

18-12 Nm I

I

1 8 -12 Nm

I

I

3Jm ,), :J¡~

~' 2

1 Rod end 2 Spherical bearing 3 Nut 4 Serrated washer 5 Control rod tube 6 Rod end

2

400640

Figure 41-75

BO 105 CHAPTER 41 Page 136

Control rod - disassembled

Revision 16

MAINTENANCE MANUAL 80 105

EUROCOPTER

41 - 80

Inspection and repair - control rods and links

Special tool: 1.

Hot air blower (200

oc

capacity)

Inspect control rods 1, 7, 18, 20, 21, 23, 27 and 28, (figure 41-1) and the three control rods of the hydraulic system CONFIGURATION I with adjustable rod ends as follows: a.

Inspect rod end and rod end threads for mechanical damage and corrosion. Check for presence of red marking compound on rod end threads. 1)

If rod end threads show signs of corros ion, replace rod ends.

2)

Polish out any damage within the limits specified in figure 41-81 and final polish with polishing cloth 400.

3)

Restore the surface finish with two-component zinc chrornate primer (CM 417) .

4)

If necessary, apply red marking compound to rod end threads over a length of 25 mm from the bottom of the threads.

b.

Check the play of rod end spherical bearings (perrnissible radial play 0.1 mm). Inspect for signs of corrosion and check for ease of movemento If any damage is detected, replace the affected rod end inc1uding the spherical bearing or replace the spherica1 bearing as outlined in chapter 02, whichever is required by the type of the assembly.

c.

Inspect tube for cracks, deforrnation, other mechanical damage and corrosion. 1)

Inspect threads in control rod tube for corros ion; replace tube if threads are corroded.

2)

Replace control rod tube if cracks or deforrnation are presento

3)

Polish out mechanical damage and corrosion as outlined in chapter 02. Refer to figure 41-79 for damage and repair limits. Restore the surface finish with two-component zinc chromate primer (CM 417) and coating lacquer (CM 402) .

Revision 16

BO 105 CHAPTER 41 Page 136A

MAINTENANCE MANUAL 80 105

EUROCOPTER

EFFECTIVITY d.

Step d. applies only to control rods on BO 105 S model helicopters.

Check the chafing protection of control rods (1 or 2, figure 41-76) in left side of fuselage for wear and security of attachment. If necessary, replace the chafing protection as follows: 1)

Remove damaged and loose pieces, taking care not to damage the control rods.

2)

Clean those areas from which the loose pieces have been removed with dry cleaning solvent (CM 202) .

3)

Cut pieces of shrink tubing as required. For length, see figure 41-76.

--rr-120t2

..... " (o:mm:

:::;:::1

I

1 - 270+5 1 - - - - - 667 +5

1 - - - - - - - 962+5------~

120

t2

Tr-

~llIlIe

1::::::;:(

1.. 1

- !-- .1

1_=------110-7_t2 1-40-2-t2-=--=--=--=--=--=--=-.. 400127.6

. Dimensions in mm Figure 41-76

1 Longitudinal control rod 2 Lateral control rod Chafing protection - installation dimensions

4)

Slide the pieces onto the control rod and position in accordance with the dimensions given in figure 41-76.

5)

During the shrinking operations protect the areas of the control rod adjacent to the fitted pieces from the effects of heating.

6)

Heat the pieces of shrink tubing with the hot air blower. The temperature must not exceed 170 oC and the shrinkage process must be complete after approximately 90 seconds.

7)

Allow the shrink tubing to cool, then check that it is correctly seated. It must fit evenly and without creases over its entire length.

BO 105 CHAPTER 41 Page 136B

Revision 16

ELlROCOPTER

2.

Control rods (1, 7, 20, 23, 27 and 28, fig. 41-1) CONFIGURATION 11, with non-adjustable rod ends. a.

b. 3.

MAINTENANCE MANUAL 80 105

Inspect rod ends for mechanical damage and corrosion. 1)

Remove damage that is within the damage and repair limits shown in fig. 41-81 and final polish with polishing cloth 400.

2)

Coat reworked area with two component zinc chromate primer (CM 417).

* *

*

Proceed with inspection according to step 1, b. thru d.

Control rod (13, figure 41-1) a.

Inspect control rod as described under steps 1. a. and c.

b.

Refer to figure 41-80 for damage and repair limits for control rod tubes.

c.

Inspect spherical bearings in rod ends for radial play (permissible: 0.1 mm) and axial play (permissible: 0.4 mm), evidence of corrosion and binding. If any such damage is present, replace assernbled rod end and spherical bearing or spherical bearing only as outlined in chapter 02.

Revision 10

BO lOS CHAP'l'ER 41 Page 137

* * * *

*

* * *

EUROCOPTER

MAINTENANCE MANUAL 80 105

~

Inspect this area of rod end for cracks. Pay particular attention to base of threads.

~

Wrap rod end and spherical bearing in adhesive tape.

400562

Figure 41-77 4.

* * * * *

5.

Crack inspection of rod end

Control rod (17, figure 41-1) a.

Inspect rod end and rod end threads for rnechanical darnage and corrosion. If any damage is detected, replace rod end.

b.

Inspect threaded area of rod end for cracks as follows: 1)

Wrap affected spherical bearing and rod end in suitable adhesive tape to prevent cleaning solvent and wet developer frorn entering the bearing (refer to fig. 41-77).

2)

Inspect threaded area of rod end for cracks, using the fluorescent-rnagnetic particle inspection or the fluorescent penetrant inspection (refer to fig. 41-77).

3)

If cracks are evident, replace rod end.

c.

Inspect spherical bearings in rod ends for radial play (perrnissible: 0.2 mm) and axial play (permissible: 0.4 mm), evidence of corros ion and binding. If any such darnage is present, replace assembled rod end and spherical bearing or spherical bearing only, depending on the configuration, as outlined in chapter 02.

d.

Inspect control rod tube in accordance with step 1.c. In addition, visually inspect collar of rods 105-13121 for cracks (refer to figure 41-80). For darnage and repair lirnits of control rod tubes refer to figure 41-80.

Control link (15, figure 41-1) a.

Inspect control link for deforrnation, rnechanical darnage and corrosion. 1)

Replace if deformed.

2)

Polish out rnechanical damage and corrosion as outlined in chapter 02 then restore surface protection. Refer to figure 41-78 for darnage and repair limits.

BO 105 CHAPTER 41 Puge 138

Revision 10

MAINTENANCE MANUAL 80 105

EUROCOPTER

b.

Inspect spherical bearings for radial play (permissible: 0.1 nun) and axial play (permissible: 0.4 nun) evidence of corrosion and binding. If any such damage is present, replace spherical bearings as outlined in chapter 02.

400641.1

TYPE OF OAMAGE

OAMAGE ANO REPAIR LIMITS ZONE 1 ZONE 2

Wdj Mechanical

Wii¡i¡i¡t!@!1

0.1 mm depth on 30% of the surface

Oamage in direction CD , 0.2 mm depth and 10 mm long

-

ZONE 3

0.1 mm depth on 10% of the surface

Damage in direction ® , 0.1 mm depth and 3 mm long Note Corrosion

0.1 mm depth on 30% of the surface after repair

0.1 mm depth on 10% of the surface after repair Note

&

& 0.1 mm depth on 10% of the surface afteJ: repair

&

Maximum of three repairs is permissible on one quarter of the circumference only. Minimum distance between two repair areas is 2 nun. Figure 41-78

Revision 10

Control links - damage and repair limits

BO 105 CHAPTER 41 Page 139

*

* *

MAINTENANCE MANUAL

EUROCOPTER

eo 105

400642

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS

-

Mechanical

-

ZONE 2

ZONE 1

0.3 mm in depth on 30% of the surface

0.3 mm in depth on 30% of the surface after repair

Damage in direction G) , 0.1 mm in depth and 10 mm in length

Damage in direction ® , 0.1 mm depth and 5 mm in length

Damage in direction ® , 0.1 mm depth and 3 mm in length

&

&

0.1 mm in depth on 10% of the surface after repair Note

~

[[ffiIT]

Damage in direction G) , 0.2 mm in depth and 20 mm in length

Note Corros ion

ZONE 3

&

Note

&

0.1 mm in depth on 10% of the surface after repair Note

&

50% of the original contact surface must remain in an area of 2 mm around the bore.

Maximum of eight repairs are permissible on one quarter of the circumference only. Minimum distance between adjacent repair areas is 2 mm. Figure 41-79

BO 105 CHAPTER 41 Page 140

Control rods - damage and repair limits (Non-boosted section)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3

3

400642.1

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS

Mechanical

-

ZONE 1

0 .3 mm in depth on 30% of the surface

-

_

ZONE 2

ZONE 3 :. .......... ......... ................... .......... .........

Damage in direction CD 0.1 mm in depth and 10 mm in length

No damage permissible

Damage in direction ® , 0.1 mm depth and 3 mm in length Note Corros ion

0.3 mm in depth on 30% of the surface after repair

0.1 mm in depth on 10% of the surface after repair Note

~

& ~

& No damage permissible

&

50% of the original contact surface must remain in an area of 2 mm around the bore. Maximum of five repairs are permissible on one quarter of the circurnference only. Minimum distance between adjacent repair areas is 2 mm. Visually inspect collar of rods 105-13121 for cracks. Figure 41-80

Control rods - damage and repair limits (Boosted section) BO 105 CHAPTER 41 Page 141

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400683

TYPE OF DAMAGE

Mechanica1 and corros ion

DAMAGE AND REPAIR LIMITS ZONE 1 ZONE 2

ZONE 3

0.1 mm in depth on 40% of the surface

No damage or repair permissible

Note

&

&

-

0.2 mm in depth on 60% of the surface

Note

&

Maximum of three repairs permissible. Figure 41-81

BO 105 CHAPTER 41

Page 142

Rod end with spherical bearing - damage and repair limits

MAINTENANCE MANUAL 80105

EUROCOPTER

41 - 81

Assembly - control rods

1.

Ensure presence of red marking compound on rod end (also refer to para 41-80, step 1.). Using grease (CM 140), lightly lubricate threads of those rod ends which have not been sealed with silicone rubber.

2.

Install nut (3, figure 41-75) to the rod end.

2A. If the rod end P/Ns are illegible, thereby making it impossible to ensure correct pairing with their corresponding rotating control rods, they must not be used on helicopter models B0105-CB-5, C8S-S and D8S-S. 3.

Place the serrated washer (4) in position. NOTE

When fitting the rod end, pay attention to the following points: o

The rotating control rods (pitch links) have right-hand threads of different pitch on either end.

o

All other control rods are furnished with one right-hand and one left-hand thread.

o

Both rod ends must be screwed in by the sa~e amount and the red markings on the thread ends must not be visible above the tightened nut.

4.

Install the rod ends in the tube of the control rod.

5."

Reset control rod to original assembled dimension 'X' (refer to figure 41-75) using the adjusting gauge and, if necessary, the extension kit. Adjust rod ends of the control rod (11, figure 41-83) to an angle of 45 degrees to each other, using the adjusting gauge; refer ~o figure 41-83, detail A.

6.

Tighten nut (3, figure 41-75) and secure with locking wi=e to serrated washer. NOTE

o If main rotor controls need not be inspected, seal rod end connection with silicone rubber. o In the case of rotating pitch links, seal the upper (coarsethreaded) rod end using silicone rubber only.

7.

Seal rod end connection with silicone rubber (CM 612 or CM 619); refer to figure 41-82.

Revisio!'! 16

BO 105 CHAPTER 41 Page 143

* * * * * * *

EUROCOPTER

MAINTENANCE MANUAL 80105

3

2

1 Rod end 2 Nut 3 Serrated washer

4 Silicone rubber Control rad

5 400682

5

4

Figure 41-82

BO 105 CHAPTER 41 Page 144

Sealing af rod ends

Revision 16

EUROCOPTER

41 - 82

1.

2.

3.

MAINTENANCE MANUAL 80 105

Installation - control rods in the non-boosted section of the controls

Installation of control rods (1, 7, 27 and 28, figure 41-1) a.

Insert control rods and secure with attaching parts.

b.

Tighten nuts to a torque value of 5-6 Nm and secure with split pins.

c.

Install rubber rope on control rods.

d.

Check control rods for freedom of movement.

e.

Carry out a foreign object check then close the access door.

Installation of control rods (20, 21 and 23, figure 41-1)

a.

Insert control rods and secure with attaching parts.

b.

Tighten nuts with a torque value of 5-6 Nm and secure with split pins.

c.

Check control rods for freedom of movement.

d.

Carry out a foreign object check.

e.

Install left floor plate of cable duct.

f.

Install bench seat, refer to chapter 800.

g.

Install left seat rails, lap belt attach fitting and copilot seat, refer to chapter 701.

Ir.stallation of control rod (18, figure 41-1) a.

Insert control rod and secure with attaching parts.

b.

Tighten nuts to a torque value of 5-6 Nm and secure with split pins.

c.

Check control rod for freedom of movement.

d.

Carry out a foreign object check.

e.

Install left cargo compartment panelling, refer to chapter 703.

f.

Install left floor plate of cable duct.

g.

Install bench seat, refer to chapter 800.

h.

Install left seat rails, lap belt attach fitting and copilot seat, refer to chapter 701.

i.

Install left engine cowling, refer to chapter 22.

Revisbn 16

BO 105 CHAPTER 41 Page 144A/B

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUALMBB - BO 105

-------------MBB

41 - 83

1.

2.

Installation - control rods and links in the boosted section of the controls

Installation of control rod (13, figure 41-1) a.

Insert control rod and secure with attaching hardware.

b.

Tighten nuts to a torque value of 5-6 Nm and secure with split pino

c.

Remove lock ring from main rotor masto

d.

Check control rod for freedom of movement.

e.

Install left engine cowling, refer to chapter 22.

Installation of control rod (17, figure 41-1) NOTE

o Tighten nut to maximum torque value. If split pin cannot be inserted, back off nut as appropriate. However, tightening torque must not be less than specified value. If necessary, replace nut. o The rod end with the coarse thread shell be connected to the control lever.

3.

a.

Install control rods and secure with attaching parts (see figure 41-83). Torque nuts and secure with split pins. Check angle of rod ends to each other, using adjusting device 105-13101 W3; refer to figure 41-83.

b.

Remove lock ring from main rotor control.

c.

Remove blade connection pins from the bores in the control levers and seal retainers of the main rotor head.

d.

Check control rods for freedom of movement.

Installation of control link (15, figure 41-1) a.

Insert control link and secure with attaching hardware.

b.

Tighten nuts to a torque value of 5-6 Nm and secure with split pins.

c.

Check control link for freedom of movement.

BO 105 CHAPTER 41 Page 145

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Configuration 1

IS-7Nm

I

A

•

6 - - - -......

~~2J .

-

-...: ..

S----...

4 - - - -......

10--"""'\ IS-7Nm

I

9~ 8

\

Configuration 111

Configuration 11 6 - - - -...... !S-7Nm

I

S ----"""'\

6-------...

I 8-10 Nm I

4 - - - -......

S ------.. 4-------...

&

3 -~:lIzDdLl:~

11-----'~ 12

10 IS-7Nm

I

12

9~. 8

IB-

\

10Nm

l

B~ -r'

8

\

7

400501.2

Configuration 1 Configuration 11 Configuration 111 ~

&

Control rod lockwasher Control rod Control rod lockwasher,

attachment with existing bores, without attachment with early type bolt and lockwasher attachment with new type stainless steel bolt, and counterbored washer

Mark assembled attaching hardware with safety lacquer. Install lockwasher oriented relative to adjoining abutment surfaces as shown Fig. 41-83 (1 of 2)

BO 105 CHAPTER 41

Page 146

Installation control rod (rotating)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

/ DETAlL

A

13--+

100248.2

1 2 3 4 5 6

Control rod (rotating) Washer Bolt Bushing Nut Split pin

Figure 41-83 (2 of 2)

7

BoH

8 9 10 11 12 13

Split pin Nut Washer Lockwasher Counterbored washer Adjusting device 105-13101 W3

Angular adjustment of rod ends rotating control rods

BO 105 CHAPTER 41 Page 147/148

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

42

TAl L R O T O R C O N T ROL S

Table of Contents

Page

Paragraph

Title

42

DESCRIPTION - TAIL ROTOR

1

CONTROLS

3

42 - 2

RIGGING - TAIL ROTOR

42 - 3

INSPECTION FOR CONDITION - TAIL ROTOR

42 - 4

P e d a 1 s

42 - 5

Removal - pedal upper assembly RH/LH

9

42 - 6

Disassembly - pedal upper assembly RH/LH

9

42 - 7

Inspection and repair - pedal upper assembly RH/LH

11

42 - 8

Removal - pedal lower assembly RH/LH

18

42 - 9

Inspection and repair - pedal lower assembly RH/LH

19

42 - 10

Installation - pedal lower assembly RH/LH

21

42 - 11

Assembly - pedal upper assembly RH/LH

22

42 - 12

Installation - pedal upper assembly RH/LH

22

42

Removal - bellcrank

23

42 - 14

Inspection and repair - bellcrank

24

42 - 15

Installation - bellcrank

27

42 - 16

RemovaJ. - jackshaft

27

42 - 17

Disassembly - jackshaft

29

42 - 18

Inspection and repair - jackshaft

30

42 - 19

Assembly - jackshaft

34

42 - 20

Installation - jackshaft

34

13

a n d e

CONTROLS

on

t rol

3

CONTROLS

1 i n k a g e

4 9

BO 105 CHAPTER 42 Page 1

MAINTENANCE MANUAL BO 105

EUROCOPTER

Title

42 - 21

Removal - torsion tube with bearing support and bearing . . .

* * 42 - 22 *

42 - 23

* * 42 - 24 * 42 - 25

34

F r e e Inspection and repair - torsion tube with bearing support and bearing

36

F r e e

Installation - torsion tube with bearing support and bearing

40

42 - 26

Removal - bellcrank

40

42 - 27

Inspection and repair - bellcrank

42

42 - 28

Installation - bellcrank

42

Removal - yaw brake .

42

42 - 28B

Inspection and repair - yaw brake

42B

42 - 28C

Installation - yaw brake

42C

42 - 29

Con t rol

42

Removal - control links and control rods in fuselage

420

42 - 31

Removal - control rods in tail boom

43

42 - 32

Oisassembly - control rods

43

42 - 33

Inspection and repair - control links and control rods

44

42 - 34

Assembly - control rods

48

42 - 35

Installation - control links and control rods in fuselage

48

42 - 36

Installation - control rods in tail boom

49

* 42 - 28A

* * * * * * * *

Page

Paragraph

30

BO 105 CHAPTER 42 Page 2

1 1n k s

a n d con t rol

r o d s

420

Revision 11

MAINTENANCE MANUAL MBB - 80 105

42 - 1

DESCRIPTION - TAI1 ROTOR CONTR01S

The tailrotor blade pitch is increased or decreased by actuating the tail rotor control pedals. The minimum and maximum blade pitch settings are limited by adjustable mechanical stops. When dual controls are fitted, the pilot's pedals are connected tothe copilot's pedals by a transverse control rod located below the floor. The pedal control inputs are transmitted by control rods and bellcranks to the sliding sleeve mounted on the tail rotor gearbox. The sliding sleeve transmits the control inputs via the two rotating pitch links to the control levers attached to the blade mounting forks, thereby changing the blade pitch angle.

42 - 2

RIGGING - TAI1 ROTOR CONTR01S

For rigging of the tail rotor controls, refer to chapter 102. NOTE

Dimension X, referred to in the following, can be determined using alignment gauge, P/N 105-41482 11 and supplementary kit, P/N 105-41482 12.

A rigging check is required in the following cases: when a new control rod is installed and it is not certain that its assembly length, dimension X (measured from center - to - center of rod end bearings), is exactly equal to the corresponding dimension of the removed control rod. when it is not certain that dimension X of a removed control rod was measured prior to its disassembly. following certain maintenance measures. when damaged stop screws have been repláced, or when it is not certain after replacement or total disassembly of parts that the rigged condition of the tail rotor controls has remained unchanged.

Revision 6

BO 105 CHAPTER 42 Page 3

* *

EUROCOPTER

42-3

MAINTENANCE MANUAL BO 105

INSPECTION FOR CONDITION - TAIL ROTOR CONTROLS

1. Check tail rotor controls for ease of movement, freedom of movement and absence of play before inspecting individual parts of the linkage system. If there is evidence of roughness, binding or play, locate damage area and perform corrective measures. •

2.

Inspect pedal upper assembly as follows: a.

Inspect visible areas of pedals (40, figure 42-1), pedal support (42) and base support (41) for mechanical damage and corrosion. Remove mechanical damage and corrosion with suitable tools and final polish with abrasive cloth 400. Refer to figure 42-3, 42-4 and 42-5 for respective damage and repair Iimits.

b. Touch up or renew damaged surface protection, using two-component wash primer (CM 423) followed by coating lacquer (CM 402) as outlined in Chapter 02.

•

3.

c.

Check that split pins are in place in all attaching hardware. If a split pin is missing, tighten the affected attaching hardware and secure with split pino

d.

Inspect boots fer tears, porosity and security of installation. Replace damaged boots.

e.

Check pedal adjusting mechanism for proper functioning. Screw spindle (43, figure 42-1) in and out several times. 80th pedals (40) must change their positions.

Inspect pedallower assembly as follows: a. Open nose access cover. b.

Inspect be!lcrank (39) for mechanical damage and corrosion. Remove mechanical damage and corrosion with suitable tools andfinal polishwith abrasivecloth400. Fordamage and repairlimits, refertofigure 42-11. Touch up or renew damaged surface protection, using two-componentwash primer (CM 423) followed by coating lacquer (CM 402) as outlined in Chapter 02,.

c.

Check stop screws (7, figure 42-7) for condition and tightness; replace damaged screws. Following the replacement of stop screws, check the tail rotor control rigging and rerig as necessary (refer to Chapter 102).

d.

Inspect control rod (1, figure 42-1). 1) Inspect control rod for mechanical damage andcorrosion. If damaged, remove control rod and . repair in accordance with Chapter 41. 2) Check spherical bearings for play and ease of movement. If radial play exceeds 0.1 mm or roughness is evident (it must be possible to move control rod by hand), replace spherical bearings as outlined in Chapter 02.

CHAPTER 42 Page4

Revision 18

EUROCOPTER

e.

MAINTENANCE MANUAL 60105

Inspect controllinks (8, 9 and 34, figure 42-1). 1) Inspect controllinks for mechanical damage and corros ion. Remove mechanical damage and corrosion with suitable tools and final polish with abrasive cloth 400. For damage and repair Iimits, refer to figure 42-23.

2) Touch up or renew damaged surface protection, using two-eomponent wash primer (CM 423) followed by coating lacquer (CM 402) as outlined in Chapter 02. 3) Inspect spherical bearings for play, signs of corrosion and ease of movement. Replace spherical bearing per Chapter 02 if radial play exceeds 0.1 mm, corrosion is evident, or ease of movement is impaired.

4. Inspect control rod (1, figure 42-24).

5.

6.

a.

Fold back floor covering as far as necessary and remove side duct cover.

b.

Inspect control rod for mechanical damage and corrosion. If damage is present, rework control rod per instructions in Chapter 41. If necessary, remove, disassemble and inspect condition of control rod per paragraphs 42-30, 42-32 and 42-33, respectively.

c.

Inspect seal on rod end of control rod forcondition. If damaged, remove seal and unscrew and remove rod end (referto chapter 41). Ifthere are signs of corros ion on rod end threads oron mating threads in the tube, replace rod end or tube as necessary. If there is no corrosion, install rod end and apply new seal (refer to Chapter 41).

d.

Check spherical bearings for play and ease of movement. If radial play exceeds 0.1 mm or roughness is evident (it must be possible to move control rod by hand), replace spherical bearings as outlined in Chapter 02.

e.

Inspect and, if necessary, replace chafe protection sleeves per paragraph 42-33, step 4.

Inspect control rod (22). a.

Remove vertical fin fairing per paragraph 42-31.

b.

Inspect control rod for mechanical damage and corrosion. If damage is present, rework control rod per instructions in Chapter 41. If necessary, remove, disassemble and inspect condition of control rod per paragraphs 42-31,42-32 and 42-33, respectively.

c.

Inspect seal on fork end of control rod for condition. If damaged, remove seal and unscrew and remove fork end (refer to chapter 41). If there is evidence of corrosion on fork end threads or on mating threads in the tube, replace fork end ortube, as applicable.lfthere is no corrosion, install fork end and apply new seal (refer to chapter 41).

d.

Check spherical bearings for play and ease of movement. If radial play exceeds 0.1 mm or roughness is evident (it must be possible to move control rod by hand), replace spherical bearings as outlined in Chapter 02.

Inspect control rod (21, figure 42-24). a.

Remove control rod per para. 42-31.

b.

Inspect control rod for mechanical damage and corrosion. If damage is present, rework control rod per instructions in Chapter 41.1f necessary, disassemble and inspect condition of control rod perparagraphs 41-79 and 41-80, respectively.

Revision 18

CHAPTER 42 Page5

•

I

EUROCOPTER

c.

MAINTENANCE MANUAL BO 105

Inspect chafe protection sleeves per paragraph 42-33 and replace as necessary.

d. Install control rod per para. 42-36. 7. Inspect bellcrank (31, figure 42-24) or, if installed, yaw brake. a. Inspect bellcrank: 1) Wherever possible in installed position, visually inspect bellcrank for cracks, corrosion, mechanical damage, and damaged surface protection. a) Replace cracked bellcrank. Refer to para 42-26 for removal procedure. b) Polish out mechanical and corrosion damage, and final polish with 400 grit abrasive cloth. See figure 42-11 for damage and repair limits. c) Touch up or renew damaged surface protection per Chapter 02, using two-component wash primer (CM 423) followed by coating lacquer (CM 402). 2) Check that all attaching hardware is secured with split pins. If split pin is missing, retighten Nylstop nut as necessary and secure with split pino See fig. 42-20 for torque loads. b.

Inspect yaw brake: 1) Remove and inspect yaw brake for condition per paragraph 42-28A and 42-288. 2) Install yaw brake and adjust per paragraph 42-28C.

8. Visually inspect bearing support (9, figure 42-17) wherever possible in installed position for cracks, corrosion, mechanical damage and damaged surface protection, and inspect surrounding fuselage structure for condition. a. If there are cracks in the surrounding fuselage structure, contact the ECO Customer Service for instructions on how to proceed. b.

Replace cracked bearing support. Refer to paragraph 42-21 for bearing support removal procedure.

c.

Polish out mechanical and corrosion damage and final polish with 400 grit abrasive cloth. See figure 42-19 for damage and repair limits.

d. Touch up or renew damaged surface protection per Chapter 02, using two-component wash primer (CM 423) followed by coating lacquer (CM 402). 9.

Reinstall vertical fin fairing, nose access door and interior panels.

CHAPTER 42 Page6

Revision 18

MAINTENANCE MANUAL MBB - BO 105

1

2 3

4 5 6 7 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Control rod Bolt Pedal lower assembly, LH Washer Nut Split pin Lever Control link Control link Floor panel Pedal upper assembly Bolt Pedal lower assembly, RH Washer Nut Split pin Bolt Washer Nut Split pin Bolt Washer Nut Split pin Bolt Washer Nut Split pin Nut Split pin Washer Washer Bolt Control link Bolt Washer Split pin Nut Bellcrank Pedal s Base support Pedal support Spindle

DETAlL

A

DETAlL

11

6

Torque value for all attaching hardware: 3-5 Nm

Figure 42-1

Revision 8

B

Removal and installation - pedal upper assembly and pedal lower assembly BO 105 CHAPTER 42 Page 7/8

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 42 - 4

P e d a 1 s

a n d

con t rol . 1 i n k a g e

42 - 5

Removal - pedal upper assembly, RH/LH

1.

Remove nose access cover.

2.

Remove mounting frame and boot from pedals.

3.

Remove attaching hardware (25 to 28, figure 42-1) from pedals and detach control links (8 and 9) .

4.

Remove attaching hardware (29 to 33) and detach pedal upper assembly (11) .

42 - 6

Disassembly - pedal upper assembly RH/LH

1.

Remove split pin (6, figure 42-2), nut (7) and washer (8).

2.

Withdraw pedal support (3) from base support (4) and unscrew and remove spindle (5) from base support.

3.

Remove split pins (14), nuts (13) and washers (12) and detach pedals (1 and 2) from pedal support (3).

4.

Remove spindle sleeve (22) from base support (4).

BO 105 CHAPTER 42 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

14

13

12 11 15

9

16

21 17

400340.1

19

18

,:r1

20 9

1 2 3 4

5 6 7 8 9 la 11

Pedal, RH Pedal, LH Pedal suppart Base suppart Spindle Split pin Nut Washer Guard washer Bushing Guard washer Figure 42-2

BO 105 CHAPTER 42 Page la

13

12 13 14 15 16 17 18 19 20 21 22

Washer Nut Split pin Flange bushing Bushing Screw Nut Lacking washer BaU BaU Spindle sleeve

Disassembly - pedal upper assembly

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Inspection and repair - pedal upper assembly, RH/LH

42 - 7

Special tool: Mounting tool 1.

Inspect pedal support (3, figure 42-2). a.

b.

2.

117-400001 W1

Visually inspect pedal support for cracks, other mechanical damage, corros ion and damaged surface protection. 1)

Replace if a crack is evident.

2)

Polish out any damage to within the repair limits specified in figure 42-3 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

Inspect bolts (20 and 21, figure 42-2). 1)

Minor thread damage is acceptable as long as it does not impair the ease of installation of nut (13).

2)

Replace bolts if thread flanks are deformed or broken.

Inspect base support (4). a.

b.

Visually inspect base support for cracks, other mechanical damage, corrosion and damaged surface protection. 1)

Replace if a crack is evident.

2)

Polish out any damage to within the repair limits specified in figure 42-4 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

Inspect spindle sleeve (22) for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. For permissible bore diameter, refer to figure 42-4.

BO 105 CHAPTER 42 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

Inspect spindle (5, figure 42-2). a.

b.

4.

Visually inspect spindle for mechanical damage, corrosion and damaged surface protection. 1)

Polish out mechanical damage and corrosion and final polish with abrasive cloth 400.

2)

Touch up damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

Inspect condition of threads. 1)

Minor thread damage is acceptable as long it does not impair the ease of installation.

2)

Discard spindle if thread flanks are deformed or broken.

Inspect pedals (1 and 2). a.

Visually inspect pedals for deformation, mechanical damage, corros ion and damaged surface protection. 1)

Replace if deformation is evident.

2)

Polish out any damage to within the repair limits specified in figure 42-5 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

b.

Inspect bushing (16, fig. 42-2) for mechanical damage and corrosion. Polish out damage with abrasive c10th 400. For permissible bore diameter, refer to figure 42-5. If necessary, replace bushing as outlined in step 5.

c.

Inspect flange bushing (15, figure 42-2) as outlined in step b.

d.

Inspect bushing (10) for condition. For permissible bore diameter, refer to figure 42-5. If necessary, replace bushing as outlined in step 6.

e.

Inspect guard washers (9 and 11) for condition. If damaged or debonded, replace as outlined in step 7.

BO 105 CHAPTER 42 Page 12

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 2

ZONE 1

l?WdI Mechanical and corros ion

0.5 mm in depth after repair on 60% of the surface

The minimum finished diameter of 22.96 mm may be 0.02 mm less on 30% of the surface

Minimum permissible diameters:

& &

dia 17.97 mm

They may be 0.02 mm less on one quarter of the circumference.

dia 13.95 mm Figure 42-3

Pedal support - damage and repair limits BO 105 CHAPTER 42 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

1·:ji:;:iji;[;¡!:¡¡[ii:ii*i!¡ji:i¡1

Mechanical

0.5 mm in depth after repair en 60% ef the surface

0.5 mm in depth after repair en 30% ef the surface

Cerresien

1.0 mm in depth after repair en 60% ef the surface

1.0 mm in depth after repair en 90% ef the surface

Mdximum permissible bere diameters: dia

Ii::::.

6.40 mm

They may be exceeded by 0.01 mm en ene quarter ef the circumference.

dia 23.02 mm Figure 42-4

BO 105 CHAPTER 42 Page 14

Base suppert - damage and repair limits

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

J H - - - - - - - J .2

((H'-------& 400662

TYPE OF OAMAGE

Mechanical and corros ion

OAMAGE ANO REPAIR LIMITS ZONE 1

ZONE 2 .............'J :::::::::::::::::::::;:

l·····.....

0.1 mm in depth after repair on 60% of the surface

0.2 mm in depth after repair on 30% of the surface

Maximum permissible bare diameters:

&

dia

~

dia 14.00 mm

6.02 mm

They may be exceeded by 0.02 mm an ane quarter af the circumference.

Figure 42-5

Pedal - damage and repair limits

BO 105 CHAPTER 42 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5.

6.

7.

Replace bushing or flange bushing as follows: a.

Press out bushing or flange bushing as shown in figure 42-6 using tool 117-400001 W1.

b.

Inspect bore for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. The maximum permissible bore diameter is 9.02 mm. It may be exceeded by 0.02 mm on one quarter of the bore circumference.

c.

Coat bushing or flange bushing with corros ion preventive paste (CM 510), chill to approx. -50 OC and préss home with mounting tool 117-400001 W1 as shown in figure 42-6.

d.

Check diameter of bushing or flange bushing bore. If necessary, hone to specified diameter of 6 ± 0.006 mm and remove burrs.

Replace bushing (10, figure 42-2) as follows: a.

Remove guard washers (9 and 11) as outlined in step 7.

b.

Press out bushing (10) with a mandrel.

c.

Inspect bore in pedal for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. The maximum permissible bore diameter is 16.02 mm. It may be exceeded by 0.02 mm on one quarter of the circurnference.

d.

Press new bushing in pedal.

e.

Bond guard washers (9 and 11) in place as outlined in step 7.

Replace guard washers (9 and 11) as follows: a.

Remove guard washers with plastic wedge.

b.

Remove adhesive residues with toluene (CM 219) .

c.

Align new guard washers with bore and bond in place with two-component adhesive (CM 601) .

BO 105 CHAPTER 42 Page 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

PRESSING OUT

1 2 3 4 5

s

Knurled screw Support Wedge Gauge block Mandrel

3

2

PRESSING IN

5

E

e

r--~~t=;.::;;;;;;*~:-t~:c:=,F--lr-'

....-.....-11

N

o

o"

+

::t

400655

2

4

Step 1

Figure 42-6

3

Step 2

Pressing-out and pressing-in of bushings with mounting tool 117-40000 Wl BO 105 CHAPTER 42

Page 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 42 - 8

Removal - pedal lower assembly RH/LH

l.

Remove nose access door.

2.

Disconnect control links and control rods from lever (2, figure 42-7).

3.

Remove split pin (3), nut (4) and guard washer (5), and detach lever (2).

6 7

8

8

9

9

:~

2

8 9 5

I 7-10 Nm I 4 3 400660

BoH Lever Split pin 4 Nut

1 2 3

&

5 6 7

&-[~

Guard washer Support piate Stop boH Bushing Flange bushing

Installed on pilot's side only Figure 42-7

BO 105 CHAPTER 42 Page 18

Removal and installation - pedal lower assembly

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Inspection and repair - pedal lower assembly RH/LH

42 - 9

Special tool: Mounting tool l.

Inspect lever (2, figure 42-7).

a.

2.

117-400001 W1

Inspect lever for cracks, other mechanical damage, corros ion and damaged surface protection. 1)

Replace if a crack is evident.

2)

Polish out any damage tb within the repair limits specified in figure 42-8 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

b.

Inspect bushing (8, figure 42-7) for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. For permissible bore diameter refer to figure 42-8. If bushing is out of dimension, replace as outlined in paragraph 42-7.

c.

Inspect flange bushing (9, figure 42-7) as outlined in step b.

d.

Check grooved ball bearings (2 and 6,fig. 42-9) for play, roughness, binding and signs of corrosion. If any such damage is evident, replace grooved ball bearing as outlined in step 3.

Inspect support plate (6, fig. 42-7) and bolt (1): a.

b.

Visually inspect support plate for mechanical damage, corrosion and damaged surface protection. 1)

Polish out mechanical damage and corros ion and final polish with abrasive cloth 400.

2)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

Inspect condition of threads of bolt (1): 1)

Minor thread damage is acceptable as long as it does not impair the ease of installation of nut (4).

2)

Replace bolts if threads are deformed or broken.

BO 105 CHAPTER 42 Page 19

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO lOS

400661

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

Mechanical and corros ion

ZONE 2

~nM¡¡¡¡¡~¡~J?1

rwa

0.3 mm in depth after repair on 30% of the surface

0.5 mm in depth after repair on SO% of the surface

Maximum permissible bore diameter of all bushings:

&

dia 6.02 mm

It may be exceeded by 0.02 mm on one quarter of the circumference. Figure 42-8

3.

Lever - damage and repair limits

Replace grooved ball bearings (2 and 6, figure 42-9) as follows: a.

Replace retaining ring (1).

b.

Press out grooved ball bearing (2).

c.

Remove washer (3), retaining ring (4) and spacer (S).

d.

Press out grooved ball bearing (6).

e.

Inspect bore in lever for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. The maximum permissible bore diameter is 32.02 mm. It may be exceeded by 0.01 mm on one quarter of the bore circumference.

BO 105 CHAPTER 42 Page 20

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 f.

Coat outer circurnference of grooved ball bearing (6) with corrosion preventive paste (CM 510) and install by hand.

g.

Insert spacer (5), retaining ring (4) and washer (3).

h.

Coat outer circumference of groove ball bearing (2) with corrosion preventive paste (CM 510), then install by hand and secure with retaining ring (1).

7----r

1

2 3 4 5 6

6 400666.1

Figure 42-9 42 - 10

7

Retaining ring Grooved ball bearing Washer Retaining ring Spacer Grooved ball bearing Lever

Replacement - grooved ball bearings and bushings

Installation - pedal lower assembly RH/LH

1.

Fit lever (2, figure 42-7) on bolt (1) of support plate (6).

2.

Position guard washer (5), tighten nut (24) and secure with split pin (3).

3.

Install control rod (1, figure 42-1) and control links (8, 9 and 34) as shown in figure 42-1.

4.

Tighten nuts and secure with split pins.

5.

Check for freedom of movement and presence of foreign objects.

6.

Insta1l nose access door. BO 105 CHAPTER 42 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 42 - 11

Assembly - pedal upper assembly RH/LH

1.

Install spindle sleeve (22, figure 42-2) in base support (4).

2.

Coat spindle (5) with grease (CM 140) and insert in base support (4).

3.

Insert pedal support (3) in base support.

4.

Install washer (8) and nut (7).

s.

Hand-tighten nut, then back nut off until hole is aligned and secure with split pin (6).

6.

Place pedals (1 and 2) on pedal support (3).

7.

Install washers (12) and nut (13).

8.

Hand-tighten nut, then back nut off until hole is aligned and secure with split pin (14).

42 - 12

Installation - pedal upper assembly RH/LH

1.

Place pedal upper assembly (11, figure 42-1) on pedal lower assembly (3 or 13) and secure with attaching hardware (29 to 33) .

2.

Connect control links (8 and 9) to pedals and secure with attaching hardware (2S to 28). Tighten nuts and secure with split pins.

3.

Install boot together with mounting frame.

4.

Check for freedom of movement and presence of foreign objects.

s.

Install nose access door.

BO lOS CHAPTER 42 Page 22

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 42 - 13

Removal - bellcrank

1.

Remove nose access door.

2.

Open access cover on RH side of helicopter.

3.

Remove attaching hardware (7 thru 10 and 11 thru 14, fig. 42-10), disconnect control rod (1) and control link (2).

4.

Remove attaching hardware (4 thru 6 and 15 thru 18) and remove bellcrank.

14 - - , 19.·--,

20----,. 13--""1. 15

;"9"----

'~~~--17

-

3

19

20 9 - -____

11

3-5 Nm

I8

I 7-9 Nm

----

11

7 _ _...o

400659·01

2

1 Control rod 2 Control link 3 Bellcrank 4 Washer 5 Nut 6 Split pin 7 Split pin

Figure 42-10

Revision 3

8 Nut 9 Washer 10 BoU 11 Split pin 12 Nut 13 Washer 14 BoU

15 16 17 18 19 20

Washer BoU Washer Washer Bushing Flange bushing

Removal and installation - bellcrank BO 105 CHAPTER 42 Page 23

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

42 - 14

Inspection and repair - bellcrank

Special tool: Mounting tool l.

Inspect bellcrank (3, figure 42-10) . a.

2.

117-400001 W1

Visually inspect bellcrank for cracks, other rnechanical darnage, corros ion and darnaged surface protection. 1)

Replace if a crack is evident.

2)

Polish out any damage to within the repair limits specified in figure 42-11 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

b.

Inspect bushing (19, figure 42-10) for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. For permissible bore diarneter refer to figure 42-11. If bushing is out of dimension, replace as outlined in para. 42-7.

c.

Inspect flange bushing (20, figure 42-10) as outlined in step b.

d.

Check grooved ball bearings (3 and 7, fig.42-12) for play, roughness, binding and signs of corrosion. Replace grooved ball bearings if any such darnage is evident, refer to step 2.

Replace grooved ball bearings as follows: a.

Rernove retaining ring (1, figure 42-12) and washer (2).

b.

Press out grooved ball bearing (7) and remove sleeve (6).

c.

Press out grooved ball bearing (3).

d.

Remove retaining ring (4).

e.

Inspect bore in bellcrank for mechanical damage and corrosion. Polish out corrosion with abrasive cloth 400. The maximum permissible bore diameter is 22.02 mm. It may be exceeded by 0.01 mm on one quarter of the bore circumference.

BO 105 CHAPTER 42

Page 24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400665

TYPE OF DAMAGE

Mechanical and corrosion

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

0.2 mm in depth after repair on 30% of the surface

0.4 mm in depth after repair on 50% of the surface

Maximum permissible bore diameter:

&

dia 6.02 mm

It may be exceeded by 0.01 mm on one quarter of the circumference.

Figure 42-11

Bellcrank - damage and repair limits

BO 105 CHAPTER 42

Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 f.

Insert retaining ring (4).

g.

Coat outer circumference of grooved ball bearing (3) with corrosion preventive paste (CM 510) and insert by hand.

h.

Insert washer (2) and retaining ring (1).

i.

Coat outer circumference of grooved ball bearing (7) with corros ion preventive paste (CM 510), insert sleeve (6) and grooved ball bearing by hand.

t---- 5

t----6

400664.1

Retaining ring Washer 3 Grooved ball bearing 4 Retaining ring

1

2

Figure 42-12

BO 105 CHAPTER 42 Page 26

BeHcrank 6 Sleeve 7 Grooved baH bearing

5

Replacement - grooved ball bearings

fteurocopter 42 - 15

MAINTENANCE MANUAL MBB - BO 105

Installation - bellcrank

1.

Insert bellcrank (3, figure 42-10) along with washers (17 and 18) in side duct and secure with attaching hardware (4 to 6, 15 and 16) .

2.

Install control rod (1) and control link (2). Tighten attaching hardware (refer to figure 42-10) and secure with split pins.

3.

Check for freedorn of movement and presence of foreign objects.

4.

Close access cover on RH side of helicopter.

5.

Install nose access door.

42 - 16

Removal - jackshaft

1.

Fold back floor covering as far as necessary.

2.

Remove cover from RH side duct in fuselage.

3.

Rernove control rods (9 and 17, figure 42-13) from jackshaft (10).

4.

Bend open locking plate (12) and remove together with screws (11).

5.

Rernove attaching hardware (1 to 4) .

6.

Withdraw jackshaft from side duct.

BO 105 CHAPTER 42 Page 27

fleurocopter

MAINTENANCE MANUAL MBB - BO 105

400667

1 2 3 4 5 6

Split pin Nut Washer Bolt Bolt Washer 7 Nut Figure 42-13

80 105 CHAPTER 42 Page 28

Split pin 9 Control rod 10 Jackshaft 11 Screw 12 Locking plate 13 Screw 14 Washer 8

15 16 17

18 19

Nut Split pin Control rod Bushing Flange bushing

Removal and installation - jackshaft

Revizion 8

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 42 - 17

Disassembly - jackshaft

1.

Bend open tang washer (9, figure 42-14), remove spanner nut (10), tang washer and spacer bushing (8).

2.

Remove retaining ring (7) and washer (6).

3.

Withdraw lever axle (1) from jackshaft (4).

4.

Displace tube (3) between the bearings as far as possible in radial direction.

5.

Press out grooved ball bearing (2).

6.

Remove tube from jackshaft.

7.

Press out grooved ball bearing (5). 5

4

7

6

8

9

10

I 3-5 Nm I

I I

I

I

L-

_- - - - - - - - - - -

---

-------

I

I

.J

3

2 400674.2

Lever axle Grooved baH bearing 3 Tube 4 Jackshaft 5 Grooved baH bearing

1 2

Figure 42-14

Washer Retaining ring 8 Spacer bushing 9 Tang washer 10 Spanner nut 6 7

Disassembly - jackshaft BO 105 CHAPTER 42 Page 29

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 42 - 18

Inspection and repair - jackshaft

Special tool: Mounting tool 1.

Inspect jackshaft (4, figure 42-14). a.

2.

117-400001 W1

Inspect jackshaft for deformation, mechanical damage and corrosion. Visually inspect weld for cracks. If cracks are suspected, carry out penetrant inspection as per MIL-STD-6866. 1)

Replace if a crack or deformation is evident.

2)

Polish out any damage to within the repair limits specified in figure 42-15 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

b.

Inspect bearing seat in jackshaft for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. The maximum permissible bore diameter is 32.02 mm. It may be exceeded by 0.02 mm on one quarter of the circumference.

c.

Inspect bushing (18, figure 42-13) for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. For permissible bore diameter refer to figure 42-15. If bushing is out of dimension, replace as outlined in paragraph 42-7.

d.

Inspect flange bushing (19, figure 42-13) as outlined in step c.

e.

Check grooved ball bearings (2 and 5, fig. 42-14) for play, roughness and ease of movement. If there are any signs of such damage, replace grooved ball bearings as outlined in paragraph 42-17.

Inspect lever axle (1, figure 42-14) for mechanical damage and corrosion. Visually inspect weld for cracks. If a crack is suspected, carry out penetrant inspection as per MIL-STD-6866. a.

Replace if a crack is evident.

b.

Polish out any damage to within the repair limits specified in figure 42-16 and final polish with abrasive cloth 400.

c.

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

BO 105 CHAPTER 42 Page 30

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

d.

Minor thread damage is acceptable as long as itdoes not impair the ease of installation.

e.

Replace lever axle if thread flanks are deformed or broken.

BO 105 CHAPTER 42

Page 31

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400668.1

TYPE OF DAMAGE

Mechanical and corrosion

DAMAGE AND REPAIR LIMITS ZONE 1 ·:··················1 1::::::::::::=:::::::.

ZONE 2

0.4 mm in depth after repair on 50% of the surface

0.2 mm in depth after repair on 30% of the surface

Maximum permissible bore diameters:

&

dia

&

dia 32.02 mm

6.02 mm

They may be exceeded by 0.01 mm on one quarter of the circumference.

Figure 42-15 BO 105 CHAPTER 42 Page 32

Jackshaft - damage and repair limits

EUROCOPTER

MAINTENANCE MANUAL 80 105

400676

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

Mechanical and corros ion

0.2 mm in depth after repair on 50% of the surface

ZONE 2

ZONE 3

I~((UH

~

The minimum finished diameter of 15.45 mm may be 0.02 mm less on 30% of the surface

0.2 mm in depth after repair on 30% of the surface

Maximum permissible bore diameter:

~ dia 8.02 mm

It may be exceeded by 0.02 mm on one quarter of the circurnference.

Figure 42-16

Lever axle - damage and repair lirnits BO 105 CHAPTER 42 Page 33

EUROCOPTER

42 - 19

Assembly - jackshaft

1.

Coat grooved ball bearing seats in jackshaft (4, figure 42-14) with corros ion preventive compound (CM 505) .

2.

Press ball bearing (5) in jackshaft (4).

3.

Insert washer (6) and retaining ring (7).

4.

Insert tube (3).

5.

Press grooved ball bearing (2) in jackshaft.

6.

Insert lever axle (1).

7.

Install spacer bushing (8) and locking plate (9) on jackshaft, tighten spanner nut (10) and secure with tang washer (9).

42 - 20

Installation - jackshaft

l.

Position jackshaft (10, figure 42-13) in installed position and secure with attaching hardware (1 to 4 and 11, 12).

2.

Install control rods (9 and 17), tighten nuts and secure with split pins.

3.

Check for presence of foreign objects.

4.

Install cover on RR side duct in fuselage.

5.

Replace floor covering.

42 - 21

* * * * * * * * * * * * *

MAINTENANCE MANUAL BO 105

Removal - torsion tube with bearing support and bearing

l.

Remove interior pdnelling as necessalY.

2.

Remove control rods (6 and 8, figure 42-17) .

3.

Remove attaching hardware (23 thru 26).

4.

Remove screws (14) and washers (13).

5.

Rold bellcrank (21) and pull torsion tube (7) out of bellcrank (21) and bea ring (l).

6.

Remove bellcrank (21).

7.

Remove bearing support (9) from torsion tube (7) and, if necessary, detach retaining ring (22) from torsion tube (7).

8.

If required, remove screws (16) and washers (17) and withdraw bearing (1).

BO 105 CHAPTER 42 Page 34

Revision 11

MAINTENANCE MANUAL 80105

EUROCOPTER

23

24-------. ¡-12---t5-N-m-1

26---

19

<-----11

17

DETAlL

16

21

7

A

8 15 20 9 400677.1

12

1 2 3 4 5 6 7

Bearing Split pin Nut Washer BoU Control rod Torsion tube

Control rod Bearing support Washer Nut Split pin 13 Washer 14 Screw 8 9 10 11 12

Figure 42 - 17

Revision 11

15 16 17 18 19 20 21

Washer Screw Washer Flange bushing Bushing Rivet Bellcrank

22 23 24 25 26

Retaining ring Screw Washer Nut Split pin

Removal and disassembly - torsion tube with bearing su?port and bearing BO 105 CHAPTER 42 Page 35

EUROCOPTER

* * 42 - 22 * *

MAINTENANCE MANUAL BO 105

F r e e

42 - 23

Inspection and repair - torsion tube with bearing support and bearing

Special tool: Mounting tool 1.

Inspect torsion tube (7, figure 42-17). a.

b. 2.

117-400001 W1

Inspect torsion tube for mechanical damage andcorrosion. Visually inspect we1d for cracks. If a crack is suspected, carry out penetrant inspection per MIL-STD-6866. 1)

Replace if a crack is evident.

2)

Polish out any damage to within the repair limits specified in figure 42-18 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

Inspect splines for condition and corrosion. Polish out minor corrosion. Replace torsion tube if splines are deformed or broken.

Inspect bellcrank (21, figure 42-17). a.

b.

Inspect bellcrank for cracks, other mechanical damage and corrosion. 1)

Replace if a crack is evident.

2)

Polish out any damage to within the repair limits specified in figure 42-18 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

Inspect splines for condition and corrosion. Polish out minor corrosion. Replace bellcrank if splines are deformed or broken.

BO 105 CHAPTER 42 Page 36

Revision 11

- - - - - - - - - - - - - M B B H~LICOPTERS- - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

c.

Inspect bushing (19, figure 42-17) for mechanical damage and corrosion. Polish out damage with abrasive cloth 400. For permissible bore diameter refer to figure 42-18. If bushing is out of dimension, replace as outlined in paragraph 42-7.

d.

Inspect flange bushing (18) as outlined in step c.

e.

Inspect bearing (1) for play, roughness and binding. Replace bearing as outlined in paragraph 42-21 if any damage is evident.

f.

Inspect rivet (20) for tight installation. Replace loose rivet.

Inspect bearing support (9). a.

b.

Visually inspect bearing support for cracks, other mechanical damage, corrosion and damaged surface protection. 1)

Replace if crack is evident.

2)

Polish out any damage to within the permissible repair limits specified in figure 42-19 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

Check spherical bearing for play, roughness and corrosion. If any such damage is evident, replace spherical bearing as outlined in chapter 02. Permissible radial play: 0.1 mm.

BO 105 CHAPTER 42 Page 37

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

I: : ¡:~: t: : : ¡: :[: !: : :¡~ Mechanical and corros ion

0.4 mm in depth after repair on 50% of the surface

0.2 mm in depth after repair on 30% of the surface

Maximum permissible bore diameter:

&

dia 6.02 mm

It may be exceeded by 0.01 mm on one quarter of the circumference.

Minimum permissible diameters: ~

dia 12.67 mm

.&

dia 24.97 mm Figure 42-18

BO 105 CHAPTER 42

Page 38

They may be 0.07 mm less on 30% of the surface .

Torsion tube and bellcrank - damage and repair limits

MAINTENANCE MANUAL BO 105

EUROCOPTER

400679

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

Mechanical and corrosion

~

-ZONE 2

0.5 mm in depth after repair on 30% of the surface

0.2 mm in depth after repair on 50% of the surface

In the area of bores, 50% of the original contact surface must still be intacto Figure 42-19

Bearing support - damage and repair limits

BO 105 CHAPTER 42 Page 39

EUROCOPTER

* * *

MAINTENANCE MANUAL BO 105

42 - 24

F r e e

42 - 25

Installation - torsion tube with bearing support and bearing

1.

If previously removed, insert bearing (1, fig. 42-17) and secure with washers (17) and screws (16).

* 2. If previously removed, attach retaining ring (22) and lubricate splines with grease (CM 120) . * * * 3. Locate bellcrank (21) in installed position and align it so that torsion * tube (7) can be installed. *

*

4.

Insert torsion tube (7) through bellcrank (21) and into bearing (1).

* * 5. Attach washer (15) and install bearing support (9). * * 6. Install washer (10) and nut (11) and secure with split pin (12). * * 7. Push bellcrank (21) so that it seats against retaining ring (22), and install attaching hardware (23 thru 26) . * * * 8. Reinstall control rods (6 and 8). * * 9. Check for freedom of movement and presence of foreign objects. * * 10. Install interior panelling. 42 - 26 1.

* 2. *

* * * * *

Removal - bellcrank

Remove vertical fin fairing. Disconnect control rods (6 and 18, fig. 42-20) from bellcrank (12), and secure control rod (6) by tying it to the vertical fin.

3.

Remove attaching hardware (1 to 5) and bellcrank (12) together with washers (11 and 13) .

4.

If replacing the intermediate gearbox, remove plates (21) per fig. 42-20.

BO 105 CHAPTER 42 Page 40

Revision 11

MAINTENANCE MANUAL BO 105

EUROCOPTER

,1----

6

--7

13

----------'~

21 22

1 7 - - - - - - -.....

I 3-5 Nm I 16 - - - - - - - , . . , 1S-------~

, f).....

2316-6.5 Nm

L~

l-24

~~--3

.~ ~)¡-4§NmJ

a-s

I T 18

20 -----.,,0/

I

25

16-6.~ Nm I

400680-01

1 Bolt Washer Washer 4 Nut 5 Split pin 6 Control rod 7 Bolt 8 Washer 9 Nut 2 3

& Plates

11

12 13 14 15 16 17 18

Split pin Washer Bellcrank Washer Bolt Washer Nut Split pin Control rod

&

&

19 20 21 22 23 24 25 26

Sc::ew Tab washer Plate Washer Nylstop nut Split pin Nut Bolt

(21) rnay be attached, using screws (19) or bolts (26)

Figure 42-20

Revision 11

10

Rernoval and installation - lever BO 105 CHAPTER 42 Page 41

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

EUROCOPTER

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

42 - 27

MAINTENANCE MANUAL 80105

Inspection and repair - bellcrank

Inspect bellcrank (12, fig. 42-20) in accordance with inspection criteria given in paragraph 42-14, and repair as necessary. 42 - 28

Instal1ation - bellcrank

lo

If plates (21, fig. 42-20) were previously removed, attach them to the intermediate gearbox, using either screws (19), tab washers (20) and nuts (25) or bolts (26), washers (22) and Nylstop nuts (23).

2.

Secure attaching hardware, using tab washers (20) or split pins (24), as appropriate. NOTE

Install washers (11 and 13) with wider shoulder facing bellcrank (12) .

3.

Install bellcrank (12) together with washers (11 and 13).

4.

Install attaching hardware (1 thru 4) and secure with split pin (5).

5.

Connect control rods (6 and 18) per para 42-36.

6.

Check for freedom of movement and presence of foreign objects.

7.

If a new bellcrank (12) has been installed, check tail rotor control rigging per Chapter 102.

8.

Reinstall vertical fin fairing.

42 - 28A

Removal - yaw brake

1.

Remove vertical fin fairing.

2.

Disconnect control rods (2 and 13, fig. 42-20A) from bellcrank (14). Secure control rod (2) by tying it to the vertical fin.

3.

Remove attaching hardware (11, 12 and 18 thru 22) and remove bel1crank (14) .

4.

Remove attaching hardware (10 and 15 thru 17) and remove plates (9) and washers (7 and 8) .

BO 105 CHAPTER 42 Page 42

Revision 11

MAINTENANCE MANUAL 80 105

EUROCOPTER

r---2

--3

7 8

& 9

I 3-5 Nm 13 10 400681

11

1 Intermediate gearbox 2 Control rod 3 BoH 4 Split pin 5 Nylstop nut 6 Washer 7 Washer &8 Washer

& Install bellcrank

9 10 11 12 13

14 15 16

Plate assembly BoH BoH Washer Control rod Be11crank Washer Nylstop nut

17

18 19 20 21 22

Split pin Split pin Nylstop nut Washer Disc spring Washer

(14) free of play, using washers (8) as necessary.

Figure 42-20A Removal and installation - yaw brake BO 105 CHAPTER 42

Revision 11

Page 42A

EUROCOPTER

42 - 28B

MAINTENANCE MANUAL 80105

Inspection and repair - yaw brake

1.

Inspect bellcrank (14, fig.42-20A) in accordance with inspection criteria given in para 42-14, and repair as necessary.

2.

Inspect plates (9) for worn brake lining. If brake lining is worn down to the metal, replace plates.

3.

If necessary, remove grooved ball bearing (6, fig. 42-20B) as follows: Special tools: Pushing-out tool 10S-41110W2 Pushing-in tool 10S-41110W1 a.

Heat bellcrank (1) in cover (2) area, then remove cover together with spring pins (5).

b.

Remove grooved ball bearing shim (4).

c.

Press out grooved ball bearing (6), using pushing-out tool P/N 10541110W2.

d.

Remove spacer bushing (3).

e.

Press out second grooved ball bearing (6), using pushing-out tool P/N 10S-41110W2.

f.

Inspect bore in bellcrank for mechanical and corros ion damage. Polish out damage with 400 grit abrasive cloth. Maximum permissible bore diameter not to exceed 22.02 mm. It may be exceeded by 0.01 mm on one quarter of the bore circumference.

1 Bellcrank 2 Cover 3 Spacer bushing 4 Grooved baH bearing shim 5 Spring pin 6 Grooved ball bearing 400682

Figure 42-20B BO 105 CHAPTER 42 Page 42B

Removal and installation - grooved ball bearing

Revision 11

EUROCOPTER

4.

MAINTENANCE MANUAL 80105

Install grooved ball bearing a.

Brush-coat bore with non-hardening corrosion preventive paste (CM 503 or CM 510) .

b.

Coo1 both covers (2) to -50°C.

c.

Fit first cover (2) on double-grooved side of bellcrank and align cover so that spring pins (5) can be inserted.

d.

Press grooved ball bearing in place, using pushing-in tool P/N 10541110W1.

e.

Install spacer bushing (3).

f.

Press second grooved ball bearing in place, using pushing in tool P/N 105-41110W1.

g.

Locate grooved ball bearing shims (4) in position.

h.

Fit second cover (2) in bellcrank and align cover so that spring pins (5) can be installed.

i.

Secure second cover (2) with spring pins (5) to prevent cover from turning. Take care that the spring pins do not protrude from covers.

42-28C

Installation - yaw brake

l.

Install plates (9, fig. 42-20A) on intermediate gearbox, using bolts (10), washers (7) and, if necessary, washers (8) so that bellcrank (14) can be inserted free of play.

2.

Install washers (15) and Nylstop nuts (16). Torque nuts (16) and secure with split pins (17).

3.

Install bellcrank (14) free of play, using bolt (11), washers (12 and 22), three disc springs (21) and washer (20).

4.

Install Nylstop nut (19), but do not tighten yet.

5.

Install control rods (2 and 13) per para 42-36.

6.

Adjust yaw brake.

NOTE

The braking action of the yaw brake is only required for tail rotor blades with a l° coning angle. It is not required for tail rotor blades with a 0° coning angle. a.

If tail rotor blades with a 1° coning angle are installed, determine pedal breakout and final forces and then adjust yaw brake per Chapter 102-27.

Revision 11

BO 105 CHAPTER 42 Page 42C

MAINTENANCE MANUAL 80 105

EUROCOPTER

b.

7.

If tail rotor blades with a 0° coning angle are installed, adjust yaw brake so that no braking effect is presento 1)

Tighten Nylstop nut (19) to the point where bolt (11) can still be rotated by hand.

2)

Back off Nylstop nut (19) to nearest split pin hole and secure with split pin (18).

Reinstall vertical fin fairing.

42 - 29

Con t rol

42 - 30

Removal - control links and control rods in fuselage

l.

2.

3.

4.

1 i n k s

a n d con t rol

r o d s

Remove control links (44, figure 42-24) as follows: a.

Remove nose access door.

b.

Remove attaching hardware (36 thru 39 and 40 thru 43) and detach control links.

Remove control link (58) as follows: a.

Remove nose access door.

b.

Open access cover on

c.

Remove attaching hardware (54 thru 57 and 60 thru 63) and detach control link.

RH

side of helicopter.

Remove control rod (49) as follows: a.

Remove nose access door.

b.

Remove attaching hardware (45 thru 48 and 50 thru 53) and detach control rod.

Remove control rod (1) as follows: a.

Remove bench seat.

b.

Fold back floor covering.

c.

Remove access cover from RH side and cover plate from aft side of helicopter.

d.

Remove RH side duct cover.

BO 105 CHAPTER 42 Page 42D

Revision 11

EUROCOPTER

5.

e.

Remove attaching hardware (64 thru 67) from bellcrank (59) and attaching hardware (2 thru 5) fromjackshaft (6).

f.

Withdraw control rod rearwards from the fuselage.

Remove control rod (11) as follows: a.

Remove interior panelling from cargo compartment and RH side duct cover from fuselage as required to obtain access.

b.

Remove attaching hardware (7 thru 10) from jackshaft (6) and attaching hardware (13 thru 16) from torsion tube (12).

c.

Remove control rod.

42 - 31 1.

2.

MAINTENANCE MANUAL BO 105

Removal - control rods in tail boom

Remove control rod (21, figure 42-24) as follows: a.

Remove interior panelling in cargo compartment as far as necessary.

b.

Remove vertical fin fairing.

c.

Remove attaching hardware (17 thru 20) from torsion tube (12) and attaching hardware (32 thru 35) from bellcrank (31).

d.

Withdraw control rod (21) rearwards from the fuselage.

Remove control rod (22) as follows: a.

Remove vertical fin fairing.

b.

Remove attaching hardware (27 thru 30).

c.

Remove bellcrank of tail rotor sliding sleeve per Chapter 33, para 33-10.

d.

Disconnect control rod from bellcrank.

42 - 32

Disassembly - control rods

For disassembly of control rods, refer to Chapter 41.

Revision 11

BO 105 CHAPTER 42 Page 43

* * * * * *

EUROCOPTER

42 - 33

MAINTENANCE MANUAL BO 105

Inspection and repair - control links and control rods

Special tool: Hot air gun, up to 200 oC

* 1. Perform inspection and repair of control rods (1, 11, 21, 22 and 49, * figure 42-24) as described in chapter 41-80, step 1. * 2.

Control links (44 and 58) a.

b.

3.

4.

Inspect control links for deformation, mechanical damage, corrosion and damaged surface protection. 1)

Replace if deformation is evident.

2)

Polish out any damage to within the repair limits specified in and figure 42-23 and final polish with abrasive cloth 400.

3)

Touch up or renew damaged surface protection with two-component wash primer (CM 423) and coating lacquer (CM 402) as outlined in chapter 02.

Check spherical bearings for play (permissible radial play is 0.1 mm), signs of corros ion and ease of movement. Replace spherical bearing as outlined in chapter 02 if any such damage is evident.

Inspect fork ends for mechanical damage and corrosion. a.

Polish out any damage to within the repair limits specified in figure 42-22 and final polish with abrasive cloth 400.

b.

Inspect fork end bores for signs of wear and, after repair of damage, check for dimensional accuracy. For maximum permissible diameter, refer to figure 42-22.

c.

Inspect blind hole in fork end for presence and condition of seal. If seal is missing or damaged, reapply new seal, using sealing compound (CM 662) .

Inspect chafe protection sleeves for condition. a.

Inspect chafe protection sleeves on control rod (1, figure 42-24) in right side duct and on control rod (21) in tail boom for damage and looseness.

b.

If necessary, replace chafe protection sleeves as follows: 1)

BO 105 CHAPTER 42 Page 44

Remove damaged or loose sleeve(s), while taking care not to damage the control rod.

Revision 14

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2)

Clean sleeve contact area on control rod with dry cleaning solvent (CM 202) .

3)

Cut shrink sleeve to specified length (refer to figure 42-21).

4)

Slide shrink sleeve on control rod and position it at the corresponding sleeve location (see fig. 42-21).

5)

When shrinking the sleeve, protect adjacent areas of control rod from the heat.

6)

Heat shrink sleeve with a hot air gun. The temperature must not exceed 170 oC, and the shrinking process must be completed within approx. 90 seco

7)

Allow shrink sleeve to cool and check for proper attachment. It must be evenly attached along its entire length and be free of creases.

-

• Flight direction

130 %2

----r--

-.:In I

-

636-1060 1476 1927 2378 2828 3280 3731 4158

Dimensions have tolerances of 3 mm unless indicated otherwise

±

---

120 --=-

857 1567 2292 300m

Dimensions have tolerances of ± 2 mm unless indicated otherwise

Dimensions in mm Figure 42-21

Location of chafe protection sleeves on control rod in tail boom and RH side duct BO 105 CHAPTER 42 Page 45

- - - - - - - - - - - . , . . . - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400684

TYPE OF OAMAGE

Mechanical and corros ion

OAMAGE ANO REPAIR LIMITS ZONE 1

ZONE 2

~

1:::::~:::::}\:::1

0.2 mm in depth after repair on 40% of the surface

0.4 mm in depth after repair on 60% of the surface

Maximum permissible bore diameter:

&

dia 6.02 mm

It may be exceeded by 0.01 mm on one quarter of the circumference.

Figure 42-22 BO 105 CHAPTER 42 Page 46

Fork end - damage and repair limits

MAINTENANCE MANUAL 80 105

EUROCOPTER

400693

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

~ Mechanical and corrosion

0.4 mm in depth after repair on 50% of the surface

Figure 42-23

0.2 mm in depth after repair on 20% of the surface

Control links - damage and repair limits

80 105 CHAPTER 42 Page 47

EUROCOPTER

42 - 34

MAINTENANCE MANUAL 80 105

Assembly - control rods Refer to chapter 41. Installation - control links and control rods in fuselage

42 - 35

After the installation of control rods, check and, if necessary, rerig the tail rotor controls (refer to chapter 102), provided requirements in para 42-2 have not been meto

NOTE

1.

2.

3.

4.

Installation of control links (44, figure 42-24) a.

Install control links. Tighten nuts and secure with split pins.

b.

Check for freedom of movement and presence of foreign objects.

c.

Install nose access door.

Installation of control link (58) a.

Install control link. Tighten nuts and secure with split pins.

b.

Check for freedom of movement and presence of foreign objects.

c.

Close access cover on RH side of helicopter.

d.

Install nose access door.

Installation of control rod (49) a.

Install control rod. Tighten nuts and secure with split pins.

b.

Check for freedom of movement and presence of foreign objects.

c.

Install nose access door.

Installation of control rod (1) a.

Slide control rod from the rear into side duct and guides.

b.

Install control rod. Tighten nuts and secure with split pins.

c.

Check for freedom of movement and presence of foreign objects.

d.

Install RH side duct cover.

e.

Close access cover on RH side and cover plate on aft side of helicopter.

BO 105 CHAPTER 42 Page 48

Revision 11

EUROCOPTER

5.

f.

Install floor covering.

g.

Install bench seat.

MAINTENANCE MANUAL 80105

Install control rod (11): a.

Install control rod. Tighten nuts and secure with split pins.

b. Check for freedom of movement and presence of foreign objects. c.

Install interior panelling in cargo compartment and RH side duct cover.

42 - 36

Installation - control rods in tail boom

1. Install control rod (21, figure 42-24):

•

a. Apply grease (CM 101) to chafe protection sleeves (shrink sleeve pieces). b. Slide control rod (21) through tail boom to torsion tube (12). c.

Connect control rod (21) to torsion tube (12), then torque nut (19) and secure with split pin (20).

d. Connect other end of control rod (21) to bellcrank (31). Install connecting bolt (32) so that the bolt head presses against the f10ating bushing of bellcrank (31). e. Torque nut (34) and secure with split pin (35).

2.

f.

Check for freedom of movement and presence of foreign objects.

g.

Install cargo compartment panels and vertical fin fairing.

Install control rod (22, figure 42-24): a. Connect control rod (22) to bellcrank of tail rotor sliding sleeve. Note direction in which bolt (23) is inserted (see fig. 33-5). b.

Install bellcrank per Chapter 33, para 33 -12.

c.

Connect other end of control rod (22) to bellcrank (31). Install connecting bolt (28) so that the bolt head presses against the floating bushing of bellcrank (31).

d. Torque nut and secure with split pin (27). e.

Reinstall vertical fin fairing.

Revision 18

CHAPTER 42 Page49

EUROCOPTER

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17

18 19 20 21

22 23 24 25 26 27 28 29 30 31 32 33

Control rod in RH side duct Bolt Split pin Nut Washer Jackshaft Bolt Washer Nut Split pin Control rod between jackshaft and torsion tube Torsion tube Split pin Nut Washer Bolt Bolt Washer Nut Split pin Control rod in tail boom Control rod in vertical fin Bolt Washer Nut Split pin Split pin Bolt Washer Nut Bellcrank oi yaw brake Bolt Washer

* * *

&

*

& Yaw brake is standard equipment

* *

MAINTENANCE MANUAL 80 105

34 Nut 35 Split pin 36 Bolt 37 Washer 38 Nut 39 Split pin 40 Bolt 41 Washer 42 Nut 43 Split pin 44 Control link 45 Bolt 46 Washer 47 Nut 48 Split pin 49 Control rod between RH and LH pedal assemblies 50 Bolt 51 Washer 52 Nut 53 Split pin 54 Bolt 55 Washer 56 Nut 57 Split pin 58 Control link 59 Bellcrank 60 Bolt 61 Washer 62 Nut 63 Split pin 64 Bolt 65 Washer 66 Nut 67 Split pin

in helicopters S/N 890 and subsq., and is retrofitted per SB-BO 105-30-103 in helicopters S/N 889 and prior.

BO 105 CHAPTER 42 Page 50

Revision 11

EUROCOPTER

MAINTENANCE MANUAL SO 105

59

DETAlL

B· DETAlL

e 6-~

2--""'-

DETAlL

A DETAlL

~ll

J

'----_--'

nut-bolt assemblies orqued to 3-5 Nm

39

Figure 42-24

Tail rotor controls BO 105

Revision 11

~37

~38

400726

CHAPTER 42 Page 51/52

r--22

3.-J1tj@ L~

F

,---AJf..-- 27

)~ 33

'--.'

.~-"'-I

'L29

--30

28

MAINTENANCE MANUAL 80 105

43 HYDRAULlC SYSTEM Table of Contents

Paragraph Title

Page

43 -1

DESCRIPTION - HYDRAULlC SYSTEM

.

5

43 - 2

TROUBLESHOOTING - HYDRAULlC SYSTEM

.

23

43 - 3

MAINTENANCE INSTRUCTIONS - HYDRAULlC SYSTEM

.

27

43 - 4

REPLENISHING - HYDRAULlC SYSTEM

.

28

43 - 5

BLEEDING - HYORAULlC SYSTEM

.

29

43 - 6

HYDRAULlC fLUID CHANGE - HYDRAULlC SYSTEM

.

30

43 -7

DRAINING Of RESERVOIR - HYDRAULlC SYSTEM

.

31

43 - 8

fREE

43 - 9

PRESERVATION ANO DE-PRESERVATION - HYDRAULlC SYSTEM

.

32

43 -10

CLEANING - HYDRAULlC SYSTEM ......................•...................

32

43 - 11

INSPECTION fOR CONDITION - HYDRAULlC SYSTEM

.

33

43 - 12

LEAKAGE CHECK - HYDRAULlC SYSTEM ...............•...................

37

43 -13

INSPECTION Of SYSTEM 1 SELECTOR VALVE fOR CORROSION

.

39

43 -14

fUNCTIONAL TESTING Of flLTER CONTAMINATION INDICATOR WITH LATERALLY INSTALLED INDICATOR PIN

.

40

43 -15

fUNCTIONAL TEST - HYDRAULlC SYSTEM

.

40

43 - 16

GROUND RUN CHECK Of SELECTOR VALVE SETTING (Applies to al! dual hydraulic units, except dual hydraulic units P/N 105-45039 and 105-450390)

.

45 •

GROUND RUN CHECK Of SELECTOR VALVE SETTING (Applies to dual hydraulic units P/N 105-45039 and 105-450390)

.

51 •

INSPECTION Of SWITCHOVER CONTROL L1NKAGE fOR PLAY (Applies for al! dual hydraulic units, except dual hydraulic units P/N 105-45039 and 105-450390)

.

53 •

INSPECTION Of SWITCHOVER CONTROL L1NKAGE fOR PLAY (Applies to dual hydraulic unit P/N 105-45039 and 105-450390)

.

60 •

43 -16A 43 -17

43 -17A 43 -18

43 - 18A 43 - 19

Revision 24

CHECK ANO ADJUSTMENT Of SWITCHOVER STROKE RANGE (Applies to al! dual hydraulic units except dual hydraulic units P/N 105-45039 and 105-450390) .................•.......•...................

60B.

CHECK ANO ADJUSTMENT Of SWITCHOVER MECHANISM (Applies To dual hydraulic units P/N 105-45039 and 105-450390)

.

64A.

fUNCTIONAL TESTING Of fLAT SPRINGS IN SYSTEM 2

.

65

CHAPTER 43 Page 1

O~~Pter

MAINTENANCE MANUAL SO 105

Paragraph Title 43 - 20

Page

TESTING OF SWITCH OPERATING POINTS OF MICROSWITCHES IN SYSTEM 1 GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

SEALlNG OF SERVO VALVE DRAINAGE CHAMBERS OF SYSTEM 2 ACTUATORS USING SEALlNG COMPOUND (Applies to all dual hydraulic units, except dual hydraulic units P/N 105-45039 and 105-450390)

.69

SEALlNG OF SERVO VALVE DRAINAGE CHAMBERS OF SYSTEM 2 ACTUATORS USING SEALlNG CAPS (Applies to dual hydraulic units P/N 105-45039 and 105-450390)

76

43 - 22

Hydraulic unit

77

43 - 23

Removal - hydraulic unit

77

43 - 24

Free

43 - 25

Installation - hydraulic unit

78

43 - 26

Hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83

43 - 27

Removal - hydraulic pumps

83

43 - 28

Inspection and repair - hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83

43 - 29

Installation - hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . . . .

83

43 - 30

Filters

85

43 - 31

Removal of the filter element - filters

85

43 - 32

Installation of the filter element - filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

43 - 33

Removal of contamination indicator - filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

43 - 34

Installation of contamination indicator - filters

85

43 - 35

Control rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • .

87

43 - 36

Removal - control rods

87

43 - 37

Disassembly - control rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

43 - 38

Inspection and repair - control rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

43 - 39

Assembly - control rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

43 - 40

Installation - control rods . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .

88

43 - 41

Pressure switches

91

43 - 42

Removal - pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

43-43

Inspection - pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

43 - 44

Installation - pressure switches

91

43 - 45

Shuttle valve

92

43 - 46

Removal - shuttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92

43 - 47

Installation - shuttle valve

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

93

43 - 48

Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93

43 - 49

Removal - solenoid valve

93

43 - 50

Inspection and repair - solenoid valve

95

43 - 51

Installation - solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95

43 - 21

• •

43 - 21A

CHAPTER 43 Page 2

Revision 24

_~~opter

MAINTENANCE MANUAL 80105 Page

Paragraph Title

97

43 - 52

Quick-disconnects

43 - 53

Removal - quick-disconnects

.

97

43 - 54

Inspection and repair - quick-disconnects

.

97

43 - 55

Installation - quick-disconnects

.

97

43 - 56

Flat springs in guides

.

98

43 - 57

Removal - flat springs

.

98

43 - 58

Installation - flat springs

.

99

Revision 24

CHAPTER 43 Page3

_~~pter

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 43 Page4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 43 - 1 1.

DESCRIPTION - HYDRAULIC SYSTEM

Hydraulic System Assembly The hydraulic system consists of the dual hydraulic unit artd the assosiated hydraulic lines which are routed according to the interior configuration of the helicopter . The dual hydraulic unit basically consists of the dual hydraulic unit, protective plate, splash guard and three control rods which connect to the mixing lever assembly. In the following the dual hydraulic unit shall be referred to as the hydraulic unit .

2.

General The hydraulic unit augments the pilot's control movements for control of longitudinal, lateral and collective pitCh, and prevents feedback forces of the main rotor from acting on the control rods located forward of the hydraulic unit. The hydraulic unit can be installed and removed without opening any of the hydraulic lines. It is possible to perform maintenance work on and functionally test the hydraulic unit when it is removed from the helicopter. Two systems, identical in design and function, but independent from each other, are linked mechanically in such a way that in the event of a control spool jamming or pressure dropping in system 1, a switch-over to system 2 occurs automatically. System 2 augments the control movements instantly. The hydraulic pumps are driven via the main transmission so that hydraulic power will be available during autorotation, too.

3.

Technical Data Hydraulic fluid:

Hydraulic oil MIL-H-5606

Operating pressure:

103 bar

Mass:

approx. 39 kg

Dimensions:

approx. 350 x 600 x 680 mm

Capacity of the hydraulic unit:

approx. 3 1

Capacity of one reservoir:

0.8 1

BO 105 CHAPTER 43 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

400519

1 2 3 4 Figure 43-1

80 105 CHAPTER 43 Page 6

Hydraulic unit

Dual hydraulic unit Protective plate Splash guard Control rod

_eurooopter

MAINTENANCE MANUAL BO 105

P/N 105-45021, 105-45023, 105-450390

1 2 3 4 5 6

External couplings Reservoir, system 2 Safety cap/Fluid level indicator Reservoir, system 1 Hydraulic pump, system 2 Hydraulic pump, system 1

Figure 43-2 Revision 22

P/N 105-83001, 105-83011

7 8

9 10 11 12 13

Input lever, system 1 Pressure relief valve, system 1 Test valve, system 1 Control rods Pressure switch, system 1 Pressure switch, system 2 Input lever, system 2

(1 of 6) Hydraulic unit CHAPTER 43 Page7

•

_eurocopter •

MAINTENANCE MANUAL 80 105

P/N 105--45021, 105--45023, 105-83001, 105-83011, 105--450390

Blif---+-+----17

19

------18

14 15 16

Pressure transfer valve Close-tolerance bolts, system 1, 2 Guide

Figure 43-2

CHAPTER 43 Page8

17 18 19

N2-lever assy Solenoid valve Drain line

(2 of 6) Hydraulic unit

Revision 22

O~~pter

MAINTENANCE MANUAL 80105

P/N 105-45028

1 2 3 4 5

P/N 105-45018

External couplings Reservoir, system 2 Safety cap/Fluid level indicator Reservoir, system 1 Hydraulic pump, system 2

6 7 8 9

10 11

Figure 43-2 Revision 24

Hydraulic pump, system 1 Input lever, system 1 Pressure relief valve, system 1 Test valve, system 1 Control rods Input lever, system 2

(3 of 6) Hydraulic unit CHAPTER 43 Page9

•

_~~pter •

MAINTENANCE MANUAL BO 105

P/N 105-45028

P/N 105-45018

I!lRf1.~-...,......-----16

~----17

\...-+-...j¡.Qi=1H----=------18

'--------------19 12 13 14 15

Pressure switch, system 2 Pressure switch, system 1 Electrical wiring Pressure transfer valve Figure 43-2

CHAPTER 43 Page 10

16 17 18 19

External couplings N2-lever assy Solenoid valve Drain line

(4 of 6) Hydraulic unit Revision 24

_eurooopter

MAINTENANCE MANUAL BO 105

•

P/N 105-45039

1 2 3 4 5

External couplings Reservoir, system 2 Safety cap/Fluid level indicator Reservoir, system 1 Hydraulic pump, system 2

Figure 43-2

Revision22

6 7 8 9 10 11

Hydraulic pump, system 1 Input lever, system 1 Pressure relief valve, system 1 Test valve, system 1 Control rods Input lever, system 2

I

(5 of 6) Hydraulic unit

CHAPTER 43 Page lOA

_eurocopter •

MAINTENANCE MANUAL SO 105

P/N 105-45039

-/------14

13----U~~~~:!=

16

12

17 18 ~I

o

'"::¡:1 0

<

°L

~I

It)

o

o al

00 19

12 13 14 15

Pressure switch, system 2 Pressure switch, system 1 Electrical wiring Pressure transfer valve

Figure 43-2 CHAPTER 43 Page 10B

16 17 18 19

External cauplings N2-lever assy Salenaid valve Drain line

(6 af 6) Hydraulic unit Revisian 22

_eurooopter

MAINTENANCE MANUAL 80105

4. Assembly and operation of the hydraulic unit a. Assembly Two hydraulic boost systems, which are independent of each other, are mounted in a sheet metal frame and are linked by couplings and control rods. The hydraulic unit consists basically of - sheet metal frame - two hydraulic boost systems including 3-axis actuator reservoir hydraulic pump tubes and hoses external couplings pressure switch electrical wiring - Pressure transfer valve - solenoid valve -couplings - control rods The 3-axis actuator consists of three actuators and the valve body manifold. An actuator consists of housing, main pistan, servo valve, input lever and override mechanism. The valve body manifold consists of selector valve, pressure relief valve, test valve, non-return valve and filter element with contamination indicator. EFFECTIVITY

AH dual hydraulic units, except dual hydraulic units P/N105-45039, 105-450390

Reservoir without trapped air indicator The reservoir consists of a cylindrical aluminium vessel which includes al low pressure pistan, high pressure pistan, low pressure safety valve, filter element with contamination indicator and relief plug.

Revision 22

CHAPTER 43 Page 11

I

_eurocopter •

MAINTENANCE MANUAL 80 105

EFFECTIVITV Dual hydraulic units P/N105-45039, 105-450390 Reservoir with trapped air indicator The existing reservoir also includes a yellow indicator ring which is fitted to the pistan rod of the low pressure pistan. If air collects in the reservoir, it is indicated by the changed position of the indicator ringo

The hydraulic pump is a constant-pressure, high-pressure pump with a variable feed rateo The pressure transfer valve, which is a differential pressure switch, consists of housing, pistan with two pistan areas at a ratio of 1:2 and one pressure line to system 1 and system 2 each. b. Operation The control spool of an actuator is operated by the pilot's control inputs via levers, control rods and input levers. The actuator augments these control inputs and transfers them to the main rotor via a controllinkage. Figure 43-3 iIIustrates the sequence of operations. A schematic differentiation is made between control inputs and augmentation and thus two superimposed, almost simultaneous movements are shown separately. Control axis is to be understood as the actuator and the opposite reserve actuator together with the related control rods.

•

The main pistan is kept in a position set by the pilot. If no control inputs are transmitted, the oil trapped in the two chambers of the hydraulic cylinder acts against forces induced by the main rotor (see figure 43-4 or 43-4A, ''without control inpuf').

•

A control input causes a displacement of the control spool of the servo valve via the input lever and thus two control passages are opened (see figure 43-4 or 43-4A, "afier control inpuf'). High pressure oi! flows through one of the control passages into one chamber of the hydraulic cylinder. Simultaneously oil from the opposite chamber is displaced and flows ¡nto the reservoir vía the return line.

CHAPTER 43 Page 12

Revision 22

MAINTENANCE MANUAL 80105

EUROCOPTER

Opening

2

6

7

J--~--5

&:::g:-:~~&--Jj21~

4

3 , 2 t----1

without control input

control input

augmentation

400523

1 Control rod Input lever Piston rod Dual actuator 5 Control spool of servo valve 6 Control rod (mixing lever assy) 7 Control rod

2 3 4

Figure 43-3

& & &

Travel of the push rod Travel of t.he control spool Travel of the main piston (augrnented)

Sequence of operations shown in a control axis diagram

The high pressure oil displaces the main piston until the previously opened control passages are closed again by the control spool, which is moved paral1el to the main piston (see fig~re 43-3) . The main pistons of two actuators located opposite to one another are linked without play, so that their motions are identical. A closed selector valve keeps the actuator of system 2 pressureless so that no resistance is offered to the motion of the main piston. As a result of the pressureless state a bypass is opened. Thus oil can flow from one chamber to the other one. A switch-over from system 1 to system 2 occurs either in case of a pressure drop below 50 bar in system 1 oder in case of a control spool jamming in system l.

Revision 10

BO 105 CHAPTER 43 Page 13

EUROCOPTER

MAINTENANCE MANUAL BO 105

In both cases the pressure transfer valve controls the selector valves in the valve body manifolds mechanically making system 1 pressureless and system 2 pressurized. In this case the main piston of system 1 performs simultaneous movements without offering any resistance. It serves as a control rod for the transmission of control forces. In case of a control spool jarnming in system 1 or system 2 an override occurs in the respective control axis. Only a hydraulic system override in system 1 initiates a system switch-overo Microswitches in the override mechanism activate a solenoid valve which is then kept in the open position by a relay energized simultaneously. A pressure line of system 1 is blocked in front of the pressure transfer valve. Simultaneously the systeln 1 side of the pressure transfer valve is connected to the return lineo Pressure is allowed to diminish on this side and a switch-over can be initiated as is the case of a pressure drop. The motion of the main piston of the collective control axis is transmitted lo the N2-control lever by the N2-lever assembly. To compensate for an increasing power requirement resulting from an increasing collective pitch the N2-control is adjusted in such a way that the RPM of turbine N2 and main rotor are kept nearly constant. The booster is monitored by two pressure switches and the related warning lights HYDR 1 and HYDR 2 indicating a pressure drop and a warning light HY BLOCK indicating a control spool jarnming. A test switch allows for a system switch-over during maintenance and preflight check (for electrical wiring diagram refer to chapter 91). Four external couplings allow connection of an external pressure supply for inspection and maintenance purposes.

BO 105 CHAPTER 43 Page 14

Revision 10

e

euro00pter

EFFECTIVITV

MAINTENANCE MANUAL 80105

AII dual hydraulic units, except collective control actuator of dual hydraulic units P/N 105-45039 and 105-450390

System 2

System 1

I

t:=:::tr:~~=w~~=tL~~--- 6 & ~++---++---------

5

r------II..-=+__ 2 without control input

I ... motion of the . , control spool

~ augmented motion , . of the main piston after control input

1 Coupling 2 Main piston 3 Ring bypass

Figure 43-4 Revision 22

4 Control spool 5 Connecting plate 6 Selector valve

& & &

Bypass closed Bypass opened System 1 operating

DiI flow in a dual hydraulic actuator - schematic diagramm CHAPTER 43 Page 15

I

_euro 00 pter •

EFFECTIVITY

MAINTENANCE MANUAL 80 105

Dual hydraulic units P/N 105-45039 and 105-450390, collective control actuator

System 2

System 1

¡-------""+--2

without control input

I ~ motion of the . , control spool

~ augmented , . motion of the main piston

after control input

1 Coupling 2 Main piston 3 Cone bypass

4 Control spool 5 Connecting plate 6 Selector valve

& & &

Bypass closed Bypass opened System 1 operating

Figure 43-4A Oil f10w in collective control actuator - schematic diagram

CHAPTER 43 Page 16

Revision 22

_eurooopter

MAINTENANCE MANUAL BO 10S

5. Hydraulic system schematic

SYSTEM 2

SYSTEM 1

I I

I I I

4

r---·-------·· -, f"-"-"---;:'1

I

:;i~q ¡ ( s I

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r.';;-"-"-"'"1,

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~

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r._._~~i~~~. .I_.

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,.._._._'.l._.:~~~~._.-:t

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! 1'86,1,-~ ';;:;,t~: . ~-r~"1XI lllI ~r415 I I ; 16 T :~J I L_-::_ T 16 ¡ i 17 tt-·_·_·_-_·_·_E_·-·-··11 ~'-'-'---'---'-'-'-"l fo:le~tive I

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actuator 11 c cOlli

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Revision 22

l' "

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17 ._._.J L.--J.._._._._._ ._._

Figure 43-5

I

actuator 1

m

:r~fmtU~~15 16! Io--

"1

Lo - - -

'* A.._._._.11

T

I

I

I.

actu~tor 1 longitudinal

. _._._.L.-. J 1

(1 of 7) Hydraulic system schematic diagram P/N 105-45021/-45023

CHAPTER 43 Page 17

cteurooopter

MAINTENANCE MANUAL 80 105

SYSTEM 2

SYSTEM 1

2l~ :-RA!

. 4

I

r-r=~--=--=~~: l:

I I

~

reservoir

r--,

! I I

RE PE _o-It- ....,

llr~i

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II i

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actuator 11 longLdin~1

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manifold

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; actuator I

I ~._._.-._.-. -.-.-.-...,, collective .., J . I 14 ~'I. ':' i lf[r~ __ tf

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r·_·_·-·_·-·_·-·_o-.. ~Iateral I I r-rID'~ _141 f-' llil r'-;41!5 ~ 7. T . I

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7

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actuator 11: 17' collective t·_·-· -.-.-._.-._.-._....

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¡ longitudinal

~

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- _ . _ - _ .- _ . _ - _ ._ _

Figure 43-5 (2 of 7) Hydraulic system schematic diagram P/N 105-83001/-83011

CHAPTER 43 Page 18

Revision 22

_~~copter

MAINTENANCE MANUAL BO 105

SYSTEM 1

SYSTEM 2

"'''~

2

I r -----------,

¡ r·~~··-~~

lt!,~u I

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Revision 22

CHAPTER 43 Page 19

O~~~pter

MAINTENANCE MANUAL 80 105

SYSTEM 2

SYSTEM 1

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• CHAPTER 43 Page 20

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Revision 24

MAINTENANCE MANUAL BO 10S

SYSTEM 2

SYSTEM 1

4

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Revision 22

CHAPTER 43 Page 21

eeurocopter

MAINTENANCE MANUAL BO 105

SYSTEM 2

SYSTEM 1

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CHAPTER 43 Page22

Revision 22

cteurocopter

MA.NTENANCE MANUAL BO 105

•

1

Reservoir

10

Test valve

2

External coupling (return line)

11

Pressure relief valve

3

Hydraulic pump

12

Non-return valve

4

Pressure switch

13

Selector valve

5

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14

Bypass

6

Low pressure safety valve

15

Mechanical override system I with microswitch

7

Filter with contamination indicator and bypass valve

16

Servo valve

8

Solenoid valve

17

Main pistan

9

Pressure transfer valve

18

Mechanical override system 11

Identification of ports HYDRAULlC PUMP

VALVE BODY MANIFOLD

P

Port for pressure line

PA

Inlet port for pressure line from external couplings

S

Port for suction line

PE

Inlet port for pressure line from hydraulic pump

CD

Port for case drain

PM

Port for measuring pressure

SO

Port for seal drain

RE

Outlet port return line/reservoir

RESERVOIR

EXTERNAL COUPLlNGS PAI/II

Port for external pressure system 1/11

S

Port for suction line

RAIIII

Port for external return line

R

Port for return line

PH

Port for pressure system 11

Pv

Port for inlet pressure

RH

Port for return line system 11

Figure 43-5 (7 of 7) Legend

Revision 22

CHAPTER 43 Page 22A

eeurocopter

MAINTENANCE MANUAL SO 10S

BLANK PAGE

CHAPTER 43 Page22B

Revision 22

MAINTENANCE MANUAL 80105

TROUBLESHOOTING - HYDRAULlC SYSTEM

43 - 2 NO. 1.

2.

Leakage

Warning Iights HYDR1 or/and HYDR2 do not illuminate

EFFECTIVITY

3.

PROBABLE CAUSE

TROUBLE SYMPTOM

CORRECTIVE ACTION

leaking hoses and tubes

tighten union nut at the leaking connection by 1/6th of a turn once only. In case of further leaking replace tube or hose line

excessive leakage at sealing elements

replace defective sealing elements (refer to REM 402 or REM 405)

electrical defect

troubleshooting acc. to chapter 91

P/N 105-45021, 105-45023, 105-45028

When suddenly moving the cyclic stick (hydraulic system override): warning Iight HY BLOCK does not illuminate, or warning Iight HY BLOCK does not extinguish subsequently when operating test switch

both microswitches of one control axis defective

check individual microswitches acc. to paragraph 43-20

or electrical defect EFFECTIVITY

P/N 105-83001, 105-83011, 105-45039, 105-450390, 105-45018

3A. When suddenly moving the cyclic stick (hydraulic system override): warning lights HY BLOCK and HYDR1 do not iIIuminate, or warning lights HY BLOCK and HYDR1 do not extinguish subsequently when operating test switch

both microswitches of one control axis defective

troubleshooting acc. to chapter 91

corrosion at bearing bushings of rework bolts to a c1ear and easy input levers and close tolerance fit acc. to paragraph 43-11 bolts

4.

Hard moving controls

5.

Pump does not produce a Warning lights HYDI or/and HYD2 do not extinguish at 60 % pressure of 85 bar in the respective system rotor speed or

Irregularities in controls when operating in system 2

check individual microswitches acc. to paragraph 43-20

or electrical defect

6.

troubleshooting acc. to chapter 91

Measure pump pressure (refert o paragraph 43-15) and replace hydraulic pump if necessary

Electrical defect

Troubleshooting acc. to chapter 91

Two broken flat springs in system 2

Check flat springs for function (refer to paragraph 43-19)

Table 43-1 (1 of 3) Troubleshooting - hydraulic system

Revision 24

CHAPTER 43 Page 23

I

MAINTENANCE MANUAL 80105

NO. 7.

TROUBLE SYMPTOM

PROBABLE CAUSE

No system switchover to system Solenoid valve does not open 1 when using test switch

or

8.

Warning Iights HYD1/HYD2 iIIuminate briefly upon control inputs

9.

Automatic switch-over from system 1 to system 2 occurs and: EFFECTIVITY

I

Main rotor at stand still: Operation of solenoid valve must be heard, otherwise electrical defecto If electrical defect can be excluded, replace solenoid valve

Electrical defect

Troubleshooting acc. to chapter 91

Internalleakage in system 1/system 2

Inspect internalleakage oil (refer to paragraph 43-15) and repair hydraulic unit if necessary (refer to REM 402 or REM 405)

P/N 105-45021, 105-45023, 105-45028

- Warning light HY BLOCK iIIuminates; warning lights HYDR1/HYDR2 briefly iIIuminate and increased control forces in one control axis occur EFFECTIVITY

CORRECTIVE ACTION

hydraulic system of a control spool jamming in one servo valve of system 1

repair hydraulic unit (refer to REM 402 or REM 405)

P/N 105-83001, 105-83011, 105-45039, 105-450390, 105-45018

- Warning Iight HY BLOCK iiluminates; warning light HYDR1 iIIuminates continuously; HYDR2 iIIuminates briefly; increased control forces in one control axis

hydraulic system of a control spool jamming in one servo valve of system 1

repair hydraulic unit (refer to REM 402 or REM 405)

- Warning Iight HYDR1 iiluminates permanently

pump pressure of system 1 below 65 bar

measure pump pressure in system 1 (refer to paragraph 43-15) and/or check reservoir of system 1 for condition (refer to paragraph 43-15) or check internal oil leakage (refer to paragraph 43-15)

or

10. Warning light HYD2 iIIuminates permanently

electrical defect

troubleshooting acc. to chapter 91

Pump pressure of system 2 below 65 bar

Measure pump pressure in system 2 (refer to paragraph 43-15) and replace hydraulic pump if necessary

or Electrical defect

Troubleshooting acc. to chapter 91

11. Warning Iight HY BLOCK Electrical defect iiluminates without increase of control forces in one control axis

Troubleshooting acc. to chapter 91

Table 43-1 (2 of 3) Troubleshooting - hydraulic system CHAPTER 43 Page 24

Revision 24

O~~ter NO.

TROUBLE SYMPTOM

12. Red indicator pin of filter contamination indicator popped out

MAINTENANCE MANUAL BO 10S

PROBABLE CAUSE Filter element clogged or bypass valve defect

CORRECTIVE ACTION 1) Inspect and clean filter element(refer to para. 43-30), bleed hydraulic system 2) Depress red indicator pin and perform a ground run or connect hydraulic ground service cart (103 bar) 3) Move cyclic stick. If red indicator pin does not pop out again, the system is serviceable 4) If red indicator pin pops out again, change filter element 5) If no residues can be found, repair bypass valve (refer to REM 402 or REM 405)

Table 43-1 (3 of 3) Troubleshooting - hydraulic system

Revision 24

CHAPTER 43 Page 25

I

O~~opter

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 43 Page 26

EUROCOPTER

43 - 3 1.

MAINTENANCE INSTRUCTIONS - HYDRAULIC SYSTEM

A hydraulic ground unit having the following operating capabilities is required for performing the maintenance work: Filtration rating: Pressure range: Delivery rate: Pressure gauge:

2.

MAINTENANCE MANUAL 80 105

3 micron absolute 0-180 bar 0-16 l/min 0-250 bar with an accuraey of 0.6%

Operating fluid Operate the hydraulic ground unit I~ith MIL-H-5606 hydraulic fluid only. Handle the hydraulie fluid in aceordanee with the applieable safety regulations. Do not reuse drained hydraulic fluid or hydraulie fluid from unsealed canso

3.

Disassembly and assembly Clean all removed and disassembled parts with dry eleaning solvent (CM 202) and dry them using lint-free cloth or compressed airo At eaeh time of disassembly, discard O-rings, sealing rings and baekup rings. Before installing O-rings and sealing rings r first wet them with hydraulie fluid. If components are to be stored for a longer period of time, fill them with preservative hydraulie fluid (CM 117) .

BO 105 CHAPTER 43 Page 27

EUROCOPTER

43 - 4

MAINTENANCE MANUAL BO 105

REPLENISHING - HYDRAULIC SYSTEM

Special tool: Hydraulic ground unit The level of the hydraulic fluid can be read off on the graduation rings of the fluid level indicator of the respective system. The upper edge of the piston sleeve, not the relief plug, is the reference lineo If the indication is below the "füllen" mark, replenish the hydraulic system. Fill system 1 and system 2 in turn, starting with system 1.

* If trapped air indicator ring is installed, remove safety cap (1, Fig. 43-6) * after filling reservoir, and push down indicator ring (11) until it is seated * on washer (12) located on the reservoir cover. Reinstall safety cap (1).

1.

Connect hydraulic ground unit to external pressure quick-disconnect RA I (RAII). Hydraulic unit switched to system 1 (system 2) .

2.

Apply a pressure of 1 bar to RA 1 (RAII). approx. 5 mm below the "max" indication.

3.

If air inclusions are suspected, bleed the hydraulic system (refer to paragraph 43-5).

4.

Perform steps 1.thru 3. for system 2. Switch over to system 2 when the system is depressurized. For this purpose, press in selector valve of system 2.

5.

Switch over to system 1 when the hydraulic system is depressurized. For this purpose, press in selector valve of system 1.

BO 105 CHAP'l'ER 43 Page 28

Fill system 1 (system 2) to

Revision 10

MAINTENANCE MANUAL 80 105

EUROCOPTER

without trapped alr indlcator

wlth trapped alr Indlcator

1 10 --+.",=••:-t

2 3

11

12

-+E--5

__

--~--6

~----7

wlth trapped sir Indlcator

400055

1 Safety cap 2 Relief plug 3 Hydraulic oil level indication (upper edge of sleeve) 4 Pistan (in uppermost position) 5 Low pressure chamber 6 High pressure chamber 7 Low pressure safety valve

Figure 43-6

Revision 10

3 9 10 11 12 13

Minimum oil level Replenishing level Maximum oil level Indicator ring lilasher Spacer sleeve

Hydraulic oil level indication

BO lOS CHAPTER 43 Page 28A/B

EUROCOPTER

43 - 5

MAINTENANCE MANUAL BO 105

BLEEDING - HYDRAULIC SYSTEM

Special tool: Hydraulic ground unit 1.

* * *

Connect hydraulic ground unit to RAI and PAI ports.

without trapped air Indicator

wlth trapped air lndlcator

~,

1._.1

400526

1 2

3 4 5 6

Figure 43-7

Safety cap Lock spring Relief plug Transparent hose Indicator ring Washer

Bleeding - hydraulic system

2.

Remove safety cap (1, figure 43-7) together with lock spring (2) from reservoir.

3.

Remove lockwire from relief plug (3) and connect transparent hose (4).

4.

Place a drip cup in position.

5.

Apply a pressure of 1.5 bar to RAI port and 15 to 20 bar to PAI port.

6.

Open relief plug (3) of system 1 by loosening it half a turno

*

7. Move cyclic stick and collective pitch stick over the full range of

control positions and turn the main rotor by hand in rotational direction. Make 10 rotations.

Revision 16

*

*

BO 105 CHAPTER 43 Page 29

EUROCOPTER

MAINTENANCE MANUAL 80 105

8. If no air bubbles come out of the relief plug, torque relief plug to a torque value of 3 Nm. 9. Make hydraulic ground unit pressureless and disconnect it irnmediately from the hydraulic unit. 10. Remove transparent hose, secure relief plug (3) with lockwire (0.4 mm) and attach safety cap (1) together with lock spring (2).

* 11. If trapped air indicator ring is installed, remove safety cap (1,

* Fig. 43-6) and push down indicator ring (11) until it is seated on washer * (12) located on the reservoir cover. Reinstall safety cap (1). * * 12. Carry out work steps 1 thru 11 for system 2.

* 43 - 6

HYDRAULIC FLUID CHANGE - HYDRAULIC SYSTEM

Special tools: Hydraulic ground unit Drain hose, tool no. 19 (105-45000 W1) refer to Chapter 04 NOTE

If a functional test is required apart from the change of hydraulic fluid, the hydraulic reservoir shall be tested for ease of movement first of all (refer to paragraph 43-15).

1.

Connect hydraulic ground unit to external pressure quick-disconnect PA l. Hydraulic unit switched to system 1.

2.

Connect drain hose (tool no. 19) (105-45000 W1) to external pressure quick-disconnect RA l. Place a drip cup at the ready.

3.

Apply a pressure of 103 bar to PA l. Move control rods of all three control axes. Used hydraulic fluid is drained via the drain line and is replaced by unused hydraulic fluid from the hydraulic ground unit. Stop the procedure after approximately 1.5 1 per system have been drained.

4.

Disconnect drain hose from RA l.

5.

Replenish system 1 (refer to paragraph 43-4) and bleed system 1 (refer to paragraph 43-5) .

* 5A. If trapped air indicator ring is installed, remove safety cap (1, * Fig. 43-6) and push down indicator ring (11) until it is seated on washer *

(12) located on the reservoir cover. Reinstall safety cap (1). 6.

Perform steps 1. thru 5. for system 2. For-this purpose, switch over to system 2. Connect external pressure quick-disconnect PA 11 and connect drain hose to external pressure quick-disconnect RA 11.

BO 105 CHAPTER 43 Page 30

Revision 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 43 - 7

DRAINING OF RESERVOIR - HYDRAULIC SYSTEM

Special tool: Hydraulic ground unit 1.

Connect hydraulic ground unit to external pressure quick-disconnects PA 1 (PA 11) and RA 1 (RA 11). Hydraulic unit system 1 (system 2) .

2.

Applya pressure of 103 bar to PA 1 (PA 11). The hydraulic reservoir is drained via return lineo The hydraulic reservoir is empty when the the piston sleeve is in its lowest position.

3.

Perforrn steps 1. and 2. for system 2. Changeover occurs automatically in step 2.

43 - 8

FREE

BO 105 CHAPTER 43 Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 43 - 9

PRESERVATION ANO DE-PRESERVATION - HYDRAULIC SYSTEM

Special tool: Hydraulic ground unit l.

De-preserve spare hydraulic units and assemblies prior to putting them into operation: Substitute normal hydraulic fluid (CM 110) for preservation hydraulic fluid (refer to paragraph 43-6) .

2.

Preserve hydraulic units and assemblies if they are to be stored for a longer period of time. Substitute preservation hydraulic fluid (CM 117) for normal hydraulic fluid (refer to paragraph 43-6) .

43 - 10

CLEANING - HYDRAULIC SYSTEM

CAUTION

DO NOT CLEAN THE HYDRAULIC SYSTEM WITH HIGH PRESSURE CLEANING DEVICES OR STEAM JET BLOWERS.

WARNING

DO NOT CLEAN THE HYDRAULIC SYSTEM WITH CLEANING AGENTS CONTAINING ALCOHOL BECAUSE HYDRAULIC FLUID MIL-H-5606 CAN REACT WITH ALCOHOL AND CAUSE THE HYDRAULIC UNIT TO MALFUNCTION.

1.

Protect hydraulic reservoir, wiring harness and electrical connector with a plastic foil.

2.

Clean hydraulic unit with dry cleaning solvent (CM 202).

BO 105 CHAPTER 43 Page 32

MAINTENANCE MANUAL SO 105

43 -11

INSPECTION FOR CONDITION - HYDRAULlC SYSTEM

1. Clean the hydraulic unit (refer to paragraph 43-10). 2. Check the hydraulic unit for condition and for loose or missing attaching hardware. Visually inspect components for cracks, chafe marks and corrosion. 3.

Inspect lockwires and split pins for correct installation and renew, if necessary.

4. Visually inspect boets fer cracks. If a crack is evident, replace boots in accordance with REM 402 or REM 405. 5.

I

Inspect placards for proper bonding. Fasten loose placards with adhesive (CM 601).

6. Visually inspect sheet metal for damage such as deformation, cracks and chafe marks. 7.

Inspect hydraulic lines: a. Visually inspect hose Iines for cracks and damage to the wire sheathing. If damage is evident, replace the affected parto b. Visually inspect tube lines fer cracks, chafe marks and dents. If damage is evident, replace the affected parto c. VisL[ally inspect the identification sleeves for location and condition, replace them if necessary.

8. Visually inspect electricallines for damage to the insulation. Check connectors for secure fit. 9. Check control rods: a. Check spherical bearings for radial play. The radial play shall not exceed 0.1 mm. Discard rod end if allowable play is exceeded. b. Visually inspect sealing of the rod ends. If sealing is damaged, remove, disassemble and inspect control rods (refer to paragraph 43-35). c.

deleted

10. Inspect seals (sealing compound) on servo valvedrainage chambers of system 2 actuators for damage and hydraulic oilleakage. Replace seal if damaged (refer to para 43-21). 10A. lrispect sealing caps on servo valve drainage chambers of system 2 actuators for damage. If seals (sealing compound) or sealing caps are damaged, apply new seal or replace sealing cap (refer to para 43-21 A).

Revision 23

CHAPTER 43 Page 33

•

-eurocopter

. . 811 EAOO

•

MAINTENANCE MANUAL 80 105

Compeny

11. Check all input levers (3 and 6, figure 43-32) for lateral play. For this purpose, subject the upper fork to a force of 5 N in a direetion perpendicular to the control axis. Repeat this step, exerting this force in the opposite direction. Total play on the fork must not exceed 0.5 mm (see figure 43-8).

~~~ - - - - + - - - ' - - - - - max. 0.5 mm

r

Input lever

Figure 43-8

Check lateral play of input lever.

12. Check all close tolerance bolts of input levers for ease of movement. The bolts shall be easy to rotate using a wrench. If bolts are hard moving, provide for ease of movement. For this purpose remove nylstop nut. Pull out close tolerance bolt as far as possible and pack with grease (CM 101). Slightly tighten nylstop nut. Then screw back to align with the split pin hole and secure with split pino

•

13. Check couplings (3, figure 43-9) of the boost pistons for correet spacing and play. The minimum spacing must not be less than 2 mm. Couplings must not have any axial play. EFFECTIVITY

•

Step 14. is a Supplementary Inspection According To Operating lime in Fh and is to be performed only on bushings, which may be rotated while installed. For time of inspection refer to chapter 101 .

14. Check guide bushings (1) for the coupling guide pins (2) for play in the angle brackets (5). The minimum contact must not fall below 0.5 mm. 15. Inspect visible areas of pistons in actuators and the pressure transfer valve for scores, and smooth with polishing cloth if necessary. 16. Visually inspect shaft of N2-lever assy for deformation.

CHAPTER 43 Page 34

Revision 22

MAINTENANCE MANUAL SO 105

DETAlL

A '8-+-1.=<--2

5

4 3

1

1 Guide bushing 2 Guide pin 3 Coupling assy 4 Piston rod 5 Bracket angle

2 Permissible clearance: 2 mm

3 4 1

5

5

a: I

'" ~,

DETAlL

1

B

J:

~

",' o

Ó

Position so that bushing abuts

ID

Figure 43-9

--1~¡"l-min. 0.5 mm

Inspection - couplings

17. Visually check fouling indicators. The red button shall not have popped out. Ifthe red button has popped out, replace the filter element (refer to paragraph 43-33 and 43-34). 18. Visually inspect fork ends of system I actuator boost pistons for corrosion. Replace_corroded fork ends.

Revision 23

CHAPTER 43 Page 35

I

MAINTENANCE MANUAL SO 105

19. Inspect couplings tor corrosion: a.

If corrosion is evident, remove couplings in accordance with REM 402 or REM 405.

b.

Inspect coupling bolts tor corrosion. If corrosion is evident, remove and replace coupling bolts in accordance with REM 402 or REM 405.

c.

If coupling bolt is to be replaced, c1ean interior ot appropriate piston and visually inspect thread for mechanical damage and corrosion. No damage permissible to the 8th thread, replace piston rod in accordance with REM 402 or REM 405, if necessary.

d.

Install couplings in accordance with REM 402 or REM 405.

20. If trapped air indicator (indicator ring) is installed on system 1 and system 2 reservoirs, inspect indicator ring (11, Fig. 43-6) for condition and free movement on piston rod. a.

Remove safety cap (1).

b.

Move indicator ring (11) by hand up and down the piston red to ensure free movement over entire range. If the indicator ring should bind, remove it and thinly lubricate its sliding area on the piston red with hydraulic oi!.

c.

Inspect indicator ring tor correct paint finish. If paint coat is damaged, touch up with two-component wash primer (CM 423) followed by two-component PUR finishing coat (CM 444).

CHAPlER 43 Page 36

Revision 23

-~~pter 43 -12

MAINTENANCE MANUAL BO 105

LEAKAGE CHECK- HYDRAULlC SYSTEM

Special tools:

Hydraulic ground unit

1. Clean the hydraulic unit (refer to paragraph 43-10). 2.Connect hydraulic ground unit to external pressure quick-disconnects PA I and RA 1. 3. Apply a pressure of 103 bar to PA I for 5 minutes. Perform 25 double strokes with each control rod. Visually check hydraulic system for leakage. The values given in table 43-4 shall not be exceeded. If excessive leakage is evident, repair the hydraulic unit as outlined in REM 402 or REM 405. 4.

Replenish system 1 (refer to paragraph 43-4).

4A. If trapped air indicator (indicator ring) is installed, remove safety cap (1, Fig. 43-6) and push down indicator ring (11) until it is seated on washer (12) located on the reservoir cover. Reinstall safety cap (1). 5.

Perform steps 2. to 4. for system 2. For this purpose connect external pressure quick-disconnect PA 11 and

AA 11. PART

MAXIMUM PERMISSIBLE LEAKAGE

Unions, fittings

No leakage permissible. Leaky union nuts may be tightened once only by 1/6 turno

Power piston seal of the actuators

1 drop per 25 double strokes.

Control spool seal of the actuators

1 drop per 25 double strokes. Table 43-4 Permissible leakage

Revision 23

CHAPTER 43 Page 37

I

MAINTENANCE MANUAL SO 105

BLANK PAGE

CHAPTER 43 Page 38

_~~pter 43 - 13

MAINTENANCE MANUAL 80105

INSPECTION OF SVSTEM 1 SELECTOR VALVE FOR CORROSION

Special tools:

Tool for unscrewing tool no. 34 refer to chapter 04

This inspection is to be carried out only on screw plug (2, figure 43-10) with a vent hole in the center, which is covered by a fine-meshed screen and not sealed. 1. Remove control rods located between input levers (refer to paragraph 43-36). 2. Remove screw plug from system 1 valve body manifold using tool no. 34. 3. Clean screw plug and opening in valve body manifold using compressed airo 4.

Inspect inside of opening for corrosion.

5.

Remove corrosion, particularly in the area of stud (3) or brazing and clean affected area with acetone. In case this area is sealed, do not remove sealing compound. Thus work step 6. may be omitted.

6. Seal area around stud or brazing with sealing compound (CM 661). 7. Wet screw plug with hydraulic oil and install in valve body manifold. Torque to 4.5 thru 5.5 Nm. 8.

Install control rods (refer to paragraph 43-40).

2 14.5-5.5 Nml

3

4

1 Valve body manifold 2 Screw plug 3 Stud or brazing 4 Sealing compound

Figure 43-10

Revision 10

Seal - screw plug - Valve body manifold

CHAPTER 43 Page 39

MAINTENANCE MANUAL BO 105

43 - 14

FUNCTIONAL TESTING OF FILTER CONTAMINATION INDICATOR WITH LATERALLY INSTALLED INDICATOR PIN

1. Move red indicator pin with suitable mandrel and check for freedom of movement. Be sure not to push the indicator pin to its outward Iimit, as it will lock in position. 2.

If the indicator pin does not move easily (due to contamination or gumming) remove filter contamination indicator, clean it an reinstall (refer to para 43-33 or 43-34).

3.

Replenish and bleed system (refer to paragraph 43-4 and 43-5) only if filter housing cover has been removed.

43 - 15

FUNCTIONAL TEST - HYDRAULlC SYSTEM

Special tools:

NOTE

Hydraulic ground unit Pressure test line Drain hose Drip cup Graduated vessel

105-45000W2 tool no. 19 (105-45000 W1) commercial commercial

refer to chapter 04

• If test requirements cannot be met and if no corrective actions are specified, proceed as outlined in the Repair Manual (REM 402 or REM 405). • If pressure is applied to quick-disconnect PA 11 only, switch-over to system 2 occurs automatically.

1. Check electrically initiated system switch-over for correct function. a. Applya pressure of 103 bar to PA I and PA 11 by means of the hydraulic ground unit. Return line must be connected to RA 1and AA 11. b. Set hydraulic test switch to "TEST' ("HYDR 11") and release.

EFFECTIVITV

P/N 105-45021, 105-45023, 105-45028

Warning light HY BLOCK must come on.

•

EFFECTIVITV

P/N 105-83001, 105-83011, 105-45039, 105-450390, 105-45018

Warning Iights HY BLOCK and HYDR 1 must come on. c.

Check that hydraulic unit has switched over to system 2 by visually inspecting it during switch-overo

CHAPTER 43 Page 40

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MAINTENANCE MANUAL SO 105

d. Set hydraulic test switch to "RESET" and release.

EFFECTIVITY

P/N 105-45021, 105-45023, 105-45028

Warning light HY BLOCK must go off.

EFFECTIVITY

P/N 105-83001 105-83011, 105-45039, 105-450390, 105-45018 J

Warning lights HY BLOCK and HYDR 1 must go off. e. 2.

Check that hydraulic unit has switched over to system 1 by visually inspecting it during switch-over.

Check switch-over from system 1 to system 2 by override for function. a. Apply a pressure of 103 bar to PA I and PA 11 by means of the hydraulic ground unit. Return line must be connected to RA I and RA 11. b.

System 1 must be engaged. Using the appropriate control element or rod, apply short quick movements to override the LONGITUDINAL control axis in one direction. Check that hydraulic unit has switched over to system 2 by visually inspecting it during switch-over.

c.

System 1 must be engaged. Using the appropriate control element or rod, apply short quick movements to override the LONGITUDINAL control axis in the opposite direction. Check that hydraulic unit has switched over to system 2 by visually inspecting it during switch-over.

d.

Perform steps b. and c. for the LATERAL and the COLLECTIVE control axes.

3. Check pressure switches separately in both systems for proper function. In case of a pressure drop, response of pressure switch must be such that warning light HYDR will iIIuminate at a pressure range of 72 to 65 bar. In case of a pressure increase, warning light HYDR must extinguish at a max. pressure of 85 bar. Deviations from these values require replacement of the affected pressure switch. a.

Connect electrical power to hydraulic unit.

b. Connect hydraulic ground unit to system 1. c.

Apply a pressure of 103 bar. Warning light HYDR 1 is off.

d. Slowly reduce pressure. Warning light HYDR 1 must illuminate at a pressure range of 72 to 65 bar. e.

Slowly increase pressure. Warning Iight HYDR 1 must extinguish at a max. pressure of 85 bar.

f.

Release system 1 pressure and disconnect hydraulic ground unit from hydraulic unit.

g.

Perform substeps b. thru f. for system 2.

Revision 24

CHAPTER 43 Page 41

•

MAINTENANCE MANUAL BO 105

CAUTION 4.

PRESSURE IN EXCESS OF 155 BAR MAY DAMAGE THE PRESSURE RELlEF VALVE.

Check opening pressure of pressure relief valves in valve body manifolds of both systems. a.

Connect hydraulic ground unit to external pressure quick-disconnects PA I and RA 1.

b. Apply a pressure of 11 Obarto PA 1. Slowly increase pressure until the pressure reliefvalve opens. when the valve opens, flow noises are perceptible. The valve shall open at a pressure of 117-133 bar. c.

Reduce pressure to zera. Perform steps a. and b. for system 2. Forthis purpose, connect external pressure quick-disconnects PA 11 and RA 11.

5. Check changeover system for ease of movement. a.

Manually switch to system1 by pulling out piston of pressure transfer valve from valve housing.

b.

Connect hydraulic ground unit to external pressure quick-disconnects PA 11 and RA 11.

c.

Slowly increase pressure until switch-overto system 2 takes place. Switch-over musttake place before a pressure of 30 bar is reached. If there is no switch-over within above limit, proceed according to work step e.

d.

Reduce pressure to zera.

NOTE e.

I

Perform step e. only if there is no switch-over within specified limit (see step c.)

Ensure free movement oftransfer lever on shaft and repeat testing described underwork steps a. to d. If the pressure still exceeds 30 bar before switch-over takes place, detach pressure transfer valve fram transfer lever and repeat testing. If no switch-over occurs below 30 bar, repair of the pressure transfer valve is required (refer to REM 402 or REM 405). If the switch-over occurs, reduce friction in transmitting elements. For this purpose, remove any corrosion and apply grease (CM 101) to transmitting elements.

6. Check opening pressure of low pressure relief valves in hydraulic reservoirs in both systems. a.

Connect hydraulic graund unitto external pressure quick-disconnect RA 1. Disconnect drain line ofthe hydraulic reservoirs on transmission deck and route into a drip cupo

CHAPTER 43 Page42

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MAINTENANCE MANUAL BO 105

b. Apply a pressure of 5 bar to RA 1. Slowly increase pressure until the low pressure relief valve opens. If hydraulic fluid flows down the drain line, it can be concluded that the valve has opened. The valve shall open at a pressure of 7,5-8,5 bar. Repeatthe test ifthe opening pressure is too high. The repeat test exeludes any possibility of the valve sticking. c.

Perform steps a. and b. for system 2. Forthis purpose, connect external pressurequick-disconnect RA 11.

d.

Connect drain line on transmission deck.

7. Check hydraulic reservoirs of both systems for ease of movement:

8.

a.

Connect hydraulic ground unitto external pressure quick-disconnect PA 1. Connect drain hose, tool no. 19 (105-45000 W1) to RA 1. Place a drip cup at the ready.

b.

Apply a pressure of 30 bar to PA 1. Collect return oil in the drip cupo The fluid level indicator shall move downward perceptibly and smoothly. If the fluid level indicator does not move or if it moves erratically, repairthe hydraulic reservoir (referto REM 402 or REM 405).

c.

If specified in chapter 101 (Inspection) change hydraulic fluid (refer to paragraph 43-6).

d.

Fill system 1 hydraulic reservoir (refer to para 43-4).

e.

Perform steps a. to d. for system 2. Forthis purpose, connect external pressure quick-disconnect PA 11 and drain hose to RA 11. Switchover to system 2 is not necessary.

Check the internal leak oil of the hydraulic unit in both systems: a.

Drain hydraulic reservoir of system 1 (refer to paragraph 43-7).

b.

Screw in shut-off plunger ofthe test valve in system 1 by hand. If screwed in too tightly, sealing surface may be damaged.

c.

Connect drain hose, tool no. 19 (105-45000 W1) to external pressure quick-disconnect RA I and route into a drip cupo Place measuring cup at the ready.

d.

Place power pistons of all actuators ofsystem 1 in their centre position. Apply a pressure of 103 barto PA 1. Do not move control rods. Collect draining hydraulic fluid in the drip cupo Wait until there is an even flow of leakoil, then collectthefluid in a measuring cupfor 1 minute. The internalleak oi! shall notexceed 35 mil mino

Revision 23

CHAPTER 43 Page 43

I

O~~~copter

MAINTENANCE MANUAL SO 105

e.

Apply a pressure of 103 barto PA l. Push control rods of all three control axes to one end position and keep them in this position. Collect hydraulic fluid drained through the drain hose in a measuring cup for 1 minute. The leak oil flow rate shall not exceed 50 ml/min.

f.

Perform step e. with the control rods in the other end position.

g.

Open shut-off plunger ofthe test valve of system 1 by 1/2turn and secure with lockwire. Disconneet drain hose from external pressure quick-disconnect.

h.

Replenish hydraulic reservoir of system 1 (refer to paragraph 43-4).

i.

Repeat steps a. to h. for system 2. To do this: drain hydraulic reservoir of system 2, applya pressure of 103 bar to system 2 via PA 11 , system 1 is nonpressurized; switch-over takes place, connect drain hose to AA 11 and screw in shut-off plunger of the test valve system 2 by hand, repeat steps d. to h. for system 2.

9.

Check the pump pressure of the hydraulic pumps in both systems: The pump pressure can be measured during a ground run or by means of the hydraulic test stand if the hydraulic unit has been removed.

NOTE

a.

Pump pressure is dependent on oil temperature. The permissible pressure range is between 101 and 108 bar at an oil temperature of 20 oC ± 10 oC. Outside the given temperature range, pressures may vary per 25 ° C as follows: - by minus 1 bar at higher temperatures. - by plus 1 bar at lower temperatures.

Measuring the pump pressure using an external pump drive. 1) Flange hydraulic pumps to the external pump drive. The hydraulic reservoirs shall be filled. Connect pressure gauge 105-45000 W2 to external pressure quick-disconnect PA 1. 2) Switch on pump drive. The pump pressure of system 1 shall be 101-108 bar. 3) Perform steps 1) and 2) for system 2. Conneet pressure gauge to PA 11.

b.

Measuring the pump pressure during a ground runo 1) Connect pressure gauge 105-45000 W2 to external pressure quick-disconnect PA 1. 2)

Perform a ground run at 96%-100% NRo. The pump pressure shall be 101-108 bar.

3)

Perform steps 1) and 2) for system 2. No switch-over to system 2 is necessary. Connect pressure gauge to PA 11.

10. Check red buttons of the fouling indicator for ease of movement. For this purpose touch the face of the red button with adhesive tape and pull it out.

CHAPTER 43 Page 44

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O~J;I~pter 43 - 16

MAINTENANCE MANUAL 80105

GROUND RUN CHECK OF SELECTOR VALVE SETTING

EFFECTIVITY

I

Applies to all dual hydraulic units, except dual hydraulic units P/N 105-45039 and P/N 105-450390

1. General Switchover response from system 1 to system 2 shall be tested under load during a ground runo NOTE

This check is to be carried out • after installation of a hydraulic unit in the helicopter • after the installation of a connecting plate (6, figure 43-15) • after installation of hex bolt (1 or S) • after installing cotter pin in a rod end (8) of selector valve (7 or 9) • after the installation of ashuttle valve • after installation of the mechanical linkage interconnecting the shuttle valve and selector valves • after inspection of switchover control linkage for play (refer to paragraph 43-17) reveals play above O.S mm and this is subsequently removed.

2.

Prior to ground run Check that the connecting plate is of the type specified for the configuration of valve block manifolds it connects (see table 43-S for combinations). The connecting plates must be color coded. See table 43-S for corresponding hole spacings.

Revision 24

CHAPTER 43 Page 4S

MAINTENANCE MANUAL BO 105

VALVE BODY MANIFOLD

CONNECTING PLATE

P/N

P/N

Distance between Bores

Color Code

105-45227.15 or 105-45227.16

25.7 mm

yellow

26.0 mm

green

105-45227.13

25.1 mm

black

Configuration

D133-756 D133-756E ZE1-126-1 ZE1-126-1 ZE2-126 ZE2-126-1 ZE2-126-1 D133-756E mod 1 D133-756E-01 ZE2-126-1 mod 1 ZE2-126-3 105-46631

} 2

Table 43-5 Assignment of connecting plates to valve body manifold configurations

3. Ground run a.

Inspect and, if necessary, adjust friction brake in accordance with Chapter 102.

b.

Release the friction brake.

c.

Perform ground check with both engines running. Maintain 97-98% rotor RPM.

d. Release collective pitch lever and cyclic stick locks, switch to hydraulic system 1 and trim cyclic control to obtain the smallest possible mast moment using longitudinal and lateral trim. e.

Determinethetorque setting at whichthe helicopterwill startto lift off. Thefollowing checks are made with 35 to 40% torque on both engines. Therefore; it must be determined whether this torque setting can be reached without the helicopter lifting off. If helicopter does lift off, add necessary ballast to helicopter.

CHAPTER 43 Page 46

Revision 10

EUROCOPTER

NOTE

f.

MAINTENANCE MANUAL 80105

During the following checks look out for switch-over reactions when switching from hydraulic system 1 to hydraulic system 2. A switchover reaction is indicated by a change in position of the collective pitch lever.

Raise the collective pitch lever steadily from its lowest position until reaching 35 to 40% torque on both engines. Maintain the collective pitch lever in this position and irnmediately rotate the cyclic stick at a radius of 1-2 cm about the neutral position in the direction of rotor rotation. Cyclic stick movement rate shall be approx. 2 seconds per full circle. While rotating the cyclic stick and after having completed at least one full circle, switch from hydraulic system 1 to system 2. While switching over to system 2, grip the collective lever with light hand pressure in order to detect any switchover reaction. If switchover reactions occur, measure the amount by which the collective pitch lever changes its position (see figure 43-11) . ..1--_-

Use a scale or rule

Measure dlstance between levar posltlons hera

400757

+

Figur~

43-]1

Measuring change in position of collective pitch lever

After switch-over has occurred, return cyclic stick to neutral, push the collective pitch lever downward and switch over hydraulic unit from system 2 to system 1. g.

Accomplish this check three times.

h.

Conclude ground run and proceed according to flowchart, step 4.

Revision 10

130 105 CHAPTER 43 Page 47/48

MAINTENANCE MANUAL BO 105

EUROCOPTER

4. Actions - - - - - - - - - - - - - - - - - - - - - - - - . ,

Oto 20 mm

aboye 20 mm

Conf. 1 wlth green conn. pi. or Conf. 2 1 - - - , (black conn. pi ate)

Configuratlon 1 wlth a yellC'w connecting plate

NO

VES (Play less than 0.5 mm)

OK, but note following: In spite of collective pitch lever altering its DOsition within the acceptable range, you are recommended to replace the yellow connecting plate with a green one as follows.

Accomplish play Inspection acc. to paragraph 43-17

OK END

Conf. 1 with green conn. pI. or Conf. 2 (black conn. plate)

Configuration 1 with a yellow connecting plate

Replace with a Check switchover green connecting t -....... Repeat ground run t--t~stroke range and plate adjust as necessary (reter to para. 43-17) (reter to para. 43-18)

OK

Oto 20 mm

aboye 20 mm

END

400758-02

Flow Chart - Actions

Revision 10

BO 105 CHAPTER 43 Page 49/50

WARNING

Play less than 0.5 mm without corrective action

Play less than 0.5 mm after corrective action

Repeat ground run

DISPLACEMENT EXCEEDING 20 mm CAN PRODUCE A SUDDEN LOSS OF HEIGHT WHICH COULD CAUSE THE HELlCOPTER TO HIT THE GROUND WHEN FLYING AT LOW LEVEL. THE AFFECTED TANDEM HYDRAULlC UNIT MUST THEREFORE NOT BE RETURNED TO FLYING SERVICE,

Notify ECO Customer Service

aboye 20 mm

_~~er

MAINTENANCE MANUAL 80105

43 - 16A GROUND RUN CHECK OF SELECTOR VALVE SETTING EFFECTIVITY

•

Applies to dual hydraulic units P/N 105-45039 and P/N 105-450390

1. General Switchover response from system 1 to system 2 shall be tested under load during a ground runo NOTE

This check is to be carried out • after installation of a hydraulic unit in the helicopter • after installation of a shuttle valve • after installation of mechanicallinkage (e.g. eyebolt (1, Fig. 43-31 B) and screws (16 and 17)) interconnecting shuttle valve and selector valves

WARNING

2.

AT A DISPLACEMENT OF THE COLLECTIVE PITCH LEVER IN EXCESS OF 20 MM, THERE IS DANGER OF LOOSING HEIGHT SUDDENLY IN FLlGHT. THIS CAN CAUSE THE HELlCOPTER TO HIT THE GROUND WHEN FLYING AT LOW LEVEL. FORTHIS REASON, THE DUAL HYDRAULlC UNIT MUST NOT BE RETURNED TO FLYING SERVICE.

Perform ground run per para 43-16, step 3. The following applies if a switchover response is felt: - If collective pitch lever displacement is less than 20 mm, dual hydraulic unit is OK. No further action is required. - If collective pitch lever displacement exceeds 20 mm, repair dual hydraulic unit (refer to REM 402 or REM 405).

Revision 24

CHAPTER 43 Page 51

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MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 43 Page 52

O~~~opter 43 - 17

MAINTENANCE MANUAL 80105

INSPECTION OF SWITCHOVER CONTROL L1NKAGE FOR PLAY

EFFECTIVITY

I

Applies for all dual hydraulic units, except dual hydraulic units P/N 105-45039 and P/N 105-450390

1. Remove cowling. 2.

Remove protective plate located next to hydraulic unit.

3.

Remove push rod of collective axis.

4.

Check system switchover controllinkage for play. This procedure is a two-man operation. a.

Remove hexagon screw (3, figure 43-12) and washer (4) to disconnect lever (5) from forkend (2) of shuttlevalve (1).

b.

Press piston of shuttle valve inward until it abuts (see figure 43-13).

c.

Press system 1 selector valve inward until it abuts.

d.

Push lever installed on eyebolt of selector valve system 2 upward against selector valve system 1, using screwdriver (see figure 43-13).

e.

Using vernier caliper, measure dimension "X 1" between lever and forkend of shuttle valve as shown in figure 43-13.

a: o'

5

t'l al

o

:I:

~

I

",'o o

'"

1 Shuttle valve 2 Forkend 3 Hex screw 4 Washer 5 Lever

2

Figure 43-12 Revision 24

Removal and installation - lever CHAPTER 43 Page 53

MAINTENANCE MANUAL 80105

f.

While keeping the system 1 selectorvalve bottomed using firmfinger pressure, press down the leverwith a screwdriver (see figure 43-14). The eyebolt of the system 1 selector valve must not be pulled out in the process.

1.--l--=t-- 3

1----& 11:

1

;: o al

1 Shuttle valve 2 Lever

ill

3 Selector valve, system 1 4 Selector valve, system 2 5 Tube

A System 1 selector valve ~ pressed in all the way

1:\ Shuttle valve piston

Figure 43-13

CHAPTER 43 Page 54

pressed in all the way

Measurement of dimension "X 1"

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

g.

Measure the new dimension "X 2" between lever and forkend of shuttle valve, using vernier caliper (see figure 43-14) .

400761

~

Keep system 1 selector valve pressed in to full extent

~

Piston of shuttle valve is pressed in to full extent

~

Lever is pressed down with screwdriver as far as possible without pulling out the eyebolt of the system 1 selector valve

Figure 43-14

Measurement of dimension "X 2"

BO 105 CHAPTER 43 Page 55

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 h.

Obtain the difference between the two dimensions. "Xl" - "X2"

=

Play

Play in excess of 0.5 mm is considered to be the result of incorrect adjustment of the shuttle valve stroke in relation to the selector valve stroke during preceding selector valve adjustments.

NOTE

If stroke adjustment has been performed incorreetly, the limit of travel of the switchover mechanism is not governed by the shuttle valve, as required, but by one of the selector valves. This will lead to excessive wear of switchover mechanism. i.

Actions If play does not exceed 0.5 mm, no further action is required. Accomplish steps 5., 6., 7. and 8. and conclude inspection for play. If play exceeds 0.5 mm, proceed with step 9.

5. Secure lever (5, figure 43-12) to forkend (2) of shuttle valve (1). 6. Install push rod of collective axis. Install protective plate next to hydaulic unit and install locking devices where previously removed. 7. Check for foreign objects.

8. Install cowlings. 9. Remove connecting plate (6, figure 43-15).

10. Inspect removed connecting plate for worn holes (see figure 43-16) . a.

Diameter of holes must not exceed 5.10 mm.

b.

Dimension C must not be greater than: 30.90 mm (yellow connecting platel 31.20 mm (green connecting platel 30.30 mm (black connecting platel

c.

Dimension D must not be less than: 20.50 mm (yellow connecting platel 20.80 mm (green connecting platel 19.90 mm (black connecting platel

d.

If limits are exceeded, replace connecting plate with one of same colour. However, if a yellow connecting plate is affected, it is recommended to replace it with a green one. The connecting plate can be locally fabricated according to figure 43-16.

BO 105 CHAPTER 43 Page 56

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11. Remove lever (10, figure 43-15). 12. Inspect holes of removed lever for wear (see figure 43-17). If out-ofround, replace lever. 13. If the inspection of the removed connecting plate (6, figure 43-15) and the lever (10) did not reveal any wear, play shall be eliminated by replacing eyebolts (8) of the system 1 selector valves (9) and system 2 selector valves (7) as follows: DETAlLA 2

12

8

2 3

9

8 6

10 11 8

4

5

7

2

Figure 43-15

12

8

1 Hex bolts 2 Washer 3 Nut 4 Split pin 5 Hex bolt 6 Connecting plat 7 Selector valve 8 Eyebolt 9 Selector valve 10 Lever 11 Nut 12 Split pin 13 Laminated shim (as required)

Removal and installation - connecting plate and eyebolts

a.

Remove split pins (12) from both eyebolts (8).

b.

Remove eyebolts (8). If an eyebolt is secured with Loctite, break adhesive bond by heating eyebolt to approx. 100 oC, using a soldering bit.

c.

Install new eyebolts. - If a new eyebolt has only one split pin hole, provide it with a second one prior to installation, in accordance with figure 43-18. - Temporarily insert one of the connecting plate attaching bolts in the eyebolt, and screw eyebolt in to full extent. Then secure eyebolt with split pin, backing off eyebolt as necessary by not more than 1/4 of a turno BO 105 CHAPTER 43 Page 57

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Connecting plate p/N

Color code

105-45227.15

yellow

25.7 + 0.1

37 ± 0.8

105-45227.16

green

26.0 + 0.1

37 ± 0.8

105-45227.13

black

25.1 + 0.1

37 ± 0.8

6

A

B

5 +0.030

C and D For wear dimensions, see items 10.b. and c.

Dimensions in mm

O

~

'll

~

\..1

.

j

6--

2m

m:l.+_

th Ick

t o LI'I ~

~

400763

j

..-

6 u m

o <

•

-(: tr-

j

I

k

Color code entire surface of connecting plate, except for boreholes. For color codes refer to above tableo Consumable materials: Zinc-chromate primer (CM 401), two-component single-layer lacquer (CM 443) in applicable color, hardener (CM 435) and thinner (CM 436)

Connectlng plate Material: 1.4544.9

Figure 43-16

Local fabrication - connecting plate

5.15 mm mallo

VIEwA

400764

Figure 43-17 BO 105 CHAPTER 43 Page 58

Wear inspection - lever

MAINTENANCE MANUAL SO 105

1.1 tO,1

-..... do

$

-...

Treat surface of new split pin hole with chemical conversion material (CM 316)

<>

U'l

Selector valve eyebolt Dimensions in mm

Figure 43-18

Second split pin hole - eyebolt

14. Installlever (see figure 43-15). Tighten nut (11) of hexagon bolt to the highest value that still allows the hex bolt to be rotated by bando 15. Install the connecting plate (6) on the system 1 selector valve and connect provisionally to the system 2 selector valve. Insert bolt through the system 2 selector valve only to the extent that allows the lever (10) to move freely. 16. Check switchover stroke range in accordance with step 5. and subsq. of paragraph 43-18.

CHAPTER 43 Page 59

MAINTENANCE MANUAL BO 105

43 - 17A INSPECTION OF SWITCHOVER CONTROL L1NKAGE FOR PLAY •

EFFECTIVITY 1.

Applies to dual hydraulic units P/N 105-45039 and P/N 105-450390

Perform work steps 1. thru 4.h. of para 43-17. a.

Related action No further action required if play does not exceed 0.5 mm. Accomplish work steps 2, 3, 4 and 5 and conclude inspection for play. If play exceeds 0.5 mm, continue with work step 6.

2.

Secure lever (5, fig. 43-12) to forkend (2) of shuttle valve (1).

3.

Install push rod of collective axis. Install protective plate next to hydraulic unit and installlocking devices where previously removed.

4.

Check for foreign objects.

5.

Install cowlings.

6.

Remove H-connector (15, fig. 43-31 B).

7.

Clean H-connector and inspect its holes forwear perfig. 43-18A. Replace H-connector ifwear limits are exceeded.

8.

Remove lever (11).

9.

Inspect lever for worn holes per fig. 43-17. Replace lever if wear is evident.

10. If the inspection of H-connector (15, fig. 43-31 B) and lever (10, fig. 43-15) did not reveal any wear, play shall be eliminated by replacing eyebolts (8) ofthe system 1 selectorvalves (9) and system 2 selectorvalves (7) as follows: a.

Remove split pins (12) from both eyebolts (8).

b.

Remove eyebolts (8). If an eyebolt is secured with Loctite, break adhesive bond by heating eyebolt to approx. 100 oC, using a seldering bit.

c.

Install new eyebolts. -

Temporarily insert H-connector attaching bolts through eyebolts and screw new eyebolt in to full extent. Then secure eyebolt with split pin, backing off eyebolt as necessary by not more than 1/4 of a turno If a new eyebolt has only one split pin hole, provide it with a second one prior te installation in accordance with figure 43-18.

CHAPTER 43 Page 60

Revision 24

MAINTENANCE MANUAL BO 105 11. Installlever (see fig. 43-15). Tighten nut (11) of hexagon bolt to the highest value that still allows the hex bolt to be rotated by hand. 12. Install H-connector (15, fig. 43-318) on system 1 and system 2 selector valves. 13. Check switchover stroke per para 43-18A.

Dimensions in mm

Maximum permissible dimensions:

05.1 mm 24.5 + 0.1 mm

19.5 mm 29.7 mm

Figure 43-18A Wear limits - H-connector

Revision 10

CHAPTER 43 Page GOA

O~~~ter 43 - 18

I

MAINTENANCE MANUAL BO 105

CHECK ANO AOJUSTMENT OF SWITCHOVER STROKE RANGE

EFFECTIVITY

Applies to all dual hydraulic units except dual hydraulic units P/N 105-45039 and P/N 105-450390

1.

Remove cowling.

2.

Remove protective plate located next to tandem hydraulic unit.

3.

Remove push rod of collective axis.

4. Remove split pin (4, figure 43-15), nut (3), washers (2) and shims (13, if installed) from hex bolt (5). Withdraw hex bolt (5) just sufficient to remove it from mating bore in eyebolt (8) of system 2 selector valve (7) to allow free movement of lever (10). NOTE

5.

The following test is performed to ensure that the shuttle valve stroke is always shorter than the selector valve stroke, and that the stroke is always limited by shuttle valve and never by the selector valves.

Compare length and position of selector valve stroke range with length and position of shuttle valve lever travel. a.

Press connecting plate upward (system 1 selector valve retracted, system 2 selector valve extended) and press selector leverupward. As a result, the selector lever hole must not be positioned above the eyebolt hole (see figure 43-19).

b.

Push connecting plate and selector lever downward (system 1 selector valve extended, system 2 selectorvalve retracted). As a result, the selector lever hole must not be positioned belowthe eyebolt hole (see figure 43-20).

System 2 selector valve ==--~ fully extended: lever borehole position must not be higher than eyebolt borehole

System 2 selector valve -=::::e:-......t--I fully retracted: lever borehole position must not be lower than eyebolt borehole System 2

Figure 43-19

CHAPTER 43 Page 608

Figure 43-20

Revision 24

MAINTENANCE MANUAL BO 105

EUROCOPTER

Lever

1. Lever travel dlstance A Is shorter than the system 2 selector valve stroke B and lever travel Is wlthIn the B stroke range.

2. If lever travel dlstance A Is more than 1 mm shorter than stroke B of selector valve. align center of travel A wlth center of stroke B (see step 7.).

Acceptable

Lever

Lever Lever

-

Lever travel dlstance A Is shorter than the system 2 selector valve stroke B• .bY! lever travel Is outslde system 2 selector valve stroke range.

or-

Lever travel dlstance A Is longer than system 2 selector valve stroke B and therefore outslde system 2 selector valve stroke range.

Not acceptable 400768

Figure 43-21

Comparison of system 2 selector valve stroke length against lever travel distance

BO 105 CHAPTER 43 Page 61

EUROCOPTER

NOTE

* 6. *

MAINTENANCE MANUAL

eo 105

The following step c. does not apply to hydraulic units P/N 105-45028 and p/N 105-45018

c.

If the travel distance of shuttle valve lever is longer than the stroke of the selector valves (see figure 43-21), reduce shuttle valve piston stroke by machining off part of the fitting (accomplish instructions per step 6.

d.

If the travel distance of the shuttle valve is more than 1 mm shorter than the stroke of the selector valves (see figure 43-21), check travel of the shuttle valve and stroke of the selector valves for symmetry. Adjust fork head on shuttle valve as necessary to achieve symmetry by performing step 7.

e.

If the travel distance of the shuttle valve is shorter than the stroke of the selector valves, but outside the stroke range of the selector valves (see figure 43-21) re-position shuttle valve lever by adjusting the fork head on the shuttle valve. Check travel of shuttle valve and stroke of the selector valves for symmetry by performing step 7.

If necessary (see step S.c.), re-work fitting p/N D133-720.03E (4, figure 43-22) as follow:

9

Figure 43-22

BO 105 CHAPTER 43 Page 62

1 2 3. 4 5 6 7 8 9 10

Tubing Fitting Washer Fitting Lockwire Selector lever Lock nut Forkhead Cotter pin Shuttle valve

Shuttle valve and attached parts

Revision 14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 If requlred, machlne here

r--/~

Fitting P/N D133-720.03E

L 400770

Before Modlflcatlon: 20.00 mm After Modlflcatlon: max. 22.00 mm. Machlnlng to 20.7 mm Is usually sufflclent.

Figure 43-23

7.

Rework - fitting

a.

Disconnect tubing (1, figure 43-22) and plug open end.

b.

Remove fitting (2) and washer (3).

c.

Remove fitting (4).

d.

Machine off fitting (4) in accordance with figure 43-23.

e.

Install fitting (4, figure 43-22), washer (3) and fitting (2) with new O-ringo Remove plug and connect tubing (1).

If required by steps S.d. and e., adjust fork head (8, figure 43-22)on shuttle valve. a.

Adjust length of fork head (8) thread engagement. Do this by removing cotter pin (9) and backing off jamnut (7). Then hold fork head and rotate shuttle valve piston in the required direction. The fork head can be adjusted in increments of either 1/2 turn or 1/6 turn to the next cotter pin hole according to the piston type.

b.

Install cotter pin (9) in fork head (8) and tighten lock nut (7) to fork head (8).

c.

If an adjustment of fork head has been performed, ensure that longitudinal movement of shuttle valve piston in conjunction with rotary motion of lever is possible throughout the entire travel range without jarnming.

BO 105 CHAPTER 43 Page 63

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

d.

If necessary, loosen nuts attaching shuttle valve to metal frame and correct its position so that piston and lever can be moved without jamming. Re-tighten attaching nuts.

8. Repeat step 5. if fitting on shuttle valve has been reworked according to step 6. or fork head on the shuttle valve has been adjusted according to step 7. 9. Install lever (10, figure 43-15) on system 2 selector valve (7). Hand tighten nuts (3) so that hexagon head bolts (1 and 5) have no axial play and can be turned by hand. Safety nut to hexagon head bolt with split pin (4), adding laminated shims (13) as necessary according to figure 43-15. with the tandem hydraulic unit pressurized to 103 bar in both systems, it must be possible to move both hex bolts by hand in system 1 ON and OFF positions. Failure of the bolts to move as required means that the shuttle valve stroke range has not been checked or adjusted properly. Therefore, you are required to proceed again from step 4. in paragraph 43-18. 10. If the switchover stroke range was checked as a result of excessive play found while performing the inspection for play outlined in paragraph 43-17, repeat check of switchover control linkage for play by performing step 4.and subsq. of paragraph 43-17. If the total play exceeds 0.5 mm, the hydraulic unit must not be returned to flight operational use. In this case notify MBB Customer Service. 11. Install push rod of collective control axis. Install protective plate next to hydraulic unit and install locking devices where previously removed. 12. If fitting D133-720.03E has been reworked, bleed the hydraulic unit in accordance with paragraph 43-5. 13. Inspect for foreign objects. 14. Install cowlings. 15. Ground run the helicopter (refer to paragraph 43-16).

BO 105 CHAPTER 43 Page 64

_~~~pter

MAINTENANCE MANUAL SO 105

43 - 18A CHECK ANO AOJUSTMENT OF SWITCHOVER MECHANISM EFFECTIVITY

Applies To dual hydraulic unit P/N 105-45039 and P/N 105-450390

•

1. Remove hex screw (8, fig. 43-23A) and washer (7) from forkend (2) of shuttle valve (1). 2. Using Vernier caliper, check shuttle valve stroke: desired stroke

= 7.0_0.2 mm.

3. Press system 1 selector valve inward to fuI! extent. 4. Push lever attached to system 2 selector valve eyebolt upward against system 1 selector valve, using screwdriver (see fig. 43-23A). 5. Using feeler gauge, measure and record clearance "Y1" shown in fig. 43-23A.

,)

...

...

h~

J

1 '"

11 8

7

2

4

1 2 3 4

Shuttle valve Forkend Lever Selector valve, system 1

>-,

5 6 7 8

Selector valve, system 2 Tube Washer Hex screw

Figure 43-23A Measurement of clearance "Y1"

Revision 24

CHAPTER 43 Page 64A

MAINTENANCE MANUAL BO 105

6.

Press system 2 selector valve inward to fuI! extent.

7.

Push lever attached to system 2 selector valve eyebolt downward against system 2 selector valve (see fig. 43-238).

8. Using feeler gauge, measure and record clearance "Y2", shown in fig. 43-238.

System 1

~I

~I ~

",' o

o lXl

Figure 43-238 Measurement of clearance "Y2"

9.

Press shuttle valve piston in to fuI! extent.

10. Check whether hole of lever (3, fig. 43-23A) aligns with hole of forkend (2) of shuttle valve and whether hex screw (8) could be inserted. 11. If this is not possible. adjust depth of thread engagement of forkend (8, fig. 43-22). Do this by removing cotter pin (9) from forkend and backing off lock nut (7). Then bold forkend and rotate shuttle valve piston in the required direction. The forkend can be adjusted in increments of 1/6 turn to the next cotter pin hole. 12. Adjust pre-set forkend (8) by unscrewing piston in fork head by 1/2 a turno

CHAPTER 43 Page 648

Revision 10

MAINTENANCE MANUAL BO 105

EUROCOPTER

13. Insert cotter pin (9) in forkend (8) and tighten lock nut (7) of forkend. 14. Attach lever (11, fig. 43-31A) to forkend (6), using screw (4) and washer (5), then secure connection. 15. Press piston of shuttle valve with attached switchover control linkage in to ful1 extent and then pull piston end again. Measure and record clearances "Xl" and "X2 " shown in fig. 42-23C.

400513-01

Figure 43-23C Measurement of clearances "Xl" and "X2" 16. If the forkend has been adjusted during this check, ensure that longitudinal movement of the shuttle valve piston and rotary motion of the lever is possible throughout the entire travel range without jarnming. If necessary, loosen nuts attaching shuttle valve, and correct its position so that free movement of piston and lever is ensured. 17. If the position of the shuttle valve has been thru 16.

Revision 10

~hanged,

repeat steps 1.

BO 105 CHAPTER 43 Page 64C

EUROCOPTER

MAINTENANCE MANUAL 80 105

18. Calculate clearance differences "D 1 " and "D 2 " as shown in the following example. Clearance "Xl" - "Y1"

Clearance "X2 "

-

=

"Y2 " =

I"D1"1

8

Values "D 1 " and "D 2 " must not differ by more than 0.2 mm. 19. If the calculated values do not correspond to the desired values, adjust forkend accordingly by decreasing or increasing thread engagement of piston in shuttle valve by increments of 1/6 of a turn (approx. 0.17 mm). 20. Repeat steps 15. thru 18 until desired values are obtained.

BO 105 CHAPTF.R 43 Page 64D

Revision 10

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 43 - 19

FUNCTIONAL TESTING OF FLAT SPRINGS IN SYSTEM 2

Special tool: Spring scale O-50 N (commercial) 1.

Check close tolerance bolts of the system for ease of movement (refer to paragraph 43-11) .

2.

Disconnect control rods of each control axis of system 2 from the lower input levers and fix in their lowest positions.

3.

Disconnect control rods between system 1 and system 2 from the lower input levers and hold upward.

4.

Check flat springs in control axis 1 (LATERAL) for function. a.

Insert hexagon bolt (1, figure 43-24) through upper bushings of input lever (2) and connect a spring scale to it.

b.

Pull spring scale upward until both guides (3) are moved upward by approximately 1 mm relative to lever guide (4). If the force required is less than 40 N, rupture of a flat spring must be sllspected. Replace ruptured flat spring (refer to paragraph 43-56) .

5.

Check flat springs in control axis 2 and 3 (COLLECTIVE and LONGITUDINAL) for function.

6.

Re-install control rods.

2

400453.1

Figure 43-24

approx. 1 mm

Hexagon bolt Input lever Guide 4 Lever guide

1 2 3

Functional test - flat springs in system 2 BO 105 CHAPTER 43 Page 65

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 43 - 20

TESTING OF SWITCH OPERATING POINTS OF MICROSWITCHES IN SYSTEM 1 GUIDES

Special tools: tool no. 22 (105-45041 W28) see chapter 04 commercial tool M1SS70-20 or M83723-31-20 (only for method B)

Support Dial gauge Insertion/extraction 1.

Method A. a.

Disconnect control rods (lower and upper) from hydraulic unit.

b.

Connect continuity tester to contacts of connector 7VEb of the guide to be tested: Guide Guide Guide Guide Guide Guide

c.

10DB1 10DB2 10DB3 10DB4 10DBS 10DB6

-

contact contact contact contact contact contact

K and R and H and N and F and L and

S J

P G M E

Fasten support tool no. 22 (105-45041 W28) to bracket of hydraulic reservoir of system 1. Attach dial gauge. position feeler parallel to servo valve onto housing of the guide to be checked. 1)

Check upper microswitch of guide: - Move control rod to get servo valve in upper end position. Set dial gauge to zero. - Override from end position until continuity tester (method A) or solenoid valve (method B) reacts. The contact travel must be 0.6-1.1 mm. If there are deviations, repair guide as outlined in the Repair Manual (REM 402) .

2)

Check lower microswitch of guide. Perform step 1) for the lower end position.

d.

Perform steps b. and c. for the remaining 5 guides.

e.

Re-install control rods.

BO 105 CHAPTER 43 Page 66

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

3.

Method B. a.

Disconnect control rods (lower and upper) frorn hydraulic unit.

b.

Fasten support tool no. 22 (105-45041 W28) to bracket of hydraulic reservoir of systern 1. Attach dial gauge.

Position feeler parallel to servo valve onto housing of the guide to be checked. a.

Applicable only for configuration GUIDES WITH CONNECTORS (standard version): disconnect electrical connector of the second guide of the sarne control axis.

b.

Applicable only for configuration GUIDES WITHOUT CONNECTORS (refer to figure 43-25). - Remove frame (12) by removing screws (5). Loosen straps (8 and 10) . Remove all twines (9). - Disconnect one electrical cable of the second guide (from left, see figure 43-25) of the same control axis from plug-in module (1) using insertion/extraction tool M15570-20 or M83723-20 or M83723-31-20 (white side). Mark contacts for re-installation.

4.

Switch on electrical power supply of hydraulic unit.

5.

Check upper microswitch of guide: a.

Move control rod to get servo valve in upper end position. Set dial gauge to zero.

b.

Override from end position until solenoid valve operates audibly. The contact travel must be 0.6-1.1 mm. If there are deviations, repair guide as outlined in the Repair Manual (REM 402).

6.

Check lower microswitch of guide: For the lower end position proceed as outlined in step 5.

7.

Reconnect electrical connectors of guides or insert cables in plug-in module (1, figure 43-25) using insertion/extraction tool (red side) .

8.

Perform steps 3. to 7. for the remaining 5 guides. Always exclude the respective second guide of the same control axis from the testing by disconnecting the electrical connector or by extracting the electrical cable from plug-in module (1).

9.

Install control rods.

BO 105 CHAPTER 43 Page 67

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

8

9

Irl ¡r;--H-!-!--13

400754

1 2 3 4

Plug-in module Screw Nut Washer

5

Screw

6 Nut 7 8

Washer Strap

9 10 11 12

13

Figure 43-25 BO 105 CHAPTER 43 Page 68

Twine Strap Cable Frame Guide

Guides of system 1 - configuration: GUIDES WITHOUT CONNECTORS

_~~ter 43 - 21

SEALlNG OF SERVO VALVE DRAINAGE CHAMBERS OF SYSTEM 2 ACTUATORS USING SEALlNG COMPOUND

EFFECTIVITY Special tools:

1.

MAINTENANCE MANUAL 80 105

I

Applies to all dual hydraulic units, except dual hydraulic units P/N 105-45039 and P/N 105-450390 Sealing tool

see figure 43-31

Remove control rod to gain access to the damaged seal of the respective actuator. If the collective control actuator seal is damaged, remove the switch-over mechanism (see figure 43-26).

2.

Carefully remove damaged sea!.

NOTE

3.

For removal of threaded plug and beáring support, refer to either figure 43-27 or figure 43-28, depending on the configuration.

Unscrew and remove threaded plug and, if required, bearing support from the servo valve drainage chambers.

CAUTION

00 NOT OEGREASE SERVO VALVE ORAINAGE CHAMBERS WITH A CLEANING AGENT.

4. Visually inspect drainage chambers for accumulation of water or hydraulic oil and blow dry with compressed air as necessary. 5. Clean threaded plug and, if removed, bearing support with acetone (CM 203). 6.

Pack grooves in threaded plugs ofthe longitudinal and lateral control actuators with grease (CM 101). Refer to figure 43-29. Take particular care when packing the recesses on the 3-axis actuator 0133-99911 with grease, that no grease enters the drainage chambers. See figure 43-28.

7.

If bearing support bas been removed, proceed as follows: a. Inspect vent bore for blockage and clear as necessary. b.

Oegrease areas to be sealed on the bearing support with acetone (CM 203).

c.

Mask bore with PVC tape (CM 685 or CM 615), 3 x 3 mm in size.

d. Apply a layer of sealant (CM 612) over the masking tape and around the bearing support (see figure 43-30), and allow sufficient time far it to cure prior to installation (approx. 2 hours at 40 oC) so that tape is not dislodged at installation. 8.

Install bearing support so that thread engagement is the same as befare removal and install a new lock washer.

9.

Install threaded plugs and tighten until the markings applied prior to removal are aligned (does not apply to actuator 0133-99911). See figure 43-27 or 43-28, as applicable, for torque values.

Revision 24

CHAPTER 43 Page 69

MAINTENANCE MANUAL 80105

10. Before applying the sealant, inspect the threaded plug and bearing support once more for cleanliness and, if necessary, clean again with solvent (CM 203). 11. Prepare tube of sealant for application as shown in figure 43-31. 12. Cover threaded plug and bearing support with the sealant so that they are enclosed in an approx. 2-mmthick coat (see figure 43-29 and 43-30). 13. A"ow suf1icient time for sealant to cure (approx. 3 hours at 20 oC). 14. Insta" switch-over mechanism, if removed. See figure 43-26. Screws (18 and 20) must be capable of being turned easily by bando Lockwire screw (4). 15. Insta" control rods (refer to paragraph 43-40). 16. Inspect switch-over mechanism for freedom of movement (refer to paragraph 43-15).

CHAPTER 43 Page 70

Revision 24

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

B

......

4

5

6

7

12

11

400396.1

13 DETAlL 17

15

16

1 Eyebolt 2 Selector valve of system 2 3 Sheet metal frame 4 Screw 5 Washer 6 Forkend 7 Shuttle valve 8 Nut 9 Split pin 10 Washer Figure 43-26

A

11 12 13

14 15 16 17 18 19 20

14

Lever BoH

Split pin Nut Washer Connecting plate Washer Screw Washer Screw

Removal and installation - lever BO 105 CHAPTER 43 Page 71

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-"---1

~

~~::;-77-;---:---:---bllnd

hole in the servo valve

1 Threaded plug 2 Bearing support 3 Threaded plug

400733

~

Do not unscrew bearing support.

~

Threaded plug need not be removed.

~

Before removing the threaded plug, mark relative position of threaded plug and actuator housing.

~

After tightening (marks aligned; torque 4 to 6 Nm), secure with lockwire.

~

See figure 43-30 for sealing of the vent hole in the bearing support.

~

See figure 43-29 for sealing of the threaded plugs. Figure 43-27

BO 105 CHAPTER 43 Page 72

3-axis actuator ZEl-193II, ZE1-l93II-1 D133-770IIE, D133-770IIE-01 (System 2)

- - - - - - - - - - - - - M B B HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105

Encrose threaded plug, servo valve, sleeve and threaded ring In a coatlng of seallng compound as shown in figure 43-29

- - - - Actuator houslng

Seal vent hole before Installlng bearlng support and completely seal after installatlon wlth seallng compound as shown In figure 43-30

~

Torque to 1.5 - 2.5 Nm

~

Torque to 25 - 27 Nm

~

Record depth to which the bearing support is installed prior to removal and reinstall to the recorded depth.

~

Do not unscrew threaded ring and under no circumstances displace the servo valve sleeve

1 2 3 4 5 6 Figure 43-28

Threaded plug Bearing support Hex nut Lock washer Threaded ring Servo valve sleeve

3-axis actuator 0133-99911 BO 105 CHAPTER 43 Page 73

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Form a watertlght boot around the threaded plug uslng sealant Pack grooves In threaded plug lull wlth grease (CM 101)

(

~~=::¡~--- Threaded plug

--11+--- Threaded plug

actuator

400732

Figure 43-29

PVC tape (CM 615 or CM 685)

Sealing of threaded plugs on the longitudinal and lateral flight control actuators

Seallng 01 bearing support after Installa1l0n

~-----

Bearlng support

A Seallng of vent bore prior to bearlng support Installatlon

400132.A

Figure 43-30 BO 105 CHAPTER 43 Page 74

0",,---

._.~_o_o .,

/

/

Sealing of threaded plug and bearing support vent bore on the collective control actuator

MAINTENANCE MANUAL 80105

Attach with adhesive tape

Bend 1.5 mm dia welding wire to required shape

Nozzle is supplied with the tube

PVC tubing, transparent approx. 5-6 mm dia

Figure 43-31

Revision 10

Locally fabricated tool for sealing the threaded plugs of the 3-axis actuator

CHAPTER 43 Page 75

MAINTENANCE MANUAL 80105

43 - 21A SEALlNG OF SERVO VALVE DRAINAGE CHAMBERS OF SYSTEM 2 ACTUATORS USING SEALlNG CAPS •

EFFECTIVITY

Applies to dual hydraulic units P/N 105-45039 and P/N 105-450390

1. Disconnect control rods from system 2 input levers and either fold them upward or remove them as necessary to enable access to the damaged actuator sea!. 2.

If the seal or sealing cap on the collective control actuator is damaged, proceed as follows: a. Remove lever (11, fig. 43-31 B). b. Carefully remove damaged seal on bearing support (6, fig. 43-31 C), using wooden spatula or similar. c.

Determine height of visible part of installed bearing support (6) and record for reinstallation purposes.

d.

Remove lockwire (1), then unscrew nut (5) and remove togetherwith sealing cap (2) and bearing support (6).

CAUTION

DO NOT DEGREASE SERVO VALVE DRAINAGE CHAMBERS WITH CLEANING AGENT.

e. Visually inspect drainage chamber for accumulation of water or hydraulic oH, and blow dry with compressed air as necessary. f.

Carefully clean bearing support (6), threaded plug (3) and sealing cap (2) contact surface on actuator using acetone (CM 203).

g.

Inspectseal oflockwiring hole (1, fig. 43-31 A) in actuatorfordamage.lfnecessary, clean holeand renew seal using silicone rubber (CM 619).

CHAPTER 43 Page 76

Revision 24

MAINTENANCE MANUAL 80105

EUROCOPTER

2

400575-01

~ with silicone rubber (CM 619)

3

1 Hole 2 Actuator 3 Hole for lockwire

Figure 43-31A Sealing of actuator h.

NOTE

Inspect vent hole (~, fig. 43-31C) in threaded plug (3) for free passage, and clear any obstruction. The cure time for silicone Iubber (CM 619) is 12 hours at 30° C for a layer 1 - 2 mm thick. Tack-free after at least 2 hours at 20° C.

i.

Inspect bearing support (6) vent hole seal for damage. If damaged, hole and renew seal using silicone rubber (CM 619) (see ffi, flg. 43-31C). ~leanovent

Revision 10

BO 105 CHAPTER 4~ Page 76A

MAINTENANCE MANUALBO 105

EUROCOPTER

DETAlL

B

......

4

5

6

7

12

400570-01

15

1 Eyebolt

2 Selector valve of system 2 3 Sheet metal frame 4 Screw 5 Washer 6 Forkend 7 Shuttle valve 8 Nut 9 Split pin

14

10 Washer 11 Lever 12 BoH

13 14 15 16 17

Split pin Nut H-connector Screw Screw

Figure 43-31B Removal and installation - lever BO 105 CHAPTER 43 Page 76B

Revision 10

EUROCOPTER

j.

Check threaded plug (3) for specified torque load. If necessary, torque-tighten to 5 ± 1 Nm.

k.

Place sealing cap (2) on threaded plug, taking care that it is seated all round on actuator housing.

l.

Screw in assembled bearing support (6) and nut (5) to same depth as prior to removal. In doing so, adjust bearing support so that bolt (12, fig. 43-31B) can be inserted from the sheet metal frame side and can be easily rotated. Torque-tighten nut (8) to 2.5 ± 0.5 Nm.

m.

Secure sealing cap with lockwire.

n.

Seal bearing support thread per fig. 43-31C using silicone rubber (CM 619) .

NOTE

Before proceeding, it is practical to allow the silicone rubber to cure. In this way, destruction of the seal due to smearing through contact will be avoided. o.

3.

MAINTENANCE MANUAL BO 105

If the sealing caps of the longitudinal and lateral actuators are not removed, install switchover control linkage as follows: 1)

Install bolt (12, fig. 43-31B) together with lever (11), washer (10) and nut (8). Secure nut (8) with split pin (9).

2)

Connect H-connector (15) to eyebolts of system 1 and system 2 selector valves using screws (16 and 17) and nuts (14). Secure nuts with split pins (13). It must be possible to turn screws (16 and 17) easily by hand.

3)

Connect lever to forkend (6) of shuttle valve (7) using screw (1) and washer (5).

4)

Il1spec: switchover mechallism for freedom of mOITemeni: (refer lo para 43-15).

If the sealing cap of the longitudinal or lateral control actuator is damaged, proceed as follows: a.

Remove lockwire (1, fig. 43-31C), then remove threaded plug (4) and detach sealing cap (2).

CAUTION

DO NOT DEGREASE SERVO VALVE DRAINAGE CHAMBERS WITH CLEANING AGENT.

b.

Visually inspect drainage chamber for accumulation of water or hydraulic oil, and blow dry with compressed air as necessary.

c.

Carefully clean threaded plug (3) and its contact surface on actuator using acetone (CM 203) .

Revision 10

BO 105 CHAPTER43 Page 76C

EUROCOPTER

MAINTENANCE MANUAL 80 105

3

4

SECTION

A- A

6

I

-.fa

~A SECTION

400574- 01

B- a

1 Lockwire

~ Coated with silicone rubber (CM 619) ~ Hole must remain free from obstruction and must not be sealed.

2 Sealing cap

3 Threaded plug 4 Th¡:eaded plug 5 Nut 6 Bearing support

Figure 43-31C Sealing of actuators

BO 105 CHAPTER 43 Page 76D

Revision 10

EUROCOPTER

4.

MAINTENANCE MANUAL 80 105

d.

Inspect seal of lockwiring hole in actuator for daroage. If necessary, clean hole and renew seal using silicone rubber (CM 619) .

e.

Inspect vent hole in threaded plug (3) for free passage and clear any obstruction.

f.

Check threaded plug for specified torque load. If necessary, torque-tighten to 5 ± 1 Nro.

g.

Place sealing cap (2) on threaded plug (3) taking care that it is seated all round on actuator housing.

h.

Install threaded plug (4) and torque-tighten to 2.5 ± 0.5 Nro.

i.

Secure threaded plug (4) and sealing cap (2) with lockwire.

j.

If not installed, install lever (11) per step 2.0.

Reconnect control rods to systero 2 input levers.

Revision 10

BO 105 CHAPTFR 43 Page 76E/F

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 43 - 22

HYd r a u 1 i e

u n i t

43 - 23

Removal - hydraulic unit

Special tool: Holding plate

105-45021 W7

l. Remove left engine cowling. 2. Remove screws from clamps at the main transmission support. 3. Remove protective plate (4, figure 43-32) from engine deck. 4. Remove splash guard (2). NOTE

The control rods (5) between the input levers of system 1 (3) and system 2 (6) may be changed in their lengths only if a syrnrnetry adjustment can be carried out subsequently or if tool 105-41482 L1 or 105-45045 W1 is used.

5. Disconnect control rods (7) from input levers of system 2 (6). 6. Disconnect control rods (1) from forked sections (10) and if the control rods are not to be removed, tie them upwards. 7. Disconnect plug and protect receptacle with a cap. 8. Loosen plug of wiring harness by unscrewing screws of clamps for the wiring harness. 9. Remove teleflex cable of N2-control from N2-lever assembly. 10. Remove safety caps from reservoirs. 11. Loosen union nut of the drain line and close ports with caps. 12. Remove screws (8). 13. Pull the hydraulic unit outboard and place it on a wooden board or similar surface about 3 cm thick. 14. Remove clamps for pump line hoses from the main transmission. 15. Remove hydraulic pumps (9) from the accessory drive assembly of the main transmission and protect splines with adhesive tape.

BO 105 CHAPTER 43 Page 77

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 16. Close the two ports at the accessory drive assembly with two plastic covers. DO NOT DAMAGE THE CONTROL RODS ANO THE TRANSMISSION SUPPORT REMAINING IN THE FUSELAGE WHEN REMOVING THE HYDRAULIC UNIT.

CAUTION

17. Lift the hydraulic unit out of the helicopter. 18. Install holding plate 105-45021 W7 on sheet metal frame and install hydraulic pumps. 19. Remove the sealing compound from the transmission deck with a scraper (hardwood, vulcanized fiber). Avoid scratches. 20. Clean transmission deck with dry cleaning solvent (CM 202) . 21. When storing the hydraulic unit for a long period of time, preserve hydraulic unit as outlined in paragraph 43-9. 43 - 24

FREE

43 - 25

Installation - hydraulic unit

Special tool: Hydraulic ground unit NOTE

The hydraulic unit to be installed must be approved for the respective helicopter variant (refer to the IPC).

1.

De-preserve the hydraulic unit, if necessary as outlined in paragraph 43-9.

2.

When the hydraulic unit has been out of operation for more than 1 year or the last inspection and functional test was carried out more than 1 year previously, carry out the inspection as required annually and the special inspection as required for calendar time.

3.

Remove safety cap from reservoir.

BO 105 CHAPTER 43 Page 78

EUROCOPTER

MAINTENANCE MANUAL 80 105

4.

Place a wooden board (approx. 3 cm thick) on transmission deck.

5.

Remove hydraulic pumps from holding plate (105-45021 W7) .

6.

Remove holding plate from the hydraulic unit.

7.

Remove the two plastic covers from the accessory drive assembly.

7A. Clean pump driveshaft, pump flange and abutment face of pump at accessory gear box. 8.

Apply a light coat of grease (CM 111 or CM 137 or CM 147) to pump driveshafts

9.

Coat flange surfaces of the hydraulic pumps with corrosion protective paste (CM 510) .

10.

Spray the lower sides of the angles of the sheet metal frame with oil.

11.

Place hydraulic unit on transmission deck.

12.

Insert pump drive shaft without using undue force into the accessory drive assembly at the main transmission.

13.

Install hydraulic pumps on accessory drive assembly. a.

Place angle for splash guard of system 1 on stud bolts.

b.

Install all four nuts and screw down equally. Torque value 6 - 6.5 Nm

* *

* *

14.

Coat the area on the transmission deck which supports the sheet metal frame in the vicinity of screw holes with sealing compound (CM 644) .

15.

Remove wooden board and cautiously place the hydraulic unit onto the transmission deck.

16.

Fasten hydraulic unit with 12 screws and washers on the deck torque screw.

17.

Remove excessive sealing compound.

18.

Coat all attachment bolts for control rods with corrosion preventive compound (CM 506) .

19.

Install control rods (7, figure 43-32) beginning at the right side. Ensure correct insertion of bolts (see figure 43-32).

20.

Install control rods (1) beginning at the left side. Ensure correct insertion of bolts (see figure 43-32).

21.

Install hydraulic unit on holding plate of main transmission with 4 screws and washers.

Revision 16

* *

tr~nsmission

BO 105 CHAPTER 43 Page 79

EUROCOPTER

MAINTENANCE MANUAL 80105

22. Connect Te!eflex cable of the N2 control to the N2-lever assembly. The N2-lever assembly of hydraulic unit with P/N's 105-45023 and 105-83011 which have two bore holes rnust be connected at the upper bore holeo 23. Check the transmission rnechanism between hydraulic unit and N2-control lever and adjust if necessary (refer to chapter 65). 24. If the same, unchanged hydraulic unit is reinstalled, the main rotor controls must be checked and rerigged as necessary. If a new or replacement or changed hydraulic unit is installed, the main rotor controls rnust be rerigged. For checkout and rigging of main rotor controls, refer to Chapter 102. 25. Install hose lines on the rnain transmission. 26. Mount splash guard on angle. 27. Fasten drain line with union nut. 28. Connect plug and fasten wiring harness with clamps. 29. Coat the area of support on the protective plate in the vicinity of bore holes with sealing compound (CM 644) . 30. Install protective plate with 3 screws and washers (torque value 6 Nm). 31. Remove excessive sealing compound. 32. Fasten three clamps. 33. Attach safety caps on reservoirs. 34. Inspect the entire assembly for secure installation, securing devices, foreign objects and freedom of movement. 35. Test switch-over with hydraulic test switch (refer to paragraph 43-15, step 1.). This test can be accomplished using the hydraulic ground unit or by perforrning a ground runo

* * 36. Perform a ground run to test the selector valve setting (refer to * paragraph 43-16 or 43-16A) .

BO 105 CHAPTER 43 Page 80

Revision 16

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 DETAlLA

1'+----10

3

.-1----11

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L -......,...."'"

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-+.----7

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100527

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Only for hydraulic unit P/N 105-45028 and 105-45018 1 Control rod 2 Splash guard 3 Input lever systern 1 4 Protective plate 5 Control rod 6 Input lever systern 2 Figure 43-32

Control rod Screw 9 Hydraulic pump 10 Fork end 11 Piston rod 12 Nut 7 8

Hydraulic systern BO 105 CHAPTER 43 Page 81/82

EUROCOPTER

MAINTENANCE MANUAL 80 105

43 - 26

H Y d r a u 1 i cpu m p s

43 - 27

Removal - hydraulic pumps

Special tool: NOTE

Hydraulic ground unit If the hydraulic pump is only to be removed for lubricating the driveshaft splines, the hydraulic lines are not to be disconnected from the hydraulic pump.

1.

Applicable only for system 1: Remove splash guard (2, figure 43-32) and disconnect hydraulic pump from accessory drive assembly.

2.

Applicable for system 2 only: Remove booster as far as necessary to separate the hydraulic pump from the accessory drive assembly.

3.

Close all ports at the accessory drive unit with plastic covers.

4.

Disconnect hose lines from hydraulic pump and close all ports with plugs.

5.

If a hydraulic pump is replaced, it is necessary to transfer unions to the new pump. Discard seal rings. Dip new seal rings in hydraulic fluid prior to installation.

43 - 28

Inspection and repair - hydraulic pumps

1.

Inspection and repair of the hydraulic pump shall be performed by the manufacturer or in accordance with the applicable vendor publication.

2.

The check of the hydraulic pump without its removal is outlined in paragraph 43-15, step: "Check the supply pressure of the hydraulic pump in both systems".

43 - 29

Installation - hydraulic pumps

NOTE

If the hydraulic pump had only been removed for lubricating the driveshaft splines and if, for this purpose, the hydraulic lines had not been disconnected, only step 4. is to be performed for installation of the hydraulic pump.

1.

De-preserve hydraulic pump if necessary.

2.

Connect hose lines; do not mix up ports. Tighten union nuts by hand only.

3.

* * *

s.

a.

Connect hose line to P and

b.

Hold opening CD upward and fill with hydraulic oil.

c.

Connect hose to CD and SD.

Apply a low pressure to the respective system and open CD line on the hydraulic pump as necessary to allow the trapped air to escape. Tighten union nut by hand only.

Revision 16

BO 105 CHAPTER 43 Page 83

* * * *

EUROCOPTER

* * 4. *

*

Install hydraulic pump on accessory gear box. a.

Clean pump driveshaft, pump flange and abutment fa ce of pump on accessory gear box.

b.

Coat pump driveshaft with a thin layer of grease (CM 111 or CM 137 or CM 147) and pump flange with corrosion preventive paste (CM 510) .

c.

Insert pump driveshaft without using undue force.

d.

Install hydraulic pump on accessory gear box and tighten nuts to 6 - 6.5 Nm. Applicable only for system I: Install splash guard (2, figure 43-32) .

*

*

* * * * * * * 5.

MAINTENANCE MANUAL BO 105

Bring hose lines in a tension-free position by loosening union nuts.

* 6. Tighten union nuts by hand and then tighten further by 1/6 turno * * 7. Install hydraulic unit. 8. Replenish the respective system (refer to paragraph 43-4) and bleed (refer to paragraph 43-5) . 9. Test pump delivery pressure (refer to paragraph 43-15).

BO 105 CHAPTER 43 Page 84

Revision

l~

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 43 - 30

F i 1 ter s

Special tool: Hydraulic ground unit Socket wrench

105-45051 W4

(only for filter type with laterally installed indicator pin)

43 - 31

Removal of the filter element - filters

NOTE

Different type filters may be installed in valve body manifolds and hydraulic reservoirs (see figure 43-33).

l.

If a filter element is contaminated, change the other filter element of the same system too.

2.

Drain hydraulic reservoir of the respective system (refer to paragraph 43-7) .

3.

Press out filter cover (1, figure 43-33) with M4 screws and take out filter element (2). Discard O-rings.

4.

Inspect filter element for the type of contamination. If metal deposits are detected in the filter element, repair hydraulic unit.

43 - 32

Installation of the filter element - filters

l.

Insert new filter element (2). Dip O-rings in hydraulic fluid prior to installation. Install filter cover (1) and secure with lockwire. Torque screws (5) and secure screws (5) with lockwire.

2.

Bleed the respective system (refer to paragraph 43-5).

43 - 33

Removal of contamination indicator - filters

l.

Drain hydraulic reservoir of the respective system.

2.

Remove contamination indicator (see figure 43-33). Discard O-rings.

43 - 34 l.

Installation of contamination indicator - filters

Install contamination indicator. Dip O-rings in hydraulic fluid prior to installation. Torque contamination indicator (7) and secure contamination indicator (7) to screw (5) with lockwire. Torque screw plugs (10, 14, 18) .

2.

Replenish the respective system (refer to paragraph 43-4) and bleed the system (refer to paragraph 43-5) .

BO 105 CHAPTER 43 Page 85

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 Configuration: axial indicator pininstallation

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Filter element:

Contamination indicator:

1 Filter cover, housing assy 2 Filter element 3 O-ring 4 O-ring 5 Screw 6 Washer

7 Contamination indicator 8 Back-up ring 9 O-ring la Screw plug 11 O-ring 12 Compression spring 13 Stop pin 14 Screw plug 15 O-ring

Figure 43-33 BO 105 CHAPTER 43 Page 86

15

16 O-ring 17 Washer 18 Screw plug 19 O-ring 20 O-ring 21 Washer 22 Compression spring piston Control 23 24 O-ring

Removal and installation - filter element and contamination indicator

O~~er 43 - 35

Control rods

Special tools:

43 - 36

MAINTENANCE MANUAL 80105

Alignment gauge for control rods Trammel 105-45045 W1

105-41482 L1

Removal - control rods

Remove control rods (5, figure 43-32).

43 - 37

Disassembly - control rods

NOTE

If adjustment for symmetry as outlined in the Repair Manual REM 402 or REM 405 is not performed, the distance between rod ends in the respective control axis is to be preserved by using an alignment gauge or trammel prior to disassembly.

I

1. Determine distance between rod ends using alignment gauge (105-41482 L1) ortrammel (105-45045 W1) and preserve distance for reassembly. 2.

Disassemble control rod (refer to chapter 41).

43 - 38

Inspection and repair - control rods

Inspect and repair control rods. Refer to chapter 41.

43 - 39

Assembly - control rods

NOTE

If original rod end distance cannot be precisely restored, adjustment for symmetry is to be performed as outlined in the Repair Manual (REM 402 or REM 405) and the main rotor control rigging is to be checked.

1. Unassigned 2.

Screw in rod ends symmetrically. Restore original distance between rod ends using alignment gauge (105-41482 L1) or trammel (105-45045 W1). Observe position of serrated disks as shown in figure 43-34.

3.. Tighten check nuts (2 and 5) with lubricated threads and secure to serrated disks (3) with lockwire. Seal lockwire with shrink sea!. Secure nut with LH thread to the left. 4.

Seal threads with silicone rubber (CM 612 or CM 619) (see figure 43-34), if no adjustment for symmetry must be performed.

Revision 23

CHAPTER 43 Page 87

I

Oeurocopter 8ft

MAINTENANCE MANUAL SO 105

EAOO Company

DETAlL

A

1 2 3 4 5 6

-+-__ 4

&.

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Figure 43-34

43 - 40

&. &.

Rod end with RH thread Nut Serrated discs Cotrol rod Nut Red end with LH thread Length determined with alignment gauge or trammel Secured with wire pos. 2 to 3 and 5 to 3 Sealed with silicone rupper (CM 612 or CM 619)

Disassembly and assembly - control rods

Installation - control rods

NOTE

Control rods with inaccurately adjusted length will cause deviations in the operating characteristics of system 1 and system 2.

1. When replacing a control rod:

I

a. Adjust control rod to originallength using alignment gauge 105-41482 L1 or trammel1 05-45045 W1 or perform adjustment for symmetry as outlined in REM 402 or REM 405. b.

Identify control rods as shown in figure 43-35.

2.

Install control rod in accordance with the identification as shown in figure 43-35. The rod end with the sealing must point upward. For identification and direction of insertion of bolts and torque value refer to figure 43-35. .

3.

Check for correct allocation of control rods to the appropriate control axis referring to figure 43-35.

4.

Check for freedom of movement and check for foreigri objects.

CHAPTER 43 Page 88

Revision 23

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

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5 6 7 8 Figure 43-35

D

Nylstop nut Washer Actuator lever, systern 2 Actuator lever, systern 1

Control rods 80 105 CHAPTER 43 Page 89/90

cteurocopter P r e s s u r e

43 - 41

MAINTENANCE MANUAL MBB - BO 105

s w i t che s

Special tool: Hydraulic ground unit Removal - pressure switches

43 - 42 l.

Disconnect plug (1, figure 43-36) from pressure switch (2).

2.

Disconnect hydraulic line from the pressure switch and close with caps immediately. Minimize hydraulic oil losses.

3.

Detach clamp (5) from side wall and remove pressure switch.

4.

Unscrew fitting (4) from pressure switch. Discard O-ringo Plug pressure switch connection lineo Inspection - pressure switches

43 - 43

For testing without removal refer to paragraph 43-15 step "Check pressure switches separately in both systems for proper function". Effective for pressure switches of system 1: Check for presence of bores in end face of pressure switch. If bores are present and not sealed, seal them with sealing compound (CM 661) . 43 - 44

Installation - pressure

s~itches

1.

Install pressure switch in reversed sequence of work steps of removal. Use new O-ringo Tighten union nut by hand only.

2.

Apply a low pressure to both systems. Slightly loosen union nuts, allow trapped air to escape and tighten union nuts again.

3.

Bleed the respective system (refer to paragraph 43-5).

4.

Check fluid levels of hydraulic reservoir.

5.

Perform functional test for pressure switches (refer to paragraph 43-15).

6.

Check for foreign objects.

Revision

a

BO 105 CHAPTER 43 Page 91

* *

*

fteurocopter

MAINTENANCE MANUAL MBB - BO 105

1 Plug Pressure switch O-ring 4 Fitting 5 Clamp 6 Union nut 7 Hydraulic line

2 3 900102.1

Figure 43-36

Removal and installation - pressure switches

43 - 45

S h u t t 1 e

43 - 46

Removal - shuttle valve

val v e

Special tool: Hydraulic ground unit 1.

Remove protective plate (4, figure 43-32) from the transmission deck.

2.

Disconnect fork end of shuttle valve piston from lever.

3.

Disconnect hydraulic lines. Plug openings.

4.

Remove shuttle valve from sheet metal frame.

BO 105 CHAPTER 43 Page 92

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 43 - 47

Installation - shuttle valve

1.

Install shuttle valve on sheet metal frame.

2.

Connect hydraulic lines. Tighten union nuts by hand only. Apply a low pressure to external pressure quick-disconnects PA 1 and PA 11. Loosen union nuts so that trapped air can escape. Tighten union nuts.

3.

Check stroke range of shuttle valve piston, refer to paragraph 43-18.

4.

Bleed both systems (refer to paragraph 43-5) .

5.

Check changeover-system for proper function and for ease of movement (refer to paragraph 43-15) .

6.

Check for foreign objects.

43 - 48

S o len o i d val v e

Special tool: Hydraulic ground unit 43 - 49

Removal - solenoid valve

1.

Remove protecting plate (4, figure 43-32) .

2.

Disconnect plug (1, figure 43-37).

3.

Loosen union nuts (6) of tubes (5).

4.

Loosen hollow screws (10).

5.

Remove solenoid valve (2) from support (4).

6.

Remove fittings (7) and adapter (13) from solenoid valve. Discard O-rings (8).

7.

Plug all open ports.

BO 105 CHAPTER 43 Page 93/94

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

43 - 50

Inspection and repair - solenoid valve

1.

For repair refer to rnanufacturer's docurnentation.

2.

For testing without rernoval refer to paragraph 43-15.

43 - 51

Installation - solenoid valve

1.

Install solenoid valve in reverse order of rernoval. Use new sealing elernents. Tighten union nuts and hollow screw by hand only.

2.

Applya low pressure to systern 1, slightly loosen union nuts and hollow screw, allow trapped air to escape and then tighten union nuts and hollow screw again.

3.

Check changeover systern for proper function (refer to 43-15).

4.

Check for foreign objects.

5.

Check fluid level for the respective systern.

5

6

7

8

.,---2

14

11 10

12

13

3

6

5

900091

1 Plug Solenoid valve Washer Support Tube

2 3 4 5

Figure 43-37

Union nut Fitting 8 O-ring 9 Hex boH 10 Hollow screw 6 7

11

12 13

14

Seal ring Banjo fitting Adapter Tube

Rernoval and installation - solenoid valve

BO 105 CHAPTER 43 Page 95/96

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 43 - 52

Q u i c k - d i s con n e c t s

43 - 53

Removal - quick-disconnects

1.

Disconnect hydraulic line from coupling half (1) and plug open end.

2.

Remove dust cap (3, figure 43-38).

3.

Remove flange (2) and take out coupling half (1).

43 - 54

Inspection and repair - quick-disconnects

Inspect and repair quick-disconnect in accordance with the manufacturer's instructions. 43 - 55

Installation - quick-disconnects

1.

Insert coupling half in sheet metal frame and tighten union nut of hydraulic line.

2.

Install flange.

3.

Bleed the respective system (refer to paragraph 43-5).

4.

Check fluid level for the respective system.

43/23

Coupling half Flange Dust cap 4 Screw 5 Washer

1 2 3

Figure 43-38

Removal and installation - quick-disconnect BO 105 CHAPTER 43 Page 97

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 43 - 56

F 1 a t

s p r i n g sin g u i d e s

Special tool: Hydraulic ground unit Fixing spring Mounting plate 43 - 57 1.

Removal - flat springs

Remove hydraulic unit (refer to paragraph 43-34). NOTE

2.

tool no. 23 (105-45041 W27) refer to chapter 04 tool no. 24 (105-45041 W26) refer to chapter 04

Displace fitted bolt (5, figure 43-39) only so much that DU washers behind guides cannot fall down.

Remove castellated nut (8) and washer (9). Push aside cover (10) to make flat spring accessible. CAUTION

WHEN TAKING OUT FLAT SPRING FROM A GUIDE OF SYSTEM 1, DO NOT BEND SPRINGS OF MICROSWITCHES.

3.

Applicable only for removal from guide of system 1: Expand springs of microswitches using tool-no. 23 (105-45041 W27) .

4.

Remove flat spring and slide blocks.

5.

Inspect the visible portion of fitted bolt (5) for proper condition. Replace fitted bolt if chromium plating is penetrated.

BO 105 CHAPTER 43 Page 98

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 43 - 58

Installation - flat springs

1.

Coat the visible area of fitted bolt (5, figure 43-39) with grease (CM 101) .

2.

Insert slide blocks (4). Fit the lower slide block using grease to assist installation. CAUTION

WHEN INSERTING FLAT SPRING IN A GUIDE OF SYSTEM 1, DO NOT BEND SPRINGS OF MICROSWITCHES.

3.

Applicable onlyfor installation in guide of system 1: Expand springs of microswitches using tool-no. 23 (105-45041 W27) .

4.

Expand flat spring with tool-no. 24 (105-45041 W26) .

5.

Relocate fitted bolt. Hold flat spring and slide blocks so that they cannot be pushed out.

6.

Applicable only for installation in guide of system 1: Check switch operating points of microswitches (refer to paragraph 43-20).

7.

Install cover (10), washer (9), castellated nut (8) and split pino The fitted bolt must be easy to rotate with a wrench.

8.

Check hydraulic unit for foreign objects.

9.

Install hydraulic unit (refer to paragraph 43-25).

BO 105 CHAPTER 43 Page 99

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~

7 8 9

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1 Guide of system 1 Flat spring 3 Spring of microswitch 4 Slide block 5 Close tolerance bolt 6 Guide of system 2 7 Split pin 8 Castellated nut 9 Washer 10 Cover 11 Lever guide 12 Actuator of system 1 13 Mounting plate tool-no. 24 14 Fixing spring tool-no. 23 2

400619

~

Remove these parts

~

Two configurations possible as to the insertion direction of close tolerance bolts Figure 43-39

BO 105 CHAPTER 43 Page 100

Removal and installation - flat spring

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 51

L AND 1 NG GE AR

Table of Contents

Paragraph

Title

51 - 1

DESCRIPTION - LANDING GEAR

3

51 - 2

INSPECTION AND REPAIR - LANDING GEAR

7

51 - 3

REMOVAL - LAND ING GEAR . .

13

51 - 4

INSTALLATION - LANDING GEAR

14

51 - 5

Skid

15

51 - 6

Disassembly - skid

15

51 - 7

Assembly - skid

17

Page

BO 105 CHAPTER 51 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 51 - 1

DESCRIPTION - LANDING GEAR

The landing gear is of the tubular skid type. It consists essentially of two cross tubes running late rally through the underside of the fuselage and attached through skid shoes and tightening clamps to the left and right landing skids. The cross tubes are attached to the fuselage mounts through bearing rings, elastomer rings and clamping rings. A step is mounted on the left and right sides of the forward cross tube to facilitate cabin entry.

BO 105 CHAPTER 51 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 1 Cross tube, aft 2 Skid shoe, aft 3 End cap 4 Tightening clamp, aft 5 Screw 6 Skid protective plate 7 Attaching hardware 8 Skid tube 9 Tightening clamp, forward 10 Tab washer 11 Screw 12 Screw 13 Skid protective plate 14 Screw 15 Skid protective plate 16 Attaching hardware 17 Skid shoe, forward 18 Washer 19 Screw 20 Tab washer 21 Screw 22 Cross tube, forward 23 Nut 24 Washer 25 Support rod 26 Washer 27 Nut 28 Step, aft long 29 Step, forward short 30 Nut 31 Cotter pin 32 Stepped washer 33 Bushing 34 Fuselage mount 35 Bearing ring 36 Close-tolerance screw 37 Lock strap 38 Tab washer 39 Necked-down bolt 40 Bonding jumper 41 Bonding jumper 42 bonding jumper 43 Cross tube, forward 44 Cross tube, aft

Figure 51-1 BO 105 CHAPTER 51 Page 4

45 46 47

48 49 50 51 52 53

54 55 56 57 58

59 60

Set screw ring Plug Plug Nut Washer Support rod Step, forward Step, aft Washer Nut Plug Screw Nut Clamp Step, forward Step, aft

~

Landing gearconfiguration 1: Wall thickness of cross tubes: 3.7 mm (forward) 5.0 mm (aft)

~

Landing gearconfiguration 11: Wall thickness of cross tubes: 5. O mm (forward) 5.0 mm (aft)

Landing gear (1 of 2)

MBB HELrCOPTERS---------------~-----------------­ ----------MA--r--N---T=EN=ANCE MANUAL MBB - BO 105 DETAlL

X

Configuratlon 11. only LH rear

Conflguration I ~1IIooliIiJ---40

34

I

29-31 Nm

33 32

1 30 --37

DETAlL

V

~----35

Configuration I

---36

I 12 Nm I

--=~----- 39

---45

'------37

-+----4~~

DETAlL

Z

29

Variant 11

3

25

24 23

18

4

19-----

5 6

60

DETAlL

11

Z

58

Variant 11I

22 58

13

59 500022

;8'

15

56

Figure 51-1

Landing gear (2 of 2) BO 105 CHAPTER 51 Page 5/6

14

12

--i

12-14 Nm

I

CDeurocopter lIll

MAINTENANCE MANUAL BO 105

EAOO Comput1y

51-2

INSPECTION ANO REPAIR - LANOING GEAR

1. Visually inspect cross tube (1 and 22, 43 and 44, fig. 51-1) for deformation, cracks, corrosion and other mechanical damage. Additionally do an internal inspection of the cross tube using a boroscope or an inspection mirror. If necessary remove skid shoes (refer to paras 51-3 and 51-4). Inspect the area of the cross tube which is located close to the rubber ring/clamping ring (45) for damage to protective finish. a.

I

If protective finish is damaged in the area close to the rubber ring/clamping ring (45) remove cross tube (refer to paragraph 51-3). Perform dye penetrant inspection in accordance with MIL-$866 on affected area and visually inspect the inward side of the cross tube for corrosion by using a boroscope. 1) If cracks are evident, replace cross tube (refer to paras 51-3 and 51-4).

I

2) If corrosion is evident, replace cross tube (refer to paras 51-3 and 51-4). b.

If cracked or corroded replace cross tube in accordance with paras 51-3 and 51-4.

c.

Mechanical damage not exceeding the damage Iimits shown in fig. 51-2 is acceptable without repair. Only blend out sharp-edged scratches and nicks to a transition radius of approx. 20 mm, using polishing cloth 400. If damage limits are exceeded, replace cross tube in accordance with paras 51-3 and 51-4.

d.

Corrosion damage not exceeding the damage limits shown in fig. 51-2A is acceptable without repair. If damage limits are exceeded, replace cross tube in accordance with paras 51-3 and 51-4. Blend out corroded areas using polishing cloth 400 in accordance with paragraph 02-4.

Zone "A" Depth of damage ffi max. 0.5 mm &, max. 0.3 mm

&,

Applies to both cross tubes of configuration 11 and to aft cross tube of configuration I (see fig. 51-1)

&,

Applies to forward cross tube of configuration I (see fig. 51-1)

Figure 51-2 Revision 25

Zone "B" Depth of damage &, max. 0.7 mm &, max. 0.5 mm

Damage zones and repair Iimits of cross tubes CHAPTER 51 Page 7

I

_eurocopter

MAINTENANCE MANUAL SO 105

~ en EAOS Compllny

seCTION

A-A

-

No corrosion allowed

Corrosion allowed up to 0.5 mm deep

Corrosion allowed up to 0.5 mm deep

No corrosion allowed

ZONEI

See Section A - A

ZONE 11

0.5 mm deep corrosion allowed over the entire circumference

Figure 51-2A Corrosion and repair limits of cross tubes

CHAPTER 51 Page 7A

Revision 25

-eurocopter •

1IIl EAOS

MAINTENANCE MANUAL SO 105

D:!mpmy

BLANK PAGE

Revision 25

CHAPTER 51 Page 7B

Aeurocopter ~lIIlfAOO~

MAINTENANCE MANUAL BO 105

e.

Touch up damaged protective paint finish with either two-component chromate primer (CM 417) or twocomponent wash primer (CM 423) and single-Iayer lacquer (CM 407). Refer to Chapter 02.

f.

Touch up coating of non-slip PUR top coat (CM 416). Refer to Chapter 02.

NOTE

Only remove bearing ring (35) and set screw ring (45) in the following cases: • inspection of c1ose-tolerance screw seat in bearing rings reveals unacceptable play (nut and c1ose-tolerance screw turn together). • repair of damaged set screw ring necessitates removal.

2. Visually inspect visible areas of installed bearing ring (35) for cracks, other mechanical damage and corrosion.

3.

a.

If cracks are evident, replace bearing ring (35). If cracks are suspected, remove bearing ring and dye penetrant inspect according to MIL-STD-6866.

b.

If bearing rings have been removed, visually inspect close-tolerance screw mating bores for mechanical damage. Remove damage with 400 grit abrasive cloth. Max. allowable bore diameter is 15.1 mm. If max. bore diameter is exceeded, replace bearing ring in accordance with paras 51-3 and 51-4.

c.

Polish out mechanical damage (scratches and nicks) and corrosion to a depth not exceeding 0.3 mm, using 400 grit abrasive c1oth. If damage exceeds this depth, replace bearing ring in accordance with paras 51-3 and 51-4.

d.

With the exception of the lacquer coating, touch up the damaged protective paint finish in accordance with Chapter 02. Lacquer coating to match fuselage color.

-

If removed, inspect close-tolerance screw (36) for mechanical damage and corrosion. a.

Replace close-tolerance screw if mechanical and/or corrosion damage extends through electrodeposited plating into base metal.

b.

Remove minor damage with 400 grit abrasive cloth. Replace close-tolerance screw if the shaft diameter is less than the minimum allowable limit of 14.9 mm.

CHAPTER 51 Page 8

-

CDeurocopter

MAINTENANCE MANUAL 80105

'" EAOS Compeny

4.

5.

If landing gear is removed, inspect bushing (33) for mechanical damage and corrosion. a.

Inspect bushing for dimensional tolerance. Replace if inner diameter exceeds 15.1 mm.

b.

Replace bushing if mechanical and/or corrosion damage extends through electrodeposited plating into base metal.

Inspect set screw ring (45) and rubber sleeve for damage and tight installation. a.

If rubber is cracked or has separated from the metal, replace set screw ring or rubber sleeve, as applicable, in accordance with paras 51-3 and 51-4.

b.

Polish out mechanical damage to a depth not exceeding 0.3 mm using 400 grit abrasive c1oth.

c.

Realign loose bushing and tighten necked-down bolt (39) to torque. Lock necked-down bolt with tab washer (38).

d.

Touch up damaged protective paint finish in accordance with step 2d.

6. Visually inspect skid tube (8) for cracks, deformation, other mechanical damage and corrosion. a.

If cracked or deformed, replace skid tube in accordance with paras 51-6. and 51-7.

b.

Mechanical damage (scratches and nicks) is acceptable to a depth of up to 0.5 mm on 30% of the total surface area of the top side of the skid tube and to a depth of up to 1.0 mm on 30% of the total surface area of the bottom side of the skid tube. Dents which do not exceed 5 mm in depth and 30 mm in diameter are acceptable. Corrosion damage is acceptable to a depth of up to 0.5 mm on the surface of the skid tUbe'l Blend out sharp-edged scratches and nicks to a transition radius of approx. 20 mm, using 400 grit abrasive cloth, in accordance with paras 02. If these damage limits are exceeded, replace skid tube per paras 51-6 and 51-7.

7.

•

c.

Inspect fiberglass laminate on flattened ends of skid tubes for damage. Repair damaged laminate with fiberglass c10th (CM 726), epoxy resin (CM 616) and hardener (CM 617).

d.

Touch up damaged protective paint finish with two-component zinc chromate primer (CM 417) or twocomponent wash primer (CM 423) and single-Iayer lacquer (CM 407). Refer to Chapter 02.

e.

Touch up coating of nonslip PUR topcoat (CM 416). Refer to Chapter 02.

Inspect skid shoes (2 and 17) for signs of damage and security of attachment. a.

If cracked or deformed, replace skid shoes in accordance with para 51-5. If welds or adjacent areas show evidence of cracks, proceed according to step C.

Revision 25

CHAPTER 51 Page 9

-eurocopter •

8.

MAINTENANCE MANUAL 80105

en EAOO Compnny

b.

Mechanical damage (scratches and nicks) is acceptable to a depth not exceeding 0.3 mm. Blend out sharp-edged scratches and nicks to a transition radius of approx. 20 mm. Use 400 grit abrasive c1oth.

c.

If welds or adjacent areas show evidence of cracks, remove skid shoe and reweld joint in accordance with FAA AC 43.13-1A.

d.

Check that screws (19 and 21) are installed tightly. Tighten loose screws and lock with tab washer (20) as required.

e.

Touch up damaged protective paint finish with two-component zinc chromate primer (CM 417) or twocomponent wash primer (CM 423) and single-Iayer lacquer (CM 407). Refer to Chapter 02.

Inspect tightening c1amps (4 and 9) for damage and security of installation.

a. If cracked or deformed, replace tightening c1amps in accordance with para 51-5. If welds or adjacent areas show evidence of cracks, proceed according to step c. b.

Mechanical damage (scratches and nicks) is acceptable to a depth not exceeding 0.2 mm. Using 400 grit abrasive c1oth, blend out sharp-edged scratches and nicks to a transition radius of approx. 20 mm.

c.

If welds or adjacent areas show evidence of cracks, remove tightening clamp and reweld joint in accordance with FAA AC 43.13-1 A.

d.

Inspect attaching hardware (10, 11) for tight installation. If screws are loose, inspect skid tubes for installation dimensions shown in fig. 51-3; readjust as necessary. Torque screws and lock with tab washers.

e.

Touch up damaged protective paint finish with two-component zinc chromate primer (CM 417) or twocomponent wash-primer (CM 423) and single-Iayer lacquer (CM 407). Refer to Chapter 02.

,/

-.~I_-

n-r I

I--~

I

/

.~

"1700 ±2

Figure 51-3

CHAPTER 51 Page 10

Skid tube installation

175±2

EUROCOPTER

9.

MAINTENANCE MANUAL BO 105

Raise helicopter: by means the ground handling wheels or a crane per Chapter 05 until there is enough ground clearance to inspect the skid protective plates. Visually inspect skid protective plates (6, 13 and 15) for excessive wear. Damage to the plates is acceptable provided they still protect the skid tube (8) and tightening clamps (4 and 9) from damage. Replace excessively damaged skid protective plates per para 51-5.

10. Inspect cap (3) for damage. Ifcracked or porous, replace cap in accordance with para 51-5. 11. Inspect bonding jumpers (40, 41, and 42, fig. 51-1) for damage and security of installation. a.

Replace damage bonding jumpers. Torque attaching hardware perfig. 51-1.

b.

Tighten loose attaching hardware.

12. Inspect attaching hardware (7 and 16) for tight installation and damage. a. Tighten loose attaching hardware. b.

Replace damaged parts. Referto para 51-7.

13. If deformation of cross tube is evident or suspected or inspection is scheduled (Chapter 101), inspect landing gear as follows: a.

With weight of helicopter on landing gear, measure ground clearance from center of fuselage underside to underside of skid tube as shown in fig. 51-4. Ground clearance must be at least 250 mm. If the clearance is less than required, proceed according to step b.

b.

Jack up helicopter evenly so that no weight is on the landing gear. Measure ground clearance from center of fuselage underside to skid tube underside as shown in fig. 51-4. If the ground clearance is less than 250 mm, replace respective cross tube as described in paras 51-3 and 51-4, and perform measures described in Chapter 101-7 (Special inspection following hard landing).

normal 400 mm mino

i

normal 350 mm 330 mm6 mino 250 mm

250 mm

BOl05_WAH_0985_A

6

Applicable to helicopters with max. gross mass 2,500 kg

Figure 51-4

Revision 18

Ground clearance check

CHAPTER 51 Page 11

I

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 14.

If fuselage shift on the cross tubes is evident or suspected, measure the length of the cross tube ends extending from either side of the fuselage as shown in figure 51-5. a.

If the dimensional tolerances are not met (see fig. 51-5), jack helicopter evenly so that landing gear is relieved of weight (refer to Chapter 05) .

b.

Remove bolts (39, figure 51-1) and tab washers (38) from affected cross tube.

c.

Centralize the cross tube so that the ends extending from either side of the fuselage are of equal length (see fig. 51-5).

d.

Instal1 bolts (39, figure 51-1) and new tab washers (38) (also attach bonding jumper attachment at locations shown in fig. 51-1). Lock bolts with tab washers.

800164

Max. allowable deviation L1 - L2 = ± 10 mm

Figure 51-5

BO 105 CHAPTER 51 Page 12

4

1 2 3 4

Centering of cross tube

Airframe Cross tube Set screw ring Skid shoe

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

51 - 3 NOTE ------

REMOVAL - LANDING GEAR If there are any components of optional equipment mounted on the side of the cross tube to be routed through the fuselage, remove them in accordance with the appropriate chapters.

1. Raise and level helicopter approx. 1.50 m. Refer to Chapter 05. 2. Remove bonding jumper in accordance with configuration (see fig. 51-1). 3. Remove skid tube (8) by removing screws (19) with washers (18) and screws (21) with tab washer (20). If necessary, use a plastic mallet to help detach the skid tube from the cross tube (1 and 22) . 4. Remove steps on forward cross tube (refer to figure 51-1). 5. Remove plug (46) or, if installed, attachment fittings for snow skids (refer to chapter 800, Optional Equipment) from aft cross tube (1). 6. Remove bolts (39) with tab washers (38). 7. Using a harnmer and wooden wedge, drive cross tube (1 and 22 as applicable) out through the bearing ring (35) until the set screw ring (45) protrudes from the bearing ring (35). Then pull displaced set screw ring off cross

tube, forcing the clamping ring apart with wedge if required. 8. Remove cross tube (1 and 22) from fuselage by pushing it out through the bearing rings (35). During removal take care not to damage the bulkheads.

9. Remove bearing rings (35) as necessary.

BO 105 CHAPTER 51 Page 13

- - - : - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 51 - 4 1.

2.

INSTALLATION - LANDING GEAR

If previously removed, install bearing ring (35, fig. 51-1) as fig. 51-1. Insert the bearing ring (35) in fuselage mount with chamfered end facing outboard. Lubricare close-tolerance screw bushing (33) with grease (CM 120) . If the castellation of nut (30) does not line up with the hole close-tolerance screw (36) when torque-tightening, replace nut retorque.

shown in the (36) and in and

Inspect set screw ring (45) for traces of paint and oil on the inside diameter of its clamping ringo Remove contamination with acetone (CM 203) .

3. . At installation of a new cross tube, install set screw ring (45) on one end of the cross tube and slide it up to the corresponding color codeo Bend clamping ring apart as necessary to facilitate installation. 4.

Pass the cross tube (1, 22) through the fuselage via the bearing rings (35) and maintain its position when an equaT length of cross tube extends from either side of the fuselage.

5.

Install the second set screw ring (45) on the other end of the cross tube (1, 22) and slide it up against bearing ring (35). Then use hammer and wooden block to drive the set screw rings firmly against the bearing rings.

6.

Install bolts (39) with tab washers (38) and torque to values shown in fig. 51-1. Lock bolts with tab washers. In configuration II (see fig. 51-1) attach the bonding jumper to left side of aft cross tube with bolt (39) and tab washer (38).

7.

After installing the aft cross tube (1), install plug-446) or attachment fittings for snow skids (refer to chapter 800).

8.

After installing the forward cross tube (22), install applicable step variant and seal with sealing compound (CM 662). See fig. 51-1 for step variants and associated torque values.

9.

Press skid tube (8) with attached tightening clamps (4 and 9) and protective plates (6, 13 and 15) evenly onto the aft and forward cross tubes, taking care not to cant the skid tube.

10.

Install screws (21) with tab washers (20) and screws (19) with washers (18). Lock screws (21) with tab washers (20). On configuration I (fig. 51-1), install the accociated bonding jumpers along with the hardware.

11.

If any components of optional equipment were previously removed, reinstall them in accordance with the appropriate chapter.

12.

Touch up damaged protective paint finish in accordance with para 51-2.

13.

Touch up coating of nonslip PUR topcoat in accorcance with para 51-2.

BO 105 CHAPTER 51 Page 1·1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 51 "':' 5

Skid

51 - 6

Disassembly - Skid

l. Raise helicopter approx. 0.5 m. Refer to Chapter 05. 2. Remove skid tube as described in para 51-3 step. 3. NOTE

The skid protective p1ate is sealed with sealing compound (CM 662). Remove strongly adhering protective plate carefully with a screwdriver.

3. Remove screws (8, 18 and 20, fig. 51-6) securing skid protective plates (9, 19 and 21) to skid tube and remove skid protective plates. 4. Straighten tab washers (7 and 16) locking the bolts (6 and 15) and remove bolts. Slide tightening clamps (5 and 17) and skid shoes (1 and 14) off skid tube (2). 5. If necessary drill out rivet (4) and remove end cap (3) with a suitable tool. 6. Remove nut (10), bolt (13) and washers (11 and 12) and nut (22), bolt (25) and washers (23 and 24) . 7. Remove nut (27) and bushing (26).

80 105 CHAPTER 51 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

13

12

14

8

I

27

l 8

11

9

10~ 16

I 15

26

--1

12 - 14 Nm

I

23

22

19

500021

1 2 3 4 5 6 7 8 9 10 11

12 13 14

Skid shoe, aft Skid tube Cap Blind rivet Tightening clamp Hex bolt Tab washer Screw Skid protective plate Nut Washer Washer Bolt Skid shoe, forward Figure 51-6

BO 105 CHAPTER 51 Page 16

15 16 17 18 19 20 21 22 23 24 25 26 27

Hex bolt Tab washer Tightening clamp Screw Skid protective plate Screw Skid protective plate Nut Washer Washer Bolt Bushing Nut

Skid tube - disassembled

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINT~~ANCE MANUAL MEB - BO 105 51 - 7

Assembly - skid

l.

Coat bushing (26, fig. 51-6) with capillar (CM 676). Coat nut (27) and shoulder of bushing (26) with sealing compound and install them in the skid tube. Torque nut (27) with specified torque value. Stake nut (27) with three center punch marks 120 0 aparto

2.

Apply a coat of sealing (CM 676) to the thread of bolt (25). Coat washers (23 and 24) with sealing compound (CM 662) and install in skid tube (2) with bolt (25). Install nut (22) and torque, then stake nut (22) and bolt (25) with three center punch marks 120 0 aparto

3.

Install tightening clamps (5 and 17) and skid shoes (1 and 14) by sliding them on skid tube (2) and aligning them as shown in fig. 51-3. Force tightening clamp apart with wedge as necesary to facilitate installation. Install bolts (6 and 15) with tab washers (7 and 16) and tighten by hand.

4.

Install bolts (13) with washers (11 and 12) and nut (10) according to procedure in step 2.

5.

If removed coat end cap (3) with sealing compound (CMN 662) and install in skid tube (2). Secure with blind rivet (4).

6.

Brush-coat skid protective plates (9, 19 and 21) with sealing compound (CM 662) at the mounting lug ends. Secure then to skid tube (2) with screws (8, 18 and 20) .

7.

Install skid tube on cross tube as described in para 51-4.

8.

Inspect installation dimensions in accordance with fig. 51-3 and correct as required.

9.

Torque bolts (6 and 15) with specified torque value. Lock bolts with tab washer.

10.

Touch up damaged protective paint finish and coating of nonslip PUR topcoat in accordance with para 51-2.

BO 105 CHAPTER 51 Page 17/18

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

61

E NG1 NE

Tab1e of Contents

Paragraph

Tit1e

61 - 1

DESCRIPTION - ENGINE

5

61 - 2

TROUBLESHOOTING - ENGINE

5

61 - 3

INSPECTION - ENGINE

5

61 - 4

REMOVAL - ENGINE

8

61 - 5

DISMANTLING - ENGINE

13

61 - 6

BUILD-UP - ENGINE

15

61 - 7

INSTALLATION - ENGINE

27

61 - 8

1 n b o r den g i n e

61 - 9

Remova1 - inboard engine mount

33

61 - 10

Inspection and repair - inboard engine mount

34

61 - 11

Insta11ation - inboard engine mount

35

61 - 12

o u t b o a r den g i n e m o u n t

39

61 - 13

Remova1 - outboard engine mount

39

61 - 14

Inspection and repair - outboard engine mount

43

61 - 15

Insta11ation - outboard engine mount

43

61 - 16

L o we r

44

61 - 17

Remova1 - lower engine mount

44

61 - 18

Inspection and repair - lower engine mount

45

61 - 19

Insta11ation - lower engine mount

46

Page

e n g i n e

mo u n t

mo u n t

33

BO 105 CHAPTER 61 Page 1

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Page

Paragraph

Title

61 - 20

S t a r t e r - gen e r a t o r

54

61 - 21

Removal - starter-generator

54

61 - 22

Inspection and repair - starter-generator

54

61 - 23

Installation - starter-generator

54

61 - 24

N1 g a s

61 - 25

Removal - NI gas producer fuel control

55

61 - 26

Inspection - NI gas producer fuel control

55

61 - 27

Installation - NI gas producer fuel control

55

61 - 28

N2 P o we r

55

61 - 29

Removal - N2 power turbine governor

55

61 - 30

Inspection - N2 power turbine governor

56

61 - 31

Installation - N2 power turbine governor

56

61 - 32

Ex h a u s t

56

61 - 33

Removal - exhaust stacks

56

61 - 34

Inspection and repair - exhaust stacks

56

61 - 35

Installation - exhaust stacks

57

61 - 36

En g i n e

pro d u c e r

f u e 1

t u r b i n e

con t rol

g o ver n o r

s t a c k s

a n t i - i c i n g

val vea c t u a t o r

55

57

Removal - engine anti-icing valve actuator

57

61 - 38

Inspection and repair - engine anti-icing valve actuator

57

61

Installation - engine anti-icing valve actuator

60

61 - 40

E n g i n e

61

61 - 41

Removal - engine stubshaft

61

61 - 42

Inspection and repair - engine stubshaft

62

61 - 43

Installation - engine stubshaft . . . . .

63

61

37

39

BO 105 CHAPTER 61 Page 2

s

t

u b s h a

f t

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Paragraph

Title

61 - 44

E n g i n e c o m par t m e n t f o r c e d ventilation .

64

61 - 45

Removal - engine compartment

64

61 - 46

Inspection and repair - engine compartment forced ventilation

64

61 - 47

Installation - engine compartment forced ventilation

64

Page

for~ed

ventilation

BO 105 CHAPTER 61

Page 3/4

MAINTENANCE MANUAL SO 105

61 - 1

DESCRIPTION - ENGINE

The SO 105 helicopter is equipped with two Allison engines of the Type 250-C18, 250-C20, or 250-C20S, depending on the helicopter model. The engines are mounted on each side of the tail boom cone in a 3-point structural support (see figure 61-1). The engine is a turboshaft engine consisting of a compressor with six axial stages and one centrifugal stage, a single combustion chamber, a two-stage gas producer turbine, a two-stage free power turbine, and an integrated accessory gearbox. A full description of the engine is provided in the AIIison OPERATION AND MAINTENANCE MANUAL NO. 5 W2 (250-C18) and 10 W2 (250-C20, 250-C20S).

TROUBLESHOOTING - ENGINE

61 - 2

For troubleshooting and remedial measures refer to the Allison Operation and Maintenance Manual NO. 5 W2 or 10 W2.

61 - 3

INSPECTION - ENGINE

1. Inspection of the engine must be carried out as specified in the ALLlSON OPERATION AND MAINTENANCE MANUAL. 2.

Inspect engine mount bushings for deformation by rocking the engine. The rubber bushings must not yield to the extent that moving parts interfere with fixed ones. If interference is evident, replace weak bushings.

3.

Inspect for freedom of movement between inboard engine mount and engine. There shall be a clearance of at least 1.5 mm between the head of the uppermost mount fitting attach screw and the bearing cap. If clearance is insufficient, make necessary adjustment according to para 61-11.

4. Wherever possible in installed position, inspect engine mounting struts for condition, welds for cracks, and attaching hardware for presence of tab washers and cotter pins. a.

Replace deformed or cracked struts.

b.

If locking hardware is missing, check attaching hardware tor specified torque and install locking hardware.

5. Visually inspect exhaust coupling clamps for cracks, especially near the retainer clamps (2, figure 61-20A) • of latches. Replace cracked clamps.

Revision 24

CHAPTER 61 Page5

MAINTENANCE MANUAL BO 105

t t - - - -tB-I--

;: I

7"""'------'- - - -

-1--------.

/j

o al

1 No. 1 engine 2 No. 2 engine 3 Outboard engine mount

Figure 61-1 CHAPTER 61 Page6

4 Inboard engine mount 5 Lower engine mount

Engine installation

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 6.

Inspect electrical wlrlng and electrical connectors for condition and bonding jumpers for security. a.

Replace damaged wiring .

b.

Re-tighten loose bonding jumpers.

7.

Inspect electrical connections of tachogenerators for condition and tightness. Replace damaged connections and tighten loose connections.

8.

Inspect engine accessory and auxiliary equipment such as startergenerator, N1/N2 controls and N1/N2 tachogenerators, for security of installation. Tighten any loose screws on flange connections.

9.

Visually inspect engine deck for evidence of oil and fuel leaks. Locate and replace leaking lines.

10. Visually inspect flexible and rigid lines for security of attachment and signs of chafing. Replace damaged lines. Tighten loose line fittings and replace damaged lines.

BO 105 CHAPTER 61 Page 7

MBB HELICOPTERS MAINTENANCE MANUAL MBB - BO 105 61 - 4

REMOVAL - ENGINE

Special tools: Adapter Engine work stand Engine stand NOTE

P/N 105-60001 W2 or Allison P/N 6796963 P/N 1121-60004 W2 P/N 105-60001 WS

The following maintenance procedures app1y to engine No. 1 and engine No. 2 unless otherwise indicated.

1. Disconnect e1ectrical power supply. 2. Remove engine cowlings (refer to Chapter 22). 3. Remove Bendix driveshaft (refer to Chapter 11). 4. Remove firewalls to extent required for engine removal (refer to Chapter 64). 5. Remove anti-icing valve actuator (4, figure 61-4) from engine. Install adapter P/N 105-60001 W2 or Allison P/N 6796963 in place of mounting bracket (3). 6. Disconnect engine wiring harness from receptacle on engine deck. Remove the cable clamps from the V-strut and the engine deck. Disconnect the electrical leads from the starter-generator. 7. Disconnect oil lines (9, 11, 12, figure 61-2) from firewall fittings on the engine side and remove the screw8 attaching hose clamp (8) to the engine deck. Cap open lines. 8. Open the quick-disconnect coupling of NI teleflex cable at frame 9. 9. Disconnect torque sensing line (14) at engine deck. Cap open connections. 10. Disconnect fuel line (20, figure 61-5) from the engine deck fitting or from the microfilter, if installed. Cap open connections. If microfilter is installed, disconnect electrical connector. 11. Disconnect bonding jumper at engine deck. 12. Remove hose (6, figure 61-7) for engine compartment forced ventilation from hose adapter (4) on starter-generator (3). 13. Remove cotter pin (40, fig. 61-12), nut (41) and washer (42) from bolt (43) attaching adjustable strut (44) to engine deck fitting, but do not withdraw bolt at this time. Do not alter the length of adjustable strut. 14. Remove bearing caps (3 and 49) of outboard and inboard engine mounts. 15. Hook hoisting device into aft hole of adapter. Check that all electrical connectors have been disconnected and that engine is free of all attachments to the airframe. BO 105 CHAPTER 61 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~8 ~ 3 2

A~ 11

9

130lNml 1---"""",,,,~~\;

12-----+

l1----I\-'H-1

10

DETAlL

-4-~..._\__+\

9

A

~------13

\..-------14

8 -----r---....--+

600210.1

7-------4",~

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Oil temperature transmitter Adapter for engine oil input line Adapter for oil pressure sensing line Adapter for torque sensing line Adapter for oil tank vent line Adapter for engine oil output line Engine deck Hose clamp Engine oil input line (from oil tank) Oil pressure sensing line oil tank vent line Engine oil output line (to oil cooler) Oil pressure transmitter Torque sensing line

Figure 61-2

~ Routing of oil line, if scavenge oil filter is installed

Engine No. 1 - oil lines and adapters BO 105 CHAPTER 61

Page 9/10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

8-1

EJ I

3 7

7 DETAlL

5

-----+------>

11-------+

'3.5 N~I

1 oil temperature transmitter 2 Adapter for engine oil input line 3 Adapter for oil pressure sensing line 4 Adapter for torque sensing line 5 Adapter for oil tank vent line 6 Adapter for engine oil output line 7 Engine oil input line (from oil tank) 8 Engine oil output line (to oil cooler) 9 Oil tank vent line la Torque sensing line 11 Engine deck 12 Hose clamp 13 Oil pressure transmitter 14 Oil pressure sensing line

13 - - - - - - - - '

~ 8

12 - - - - - - - - - - - ' o::::...-

~':-~_-..,.

1íI---------1Q

~-----11

~ Routing of oil line, if scavenge oil filter is installed

Figure 61-3

9

A 6

600211.1

14

8

Engine No. 2 - oil lines and adapters BO 105

CHAPTER 61 Page 11/12

EUROCOPTER

MAINTENANCE MANUAL BO 105

16. Remove bolt (43) from adjustable strut (44). Carefully Iift engine from installed position and lower it onto engine work stand, P/N 1121-6004 W2. 17. With the engine removed, perform the tollowing inspections: a.

Remove V-struts and inspect attach tittings tor condition per paragraph 21-3, step 8.

b. The tollowing inspection item applies only to mount tittings tor V-struts P/N 105-60351.06, 105-60353.06,105-60354.06,0133-364,0133-388 and 0133-389: Inspect f1ange for cracks in the shaft area and in the area where the shaft joins the flange. Penetrant inspect per MIL-STO-6866. Replace cracked flange.

61-5

DISMANTLlNG - ENGINE

Special tools: Adapter Engine work stand Engine stand Socket wrench Counter-hold tool Orift Puller

NOTE

105-60001 W2 or AIIison 6796963 1121-60004 W2 105-60001 W5 105-60701 W1 105-60701 W4 105-60701 W3 105-60701 W5 The following maintenance procedures apply to engine No. 1 and engine No. 2 unless otherwise indicated.

1. Remove screws attaching the air intake fairing (11, figure 61-4) and firewall ring casing (12) to the compressor front support (13). Remove air intake fairing and firewall ring casing, and place a cover over compressor front support (13). 2. It still connected, remove engine anti-icing valve actuator (4) from engine. 3. Remove N1 and N2 tachogenerators (2, 1) from the engine. 4. Remove both fire detectors (5 and 10) together with their attaching brackets (6 and 9). 5.

Remove ¡nboard and outboard exhaust stacks (6 and 1, figure 61-8). Oisconnect vent fine (7) from adapter (8) on the engine. Remove inboard exhaust stack (6) with attached vent line (7).Place covers over exhaust ducts (3, 4).

6.

Unscrew and remove oillines (9,11,12, figure 61-2), oil pressure sensing fine (10) and torque sensing fine (14) from their respective adapters (2, 5, 6, 3 and 4). Remove oilfines from the engine, along with hose clamp (8) and oil pressure transmitter (13). Cap open lines and fittings.

7. Loosen coupling clamp (2, figure 61-7) and detach starter-generator (3) from mounting pad (1). Remove the four nuts securing the mounting pad to the engine. Take care to use a socket wrench with an outer diameter that will not break the mounting pad. Remove mounting pad.

Revision 18

CHAPTER 61 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. Pull stubshaft (2, figure 61-9) of configuration 2 and 3 out of engine reduction gearbox. Remove stubshaft (2) of configuration 1 as follows: a.

Remove cover plate (8).

b.

Remove Shurlock washer (7). If Shurlock washer has external threads, remove with puller P/N 105-60701 W5.

c.

Using socket wrench P/N 105-60701 W1, remove lock nut (6) from stubshaft (2) while holding the stubshaft steady with counter-hold tool P/N 105-60701 W4.

d.

Pull stubshaft (2) out of engine reduction gearbox together with the laminated shims (4), then remove spacer (5) from the opposite side.

9. With the exception of the TOT cable, disconnect all electrical cables from the engine. 10. Engine No. 2 only: Remove clamp (7, figure 61-6) attaching fuel line (19) to firewall (8). 11. Unscrew fuel line (20, figure 61-5) from connection (10). 12. Remove drain lines (8, 7, 6 and 5) from fuel pump, combustion chamber, engine firewall, exhaust collector and, if the Ceco fuel control system is installed, from the N1 fuel control and from the N2 power turbine governor. Remove connection (10) together with fuel pressure transmitter (9) and support bracket (16). 13. Unscrew and remove banjo bolt (14) from fuel filter drain valve (15). Remove fitting (12) with attached drain valve (15) and hose. 14. Disconnect both differential pressure lines (18 and 19) from the fuel pump (1). Detach differential pressure switch (21) and remove together with attached lines (18 and 19) . 15. Unscrew and remove adapters for oil lines (2, 3, 4 and 5, figure 61-2), vent line (8, figure 61-8) and fuel lines (2, 3, 4 and 17, figure 61-5). 16. Remove bracket for attaching the N1 mechanical linkage to the engine, and remove gas producer control lever from its shaft. Remove disconnected linkage from engine, together with bracket and gas producer control lever (refer to Chapter 65). 17. Install adapter P/N 105-60001 W2 or Allison P/N 6796963 in place of engine anti-icing valve actuator mount. 18. Hook hoisting device in rear eye of adapter and lift engine clear of the work stand. 19. Remove nut securing N2 governor lever to mating shaft.

BO 105 CHAPTER 61 Page 14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

NOTE

Do not unscrew the nuts (7 and 61, figure 61-12) securing the engine bushings to the mount fittings (21 and 54) .

20. Engine No. 1 only: Remove bolts attaching the outboard mount fitting (21, figure 61-12) to the engine, then rernove the outboard mount fitting from the engine, together with attached N2 Teleflex cable, actuator and governor lever, refer to Chapter 65. Remove inboard mount fitting (54). 21. Engine No. 2 only: Rernove the inboard rnount fitting (47, figure 61-13) from engine together with attached N2 Teleflex cable, actuator and governor lever, refer to Chapter 65. Remove outboard mount fitting (8). 22. Rernove lower mount fitting (24, figure 61-12) frorn engine, together with adjustable strut (44). 23. Lower the engine onto engine stand P/N 105-60001 W5. Unhook hoisting device from adapter and rernove adapter P/N 10ó-60001 W2 or Allison P/N 6796963 from engine. 24. If the engine is to be sent for repair or overhaul, prepare the engine for shiprnent in the shipping container as described in the ALLISON OPERATION ANO MAINTENANCE MANUAL NO. 5W2 or NO. 10W2.

61 - 6

BUILO-UP - ENGINE

Special too1s: Adapter Engine work stand Engine stand Socket wrench Counter-ho1d too1 orift

Puller

NOTE

P/N 105-60001 W2 or Allison P/N 6796963 P/N 1121-60004 W2 P/N 105-60001 W5 P/N 105-60701 W1 P/N 105-60701 W4 P/N 105-60701 W3 P/N 105-60701 W5

The fo1lowing rnaintenance procedures apply to engine No. 1 and engine No. 2 un1ess otherwise indicated.

1.

When building up a new or overhau1ed engine, rernove engine frorn the shipping container and depreserve in accordance with Allison OPERATION ANO MAINTENANCE MANUAL 5W2 or 10W2.

2.

Insta11 adapter P/N 105-60001 W2 or Allison P/N 6796963 on engine.

BO 105 CHAPTER 61 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3. Attach hoisting device to rear eye of the adapter and lift engine sufficiently to provide access from the sides and from below. 4. Apply a thin coat of corros ion preventive compound (CM 505) to the mating surfaces and install assembled lower mount fitting (24, figure 61-12) and adjustable support strut (44) on engine. 5. Engine No. 1 only: Apply a thin coat of corrosion preventive compound (CM 505) to the mating surfaces, spray-coat bores with corrosion preventive compound (CM 508) and install assembled inboard mount fitting (54) and bushing (50) on engine. Install assembled outboard mount fitting (21) and bushing (4), bonding strap (22), bracket for N2 mechanical linkage, Teleflex cable, and actuator on the engine, refer to Chapter 65. Do not install governor . lever tightly at this time. 6. Engine No. 2 only: Apply a thin coat of corrosion preventive compound (CM 505) to the mating surfaces, spray-coat bores with corros ion preventive compound (CM 508) and install assembled inboard mount fitting (47, figure 61-13) and bushing (51), bracket for N2 mechanical linkage, Teleflex cable and actuator on the engine, refer to Chapter 65. Do not install governor lever tightly at this time. Install assembled outboard mount fitting (8) and bushing (18). Install bonding strap (3) on outboard mount fitting with upper attaching screw. 7. Lower engine onto engine work stand P/N 1121-60004 W2. Remove hoisting device. 8. Screw in the oil line adapters (2, 3, 4 and 5, figure 61-2), vent line adapters (8, figure 61-8) and fuel line adapters (2, 3, 4 and 17, figure 61-5) together with O-rings. Take care to screw the inch-threaded end of the adapter (coarse compared with the metric thread on the other end) into the engine. Secure the adapters with lockwire. 9. Install fuel line connection (10, figure 61-5), including attached pressure transmitter (9) and support bracket (16), and fuel pump drain line (8) to fuel pump. Connect firewall drain line (6), combustion chamber drain line (7) and exhaust collector drain line (5), including drain lines for N1 fuel control and N2 governor (CECO only), to their respective connections. 10. Install fitting (12) and drain valve (15) on fuel filter (22) with banjo bolt (14) and two new sealing rings (11, 13). 11. Install differential pressure switch (21) on engine with clamp, and connect differential pressure lines (18, 19) to fuel pump (1). 12. Engine No. 1 only: Connect fuel line (20) to connection (10). 13. Engine No. 2 only: Connect fuel line (19, figure 61-6) to connection (12) and secure to engine firewall (8) with clamp (7). BO 105 CHAPTER 61 Page 16

----..--:....-------MBB HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

4

!:"(¡'...---5

.J-------6

7--~

~"V.¡...---8

3 ---+-----"f~.~~~

Engine No. 2

9

DETAlL

13

A

Engine No. 1

12

2 600212

11

1 N2 tachogenerator 2 NI tachogenerator 3 Actuator mounting bracket 4 Engine anti-icing valve actuator 5 Fire detector 6 Bracket 7 Bracket 8 F ire detector 9 Bracket 10 Fire detector 11 Air-intake fairing 12 Firewall ring casing 13 Compressor front support

Figure 61-4

... A

Engine accessories BO 105 CHAPTER 61 Page 17/18

10

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Configuration 2

,/

IL-

I

O.6Nm

i

I

I

I

2

3

4

___

"

22----~~

'-------7 600219

----------8 ~A~~_=::'~------------9 ~

+ - - - - - - - - - -__ 10 ~~_____=----------

11

---------12 ------13

1 2 3

4 5

6 7 8 9

10 11

12 13 14 15

16 17

18 19 20

21 22

Figure 61-5

------14~

18

Fuel pump (engine driven) Adapter for differential pressure line Adapter for fuel pump drain line Adapter for differential pressure line Exhaust col lector drain line Firewall drain line Combustion chamber drain line Fuel pump drain line Fuel pressure transmitter Connector Sealing ring Fitting Sealing ring Banjo bolt Drain valve Support bracket Adapter for fuel line Differential pressure line Differential pressure line Fuel line Differential pressure switch Fuel filter

'--------15~

DETAlL

20

19

18

17 1

11.2 Nm I

Engine No. 1 - fuel and drain lines BO 105 CHAPTER 61 Page 19/20

16

A

_ _ _ _ _ _ _ _ _ _ _ _ _ MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~

234

24

5

6

---f:..-..::'4-----::>~

600220 23---~

Configuration 1

8

1 2

3 4 5 6 7 8

9

10 11

12 13 14

15 16 17 18 19

20 21 22

23 24

Fuel pump (engine driven) Adapter for differential pressure line Adapter for fuel pump drain line Adapter for differential pressure line Exhaust col lector drain line Firewall drain line Clamp Engine firewall Combustion chamber drain line Fuel pump drain line Fuel pressure transmitter Connector Sealing ring Fitting Sealing ring Banjo bolt Drain valve Support bracket Fuel line Adapter for fuel line Differential pressure line Differential pressure line Differential pressure switch Fuel filter

Figure 61-6

9 10 11 120 Nml

12 13 22

21

20 19

11. -

21Nm

18

14

l

15

Configuration 2

120 Nml

DETAlL

22

23

Engine No. 2 - fuel and drain lines BO 105 CHAPTER 61 Page 21/22

A

17

~

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

--------

l

~~~-l I

) 6 5 600224

4

3

2

1 2 3 4 5 6

Starter-generator mounting pad Coupling clamp Starter-generator Hose adapter Clamp Hose Figure 61-7

.~

..

Starter-generator BO 105 CHAPTER 61

Page 23 .;. ..

EUROCOPTER

MAINTENANCE MANUAL BO 10S

14. Lubricate drive splines of the Nl and N2 tachometer generator (2, 1, figure 61-4) with grease (CM 101) and install tachometer generators on the engine. 15. Mount starter-generator mounting pad (1, figure 61-7) on engine. When tightening the retaining nuts, take care to use a socket wrench with an outer diameter that will not cause damage the mounting pad. 16. Using a brush, lubricamte drive-end spline of starter-generator drive shaft with grease (CM 101, "dry spline" drive shaft) , or with lubricating oil (CM 103, "wet spline" drive shaft). Install starter-generator (3) on mounting pad (1) with coupling clamp (2). Position coupling clamp (2) so that it does not ¡nterfere with freedom of movement of Nl engine control linkage. Check torque of clamp nut after performing ¡nitial ground run and retighten nut as necessary. 17. Install assembled fire detectors (S, lO, figure 61-4) and mounting brackets (6, 9), on above each engine between the exhaust ducts, and one at the rear of each engine (on left side of engine No. 1 and on right side of engine No. 2). 18. Install N1 engine controllinkage on engine, together with attached bracket and gas producer controllever. 19. Install inboard and outboard exhaust stracks (1, 6, figure 61-8) as follows: CAUTION

INCORRECTLY INSTALLED CLAMPS MAY WORK LOaSE AND DAMAGE THE HELlCOPTER.

a. Inspect self-Iocking nuts of exhaust coupling clamp for minimum frictional torque of 1.5 Nm.lf minimum frictional torque does not exist, replace nut. b. Remove the covers from twin ducts (3,4). Fit exhaust stacks (1,6) on twin exhaust ducts (3, 4). Install coupling clamps and tighten the nuts until the coupling clamps fit tightly.lnstall the nuts on both "T" bolts of a coupling clamp as evenly as possible. c.

Torque nuts to 2 Nm while at the same time tapping the clamp with a plastic mallet to obtain a snug fit.

d. Back off both nuts enough to relieve tension on the ''T'' bolts. e. Connect oil vent line (7) to inboard exhaust stack (6). 20. Remove cover from compressor front support (13, figure 61-4). Install fire wall ring casing (12) and air intake fairing (11) on compressor front support (13). 21. Connect oillines (9, 11, 12, figure 61-2) oil pressure sensing line (10), and torque sensing line (14) to their respective adapters (2, 5, 6, 3 and 4). 22. Connect electrical cables to the engine. 23. Check whether the compressor scroll-to bleed valve air sensing tube assembly P/N 6876294, is installed. Refer to Allison CEB (25D-C20 Installation Bulletin No. 1003).

CHAPTER 61 Page 24

Revision 19

MAINTENANCE MANUAL 801 OS

EUROCOPTER

2

3

4

5

6

6

5

4

3

2

7

7

1 Outboard exhaust stack

2 Coupling clamp 3 Exhaust duct 4 Exhaust duct 5 Coupling clamp 6 Inboard exhaust stack 7 on vent fine 8 Adapter for vent line

ISNm I

ISNml

I

Engine No. I

Do not use lockwire. Use self-locking nuts only.

I

Figure 61-8 Exhaust stacks

Revision 17

8

I

Engine No. I

ffi

e

CHAPTER 61 Page 25/26

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 61 - 7

INSTALLATION - ENGINE

Special tools: Adapter Engine work stand Engine stand Engine alignment device Socket wrench Counter-hold too1 Drift

NOTE

P/N 105-60001 W2 or A1lison P/N 6796963 P/N 1121-60004 W2 P/N 105-60001 WS P/N 105-60101 W4 P/N 105-60701 W1 P/N 105-60701 W4 P/N 105-60701 W3

The following maintenance procedures apply to engine No. 1 and engine No. 2 unless otherwise indicated.

1.

Install adapter P/N 105-60001 W2 or Al1ison P/N 6796963 on engine, in place of mounting bracket (3, figure 61-4).

2.

Make certain that there are no foreign objects on engine deck.

3.

Hook hoisting device into rear adapter eye. Carefully lift engine clear of engine work stand and position it in mounting position above the engine deck.

CAUTION

WHEN LOWERING THE ENGINE IN POSITION BE CAREFUL NOT TO DAMAGE THE TAIL ROTOR DRIVE SHAFT.

4.

Swing up adjustable strut (44, figure 61-12) forward as far as possible and secure in this position. Lower the engine carefully so that the bushings (4, 50) on the mount fittings (21, 54) rest on the engine mounts.

5.

Locate bearing caps (3, 49) on outboard and inboard engine mounts and secure them, and bonding jumper (22),with bolts. Do not safety the bolts at this time.

6.

Swing down adjustable strut (44) and install it to engine deck-mounted lug. Torque nut (41) and secure with cotter pin (40).

7.

Unscrew and remove the adapter. Install mounting bracket (3, figure 61-4) and anti-icing valve actuator (4), and adjust actuator as described in paragraph 61-39.

8.

Connect N1 Teleflex cable and close the quick-disconnect coupling.

BO 105 CHAPTER 61 Page 27

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

*

Stub shaft, Configuration

* * * *

*

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

Drive shaft, Configuration 1

2

140-50

Nml

Stub shaft, Configuration 11 wlthout pos. 3, 4, 5 6 and 7

10

2

Drive shaft, Configuration 11

L/'

Stub ,shaft, Conflguratlon 111 ~ Retrofitted acc. to SB 60-54. Series installation on S 551 subsequent 1 2 3

4 5

10

6 7

E600250-01

8 9 10 Figure 61-9 BO 105 CHAPTER 61 Page 28

Drive shaft stub shaft Steel washer Laminated shims Spacer Shurlock locknut Shurlock lockwasher Cover plate Thrust plate Main transmission drive flange

Drive shaft and stub shaft configurations and possible means of installations Revision 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 9.

Install stubshaft (2, figure 61-9) as follows: Configuration 1 a.

Temporarily install stubshaft (2) in engine together with spacer (5), but without the steel and laminated shims (3, 4). Install locknut (6) fingertight.

b.

Connect driveshaft (1) to main transmission drive flange (10). Support the free end of the driveshaft to prevent diaphragms from being distorted.

c.

With the stubshaft pulled towards the main transmission, measure the clearance between the flange on the aft end of the driveshaft and the mating flange on the stubshaft.

d.

Assemble a combination of steel washers (3) and laminated shims (4) corresponding to the width of the gap between the mating flanges.

e.

Remove driveshaft (1) and stubshaft (2).

f.

Slide assembled shims and washers over the stubshaft spline to rest· against the shoulder of the shaft. Lubricate shaft seat forward of shaft spline, shaft spline and spacer (5) with grease (CM 101 or CM 120). Slide spacer onto shaft.

g.

Install stubshaft (2) and retaining nut (6). Torque retaining nut and secure with lockwasher (7). Install cover plate (8).

Configuration 2 and 3 Lubricate spline of stubshaft (2) with grease (CM 101 or CM 120) and insert stubshaft as far as possible into the main output drive shaft of the engine. 10. If reinstalling the same engine, tnis steps a. thru g. may be omitted so long as the engine mounts have not been shifted since engine removal. Otherwise check engine alignment and, if necessary, adjust as follows: a.

Install engine alignment device 105-60101 W4 in place of driveshaft between the main transmission drive flange and the stubshaft flange. Push the knurled rings (2 and 5, figure 61-10) outboard to their respective shaft ends. Hand-tighten nuts (1).

b.

The knurled rings (2 and 5) must move inboard smoothly frem their outboard position. This indicates that engine-to-main transmission alignment is within the tolerance limits.

c.

If knurled ring (2) contacts front end of inner tube (4), or knurled ring (5) contacts front end of outer tube (3), engine-to-main transmission alignment is outside the tolerance limits. The point of contact between tube and knurled ring can be observed either internally through the four cutouts in tube (3) or externally between tube (3) and knurled nut (5).

BO 105 CHAPTER 61 Page 29

- - - - - - ' - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

3

2

-+"-~'++

..L.-_ _

5

4

tj', H - - - _---'_...J -lLMiloOOll'---'t+-A-

JJ

1 6

7

Alignment device, knurled rings outboard

2

600225

3

5

4

7

Alignment device, knurled rings inboard

1

Nut

2 Knurled ring 3 Tube, outer 4 Tube, inner

Figure 61-10 BO 105 CHAPTER 61 Page 30

5 Knurled ring 6 Stubshaft 7 Main transmission drive flange "

,

",

Engine alignment

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

In figure 61-11, the circumference of each tube (3 and 4) is divided into 8sectors, designated A thru H as viewed in the direction of flight. If contact as described in step c. occurs in one of these sectors during the alignment check, readjust the engine mounting as specified in figure 61-11.

e.

Repeat engine alignment check. If repeated adjustment of the engine mounts fails to produce alignment, adjustments must be made to the main transmission (refer to Chapter 11).

f.

When engine-to-main transmission alignment is within the tolerance limits, remove the engine alignment device from the helicopter.

g.

If the length of the adjustable strut has been altered, check for play between the stubshaft flange and the driveshaft flange (applies to the stubshaft in configuration 1 only) .

11. Install driveshaft and firewall (refer to Chapters 11 and 64 respectively) . 12. Remove caps from fuel lines. Connect fuel line (20, figure 61-5) to engine deck fitting or to the microfilter, if installed. Connect electrical cable to the microfilter, if installed. 13. Remove caps from oil lines (9, 11, 12, figure 61-2) and connect lines to the firewall fitting inside the engine compartment. Install hose clamp (8) on engine deck with screws. 14. Remove oil from torque sensing line (14) before connecting it. Do this by opening the torque sensing line at the instrument panel and blowing air through it. Remove battery if installed there. Connect torque sensing line (14) to fitting in engine deck and to instrument panel. Reinstall battery. 15. Connect engine wiring harness connector to the receptacle in engine deck and connect electrical cables to the starter-generator. Install cable clamp and bonding jumper on engine deck. 16. Connect hose (6, figure 61-7) for forced ventilation of engine compartment to starter-generator (1). 17. Service engine with lubricating oil (refer to Chapter 63). 18. Vent fuel system (refer to Chapter 62). 19. Check N1 and N2 engine controls for propet function and adjust as required (refer to Chapter 65). 20. Perform ground run (refer to Chapter 105) . 21. Install engine cowling (refer to Chapter 22).

BO 105 CHAPTER El Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

... ....

5 600221

1

2 3

4 5 6 7

2 6

Nut Knurled ring Tube, outer Tube, inner Knurled ring Stubshaft Main transmission drive flange Contact in Sector:

\ \

Adjustment procedures:

A

Increase length of adjustable strut

B

Combine adjustment procedures specified for sectors A and C.

C

No. 1 shims No. 2 shims

D

Combine adjustment procedures specified for sectors C and E.

E

Shorten adjustable strut.

F

Combine adjustment procedures specified for sectors E and G.

G

No. 1 shims No. 2 shims

H

Combine adjustment procedures specified for sectors G and A.

Figure 61-11 BO 105 CHAPTER 61 Page 32

Engine: Increase overall thickness of on the inboard engine mount. Engine: Decrease overall thickness of on the inboard engine mount.

Engine: Decrease overall thickness of on the inboard engine mount. Engine: Increase overall thickness of on the inboard engine mount.

Correction of engine-to-main transmission misalignment

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 61 - 8

I n b o a r den g i n e

mo u n t

61 - 9

Removal - inboard engine mount

Special too1s: Adapter

P/N 105-60001 W2 or Allison P/N 6796963

NOTE

The following maintenance procedures apply to engine No. 1 and engine No. 2 unless otherwise indicated.

1.

Remove engine cowling (refer to Chapter 22).

2.

Remove driveshaft (refer to Chapter 11).

3.

Disconnect the NI and N2 Teleflex cables at the quick disconnect couplings.

4.

Engine No. 1 only: Remove flanges from firewall passage for N2 Teleflex cable.

5.

Remove cotter pin (62, figure 61-12), nut (61) and washer (60).

6.

Unlock screws (47). Remove screws (47) and tab washers (48). Remove bearing cap (49).

7.

Install adapter P/N 105-60001 w2 or Allison P/N 6796963 in place of actuator mounting bracket (3, figure 61-4). Connect hoist to rear hole of adapter. Carefully raise engine just enough to take the weight off the inboard mount.

8.

Remove bushing (50, figure 61-12), laminated shim (51) and washer (55) from mount fitting (54). Keep laminated shim (51) for reinstallation at the original location on the same engine.

9.

Remove mount fitting (54).

BO 105 CHAPTER 61 Page 33

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - ' - - - - - - - MAINTENANCE MANUAL MBB - BO 105 61 - 10 l.

2.

3.

4.

Inspection and repair - inboard engine mount

Visually inspect mount fitting (54, figure 61-12) for cracks, other mechanical damage, and corrosion. a.

If cracked, or if other mechanical damage or corros ion exceeds the allowable limits, replace mount fitting.

b.

Polish out any damage not exceeding the acceptable damage limits specified in figure 61-15. Final polish with No. 400grit abrasive cloth.

c.

Thread damage that prevents the mating nut from being installed by hand is not permitted.

Visually inspect bearing cap (49) for cracks, other mechanical damage and corrosion. a.

If cracked, or if other mechanical damage or corros ion exceeds the a1lowable limits, replace bearing cap.

b.

Polish out any damage not exceeding the acceptable damage limits specified in figure 61-19. Final polish with No. 400 grit abrasive cloth.

Visua1ly inspect mount (57) for cracks, other mechanical damage and corrosion. a.

Replace mount if cracks are evident, or if other mechanical damage or corros ion exceeds the allowable limits.

b.

Polish out any damage not exceeding the acceptable damage limits specified in figure 61-19. Final polish with No. 400 grit abrasive cloth.

Inspect bushing (51) for deformation and for separation of rubber. Inspect steel part of bushing for mechanical damage and corrosion. a.

If the rubber has separated or deformation is evident, or there ist damage exceeding the acceptable damage limits specified in figure 61-20, replace bushing.

b.

Polish out any damage not exceeding the acceptable damage limits specified in figure 61-20. Final polish with No. 400 grit abrasive cloth.

BO 105 CHAPTER 61 Page 34

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 61 - 11

Installation - inboard engine mount

Special tools: Adapter

P/N 105-60001 W2 or Allison p/N 6796963

NOTE

The following maintenance procedures apply to engine No. 1 and engine No. 2 unless otherwise indicated.

1.

Install mount fitting (54, figure 61-12) on engine.

2.

Install washer (55), laminated shim (51), bushing (50), and washer (60) on mount fitting (54) and secure with nut (61).

3.

Lower the engine carefully so that bushing (50) rests on mount (57).

4~

Fit bearing cap (49) over the bushing and secure to mount with screws (47) and tab washers (48).

5.

Remove the hoist from the helicopter and remove adapter p/N 105-60001 W2 or Allison p/N 6796963 from engine mounting pad. Reinstall actuator mounting bracket (3, figure 61-4) and actuator (4), and adjust actuator in accordance with paragraph 61-39.

6.

Tighten nut (61, figure 61-12) and safety with cotter pin (62).

2 3

1 2 3 4 5

Bearing cap Screw Washer Flange Laminated shim

600119.3

Figure 61-11A

Inspection for freedom of movement

BO 105 CHAPTER 61 Page 35

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 7.

Inspect for freedom of movement between inboard engine mount and engine (fig. 61-11A) and make necessary adjustment as follows: a.

Measure clearance between head of screw (2) and bearing cap (1); clearance shall be at least 1.5 mm.

b.

If clearance is less than 1.5 mm, check whether washer (3) p/N AN960-516L (0.6 mm thick) is installed. If existing washer is thicker, replace with 0.6 mm thick washer.

c.

Repeat measurement of clearance between head of screw (2) and bearing cap (1). Freedom of movement is obtained if clearance measures 1.5 mm. If clearance is less than required, make up difference with laminated shims (5). In this case the engine must be aligned as described in para 61-7.

1 2 3 4 5 6 7 8 9 10 11

12 13

14 15 16 17

18 19 20 21 22 23 24 25 26 27 28 29 30 31

Screw Tab washer Bearing cap Bushing Washer Cotter pin Nut V-strut Washer Cotter pin Nut Screw Washer Cotter pin Nut Screw Washer Washer Screw Washer Mount fitting Bonding jumper BoH Mount fitting Washer Screw Washer Cotter pin Nut Washer Washer Figure 61-12

BO 105 CHAPTER 61 Page 36

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Circlip Bushing End fitting Tab washer Nut Screw fitting Nut Tab washer Cotter pin Nut Washer Screw Adjustable strut Washer Washer Screw Tab washer Bearing cap Bushing Laminated shim Screw Washer Mount fitting Washer Screw Mount Washer Nut Washer Nut Cotter pin

Engine mounts - engine No. 1

(1 of 3)

--

MBB HELICOPTERS_ BO 105 -----:MA;:I[NNrTTEEliNANCE MANUAL MBB 1

---l

12·14 Nm

I EFFECTIVITY

S/N 21 and su bsequent 12-14 Nm

49

24

23 1I

I 52 53

20

17

54

32 30

¡ 37

B

A

, mount Lower englna

. e mount Outboard engln

----.J 41 -1 42

Figure 61-12

Engl'ne rnounts - engine No. 1

e

, e mount Inboard engln

DETAlL

DETAlL

DETAlL

(2 of 3)

BO 105 CHAPTER 61 Page 37/38

6-8 Nm

I

A ¿U

(54),

With rnount fl'ttlng 06 larninate d IN 105-60351. 'her 155) him P 1511 and order. S l' nstalled ln are ,

S

~asreverse

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 EFFECTIVITY

S/N 11-20

Outboard engine mount , 12-14 Nm 23-26 Nm 12·14 Nm

12-14 Nm 12-14 Nm

Lamlnated shim

DETAlL

e

Inboard engine mount

&

Interpose laminated ~ shims when ~ connecting clevis. Max. play is 0.05 mm DETAlLA

Lower engine mount 600119.2

Figure 61-12

Engine mounts - engine No. 1

(3 of 3) BO 105 CHAPTER 61 Page 38A/B

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. Engine No. 1 only: Instal1 f1anges to firewa1l passage for N2 Teleflex cable. 9. Connect the N1 and N2 Teleflex cables to the quick disconnect couplings. 10. Install driveshaft (refer to Chapter 11). 11. Install engine cowling (refer to Chapter 22) .

61 - 12

O u t b o a r den g i n e m o u n t

61 - 13

Removal - outboard engine mount

Special tools': Adapter

P!N 105-60001 W2 or Allison P/N 6796963

NOTE

The following procedures apply to engine No. 1 and engine No. 2 unless otherwise indicated.

l.

Remove engine cowlings (refer to Chapter 22) .

2.

Remove driveshaft (refer to Chapter 11).

3.

Disconnect the N1 and N2 Teleflex cables at the quick disconnect couplings.

4.

Engine No. 1 only: Remove flanges from engine firewall passage for N2 Teleflex cable.

5.

Unlock screws (1, figure 61-12). Remove screws (1) and tab washers (2), and remove bearing cap (3). If the bearing cap cannot be removed, remove the uppermost screw securing mount fitting (21) to the engine.

6.

Remove cotter pin (6), nut (7), and washer (5).

7.

Installadapter 105-60001 W2 or Allison P!N 6796963 in place of actuator mounting bracket (3, figure 61-4). Connect a suitable hoist to rear hole of adapter. Carefully raise the engine just enough to take the weight off the outboard mount.

8.

Remove bushing (4, figure 61-12) and washer (17 and 18) from mouht fitting (21).

9.

Remove mount fitting (21) from engine.

BO 105 CHAPTER 61 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 2 3 4 5 6 7 8 9 10 11

12 13

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Screw Tab washer Bonding jumper Screw Washer Washer Washer Mount fitting V-strut Screw Washer Nut Cotter pin Screw Washer Nut Cotter pin Bushing Washer Nut Cotter pin Bearing cap Bolt Mount fitting Washer Screw Washer Cotter pin Nut Washer Washer

Figure 61-13 BO 105 CHAPTER 61 Page 40

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Circlip Bushing End fitting Tab washer Nut Screw Nut Tab washer Cotter pin Nut Washer Screw Adjustable strut Washer Washer Mount fitting Screw Tab washer Bearing cap Bushing Cotter pin Nut Washer Nut Washer Mount Screw Laminated shim Washer Screw Washer

Engine mounts - engine No. 2

(1 of 3)

----------;;;rEN~

MBB HELICOPTERS BO 105 MAINTENANCE MANUAL MBB - ____

I

EFFECTIVITY

12-14 Nm

S/N 21 and su b s equent 12-14 Nm

I 48

47

22--~

.....

51

1918 12-14 Nm

I 12-14 Nm 57 20-JO Nm

8

\.---

9 6-8Nm

DETAlL 13

12

i'

/~f"<.~~...,

11

'1,-9)

I

\ !

-12--14 Nm

/1"

Al","

--10

Inboard englne mount

>:J

;,'F"' I

I'\:==l~,=:::J

39

y;./4/

DETAlL DETAlL

A

Lower engine mount

B

Outboard engm e mount !

6-8 Nm

43 ~.

6-8 Nm 600120.1

Figure 61-13

Engine mounts - engine No. 2

(2

e

of 3)

BO 105 CHAPTER 61 Page 41/42

42

I

------

MEB MAINTENANCE ----=:u

EFFECTIVITY

HELICOPTE:S_ BO 105 MANUAL ME

S/N 11-20

DETAlL

B

Outboard engine

DETAlL

e

.ne

Inboard engl.

moun t

mount

1- Interpose laminated

~

. s when . shl.m . g clevl.s. connectl.n 0.05 mm Max. play iS

DETAlL

A . ne

Lower engl

mount

600120.2

Figure b-1 - 13

Engl.'ne mounts - engine No. 2

(3 of 3)

BO 105 CHAPTER 61 Page 42A/B

EUROCOPTER

MAINTENANCE MANUAL BO 105

10. Remove cotter pins (10 and 14), nuts (11 and 15), washers (9 and 13) and screws (12 and 16) from V-strut (8). Remove V-strut (8) form engine deck-mounted lugs.

61 - 14

INSPECTION AND REPAIR - OUTBOARD ENGINE MOUNT

1. Inspect mount fitting (21, figure 61-12), bearing cap (3) and bushing (4), applying same criteria as for the corresponding parts of the inboard engine mount. Refer to figures 61-15 and 61-20 for damage and rework Iimitations.The following inspection item applies only to mount fittings for V-struts P/N 105-60351.06, 105-60353.06,105-60354.06,0133-364,0133-388 and 0133-389: Inspect flange for cracks in the shaft area and in the area where the shaft joins the flange. Penetrant inspect per MIL-ST0-6866. Replace cracked flange. 2.

3.

Inspect V-strut for mechanical and corrosion damage, cracked welds, deformation and damaged surface protection. a.

Polish out any mechanical and corrosion damage not exceeding the acceptable damage Iimits specified in figure 61-14 with 400 grit abrasive cloth.

b.

If there is evidence of cracks, deformation or corrosion, replace V-strut (see fig. 61-14).

c.

Touch up surface protection with PUR topcoat (CM 412).

Inspect screws (12 and 16, fig. 61-12) and screws (10 and 14, fig. 61-13) for mechanical and corrosion damage. Polish out mechanical damage. such as scratches, nicks and scores, and local corrosion spots with 400 grit abrasive cloth. Thread damage is permissible only if the screws can be easily installed by hand.

Revision 18

CHAPTER 61 Page 43

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 61 - 15

Insta1lation - outboard engine mount

Special tools: Adapter

P/N 105-60001 W2 or Allison p/N 6796963

NOTE

The following maintenance procedures app1y to engine No. 1 and engine No. 2 unless otherwise indicated.

1. Install mount fitting (21, figure 61-12) on engine and safety with lockwire. 2. Fit washers (17 and 18), bushing (4), and washer (5) on mount fitting (21) and secure with nut (7). Tighten nut (7) and safety with cotter pin (6) •

3. Connect V-strut (8) to engine deck-mounted lugs. 4. Lower engine carefully unti1 bushing (4) rests in the apex support of the V-strut. 5. Install bearing cap (3) over the seated bushing and secure to V-strut with screws (1). Lock screws with tab washers (2). 6. Move hoist clear of helicopter and remove adapter p/N 105-60001 W2 or Allison p/N 6796963 from engine mounting pad. Reinstall actuator mounting bracket (3, figure 61-4) and actuator (4) and adjust actuator in accordance with paragraph 61-39. 7. Engine No. lonly: Install flanges to firewall passage for N2 Teleflex cable. 8. Connect the NI and N2 Teleflex cables to the quick disconnect couplings. 9. Install driveshaft (refer to Chapter 11) . 10. Install engine cowlings (refer to Chapter 22).

BO 105 CHAPTER 61 Page 44

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 61 - 16

L o we r

e n g i n e mo u n t

61 - 17

Removal - lower engine mount

Special tools: Adapter

p/N 105-60001 W2 or Allison p/N 6796963

NOTE

The following maintenance procedures apply to engine No. 1 and engine No. 2 unless otherwise indicated.

1.

Remove engine cowlings (refer toChapter 22) .

2.

Remove driveshaft (refer to Chapter 11).

3.

Disconnect the NI and N2 Teleflex cables at the quick disconnect couplings.

4.

Engine No. 1 only: Remove flanges from No. 1 engine firewall passage for N2 Teleflex cable.

5.

Remove cotter pins (40 and 28, figure 61-12), nuts (41 and 29) and washers (42 and 27) .

6.

Install adapter p/N 105-60001 W2 or Allison P/N 6796963 in place of actuator mounting bracket (3, figure 61-4). Connect a suitable hoist to the rear hole of the adapter. Carefully raise the engine just enough to relieve the weight on the adjustable strut (44, figure 61-12).

7.

Remove bolts (23 and 43). Remove adjustable strut (44), washers (31 and 45) and washers (30 and 46). Keep washers (30 and 46) for reinstallation at their original positions.

8.

Remove the left and right panels of forward firewall and remove the protective plate from the tandem hydraulic unit. Remove mount fitting (24) from engine case.

80 105 CHAPTER 61 Page 44A/B

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 61 - 18

Inspection and repair - lower engine mount

1.

Measure and record the length of the adjustable strut. nisassemble adjustable strut as shown in figure 61-12.

2.

Perform inspection of bushing (33) applying same criteria as for bushing of inboard engine mount.

3.

Inspect end fitting (34) for cracks, other mechanical damage and corrosion.

4.

a.

If cracks are evident, replace end fitting.

b.

Polish out any mechanical and corrosion damage within the acceptable damage limits specified in figures 61-18 or 61-17A. Final polish with No. 400 grit abrasive cloth.

Inspect adjustable strut (tubular section) for deformation, corros ion and cracks, especially cracks in welds. a.

If strut is cracked or deformed, replace strut.

b.

Polish out any mechanical and corros ion damage within the acceptab1e damage limits specified in figure 61-17. Final polish with 400 grit abrasive cloth.

c.

Touch up surface protection as described in Chapter 02.

5.

Inspect bolt (23, fig. 61-12) and screw (43) for mechanical and corrosion damage. Polish out mechanical damage, such as scratches, nicks and scores, and local corros ion spots with 400 grit abrasive cloth. Thread damage is permissible only if the bolt or screw can be easily installed byhand.

6.

Inspect mount fitting (24, figure 61-12) for cracks, other mechanical damage and corrosion.

7.

a.

If cracks are evident, replace mount fitting.

b.

Polish out any damage within the acceptable damage limits specified in figures 61-16 or 61-1sA. Final polish with No. 400 grit abrasive cloth.

Assemble adjustable strut as shown in figure 61-12. Install bushing (33) and adjust strut to length recorded in step 1.

BO 105 CHAPTER 61 Page 45

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - ' - - - - - - - - - . MAINTENANCE MANUAL MBB - BO 105 61 - 19

Installation - lower engine mount

Special tools: Adapter

P/N 105-60001 W2 or Allison P/N 6796963 Guide sleeve P/N 105-60356 W1 NOTE 1.

The following maintenance procedures apply to engine No. 1 and engine No. 2 unless otherwise indicated. Before installing mount fitting (24, figure 61-12), brush-coat faying surfaces of mount fitting and engine with corrosion preventive compound (CM 505). Install mount fitting on engine, and wire-lock bolts (26).

2. Connect adjustable strut (44) to the engine-mounted fitting (24) and to the deck-mounted lug using bolt (23), washers (46, 45, 31, and 30) and washer (27), nut (29), and screw (43), washer (42) and nut (41), respectively. Do not tighten nuts (29 and 41) at this time. 3.

Lower engine carefully. Tighten nuts (29 and 41) and secure with cotter pins (28 and 40). Move hoist clear of engine.

4.

If the length of the adjustable strut has been altered or a new one installed, align the engine as described in paragraph 61-7.

5.

Remove adapter P/N 105-60001 W2 or Allison P/N 6796963 from engine. Install actuator mounting bracket (3, figure 61-4) and actuator (4), and adjust actuator (refer to paragraph 61-39) .

6.

Install left and right panels of forward firewall, and install protective plate on tandem hydraulic unit.

7.

Engine No. 10nly: Install flanges to No. 1 engine firewall passage for N2 Teleflex cable.

8.

Connect the NI and N2 Teleflex cables to the quick disconnect coupling.

9.

Install driveshaft (refer to Chapter 11) .

10. Install engine cowling (refer to Chapter 22) .

BO 105 CHAPTER 61 Page 46

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

........,~+-----

Bearlng cap

640017.1

TYPE OF OAMAGE

OAMAGE ANO REPAIR LIMITS ZONE 1 ZONE 2 ........ ......... ........ ......... .........

[[EJ. Mechanical and corros ion

0.15 mm deep on 25% of surface area

-

0.1 mm deep on 25% of surface area

ZONE 3

m

0.05 mm deep on 25% of surface are a

Maximum allowable diameter:

&

10.02 mm

~

8.02 mm

Maximum allowable bore diamter may be exceeded by 0.02 mm on one quarter of circumference

Figure 61-14

V-strut - damage and repair limits BO 105 CHAPTER 61 Page 47

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ~ ZONE 1

mm

Mechanica1 and corros ion

The minimum allowable diameter is 13.96 mm. It may be exceeded by 0.05 mm on ene quarter ef the circumference

-

ZONE 2

0 .1 mm deep en 25% ef surface area

Allowable diameter:

&

8.65 mm

~

The minimum allowable diameter of spigot is 31.68 mm. It may be 0.02 mm less on one quarter of the circumference.

~

If mount fitting threads are damaged, replace mount fitting.

The maximum allowable bore diameter may be exceeded by 0.05 mm on one quarter of the circumference

Figure 61-15 BO 105 CHAPTER 61 Page 48

Mount fitting - damage and repair limits

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

640019.1

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS

-

ZONE

Mechanical and corros ion

0.1 mm deep on 25% of surface area

Maximum allowable diameter: 35.25 mm 8.65 mm

The maximum allowable bore diameter may be exceeded by 0.05 mm on one quarter of the circumference.

The minimum allowable diameter of the spigot is 31.68 mm. It may be 0.02 mm less on one quarter of the circumference. , Figure 61-15A

Mount fitting - damage and repair limits BO 105 CHAPTER 61 Page 48A/B

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS

Mechanical and corrosion

-

ZONE 1

ZONE 2 ......... ......... ......... ........

EillI]. ..........

0 .1 mm deep on 25% of surface are a

0.15 mm deep on 25% of surface area

Maximum allowable diameter: 14.55 mm 8.65 mm

The maximum allowable bore diameter may be exceeded by 0.05 mm on one quarter of the circumference.

The minimum allowable diameter of the spigot is 31.68 mm. It may be 0.02 mm less on one quarter of the circumference. Figure 61-16

Mount fitting - damage and repair limits BO 105 CHAPTER 61 Page 49

- - - - - - - - - - - - - . - M B B HELICOPTERS ---~--------­ MAINTENANCE MANUAL MBB - BO 105

/

/

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS

Mechanical and corros ion

-

ZONE 1

0 .1 mm deep on 25% of surface area

-

ZONE 2

0 .15 mm deep on 25% of surface area

~

The maximum allowable bore diameter is 8.02 mm. It may be exceeded by 0.02 mm on one quarter of the circumference.

~

If adjustable strut threads are damaged, replace adjustable strut.

Figure 61-17

BO 105 CHAPTER 61

Page 50

Adjustable strut - damage and repair limits

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

640019.2

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE

Mechanical and corros ion

-

0.15 mm deep on 25% of surface are a

~

The maximum allowable inner diameter is 14.05 mm. It may be exceeded by 0.05 mm on one quarter of the circumference.

~

Replace end fitting if its threads are damaged.

Figure 61-17A

End fitting - damage and repair limits

BO 105 CHAPTER 61 Page 50A/B

- - - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

640020

DAMAGE AND REPAIR LIMITS ~

The maximum allowable inner diameter is 35.25 mm. It may be exceeded by 0.05 mm on one quarter of the circumference.

~

If end fitting threads are damaged, replace end fitting.

Figure 61-18

End fitting - damage and repair limits BO 105 CHAPTER 61 Page 51

--~----------MBB

HEL'ICOPTERS -------=----~---­ MAINTENANCE MANUAL MBB - BO 105

Bearing cap

TYPE OF DAMAGE

Mechanica1 and cerresien

~

DAMAGE AND REPAIR LIMITS

-

ZONE 1

ZONE 2

0 .1 mm deep

O. 05 mm deep en 25% ef surface are a

en 25% ef surface area

The maximum allawable bare diameter is 8.0 mm. It may be exceeded by 0.05 mm an ane quarter af the circumference. Figure 61-19

BO 105 CHAPTER 61

Page 52

Maunt - damage and repair limits

MAINTENANCE MANUAL BO 105

EUROCOPTER

640003

OAMAGE ANO REPAIR LIMITS ZONE 2 ......... ........ .........

ZONE 1

········ EIJ ••• t

Mechanical and corros ion damage to a depth of 0.05 mm on 50% of the surface area

Figure 61-20

•••••

Separation of rubber at the edges is acceptable. If separation is more extensive, or distortion exists, replace bushing

Bushing - damage and repair limits

BO 105 CHAPTER 61 Page 53

EUROCOPTER

61 - 20

S t a r t e r - gen e r a t o r

61 - 21

Removal - Starter-generator

MAINTI:NANCE MANUAL BO 105

1.

Check that all electrical power is OFF.

2.

Remove engine cowling (refer to Chapter 22).

3.

If engine compartment forced ventilation is installed, remove hose (6, figure 61-7) from hose adapter (4) on starter-generator (3).

4.

Disconnect electrical leads from starter-generator (3).

5.

Loosen the nut on T-bolt of coupling clamp (2) and unlatch T-bolt from coupling clamp. Carefully remove starter-generator from engine.

6.

Remove hose adapter (4) from starter-generator.

61 - 22

Inspection and repair - starter-generator

*

* Refer to Chapter 92, Inspection and Maintenance-starter-generators * 61 - 23 1.

Installation - starter-generator

Instal1 hose adapter (4, figure 61-7) on starter-generator (3).

NOTE

Starter-generators with engine oil lubrication, identified by a packing groove behind the drive spline on the drive shaft, are used only on engine gearboxes that feature a wet spline starter-generator gearshaft. Refer to Allison CEB-1082 (2S0-C20/C20B) and CEB-179 (2S0-C18). On engines with dry spline starter-generator gearshafts, the starter-generator drive spline must be lubricated with grease (CM 101) when the starter-generator is installed.

2.

With the T-bolt unlatched, place coupling clamp (2) on starter-generator, between the mounting flange and terminal block.

3.

Lubricate starter-generator drive shaft spline (dry spline configuration only) with grease (CM 101). Locate starter-generator (3) on mounting pad (1) so that the splined shaft engages with the engine spline and, holding starter-generator flush up against mounting pad, position coupling clamp over mating flanges and latch the T-bolt. The clamp installation must allow freedom of movement of NI engine control linkage. Tighten clamp nut. Check torque after first ground run and retighten as necessary.·

4.

Reconnect electrical leads to starter-generator (3).

BO 105 CHAPTER 61 Page 54

Revision 14

_~~pter

MAINTENANCE MANUAL BO 105

5. Connect hose (6) to hose adapter (4) with clamp (5). 6.

If a new or overhauled starter-generator is installed, or the carbon brushes have been replaced, functionally test the generator system and adjust the generator voltage as necessary (refer to chapter 92).

7.

Install engine cowlings (refer to Chapter 22)

61 - 24

61 - 25

N1 gas producer fuel control

Removal - N1 gas producer fuel control

1. Check that all electrical power is OFF. 2. No. 1 engine only: Remove left engine cowling and remove aft and center firewalls as necessary. No. 2 engine only: Open right access door. 3.

Oisconnect angle joint from N1 fuel controllever. Refer to chapter 65.

4.

Proceed with removal in accordance with the Allison OPERATION ANO MAINTENANCE MANUAL No. 5W2 (250-C18) or 10W2 (250-C20/C20S).

61 - 26

Inspection - N1 gas producer fuel control

Refer to Allison OPERATION ANO MAINTENANCE MANUAL No. 5W2 or No. 10W2.

61 - 27

Installation - N1 gas producer fuel control

1. Install the gas producer fuel control in accordance with the Allison OPERATION ANO MAINTENANCE MANUAL No. 5W2 or 10W2. 2. Connect angle joint of N1 Teleflex cable to fuel controllever. Check N1 fuel control rigging and adjust as necessary (refer to Chapter 65). 3.

No. 1 engine only: If previously removed, install aft and center firewalls. Installleft engine cowling. No. 2 engine only: Close right access door.

61 - 28

61 - 29

N2 power turbine governor

Removal - N2 power turbine governor

1. Check that all electrical power is OFF. Revision 14

CHAPTER 61 Page 55

I

MAINTENANCE MANUAL 80 105

2. No. 1 engine only: Open left access door. No. 2 engine only: Remove right engine cowling and remove aft and center firewalls as necessary. 3.

Detach spring from governor lever, depending on configuration. Disconnect actuator governor lever, and remove governor lever (refer to Chapter 65).

4.

Proceed with removal in accordance with Allison OPERATION AND MAINTENANCE MANUAL No. 5W2 or 10W2.

61 - 30

Inspection - N2 power turbine governor

Refer to Allison OPERATION AND MAINTENANCE MANUAL No. 5W2 or No. 10W2.

Installation - N2 power turbine governor

61 - 31

1. Install the governor as described in the Allison OPERATION AND MAINTENANCE MANUAL No. 5W2 or NO.10W2. 2.

Install governor lever on governor (refer to Chapter 65). Connect actuator to governor lever. Attach spring if applicable. Check N2 governor rigging and adjust as necessary (refer to Chapter 65).

3.

No. 1 engine only: Close left access door. No. 2 engine only: If previously removed, install center and aft firewalls. Install right engine cowling.

61 - 32 61 - 33

Exhaust stacks Removal - exhaust stacks

Refer to paragraph 61-5, Dismantling - engine.

61 - 34

Inspection and repair - exhaust stacks

1. Inspect exhaust stack for cracks and deformation. If damaged, repair or replace exhaust stack. 2.

Inspect exhaust coupling c1amps for corrosion and cracks. a. Clean removed coupling clamps. b. Visually inspect retainer clamps (2, figure 61- 20A) for corrosion in the dot-dash marked area (see detail A) on all four latches. If corroded, replace coupling clamp. c.

Inspect retainer clamps (2, figure 61-20A) for cracks in accordance with dye-penetrant procedure ASTM- E-1417 in thedot-dash marked area (seedetail A) on allfour latches. If cracks are found, replace coupling clamp.

d. Visually inspect remainig areas of exhaust coupling c1amps for cracks. If cracks are found, replace coupling clamps. CHAPTER 61 Page 56

Revision 24

O~~pter

MAl NTENANCE MANUAL 80 105

DETAlL

A

SCHNITT

A- A

2

1 Coupling clamp 2 Retainer clamp

Figure 61 - 20A Inspection of exhaust coupling clamps for corrosion and cracks

Revision 24

CHAPTER 61 Page 56A

O~~~Pter

MAINTENANCE MANUAL 80 105

BLANK PAGE

CHAPTER 61 Page 568

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 61 - 35

Installation - exhaust stacks

Refer to paragraph 61-6, Build-up - engine. 61 - 36

En g i n e

a n t i - i c i n g val vea c t u a t o r

61 - 37

Removal - engine anti-icing valve actuator

l.

Check that all electrical power is OFF.

2.

Disconnect electrical connector from receptacle (8, figure 61-21) on actuator (9).

3.

Remove lockwire from screws securing actuator mounting bracket (4). Remove screw (2) and washer (3) to release bonding jumper .(1) .

4.

Remove cotter pin (10), pin (14) and washers (11).

5.

Remove cotter pin (6), pin (5) and washer (7); remove actuator (9).

6.

Remove the two remaining retaining screws from actuator mounting bracket (4) and remove the mounting bracket.

61 - 38

Inspection and repair - engine anti-icing valve actuator

l.

Visually inspect actuator for external mechanical damage and corrosion. Remove minor mechanical damage and corros ion and final polish with 400 grit abrasive cloth. Otherwise replace actuator.

2.

Inspect mounting bracket for cracks, corrosion and elongated holes in the lugs. a.

If cracked, replace mounting bracket.

b.

Polish out corrosion with 400 grit abrasive cloth.

c.

Mounting bracket without bushing: bush oversize holes (play exceeds 0.2 mm) as described in SB 60-53. Mounting bracket with bushing: replace bushing having oversize hole (playexceeds 0.2 mm) as follows. To prevent the mounting bracket from being bent during bushing instollation, fabricate a split spacer from hard PVC or similar material to dimensions shown in fig. 61-22, and fit it tightly between the mounting bracket lugs. Press deformed bushing from lugs discard.

BO 105 CHAPTER 61 Page 57

- - - - - - - - - - - - . , . - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

---2 ----3

12-13 Nm

15

I

I@ · J ~i'

14

9

13

11 10

900096

Bonding jumper Screw Washer 4 Mounting bracket 5 Pin

1 2 3

Figure 61-21

6 Cotter pin Washer Receptacle 9 Actuator 10 Cotter pin 7 8

Washer Valve actuating lever 13 Eye bolt 14 Pin 15 Jamnut 11

12

Engine anti-icing valve actuator

Inspect hole in lugs. If hole size exceeds that shown in fig. 61-23, replace mounting bracket. Degrease holes and mating bushing with acetone (CM 203) and coat with corros ion preventive paste (CM 510) . Press bushing into holes and then remove split spacer from between lugs.

BO 105 CHAPTER 61 Page 58

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

11

20 600086

Dirnensions in mm Figure 61-22

Split spacer

8 -0.015

L~~~.lliil~--""'" Spllt spacer

,

Degrease hole and apply corrosion preventiva paste (CM 510)

O_LU

9

600085

Dirnensions in mm Figure 61-23

Actuator rnounting bracket BO 105 CHAPTER 61 Page 59

MBB HEIiICOPTERS .- ---'-------=-------'----MAINTENANCE MANUAL MEB - BO 105

-----------~-

Install bushing with a coat 01 corroslon preventive paste (CM 510)

600084

Figure 61-24

Actuator mounting bracket with bushing

Installation - engine anti-icing valve actuator

61 - 39

l.

Install mounting bracket (4, figure 61-21) on anti-icing valve actuator pad. Do not tighten screws (2) yet.

2.

Connect actuator (9) to mounting bracket (4) with pin (5), washer (7) and cotter pin (6).

3.

Secure bonding jumper (1) to rnounting bracket (4) with screw (2) and washer (3). Lockwire all three screws to each other.

4.

Connect electrical connector to receptacle (8).

5.

Adjust eye bolt (13).

6.

a.

Extend actuator (9) and close engine anti-icing valve by hand with lever (12).

b.

Loosen jarnnut (15) and align hole in eyebolt (13) with hole in lever (12). Tighten jamnut (15).

Connect lever (12) to eyebolt (13) with pin (14), and secure pin with washer (11) and cotter pin (10).

BO 105 CHAPTER 61 Page 60

_eurocopter lIIl EADS

7.

MAINTENANCE MANUAL 80 105

Comp.",y

Functionally test engine anti-icing valve actuator The functional test, which is performed with the engines shut down, is identical for both actuators (no. 1 and no. 2 engines).

NOTE

a.

b.

Depress circuit breakers ENG. ANTI-ICING 1-11 and move toggle switches ENG. ANTI-ICING 1-11 to ON. -

actuator must retract and engine anti-icing valve must open

-

actuator must automatically switch off in end position and indicator light (9 HL) must come on.

Move toggle switches ENG. ANTI-ICING 1-11 to OFF. -

actuator must extend and engine anti-icing valve must close. The indicator light must remain on while valve is being closed.

-

In the end position the actuator must automatically switch itself off and the indicator Iight must go out.

61 - 40

61 - 41

Engine stubshaft

Removal - engine stubshaft

1. Remove driveshaft (refer to Chapter 11). 2.

Remove stubshaft (refer to paragraph 61-5, Dismantling - engine).

CHAPTER 61 Page 61

Oeurocopter

MAINTENANCE MANUAL 80 105

lIIlEAOS~

61-42

Inspection and repair - engine stubshaft

Inspect stubshaft for mechanical damage and corrosion, and repair in accordance with the following damage and repair Iimits.

1a

2

3

6

5

4

7

8

= --=- ---_._.- -======~.

=

Minimum f1ange thickness 3.6 mm

VIEwA

Figure 61-25

Engine stubshaft - repair areas and limits

Zone 1: Polish out mechanical damage and corrosion on entire surface to depth not exceeding 0.2 mm, using 600 grit abrasive c1oth. To prevent the f1ange from being bent when tightened against its counterflange, attention must be paid at repair that:

•

-

the partial areas 1a of the f1ange area are Iying in one and the same plane

-

no point of the remaining flange area protrudes over this plane.

-

the minimum f1ange thickness is not less than 3.6 mm.

Check compliance using a straight edge. Zone 2: Polish out mechanical damage and corrosion on entire circumference to depth not exceeding 0.2 mm, using 600 grit abrasive cloth. Zone 3: Polish out mechanical damage and corrosion with 600 grit abrasive cloth. Minimum allowable diameter is 34.85 mm. Corrosion is allowed at three places on the circumference. Each damage area must not exceed 40 mm2 with a minimum spacing of at least 25 mm.

CHAPTER 61 Page 62

Revision 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 ZONE 4: Refer to damage and repair limits for Zone 2. ZONE 5: Polish out individual lengthwisescratches and corros ion on flanks of splined teeth to depth not exceeding 0.2 mm, using 600 grit abrasive c10th. Removal of material by wear is permissible to a depth of 0.1 mm over the entire length of splines. No repair work is required. . Damage such as corrosion pits, nicks and scores at base of splines is not permitted. NOTE

Zones 6 to 8 are not present on short stubshafts.

ZONE 6: Refer to damage and repair limits for Zone 2. ZONE 7: Polish out mechanical damage and corros ion with 600 grit abrasive cloth. Minimum allowable diameter is 25.97 mm. Corrosion is allowed at three places on the circumference. Each damage area must not exceed 30 mm2 and must be at least 15 mm away from the others. ZONE 8: Damage is allowed so long as the mating nut can be installed by hand (only applicable when not installed according to SB 60-50). 61 - 43

Installation - engine stubshaft

Refer to paragraph 61-7, Installation - engine, for procedural steps.

BO 105 CHAPTER 61 Page 63

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 61 - 44

E n g i n e c o m par t m e n t ven t i 1 a t ion

61 - 45

Removal - engine compartment forced ventilation

NOTE

f o r c e d

The procedures for removing and installing the engine compartment forced ventilation are identical for both engines.

l.

Remove engine cowling (refer to Chapter 22) .

2.

Slacken clamp (5, figure 61-26) and remove hose (4) from hose adapter (6) •

3.

Remove screw (8) from bracket (2). Detach bracket and move it clear of helicopter, together with the attached hose (4).

4.

If required, remove hose adapter (6) from starter-generator (7).

5.

Slacken clamp (3). Separate hose (4) from air-intake port (1) and remove air-intake port (1) from bracket (2).

61 - 46 l.

Inspection and repair - engine compartment forced ventilation

Inspect bracket for cracks and plate nuts for looseness. a.

If cracked, repair or replace bracket.

b.

Replace loose plate nuts.

2.

Inspect hose adapter for damage. If cracked, replace hose adapter.

3.

Inspect hose for cuts and porosity. If either condition is evident, replace hose.

61 - 47

Installation - engine compartment forced ventilation

l.

Install air-intake port (1, figure 61-26) to bracket (2). Connect hose (4) to air-intake port (1) with clamp (3).

2.

If previously removed, install hose adapter (6) on starter-generator (7).

3.

Secure bracket (2) to engine deck.

4.

Connect hose (4) to hose adapter (6) with clamp (3).

5.

Install engine cowling (refer to Chapter 22) .

BO 105 CHAPTER 61 Page 64

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A

4

3

8

7

1 2 3

4 5

6 7 8

Air-intake port Bracket Clamp Hose Clamp Hose adapter Starter-generator Screw Figure 61-26

6

1

5

DETAlL

B

Engine compartment forced ventilation BO 105 CHAPTER 61 Page 65/66

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

62

F UE L S YS T EM

Table of Contents

Paragraph

Title

62 - 1

DESCRIPTION - FUEL SYSTEM

3

62 - 2

TROUBLESHOOTING - FUEL SYSTEM

7

62 - 3

INSPECTION - FUEL SYSTEM

9

62 - 4

F o r w a r d m a i n f u e 1 tan k

10

62 - 5

Removal - forward main fuel tank

10

62 - 6

Inspection - forward main fuel tank

11

62 - 7

Installation - forward main fuel tank

11

62 - 8

Af t

17

62 - 9

Removal - aft main fuel tank

17

62 - 10

Inspection - aft main fuel tank

17

62 -11

Installation - aft main fuel tank

18

62 - 12

s u p.p 1 Y tan k

21

62 - 13

Removal - supply tank

21

62 - 14

Inspection - supply tank

22

62 - 15

Installation - supply tank

22

62 - 16

D r a i n val v e

62 - 17

Removal - drain valve

27

62 - 18

Installation - drain valve

27

62 - 19

F u e 1 p u mp

28

62 - 20

Removal - fuel pump

28

Page

m a i n f u e 1 tan k

. ..

27

BO 105 CHAPTER 62 Page 1

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 Paragraph

Title

62 - 21

Installation - fuel pump

29

62

Lo w 1 e v e 1 wa r n i n g s wi t c h

31

62 - 23

Rerooval - low level warning switch

31

62 - 24

Installation - low level warning switch

31

62 - 25

F u e 1 q u a n t i t Y t r a n s ro i t t e r

32

62 - 26

Rerooval - fuel quantity transroitter

32

62 - 27

Installation - fuel quantity transroitter

32

62 - 28

F u e 1 s h u t off

33

62 - 29

Rerooval - fuel shutoff valve

33

62 - 30

Installation - fuel shutoff valve

34

22

*

* 62 - 31 *

* 62 - 32 * * 62 - 33 *

Page

val v e

Del e t e d Del e t e d Del e t e d

62 - 34

Pressure relief valve

39

62 - 35

Rerooval - pressure relief valve

39

62 - 36

Installation - pressure relief valve

39

62

D i f f e r e n tia 1 p r e s s u r e

37

s wi t c h

41

62 - 38

Rerooval - differential pressure switch

41

62 - 39

Installation - differential pressure switch

43

62

P r e s s u r e

43

40

t r a n s ro i t t e r

62 - 41

Rerooval - pressure transroitter

43

62 - 42

Installation - pressure transroitter

44

62 - 43

P r e s s u r e

62 - 44

F u n c t ion a 1 t e s t - f u e 1 s y s t e ro

48

62 - 45

Han d 1 i n g a n d tan k s

49

BO 105 CHAPTER 62 Page 2

t e s t - f u e 1

s y s t e ro

s t o r a g e

o

f

f

46

u e 1

Revision 2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB ~ BO 105 62 - 1 1.

DESCRIPTION - FUEL SYSTEM

Fuel system: The fuel system comprises the fuel storage, the fuel delivery and the fuel monitoring systems (see figures 62-1 and 62-2). Engine - furnished components of the fuel system, such as fuel pumps, fuel filters, and fuel controls are described in the Allison Operation and Maintenance Manual, No. 10 W2 (250-C18, No. 5W2).

2.

Fuel storage system: The fuel storage system comprises the forward and aft main fuel tanks, the supply tank and the vent and fuel lines. The supply tank and the forward main fuel tank each have two electrically operated fuel pumps and one fuel quantity transmitter installed in them. In addition, a low level warning switch is installed in the supply tank. Each of the three fuel tanks has a drain valve. The system is fuelled through the filler neck on the forward main fuel tank. The tanks, which are arranged one behind the other, have a total fuel content of 580 liters (464 kg), of which 10 liters (8 kg) are unusable.

3.

Fuel delivery system: Two electrically operated fuel pumps supply the engine with fuel from the fuel supply tank. Two electrically operated fuel pumps in the forward main fuel tank ensure that the supply tank is constantly replenished from the two main fuel tanks. Each of the fuel supply lines incorporates an electrically operated fuel shutoff valve, so that the fuel supply to the engines can be interrupted in an emergency.

4.

Fuel monitoring system: A fuel quantity transmitter in the forward main tank and supply tank transmits an electrical signal to a dual fuel quantity indicator which shows the amount of fuel contained in the respective tanks. Also installed in the main tank is a low level warning switch which energizes the REST warning light when the fuel content in thetank is less than 75 liters (60 kg). A dual fuel pressure indicator, located on the instrument panel, monitors fuel pressure from the supply tank pumps. It is provided with electrical signals from a pressure transmitter in the line to each engine. A differential pressure switch connected to each fuel- filter energizes the respective filter warning light FILT 1 or 11, whenever filter clogging occurs.

BO 105 CHAPTER 62 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

14

600096.1

1 2 3 4 5 6 7

Supply tank Overflow Vent line Forward main fuel tank Aft main fuel tank Fuel shutoff valve Drip pan

Figure 62-1 BO 105 CHAPTER 62 Page 4

8 9 10 11 12 13 14 15

Drain valve Filler neck Connection pipe Fuel pump Fuel quantity transmitter Inspection cover Fuel line Low level warning switch

Fuel system

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

r-----------r---------.-------,

1

r

i ---- U·

L._---

TI

FUELLOW

!

r-f

FILTl

-.1.~· __I

·

i

I@ @ --+-----J r I

!

...--1------4-'

Fuel quantity transmitter

1 ......J

1

.

!

Fuel filter with bypass

1-

FILT2

L

~--.------_ ~ __

._.-.,;

Differential pressure switch Low level warning switch Fuel shutoff valve

~

(&)

Fuel filter

11

I I I

I

Drain valve

---------1

~

Ir-k ~ I

i'¡;;

~'" ... II,rul'2

I

L

l - - - - - - r - . J - - - -..., 1

I

i

&

Conflguration

I

Fuel pump (electrically operated) Fuelpump (engine-driven)

&

Conflguratlon

LEFT ENGINE

RIGHT ENGINE

II I

1 '1

I

I

I

I

aHUTO" VALVfS

I

1 1

I

I

L

~

I

1

'UEL

2

.HUTO" YALYeS

_

JI

Fuel pressure transmitter Pressure relief valve

••••

& & &

Fuel line S/N

7-160

....----..........- -...

S/N 161 and subsq. and D series S/N 7-160

FORWARD

MAINTAÑ~

~

S/N 161 and subsq. , incl. D series

~

S/N 7-250

_

):iM ............

r;¡=}w. .. 1:...

....----------,-.......-

- -

.-------.-....1- - - -

r-··--.---

¡ ... I

MAIN T. SUPPLY T.

L_~~U~~_ ~----~~~I---------~

SUPPLY TANK

600118

Figure 62-2

Fuel systern schernatic BO 105 CHAPTER 62

Revision 2

Page 5/6

iOp:=--~l:i't:(tM~o

- 1

l@M!):l:1@ -~ptl

..,..-

Conflguration

I

&

Configuratlon

11

~

Revision 19

CHAPTER 62 Page7

MAINTENANCE MANUAL 80 105

EUROCOPTER

NO.

7.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Fuel on drain valves or on fairings of fuel pumps or access cover

Damage to drain valve or pump flanges or gaskets

Check attaching hardware for specified torque (see fig. 62-5, fig. 62-6 or Chapter 867), otherwise remove fuel pump (refer para. 62-19 or Chapter 867) and inspect access cover or gasket for damage andlor remove drain valve (refer to para. 62-16) and inspect gasket for damage. Replace any defetive parts.

Table 62-1 Troubleshooting (2 of 2)

CHAPTER 62 Page8

Revision 19

- - - - - - - - - - - - ' - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSPECTION - FUEL SYSTEM

62 - 3 1.

Inspect cable connections and plugs for security of installation; cables for chafing. Secure any loose cable connections and p1ugs, and replace any damaged cables.

2.

Check fuel lines and vent lines for loose connections, leakage and evidence of damage. a.

Secure any loose lines; replace any damaged lines.

b.

If fuel line connections are leaking, tighten the respective union nuts 1/6 of a turno If leakage continues, replace sealing elements or connections.

c.

If f1anges show evidence of leakage, torque screws of the respective flanges to 2.5 to 3 Nm.

3.

9heck drain holes of bottom shell for leaking fuel. If leakage is evident, perform system pressure test in accordance with paragraph 62-43. If leaks cannot be repaired, remove fuel tanks (refer to paragraphs 62-4 thru 62-15).

4.

Check vent line drain holes in the side shell for obstruction and clear as necessary.

5.

Check drain valves for leaking fuel. If leakage is evident, check attaching hardware for specified torque, otherwise replace leaking drain valves (refer to paragraph 62-16).

6.

Switch on fuel pumps. Check engine-mounted fuel filters for security of installation, leakage, and mechanical damage (for further action refer to Allison Operation and Maintenance Manual No. 10W2; for 2S0-C18, refer to No. SW2).

7.

a.

If filter is leaking fuel, tighten housing by hand; replace O-ring if necessary (refer to Allison Operation and Maintenance Manual) .

b.

If damaged, remove fuel filter and evaluate damage (refer to Allison Operation and Maintenance Manual) .

*

Visually inspect differential pressure switch and pressure transmitter * for leakage. If leakage is present, tighten connections. If leakage contin- * ues, replace respective seals (O-rings or sealing rings, as applicable) . Swi~ch off fuel pumps.

Revision 2

BO 105 CHAPTER 62 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 62 - 4

F o r w a r d m a i n f u e 1 tan k TO AVOID FIRE AND EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS.

WARNING

62 - 5

Removal - forward main fuel tank

WARNING

DO NOT BEGIN WITH FUEL TANK REMOVAL PROCEDURE UNTIL FUEL TANK HAS BEEN SCAVENGED (REFER TO STEP 3.).

1.

Defuel helicopter according to Chapter 06.

2.

Disconnect battery and external power source (refer to Chapter 92).

3.

Scavenge fuel tanks with air or nitrogen as follows: a.

Open all drain valves. For this purpose pushvalve stem upward and turno

b.

Open fuel filler cap. Insert hose line for the scavenger and seal off with adhesive tape (CM 614) .

c.

Scavenge tanks with filtered, compressed air for approximately 2 hours at a pressure of 2 to 4 bar or with nitrogen for approx-

imately 2 hours at a feed rate of 0.5 kg per minute. d.

After scavenging, remove hose line and wait approximately 1 hour before beginning with removal procedure.

4.

Remove rear bench seat, LH side wall and floor panelling.

5.

Remove cover plate (40) by removing screws (39, figure 62-3). Remove reinforcing ring (38), inspection cover (37) and gasket (36) by removing nuts (41) and washers (42).

6.

Remove screw (8) and washer (7).

7.

Remove tank access cover (9) and fuel quantity transmitter (16) as follows: a.

Remove cover plate (11) by removing screws (12).

b.

Disconnect electrical leads from fuel quantity transmitter (16).

c.

Remove nuts and washers (17), and detach cover (9) together with reinforcing ring (10) and fuel quantity transmitter (16) from the fuel tank bolt ringo

BO 105 CHAPTER 62 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. Remove fuel pumps (22 and 48) (refer to paragraph 62-19). 9. Remove drain valve (32) (refer to paragraph 62-17). 10. Remove rubber boot (25) and hose clip (24) from connector on aft main fuel tank. 11. Remove rubber boots (2 and 43) and hose clips (1 and 44) from the two overflows of forward main fuel tank. 12. Remove screw (3) and washer (4). Pull fuel lines (45 and 50) out of overflows (49) and remove from forward main fuel tank. 13. Release hose clips (28) on filler neck and pull filler neck and protective sleeve off the filler neck pipe. 14. Remove screws (51 and 21), washers (52 and 20), and washers (54 and 19) securing tank pad rings to floor panel. 15. Release colletted studs of forward main fuel tank from mating holes in tank compartment lining and carefully withdraw tank through tank access cover aperture. 62 - 6

Inspection - forward main fuel tank

Inspect fuel tank in accordance with manufacturer's instructions. 62 - 7

Installation - forward main fuel tan k

1. Ensure that all sharp edges, corners, anchor nuts, rivet heads, and tank

support studs are masked with adhesive tape (CM 614). Inspect support studs and mating holes for wear. 2. Inspect foam pads in tank compartment for separation. 3. Check vent lines in floor panel for obstructions.

4. Rub talcum (CM 108) onto forward main fuel tank. 5. Make sure there are no foreign objects in the tank compartment. 6. Through tank access cover aperture, carefully insert forward main tank into tank compartment. 7. Push forward main fuel tank filler neck and protective sleeve to a

distance of at least 20 mm onto filler neck pipe and secure with hose clips (28, figure 62-3). 8. Fit forward main fuel tank onto connection pipe (10, figure 62-1).

BO 105 CHAPTER 62 Page 11

HELICOPTERS - - - - - - - - - - - - .MAINTENANCE MANUAL MBB - BO 105

-----------~-MBB

NOTE

Tighten all hose clips in fuel tank using a screwdriver with edge protection only.

9. Clamp forward main fuel tank tightly to connection pipe with hose clip (24, figure 62-3), and cover hose clip with rubber boot (25). 10. Engage colletted studs of forward main fuel tank with mating holes in aft and forward partitions of tank compartment and in bottom shell. Position fuel line (50) for installation. 11. Connect both main fuel tank overflow connections to overflows (49). 12. Secure pad rings in tank skin to floor panel with screws (51 and 21), gaskets (54 and 19), and washers (52 and 20). Use one of the screws (51) to install fuel line (50) angle bracket. For torque value, see figure 62-3. 13. Fasten remaining forward main fuel tank support studs to the floor panel. 14. Secure overflows (49) with hose clips (1 and 44), and fit rubber boots (2 and 43) over hose clips. 15. Insert fuel lines (45 and 50) into the two overflows (49) and install fuel pump (22) (refer to paragraph 62-21). Secure fuel line (50) to angle bracket with clamp (53), screw (3) and washer (4). 16. Install tank access cover (9) together with fuel quantity transmitter (16) : a.

Brush-coat lower surface of tank access cover (9) with sealing compound (CM 644) .

b.

Install tank access cover (9) and reinforcement ring (10) on bolt ring and secure with nuts and washers (17). Torque as shown in figure 62-3.

c.

Connect electrical leads to fuel quantity transmitter (16) and brush-coat connecting screw with corrosion-preventive lacquer (CM 501) .

d.

Attach fuel line (50, figure 62-3) to tank access cover (9) with clamp (6), screw (8) and washer (7).

17. Install fuel pump (48) (refer to paragraph 62-21).

18. Install drain valve (32) (refer to paragraph 62-18). 19. Install inspection cover (37), gasket (36) and ring (38) with nuts (41) and washers (42). Torque according to figure 62-3.

BO 105 CHAPTER 62 Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 20. Perform pressure and functional tests (refer to paragraphs 62-43 and 62-44 respectively). CAUTION

THE COVER PLATE (11) MUST NOT BE INTERCHANGED, THIS COULO SHORT-CIRCUIT THE FUEL QUANTITY TRANSMITTER.

AS

21. Install all cover plates, LH side wall and floor panelling, and rear bench seat.

BO 105 CHAPTER 62 Page 13/14

_ _ _ _ _ _-------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 1 Hose clip DETAlL A 11---..''2 Rubber boot 3 Screw 4 Washer 5 Vent line 6 Clamp 7 Washer 8 Screw 9 Tank access cover 10 Ring 11 Cover plate 12 Screw 13 Screw 14 Washer 15 Gasket 16 Fuel quantity transmitter 17 Nut/washer 18 Vent line 19 Gasket 20 Washer 21 Screw 22 Fuel pump 23 Fuel line connection 24 Hose clip 25 Rubber boot 26 Forward main fuel tank 27 Cover/fuel filler socket 28 Hose clips 29 Fuel tan k bolt ring 49 30 Bottom shell 31 Gasket 32 Drain valve 33 Washer 34 Nut 35 Fuel tan k bolt ring 48----:36 Gasket 37 Inspection cover --:?'""----f-- 35 38 Ring 39 Screw 40 Cover plate 41 Nut 42 Washer DETAlL F 43 Rubber boot 44 Hose clip 45 Fuel line 600174 46 Nut 47 Washer -~48 Fuel pump 49 Overflow '2 5 O Fuel line 51 Screw 52 Washer 39 53 Clamp DETAlL E 54 Gasket

~'---~!

==t:=i 25-JN+:~A

Figure 62-3

Forward main fuel tank - removal and installation

BO 105 CHAPTER 62 Page 15/16

: 1 =1'.1

-------...~---18

.......- - - - - 1 9

CIo)-------20 r - - - - - - - 2 1 -l2.5-3 Nm

I

....,....-----22 ~-..._._----23

DETAlL

.~

B

2'

DETAlL

@1 :: ;§'!-:.

,----32

~

33

@

18------ 34 _: DETAlL

O

2.5-3 Nm I

e

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO lOS

----------~--MBB

62 - 8 WARNING

62 - 9 WARNING

Af t

ma i n

f u e 1 tan k

TO AVOID FIRE AND EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS. Removal - aft rnain fuel tank DO NOT BEGIN WITH FUEL TANK REMOVAL PROCEDURE UNTIL FUEL TANK HAS BEEN SCAVENGED (REFER TO STEP 3.).

l.

Defuel helicopter according Chapter 06.

2.

Disconnect the battery and external power source (refer to Chapter' 92) .

3.

Scavenge fuel tanks with air or nitrogen as fo1lows: a.

Open all drain valves. For this purpose push valve stem upward and turno

b.

Open fuel filler cap. Insert hose line for the scavenger and seal off with adhesive tape (CM 614).

c.

Scavenge tanks with filtered, compressed air for approximately 2 hours at a pressure of 2 to 4 bar or with nitrogen for' approximately 2 hours at a feed rate of 0.5 kg per minute.

d.

After scavenging, remove hose line and wait approximately 1 hour before beginning with removal procedure.

4.

Open floor access cover of small baggage compartment and remove tank cover (9, figure 62-4) by removing nuts (6), washers (7) and ring (8). Remove gasket (10).

5.

Remove drain valve (15) (refer to paragraph 62-17).

6.

Rernove rubber boot (18). Loosen and remove hose clip (19). Detach aft rnain fuel tank (20) frorn connection pipe (21).

7.

Rernove screws (5), washers (4) and gasket (3) frorn tank pad ring (2).

8.

Disengage aft rnain fuel tank support studs and carefully withdraw tank through the cover (9) aperture.

62 - 10

Inspection - aft rnain fuel tank

Inspect fuel tank in accordance with manufacturer's handbook.

BO 105 CHAPTER 62 Page 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 62 - 11

Installation - aft main fuel'tank

l. Ensure that all sharp edges, corners, anchor nuts, rivet heads, and tank support studs are masked with adhesive tape (CM 614). Inspect support studs and mating holes for wear. 2. Inspect foam pads in tank compartment for separation. 3. Check vent lines in floor panel for obstructions. 4. Rub talcum (CM 108) onto aft main fuel tank.

5. Make sure there are no foreign objects in the tank compartment. 6. Through tank access cover (9, figure 62-4) aperture, carefully insert aft

main fuel tank into tank compartment. 7. Fit aft main fuel tank onto connection pipe (21). Connect tank pad ring to floor panel (23) with screws (5), washers (4) and gasket (3). Torque according to figure 62-4.

8. Engage all tank support studs with mating holes in tank compartment lining.

NOTE

Tighten hose clip (19) in tank compartment using a screwdriver with edge protection only.

9. Clamp aft main tank tightly to connection pipe with hose clip (19) and

cover hose clip with rubber boot (18). 10. Install drain valve (15) (refer to paragraph 62-18). 11. Secure cover (9) to tank bolt ring (11) with washers (7) and nuts (6); see figure 62-4 for torque value. 12. Pressure test fuel system and functionally test drain valve (15) (refer to paragraphs 62-43 and 62-44 respectively) .

13. Close floor access cover of small baggage compartment.

BO 105 CHAPTER 62 Page 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 DETAlL

A DETAlL

B ---- 6

23 --'7"--r--

12.5-3 Nm I

------7 ~----8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

+;~---9

1-----3

,~-----10

.------4

Vent line . 2 Tank pad ring 3 Gasket 4Washer 5 Screw 6 Nut 7 Washer 1

8

--+----2

--5

JJ-+lf----\--------11

1205-'3 Nm I

lUng

Cover Gasket Bolt ring Bolt ring Bottorn shell Gasket Drain valve Washer Nut Rubber boot Hose clip Aft main fuel tank Connection pipe Frarne Floor panel

DETAlL

600175

DETAlL

Figure 62-4

Aft rnain fuel tank - removal and installation BO 105 62 Page 19/20

CHAPTER

o

e

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 62 - 12 WARNING 62 - 13 WARNING

S u P P 1 Y tan k TO AVOID FIRE AND EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS. Removal- supply tank DO NOT BEGIN WITH FUEL TANK REMOVAL PROCEDURE UNTIL FUEL TANK HAS BEEN SCAVENGED (REFER TO STEP 3.).

l. Defuel helicopter according to Chapter 06. 2. Disconnect the battery and external power source (referto Chapter 92). 3. Scavenge fuel tanks with air or nitrogen as follows: a.

Open all drain valves. For this purpose push valve stem upward and turno

b.

Open fuel filler cap. Insert hose line for the scavenger and seal off with adhesive tape (CM 614) .

c.

Scavenge tanks with filtered, compressed air for approximately 2 hours at a pressure of 2 to 4 bar or with nitrogen for approximately 2 hours at a feed rate of 0.5 kg per minute.

d.

After scavenging, remove hose line and wait approximately 1 hour before beginning with removal procedure.

4. Remove rear bench seat and forward RH lateral floor panelling; detach

forward LH lateral floor panelling to approximately as far as the centre (vent line connection) and attach to pilot's seat with safety wire. Detach cable guide rail under forward RH lateral floor panelling and push to one side. 5. Remove cover plates (1 and 25, figure 62-5) by removing screws (2 and 24) • 6. Remove tank access cover (36) with installed quantity transmitter (6) and low level warning switch (37) as follows: a.

Identify and disconnect electrical leads of fuel quantity transmitter (6) and low level warning switch (37).

b.

Remove nuts (7) and washers (8), and detach access cover (36) together with ring (38) and fuel quantity transmitter (6) from tank boH ring.

BO 105 CHAPTER 62 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 7. Remove left and right fuel pumps (26 and 33) (refer to paragraph 62-20).

8. Remove fuel lines (23 and 24) and disconnect vent line (10) from supply tank by removing screws (15), washers (16) and gasket (17). 9. Remove drain valve (29) (refer to paragraph 62-17). 10. Remove nuts (43) and washers (44), and detach cover (42) with gasket (41). 11. Remove rubber boot (11) and hose clip (12) from the two overflows (2, figure 62-1) and (13, figure 62-5). 12. Detach rubber sleeve (18) bonded to the airframe, and remove fuel line (21) by removing banjo bolt (19) and gasket (20) from fuel line fitting (22). Repeat this procedure to remove corresponding fuel line from fuel line fitting (35). 13. Disengage supply tank studs from mating holes in tank compartment, then detach tank from the overflows and carefully withdraw it upward through the tank access cover (36) aperture. 14. If required (e. g. when supply tank is replaced), remove nuts (45) and washers (46) and detach fuel line fittings (22 and 35) . 62 - 14

Inspection - supply tank

Inspect supply tank in accordance with instructions given in manufacturer's handbook. 62 - 15

Installation - supply tank

l.

Ensure that all sharp edges, corners, anchor nuts, rivet heads, and tank support studs are masked with adhesive tape (CM 614). Inspect support studs and mating holes for wear.

2.

Inspect foam pads in tank compartment for separation.

3.

Check vent line in floor panel for obstructions.

4.

If previously removed, install fuel line fittings (22 and 35, figure 62-5) with washers (46) and nuts (45).

5.

Rub talcum (CM 108) onto supply tank.

6.

Make certain that no foreign objects are in the tank compartment.

7.

From above, carefully insert supply tank through cover (36) aperture into tank compartment.

8.

Fit supply tank onto overflows (2, figure. 62-1), and connect tank pad ring to floor panel with screws (15, figure 62-5), washer (16) and gasket (17). Torque load as shown in figure 62-5.

BO 105 CHAPTER 62 Page 22

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 9. Engage all tank support studs with mating holes in tank compartment lining. NOTE

Tighten hose clips in supply tank using a screw driver with edge protection only.

10. Secure supply tank to the two overflows (2, figure 62-1) with hose clips (12), and cover hose clips with rubber boots (11, figure 62-S). 11. Make certain that rubber sleeve (18) with hose clip is installed on fuel line (21). Connect fuel line (21) to fuel line fitting (22) using banjo bolt (19), interposing a new gasket (20) between banjo bolt head and fuel line and between fuel line and fuel line fitting (22). See figure 62-S. Install lockwire. Perform same procedure on corresponding fuel line fitting (3S). 12. Loosely fit fuel lines (23 and 34) to both fuel line fittings (22 and 3S). Install fuel pumps (26 and 33) according to paragraph 62-21, then tighten up fuel lines against fuel line fittings (22 and 3S) . 13. Install cover (42) and gasket (41) with washers (44) and nuts (43). 14. Install drain valve (29) (refer to paragraph 62-18). lS. Install tank access cover (36) together with fuel quantity transmitter (6) and low level warning switch (37) as follows:

a.

Coat bottom of cover (36) with sealing compound (CM 644) .

b.

Install cover (36) and reinforcement ring (38) on tank bolt ring and secure with nuts (7) and washers (8). Torque as shown in figure 62-S.

c.

Connect electrical leads to fuel quantity transmitter (6) and low level warning switch (37). Brush-coat connecting screw with corrosion-preventive lacquer (CM SOl) .

16. Perform pressure and functional tests (refer to paragraphs 62-43 and 62-44 respectively). 17. Bond left and right rubber sleeves (18) to wall of airframe with cement (CM 6S3) or contact adhesive (CM 60S) and tighten hose clip. 18. Install cable guide rail, LH and RH lateral floor panelling, and bench seat. Install all cover plates.

BO lOS CHAPTER 62 Page 23/24

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1

2 3 4 5 6

7 8

9

10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25 26 27 28 29 30

31 32

33

34 35 36 37 38 39

40 41 42 43 44 45

46

Cover plate Screw Screw Washer Gasket Fuel quantity transmitter Nut Washer Gasket Vent line aubber boot Hose clip Overflow Colletted studs Screw Washer Gasket Rubber sleeve Banjo bolt Gasket FueI line Fuel line fitting FueI line Screw Cover pI ate Fuel pump Nut Washer Drain vaIve Gasket Bottom shell Bolt ring in supply tank Fuel purnp FueI line Fuel line fitting Tank access cover Low level warning switch Ring Washer Screw Gasket Cover Nut Washer Nut Washer

11 DETAlL

35 --i---,!--+-f.,

I 2.5-3 Nm r-:~

34_~--....:::lL-

~"

~---"---_

14

33 --~----~:---.....::lió:::""""-4-

32 31 ----1

.. ~~~

30

2.

A ..

18

.....-28

~ 600176

DETAlL

27

~ 2.5-3 Nm I

B 25

24--! Figure 62-5

A

Supply tank - rernoval and installation BO 105 CHAPTER 62 Page 25/26

EUROCOPTER

62 - 16

MAINTENANCE MANUAL 80105

O r a i n val v e

NOTE

The drain valve removal and installation procedures are the same for all three fuel tanks.

WARNING

TO AVOID FIRE ANO EXPLOSION HAZAROS OBSERVE ALL SAFETY PRECAUTIONS.

62 - 17 WARNING

Removal - drain valve DO NOT BEGIN WITH ORAIN VALVE REMOVAL PROCEOURE UNTIL THE AFFECTEO FUEL TANK HAS BEEN SCAVENGEO (REFER TO STEP 3.).

l.

Oefuel helicopter according to Chapter 06.

2.

Oisconnect battery and external power source (refer to Chapter 92).

3.

Scavenge fuel tanks with air or nitrogen as follows:

4.

a.

Open all drain valves. For this purpose push valve stem upward and turno

b.

Open fuel filler cap. Insert hose line for the scavenger and seal off with adhesive tape (CM 614) .

c.

Scavenge tanks with filtered, compressed air for approximately 2 hours at a pressure of 2 to 4 bar or with nitrogen for approximately 2 hours at a feed rate of 0.5 kg per minute.

d.

After scavenging, remove hose line and wait approximately 1 hour before beginning with removal procedure.

Remove nuts (27, fig. 62-5) and washers (28), then remove drain valve (29) together with gasket (30) from tank bolt ring (32) and bottom shell (31) .

62 - 18

Installation - drain valve

1.

Check gasket (30, figure 62-5) for condition and replace if damaged.

2.

Coat all sealing and contact surfaces with grease (CM 101).

3.

Coat both sides of gasket (30) with grease (CM 101) and fit over drain valve (29). Carefully insert drain valve through bolt ring (32) of supply tank, taking care not todeflect ring bolts inwards. Secure drain valve against bottom shell (31) with nuts (27) and washers (28). Torque nuts according to figure 62-5. BO 105 CHAPTER 62 Page 27

EUROCOPTER

MAINTENANCE MANUAL BO 105

4.

Refuel helicopter according to Chapter 06.

5.

Check drain valve (29) for leakage and function (refer to paragraph 62-44) .

6.

Connect battery and external power source (refer to Chapter 92).

62 - 19

F u e 1 p u rn p

NOTE

The following removal and installation procedures apply to all four fuel pumps.

WARNING

TO AVOID FlRE ANO EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS.

62 7 20

Removal - fuel pump

WARNING

DO NOT BEGIN WITH FUEL PUMP REMOVAL PROCEDURE UNTIL THE AFFECTED FUEL TANK HAS BEEN SCAVENGED (REFER TO STEP 3.).

1.

Defuel helicopter according to Chapter 06.

2.

Disconnect battery and external power source (refer to Chapter 92).

3.

Scavenge fuel tanks with air or nitrogen as follows: a.

Open all drain valves. For this purpose push valve stem upward and turno

b.

Open fuel filler cap. Insert hose line for the scavenger and seal off with adhesive tape (CM 614).

c.

Scavenge tanks with filtered, cornpressed air forapproximately 2 hours at a pressure of 2 to 4 bar or with nitrogen for approxirnately 2 hours at a feed rate of 0.5 kg per minute.

d.

After scavenging remove hose line and wait approxirnately 1 hour before beginning with rernoval procedure.

4.

Rernove cover plate (12, figure 62-6) by rernoving screws (11).

5.

Disconnect electrical connector (19) and detach bonding jurnper (16) by rernoving screw (10) and washer (9).

BO 105 CHAPTER 62 Page 28

Revision 16

EUROCOPTER

MAINTENANCE MANUAL 80 105

6. Detach fuelline (1) with connecting piece (2) by removing screw (13), washer (14), Q-rings (15 and 18) and spacer (17). Discard O-rings (15 and 18). If connecting piece (2) is stuck, screw in a suitably long M6 screw and press it out upwards. 7.

Remove nut (8) and washers (7) and carefully remove fuel pump (6) and gasket (5) from bolt ring (3).

NOTE

Revision 19

If the fuel pump is to be sent for repair, be sure to ¡nelude the connecting piece. In-I stead of removing the connecting piece lacated in the tank, you are recommended to send the connecting piece of the replacement fuel pump to the repair facility.

CHAPTER 62 Paga 28A

MAINTENANCE MANUAL BO 105

EUROCOPTER

BLANK PAGE

CHAPTER 62 Page28B

Revision 19

EUROCOPTER

62 - 21

MAINTENANCE MANUAL 80 105

Installatlon - fuel pump

1. If the connecting piece is left in the fuel tank, remove connecting piece from the pump to be installed. If connecting piece (2, fig. 62-6) is removed, install connecting piece of the new pump to fuel pipe (1). 2. Inspect gasket (5) for condition and replace if damaged. 3. Coat gasket (5) with grease (CM 101) and position on flange of fuel pump (6). 4. To facilitate installation of the fuel pump, screw an approx. 200mm long, headless M6 threaded bolt into the connecting piece (2). 5. Insert fuel pump (6) and gasket (5) into fuel tank so that the headless threaded bolt in the connecting piece passes through the connecting piece mating hole in the pump. Then attach pump loosely to tank bolt ring with three nuts (8) and washers (7). 6. Pull connecting piece (2) down into its mating hole in the pump using the threaded bolt. Then remove threaded bolt and install in its place screw (13) together with washer (14), G-rings (15 and 16) and spacer (17). See figure 62-6 for torque value. 7. Install remaining nuts (8) and washers (7) against the fuel pump. Torque all nuts according to figure 62-6. 8. Connect electrical connector (19) and attach bonding jumper (16) to fuel pump with screw (10) and washer (9). Coat screw (10) with safety lacquer (CM 501 ). 9. Refuel fuel system according to Chapter 06 and functionally test fuel pump, (refer to Chapter 92, para. 92-79). 10. leak test the fuel pump. 11. Attach cover plate (12) to bottom shell with screws (11).

Revision 19

CHAPTER 62 Page29

I

MAINTENANCE MANUAL

EUROCOPTER

---3

4

1---6

19

18----..17 - - - - - - -

16 - - - -.....~~ __~....

~-----9

1-------10

15

8-

-,,-......=::::::;:;!::;--c::¡----

14

-----,,(IC....----KPJJ~

13

--':---~'-

12-----

C::::l~-11

600105.2

1 Fuel line Connecting piece Bolt ring (fuel tank) 4 Bottom shell 5 Gasket 6 Fuel pump 7 Washer 8 Nut 9 Washer 10 Screw 2 3

Figure 62-6 BO 105 CHAPTER 62 Page 30

11 Screw 12 Cover pIate 13 Screw 14 Washer 15 O-ring 16 Bonding jumper 17 Spacer 18 O-ring 19 Electrical connection (i.e., electrical connectors or spIice connectors. Refer to WDM and SB 90-21)

Fuel pump - removal and instalIation

ea 105

EUROCOPTER

62 - 22 WARNING

62 - 23 1.

MAINTENANCE MANUAL 80105

L o w 1 e v e 1 wa r n i n g s wi t c h TO AVOIO FlRE ANO EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS. Removal - low level warning switch

If indicated fuel contents exceed the quantities given below, drain off excessive fuel. Main fuel tank: . 300 kg Supply tank: 30 kg

2.

Disconnect the battery and external power source (refer to Chapter 92).

3.

Remove cover plate (1, figure 62-5) by removing screws (2).

4.

Disconnect electrical leads.

5.

Remove low level warning switch (37) and gasket (9) from cover (36) by removing screws (40) and washers (39).

6.

Blank off opening in fuel tank.

62 - 24

Installation - low level warning switch

1.. Check gasket (9, figure 62-5) for condition and replace if damaged. 2.

Lightly coat gasket (9) with grease (CM 101) and install in cover (36) together with low level warning switch. Withthe exception of one screw for attaching the bonding jumper, coat all other screws (40) with sealing compound (CM 644) and install these screws to secure low level warning switch (37) to cover. See figure 62-5 for torque value.

3.

Connect electrical leads. Attach bonding jumper with remaining screw (40), then brush-coat screw head with corrosion-preventive lacquer (CM 501) .

4.

Connect battery and external power source (refer to Chapter 92).

5.

Refuel helicopter (refer to Chapter 06). While refuelling, check low-level warning switch for correct functioning (refer to paragraph 62-44, step 4).

6.

Install cover plate (1) with screws (2).

BO 105 CHAPTER 62 Page 31

EUROCOPTER

62 - 25

Fu e 1 q u a

WARNING 62 - 26 1.

MAINTENANCE MANUAL 80105

t i t Y t r a n s m i t ter

TO AVOIO FIRE ANO EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS. Removal - fuel quantity transmitter

If indicated fuel contents exceed the quantities given below, drain off excessive fuel. Main fuel tank: Supply tank:

2.

ti

300 kg 30 kg

Oisconnect battery and external power source (refer to Chapter 92). NOTE

The following procedures for removing and installing the fuel quantity transmitter in the supply tank apply equally to the fuel quantity transmitter in the main fuel tank.

3.

Remove tank access

4.

Oisconnect electrical leads.

5.

Remove fuel quantity transmitter (6) and gasket (5) from cover (36) by removing screws (3) and washers (4).

6.

Cover exposed opening in fuel tank.

62 - 27

cov~r

(1, figure 62-5) by removing screws (2).

Installation - fuel quantity transmitter

1.

Check gasket (5, figure 62-5) for condition and replace if damaged.

2.

Coat gasket (5) with grease (CM 101) and install in cover (36) together with fuel quantity transmitter (6). With the exception of one screw for attaching the bonding jumper, coat screws (3) with sealing compound (CM 644) and install these screws to secure fuel quantity transmitter (6) to cover. See figure 62-5 for torque value.

* CAUTION 00 NOT OVERTORQUE THE NUTS FOR ELECTRICAL LEADS. THIS COULD * CAUSE OAMAGE ANO MALFUNCTION Of THE TRANSMITTER. * * * 3. Connect electrical leads. Torque value for nut 1 Nm. Attach bonding jumper with remaining screw (3),then brush-coat screw head and electrical * leads connection with corros ion preventive lacquer (CM 501) . * 4.

Connect battery and external power source (refer to Chapter 92).

5.

Refuel helicopter (refer to Chapter 06). While refueling, check fuel quantity transmitter for correct functioning (refer to paragraph 62-44, step 4).

6.

Install tank access cover (1) with screws (2).

BO 105 CHAPTER 62 Page 32

Revision 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 F u e 1 s h u t

62 - 28

Ó

f f

val v e

NOTE ------

The following procedures for removing and installing the right fuel shutoff valve apply equally to the left fuel shutoff valve.

WARNING

TO AVOID FIRE ANO EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS. Removal - fuel shutoff valve

62 - 29 1.

Remove right lateral interior panelling.

2.

Remove right fuel shutoff valve as follows: a.

Configuration 1: 1)

Remove cover (16, figure 62-7) and gasket (15) by removing screws (1) •

b.

2)

Loosen clamp (7) and detach rubber sleeve (5) bonded to housing (3) .

3)

Disconnect fuel lines (4 and 14) from fuel shutoff valve (13).

4)

Disconnect electrical connectors (15) from receptacles.

5)

Remove bolts (9), nuts (12) and washers (8 and 11) attaching fuel shutoff valve (13) to housing (3), and remove fuel shutoff valve from housing.

Configuration 11: 1)

Remove cover (2, figure 62-8) and gasket (1) by removing screws (4) •

2)

Loosen clamp (12) and detach bonded rubber sleeve (11) from housing (9).

3)

Disconnect fuel lines (5 and 10) from fuel shutoff valve (8) and remove electrical connectors (15).

4)

Remove screws (6 and 13) and washers (7 and 14) attaching fuel shutoff valve (8) to housing (9), and remove fuel shutoff valve from housing.

BO 105 CHAPTER 62 Page 33

- - - - - - - - - - - - - . MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 62 - 30 1.

Installation - fuel shutoff valve

Install right fuel shutoff valve as follows: a.

b.

Configuration 1: 1)

Check gasket (15, figure 62-7) for condition and replace if damaged.

2)

Insta1l fuel shutoff valve (13) in housing (3). Brush-coat bolts (9) with sealing compound (CM 622) and install fuel shutoff va1ve in housing (3) with bolts (9), washers (8 and 11) and nuts (12).

3)

Connect fuel lines (4 and 14) and electrical connector (15) to fuel shutoff valve.

4)

Bond one end of rubber sleeve (5) to housing (3) with cement (CM 653) and secure other end to fuel line (4) with clamp (7).

Configuration 11: 1)

Check gasket (1, figure 62-8) for condition and replace if damaged.

2)

Install fuel shutoff valve (8) in housing (9). Brush-coat screws (6 and 13) with sealing compound (CM 622) and install fuel shutoff valve (8) in housing (9) with screws (6 and 13) and washers (7 and 14) .

3)

Connect fuel lines (5 and 10) and electrical connector (15) to fuel shutoff valve (8).

4)

Bond one end of rubber sleeve (11) to housing (9) with cement (CM 653) and secure other end to fuel line (10) with clamp (12).

5)

Bond detached gasket (16) to fuel line passage in housing (9) using rubber cement (CM 653).

2.

Perform functional test (refer to paragraph 62-44, steps 5 thru 7) and test fuel shutoff valve for leaks (refer to chapter 92-83).

3.

Fit cover (16, figure 62-7 or 2, figure 62-8) on housing, together with gas.ket.

4.

Install right lateral interior panelling.

BO 105 CHAPTER 62 Page 34

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - . , - - - MAINTENANCE MANUAL MEB - BO 105 Configuration 1: S/N 7-350 and helicopters on which SB 60-64 was not accomplished

~.

1-~

+-----

2

~

,.,

:

Q:

16 - - - - - 1 1

..

15 - - - - i t - - t

14 - - - - - - - -......

13 - - - 4

~J L..-----

I 600194

1 2 3

4 5 6 7 8

Screw Fuel line Housing Fuel line Rubber sleeve Spacer Clamp Washer Figure 62-7

9

10 11 12

a--'r

-----1

BoH

Electrical connector Washer Nut

13 Fuel shutoff valve 14 Fuel line 15 Gasket 16 Cover Fuel shutoff valve - removal and installation BO 105 CHAPTER 62 Page 35

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Configuration II: S/N 351 and subsq and helicopters on which SB 60-64 was accomplished

-ii-----------~

4

3

------f i _ r--------

2

5

6

=--------7

--------R':

8

16

9 /

15

( +-14

!

13 10

15

~~~-------~ 11

600m

~

----------~12

1 Gasket 2 Cover 3 Washer 4 Screw 5 Fuel line 6 Screw 7 Washer 8 Fuel shutoff valve

Figure 62-8 BO 105 CHAPTER 62 Page 36

9 Housing 10 Fuel line 11 Rubber sleeve 12 Clamp 13 Screw 14 Washer 15 Electrical connector 16 Gasket

Fuel shutoff valve - removal and installation

HELICOPTERS - - - - - - - - ' - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

62 - 31

Del e t e d

62 - 32

Del e t e d

62 - 33

Del e t e d

Revision 2

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * BO 105 CHAPTER 62 Page 37

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

* * *

*

* * * * * * * * *

* *

*

* * * * * * * * * * * * * * * * *

*

* * * * * * * * * * * *

Figure 62-9

BO 105 CHAPTER 62 Page 38

Del e t e d

Revision 2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY 62 - 34

p/N 7 - 250

Pressure relief valve

NOTE

The removal and installation procedures are the same for either left or right pressure relief valve. The following procedure is for the left one.

WARNING

TO AVOID FIRE AND EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS.

62 - 35

Removal - pressure relief valve

1.

Remove No. 1 engine cowling (refer to Chapter 22) and place drip pan in position to catch draining fuel.

2.

Disconnect battery and external power source (refer to Chapter 92).

3.

Remove lockwire and straighten tabs on tab washer (see figure 62-10).

4.

Remove nut (6) with tab washer (5).

5.

Pull pressure relief valve (3) and connecting piece (1) out of support bracket (4) and remove pressure relief valve and packing (2) from connecting piece (1).

6.

Replace damaged packing (2).

62 - 36

Installation - pressure relief valve

1.

Install pressure relief valve (3, figure 62-10) and packing (2) on connecting piece (1) and secure in support bracket (4) with nut (6).

2.

Secure nut (6) with tab washer (5).

3.

Lockwire pressure relief valve (3).

4.

Connect battery and external power source (see Chapter 92).

5.

Test pressure relief valve for leakage by switching on fuel pump SUPPLY TANK ENG 1 (ENG 2 for right pressure valve) .

6.

Install No. 1 engine cowling (refer to Chapter 22).

BO 105 CHAPTER 62 Page 39

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO lOS

EFFECTIVITY

p/N 7 - 2S0

600192

1 Connecting piece Packing Pressure relief valve

2 3

Figure 62-10

BO 105 CHAPTER 62

Page 40

4 Support bracket S Tab washer 6 Nut

Pressure relief valve - removal and installation

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 62 - 37

D i f f e r e n tia 1 p r e s s u r e

s wi t c h

NOTE

The removal and installation procedures are the same for either left or right differential pressure switch. The following procedure is for the left one.

WARNING

TO AVOID FlRE ANO EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS.

62 - 38

Removal - differential pressure switch

1.

Remove No. 1 engine cowling (refer to Chapter 22) and place drip pan in position to catch draining fuel.

2.

Disconnect battery and external power source (refer to Chapter 92) .

3.

Remove differential pressure switch as follows: a.

b.

Configuration 1, figure 62-11 1)

Remove lockwires. Remove both banjo bolts (5) with packings (2). Discard packings.

2)

Disconnect electrical connector (3).

3)

Straighten tabs on tab washer (8) and remove bolt (7).

4)

Remove differential pressure switch (1) from clamp (9).

Configuration 11, figure 62-12 1)

Remove lockwires. Remove both banjo"bolts (5) with packings (2). Discard packings.

2)

Disconnect electrical connector (3).

3)

Remove nut and washer (12), disconnect electrical connector, and remove angle bracket (10) together with differential pressure switch (1) and receptacle (11).

4)

Unsolder electrical leads from receptacle (11).

5)

Loosen bolt (7) and remove pressure differential switch (1) from clamp (8).

BO 105 CHAPTER 62 Page 41

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

<7 ......

5

51

6

1 Differential pressure switch 2 Sealing ring 3 Electrical connector 4 Fuel line 5 Banjo bolt 6 Ring fitting 7 Bolt 8 Tab washer 9 Clamp 10 Fuel line

4

900101

10

Figure 62-11

Differential pressure switch - removal and installation, Configuration 1

10 11 12

7

2,5 6

2.5 6 4

8

1 Differential pressure switch 2 Sealing ring 3 Electrical connector 4 Fuel line 5 Banjo bolt 6 Ring f i tt ing 7 Bolt 8 Clamp 9 Fuel line 10 Angle bracket 11 Receptacle 12 Nut / washer

3

900331

Figure 62-12

BO 105 CHAPTER 62 Page 42

Differential pressure switch - removal and installation, Configuration 11

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

62 - 39

Installation - differential pressure switch

1.

Install differential pressure switch in reverse order of removal, but do not connect fuel line (4, figure 62-11 and 62-12) until after the functional test.

2.

Functionally test differential pressure switch (1) as follows:

3.

a.

Blank off fuel line (4).

b.

Connect battery and external power source (refer to Chapter 92).

c.

Switch on related fuel pump in supply tank (see figure 62-2) and momentarily open corresponding fuel shutoff valve.

d.

Warning light FILT l/FILT 2 must come on.

e.

Switch off fuel pumpi warning light FILT l/FILT 2 must go out.

f.

Remove blank from fuel line (4, figure 62-11). Connect fuel line to the differential pressure switch (1) and secure with lockwire.

Install No. 1 engine cowling (refer to Chapter 22).

62 - 40

NOTE ------

WARNING

62 - 41

P r e s s u r e

t r a n s m i t ter

The removal and installation procedures are the same for either left or right pressure transmitter. The following procedure is for the left pressure transmitter. TO AVOIO ~IRE ANO EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS. Removal - pressure transmitter

1.

Remove No. 1 engine cowling (refer to Chapter 22) and place drip pan in position to catch draining fuel.

2.

Oisconnect battery and external power source (refer to Chapter 92).

BO 105 CHAPTER 62 Page 43

-----------'----MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

Remove protective cap (1, figure 62-13), knurled nut (2), nut (3), and electrical lead (5) and washers (4).

4.

Remove lockwire and unscrew pressure transmitter (6) from connecting piece (8); remove bonding jumper (7) from threaded end of pressure transmitter. Installation - pressure transmitter

62 - 42

1.

Install pressure transmitter in reverse order of removal.

2.

Functionally test pressure transmitter (6, figure 62-13) as follows:

3.

a.

Connect battery and external power source (refer to Chapter 92) .

b.

Unscrew fuel line from fuel filter inlet port and blank off open end.

c.

Switch on related fuel pump in supply tank (see figure 62-2) and momentarily open corresponding fuel shutoff valve.

d.

The pressure indicator located on the instrument panel must show at least 0.7 kp/cm2 •

e.

Switch off fuel pump.

f.

Remove blank from fuel line and connect fuel line to the fuel filter inlet port. Secure with lockwire.

Install No. 1 engine cowling (refer to Chapter 22).

BO 105 CHAPTER 62 Page 44

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~7 ~~--\--~ 1 - - - - 8

1 2 3

4 600192.1

5 6 7

8

Figure

62-13

Protective cap Knurled nut Nut Washer Electrical lead Pressure transmitter Bonding jumper Connecting piece

Pressure transmitter - removal and installation

BO 105 CHAPTER 62 Page 45

- - - - - - - - - - - - : - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 P r e s s u r e

62 - 43

t e s t

-

f u e 1 s y s t e m

o TO AVOID FlRE ANO EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS.

WARNING

o THE HELICOPTER MUST BE EARTHED DURING TESTING. Special tools: Leakage test set 105-60901 W1 or the following tools/auxiliaries: U-tube manometer, commercial or local fabricated per chapter 04, tool no. 35 or aneroid manometer (range at least 0.05 to 0.20 bar, measuring accuracy at least 0.01 bar) Shutoff valve Hoses and clamps for manometer and shutoff valve Two caps for fuel lines (bulkhead nipples) 1.

Defuel tanks as directed in Chapter 06.

2.

Remove lateral interior panelling, LH and RH lateral floor panels, access covers in the floor, and fairings of bottom shell.

3.

Disconnect fuel lines from connections above the engine deck and blank off with caps. Open fuel shutoff valves.

4.

Disconnect aft vent hose (refer to figure 62-1) from vent pipe in floor panel and connect shutoff valve to vent pipe.

5.

Disconnect forward vent hose (refer to figure 62-1) from vent pipe in floor panel and connect manometer to vent pipe.

6.

CAU'I' ION

THE TEST PRESSURE MUST NOT EXCEED 1000 mm ~qATP.R COLUMN (0.1 BAR) AS DAMAGE TO STRUCTURE MAY RESULT.

NOTE

Perforrn pressure test at constant room temperature

Perform pressure test as follows: a.

Apply a test pressure of 800 mm of water colurnn (0.08 bar) (refer to figure 62-14 when testing with a U-tube manometer), then close shutoff valve and allow pressure to stabilize. There must be no loss of set pressure over a 3D-minute period (note temperature variations) .

BO 105 CHAPTER 62 Page 46

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Non-pressurlzed conditlon

approx. 1m fllled with water

600243

Test pressure: SOO mm water column (l. e., O.OS bar)

SOOmm

Pressurlzed conditlon

Figure 62-14

Pressure test using U - tube rnanorneter BO 105 CHAPTER 62

Page 47

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

----------~--MBB

b.

If the pressure drops, check all accessible areas of the fuel tanks for leaks using leak detection spray (CM 711) or leak detection agent (CM 758). If tank skin is leaking fuel, remove tank and repair it as instructed by the manufacturero If fuel is leaking from tank connections, tighten up screws if possible, otherwise replace packings. Repeat pressure test.

7.

Release pressure from tanks and remove manometer and shutoff valve. Connect vent hoses.

8.

Remove caps from fuel lines.

9.

Connect fuel lines to connections above engine deck and close shutoff valves.

10. Check fuel lines between supply tank and engines for leaks according to paragraph 62-44, step 7. If connections leak fuel, tighten if possible, otherwise replace damaged parts. 11. Install lateral interior panelling, LH and RH lateral floor panels, access covers in the floor, and fairings of bottom shell.

62 - 44 WARNING

F u n c t ion a l

t e s t

f

u e 1 s y s t e m

o TO AVOID FIRE AND EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS. o THE HELICOPTER MUST BE EARTHED DURING TESTING.

1.

Defuel tanks as directed in Chapter 06.

2.

Remove the lateral interior panelling.

3.

Inspect both vent line outlets for obstruction and clear if necessary.

4.

Refuel the helicopter (refer to Chapter 06). During refuelling, check that air is flowing from both vent lineoutlets and that refuelling is being indicated by movement of the dual fuel quantity indicator pointer across the main and supply tank calibrated scales. In addition, the supply tank REST warning light on the annunciator panel must go out as soon as more than 60 kg (75 liters) of fuel are in the tank.

5.

After refuelling, compare the sum of the readings on the MAIN and SUPPLY scales of the dual fuel quantity indicator with the quantity of fuel indicated by the service unit. Add approximately 8 kg (10 1) to the sum of the fuel quantity readings, because the fuel quantity indicator shows only the usable fuel quantity. When the tanks are full, the two values should be approximately the same.

BO 105 CHAPTER 62 Page 48

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

6. Switch on the fuel pumps in the main fuel tank and check for quiet and smooth operation. 7. Check function of fuel shutoff valves by moving the switches FUEL SHUTOFF VALVES 1 and 2 from CLOSED to OPEN position. The fuel shutoff valves must be heard to open. Switch on fuel pumps SUPPLY TANK ENG 1 and ENG 2. The pressure indicator on the instrument panel must show at least 0.7 bar for both pumps.

8. Switch off all fuel pumps and close both fuel shutoff valves. 9. Disconnect the fuel lines from their respective connections at engine inlets. Place drip pan in position to collect fuel spillage. Check that the fuel lines and both microfilters (if installed) are free of obstructions by switching on the fuel pumps in the supply tank and briefly opening the fuel shutoff valves. Switch off fuel pumps and connect fuel lines to the LH and RH engine inlets. 10. Inspect pressure transmitters and differential pressure switches for leaks by switching on the fuel pumps in the supply tank and briefly opening the fuel shutoff valves. Switch off the fuel pumps. 11. Inspect the three drain valves in the bottom shell for correct functioning. If the valves are pushed upward, fuel must flow from the respective valve.

12. Check all fuel pumps for secure attachment, and check all connections, flanges, covers and hose connections for correct installation, leakage and secure attachment.

62 - 45 l.

Han d 1 i n g a n d

s t o r a g e

o f f u e 1 tan k s

Storage and service life. Tanks in store or awaiting installation in the helicopter must not be removed from their outer container or inner polythene bag unless they are about to be installed. Maximum storage life is 5 years. They must be stacked in the original containers not more than four deep, and should be stored under dry, draught-proof conditions within a temperature range of O OC to 25 oC. If a tank is to be stored after removal from service, if must be thoroughly dried out beforehand. Provide ring bolts in tank 'skin with protective covers, and place tank in polythene bag and heat seal. Inspect tank skin before re-installation (refer to step 3.). After the maximum five year storage life, return tanks to manufacturer for inspection.

Revision 2

BO 105 CHAPTER 62 Page 49

* * * * * * * * *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Maintenance and preservation. The inner lining of used tariks which remain on the helicopter without fuel must not be allowed dry out. NOTE

Ensure tank inner lining and fittings remain moist.

When tanks remain out of service for - up to 3 months, all tank openings must be closed after tank has been completely drained of fuel. - a period of 3 to 6 months, brush-, spray-coat, or swill inner lining of tank with lubricating oil (CM 105), then close all openings¡ - longer than 6 months, the inner lining of the tanks must be remoistened every 6 months. 3.

Inspection of tank skin Carefully inspect external and internal surfaces of tank for cuts, holes, chafe marks, lifting of seams and vulcanized areas. If there is any damage likely to result in leakage, the tank must be leak tested by the manufacturer or his approved agents.

BO 105 CHAPTER 62 Page 50

fteurocopter

63

MAINTENANCE MANUAL Mee· eo 105

L U B R I C A T ION

S YS T E M

Tab1e of Contents

Page

Paragraph

Tit1e

63 - 1

DESCRIPTION - LUBRICATION SYSTEM

3

63 - 2

TROUBLESHOOTING - LUBRICATION SYSTEM

9

63 - 3

INSPECTION - LUBRICATION

63 - 4

OIL CHANGE - LUBRICATION SYSTEM (ENGINES)

15

63 - 5

oi 1 e o o 1 e r

16

63 - 6

Rernoval - oil coo1er

16

63 - 7

Cleaning - oi1 cooler

17

63 - 8

Insta11ation - oi1 coo1er

19

63 - 9

Oi 1

20

63 - 10

Rernova1 - oil tank

20

63 - 11

Cleaning - oi1 tank

21

63 - 12

Insta11ation - oil tank

21

63 - 13

Oi 1 a n d

63 - 14

Rernoval - oil and vent lines

25

63 - 15

C1eaning - oil and vent 1ines

26

63 - 16

Insta11ation - oil and vent 1ines

26

63 - 17

R a rn

34

63 - 18

Rernova1 - rarn air duct

34

63 - 19

Insta11ation - rarn air duct

35

SYSTEM

tan k

a i r

ven t

1 i n e s

d u e t

13

25

BO 105 CHAPTER 63 Page 1

MAINTENANCE MANUAL MBB - BO 105

Page

Paragraph

Title

63 - 20

O i 1 t e mp e r a t u r e

63 - 21

Removal - oil temperature transmitter

39

63 - 22

Installation - oil temperature transmitter

39

63 - 23

Oi 1

40

63 - 24

Removal - oil pressure transmitter

40

63 - 25

Installation - oil pressure transmitter

40

63 - 26

Ma g n e tic

d r a i n p 1 u g

41

63 - 27

s

o i 1

63 - 28

Remova1 - scavenge oil filter

42

63 - 29

Installation - scavenge oil filter

42

Replacement of filter elements

44

* 63 - 30

BO 105 CHAP'i'ER 63 Page 2

P r e s s u r e

e a ven g e

t r a n s m i t ter

t r a n s m i t ter

f i 1 ter

(indicating type)

39

42

Revision 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 63 - 1 1.

DESCRIPTION - LUBRICATION SYSTEM

General The Lubrication system consists primarily of an 2-section oil tank, oil cooler, oil cooler fan with housing, and oil lines (see figure 63-1). The main transmission and engines each have a separate lubrication system. While the main transmission has a wet-type oil sump formed by the lower casing, each engine has an externally mounted oil tank. The oil in the three separate systems is circulated through the externally mounted 3-section oil cooler. The oil cooler fan, which is driven by the main transmission, draws in cooling air from the transmission compartment and directs it through the oil cooler. Helicopters S/N 451 and subsq., and those modified by SB 60-37, are additionally equipped with forced-air ventilation.

2.

Oil tank Each section of the oil tank has a filler neck with a screen-type filter, oil level sight gauge, magnetic plug and self-closing valve, and port fittings for oil supply, oil pressure feed, and vent lines. Each reservoir must be filled to not more than approx. 4 liters of the total reservoircapacity of 5.5 liters. The unused volume of 1.5 liters provides space for expansiono

3.

Oil cooler The oil cooler is mounted above the oil tank. In relation to FWD, each section is allocated as follows: Forward oil cooler section - No. 1 engine Center oil cooler section - main rotor transmission Aft oil cooler section - No. 2 engine Installed on the side of the forward section of the oil cooler is an oil filter (with filter bypass) for the main transmission oil system. On modified helicopters, two optional scavenge oil filters with filter bypass indication, one for each engine, are installed on the side of the aft section of the oil cooler.

BO 105 CHAPTER 63 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS ---~--------­ MAINTENANCE MANUAL MBB - BO 105

VIEW

A

3

Oí! cooler 2 Cooler fan 3 Main transmission

1

~

Oil temperature transmitter installed in helicopters S/N 7 thru 160

~

Oil temperature transmitter installed in helicopters S/N 161 and subsq. (refer to Chapter 11) . Figure 63-1

BO 105 CHAPTER 63 Page 4

Lubrication system

(1 of 2)

- - - - - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

VIEW

B

~5--~

/

3

1 2 3 .. 4 5

~ Scavenge oil filters are

installed if the helicopter is equipped with the appropriate optional equipment

Figure 63-1

Oil system· (2 of 2) BO 105 CHAPTER 63

Page 5/6

Oil cooler Cooler fan Main transmission Scavenge oil f il ter (No. 1 engine) ~ Scavenge oil f il ter (No. 2 engine) ~

_ _ _ _ _ _ _ _ _ _ _ _ _ MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

.... ,

Oi1 pressure feed

MeMaM

Oi1 supply 1ine (from oi1 tank)

g Q

Oi1 tank vent 1ine

oa

Drain valve Fi1ter Cooling air Pump (mech. driven) -Magnetic drain p1ug Magnetic drain p1ug (indicating type) OIL TANK

Differential pressure switch

OIL TANK

Filter bypass valve OIL COOLER

~IIX~

OIL COOLER

OIL COOLER

Temperature switch Temperature transmitter Pressure transmitter Pressure switch Ven1:

~

Ij

T

MAIN TRANSMISSION

S/N 7 thru 160

__....I ENGINE 2

ENGINE 1

~

S/N 161 and subsq.

~

Ins1:a11ed on he1icopters modified by SB 60-37; standard installation on S/N 451 and subsq.

~

1 '----

600231.1

Scavenge oi1 fi1ters are insta11ed if the he1icopter i5 equipped with the appropriate optiona1 equipment

Figure 63-2

I...._ _-=~

Oi1 system schematic BO 105 CHAPTER 63

Page 7/8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 63 - 2

TROUBLESHOOTING - LUBRICATION SYSTEM

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Engine oil pressure indication too high

Oil pressure transmitter defective

Check oil pressure transmitter and replace as necessary (refer to para 63-23)

Oil pressure indicator defective

Check oil pressure indicator and replace as necessary (refer to Chapter 91)

Pressure regulating valve not adjusted properly

Adjust pressure regulating valve (refer to Allison Operation and Maintenance Manual)

Engine internal oil supply circuit defective

Check engine oil system (refer to Allison Operation and Maintenance Manual)

Insufficient oil in tank

Replenish oil tank (refer to para 63-4)

Leaking oi! line connections

Visually inspect oil line connections for leaks. Replace defective 1;¡.nes (refer to para 63-13)

Oil filter clogged

Remove and clean oil filter (refer to Allison Operation and Maintenance Manual)

Scavenge oil filter clogged (if OPT scavenge oil filter is embodied)

Check scavenge oil filter (refer to para 63-27)

Oil pressure transmitter defective

Check oil pressure transmitter and replace as necessary (refer to para 63-23)

2

Engine oil pressure indication too low

Table 63-1

Troubleshooting

(1 of 4)

BO 105 CHAPTER 63 Page 9

----------~----MBB

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

TROUBLESHOOTING (continued) No.

3

TROUBLE SYMPTOM

Engine oil temperature indication too high

PROBABLE CAUSE

CORRECTlVE ACTION

Oil pressure indicatar defective

Check oil pressure indicator and replace as necessary (refer to Chapter 91)

Pressure regulating valve not adjusted properly

Adjust pressure regulating valve (refer to Allison Operation and Maintenance Manual)

Engine internal oil supply circuit defective

Check engine oil system (refer to Allison Operation and Maintenance Manual)

Wiring defective

Check wiring. Replace defective wiring

Oil pump defective

Replace oil pump (refer to Allison Operation and Maintenance Manual)

Lack of oil in oil tank

Rep1enish oil tank (refer to para 63-4)

Engine internal oil supply circuit defective

Check engine oil system (refer to Allison Operation and Maintenance Manual)

Dirty cooler fan

Clean cooler fan

Defective cooler fan

Replace defective cooler fan (refer to Chapter 11)

Table 63-1 BO 105 CHAPTER 63 Page 10

Dirty oil cooler

Clean oil cooler (refer to para 63-7)

Oil temperature transmitter defective

Check oil temperature transmitter and replace as necessary (refer to para 63-20)

Troubleshooting

(2 of 4)

_eurocopter

MAINTENANCE MANUAL MBB - BO 105

TROUBLESHOOTING (continued) No.

4

5

6

TROUBLE SYMPTOM

Engine oil temperature indication too low

Fluctuating oil pressure indication

Excessive engine oil consumption

Table 63-1

PROBABLE CAUSE

CORRECTIVE ACTION

Oil temperature indicator defective

Check oil temperature indicator and replace as necessary (refer to Chapter 91)

Oil temperature transmitter defective

Check oil temperature transmitter and replace as necessary (refer to para 63-20)

Oil temperature indicator defective

Check oil temperature indicator and replace as necessary (refer to Chapter 91)

Oil pressure transmitter defective

Check oil pressure transmitter and replace as necessary (refer to para 63-23)

Oil pressure indicator defective

Check oil pressure indicator and replace as necessary (refer to Chapter 91)

Defective oil pump

Replace defective oil pump (refer to Allison Operation and Maintenance Manual)

Oil foaming

For corrective action refer to Allison CSL 1052

Leak.in oil lines, oil cooler, oil tank or magnetic drain plugs

Check oil lines, oil cooler, oil tank and magnetic drain plugs for leakage; replace defective parts as necessary

Engine defective

Refer to Allison Operation and Maintenance Manual

Troubleshooting

(3 of 4) BO 105 CHAPTER 63 Page 11

MAINTENANCE MANUAL MBB - BO 105

TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

7

Chip indication by MAG PLUG 1 or MAG PLUG 11 warning

Metal debris in corresponding engine

Remove and examine magnetic plug for metal deposits. if any are found, proceed according to the Allison Operation and Maintenance Manual. On helicopters without scavenge oil filters, clean oil cooler, oil tank and oil lines in accordance with paras 63-7, 63-11 and p3-13 respectively. . On helicopters with scavenge oil filters, replace filter elements in accordance with para 63-30. If uncertainly exists as to whether or not filter bypass has occurred, also clean oil cooler, oil tank and oil lines in accordance with paras 63-7, 63-11 and 63-13, respectively.

Defective magnetic plug

Functionally test magnetic plug (refer to Chapter 92)

Metal debris or carbon deposits in the oil circuit of the corresponding engine

Inspect engine in accordance with Allison Operation and Maintenance Manual. Replace filter elements in accordance with para. 63-30. If uncertainly exists as to whetheror not filter bypass has occurred, also clean oil cooler, oil tank and oil lines in accordance with paras 63-7, 63-11 and 63-13, respectively.

*

8

*

On helicopters equipped with scavenge oil filters: differential pressure indicator of filter extended

NOTE

Troubleshooting the main transmission lubricating system is described in Chapter 11. Table 63-1

BO 105 CHAPTER 63 Page 12

Troubleshooting

(4 of 4)

Revision 8

EUROCOPTER

63-3

MAINTENANCE MANUAL 80 105

INSPECTION - LUBRICATION SYSTEM

1. Check oHlevel in oH tank and replenish as necessary (refer to paragraph 63-4). 2. Visually inspect oH tank for security of installation and for general condition, especially for cracked welds. a.

If cracks are evident, remove the oil tank (refer to para. 63-10) and return to the manufacturer for repair.

b. Tighten loose attaching screws. 3.

Visually inspect oH tank hose connections for leaks. If possible,stop any leaks by tightening unions, otherwise renew sealing rings.

4.

Check that fluid level is easily visible through the glass window of the sight gauges and that there is no leakage past the gaskets.

5.

a.

Replace leaking gaskets (referto step 10).

b.

Clean oil-stained or otherwise contaminated glass window using cleaner (CM 721). If oillevel is still impossible to read, replace sight gauge (refer to step 10).

Inspect oil hose tines for chafing, and hose connections for security. Replace damaged oil hose lines. Tighten connections as necessary.

6. Visually inspect oil cooler for clogged air passages, contaminated outer surfaces and security of attachment, and visually inspect all welds and the cooler support bracket attached to the V-strut for cracks.

7.

a.

If there is only slight contamination, c1ean oil cooler per paragraph 63-7, step 2.d. If the oH cooler air passages are clogged and outside surfaces of core are severely contaminated, remove and clean the oil cooler per paragraph 63-6 thru paragraph 63-8.

b.

Remove oH cooler if cracks are present (referto paragraph 63-6) and return the oH coolerto the manufacturer for repair.

c.

Tighten loose attaching screws.

If installed, inspect retaining plates for condition and security of attachment. Make sure none are missing. Replace damaged and missing retaining plates (reter to Chapter 11).

8. Visually inspect cooler fan housing for damage and security of attachment. It damaged or loose, proceed in accordance with Chapter 11. 9.

Visually inspect electrical connectors tor security ot attachment and evidence ot damage.

Revision 18

CHAPTER 63 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

10.

Replacing the oil level sight gauge gasket. a.

Drain oil from oil reservoir (refer to paragraph 63-4).

b.

Remove placard (with oil level markings), sight gauge and gasket (see figure 63-3). Discard the gasket.

c.

Clean gasket mounting surface. Secure new gasket (4), sight gauge (3) and placard (6) to reservoir (5) with screws (1) and washers (2). For torque values, see figure 63-3.

d.

Fill reservoir with oil (refer to paragraph 63-4).

e.

Visually inspect sight gauge for evidence of leakage.

5

é \

\

-#"----6

600153

1 2 3 4 5 6

Figure 63-3 BO 105 CHAPTER

Page 14

63

Screw Washer Sight gauge Gasket Oil reservoir Placard (with oil level markings)

Replacing the oil level sight gauge gasket

MAINTENANCE MANUAL BO 105

EUROCOPTER

OIL CHANGE - LUBRICATION SYSTEM (ENGINES)

63 - 4

Special tools: oil drain hose, P/N 1x56 137 035 1.

Drain oil tank: NOTE

2.

Whenever possible, change oil when it is at operating temperature.

a.

Raise and turn locking device on filler cap (37, figure 63-5) counterclockwise, then turn filler cap counterclockwise and remove.

b.

Cut lockwire (36) and remove magnetic plug (35). Inspect the magnetic plug for metal particles. If metal particles are present, follow procedure described in the Allison Operation and Maintenance Manual (Troubleshooting paragraph) .

c.

Connect oil drain hose to drain valve and drain all the oil from oil tank. Remove hose and reinstall the magnetic plug. Lockwire the magnetic plug.

Reservice oil tank: NOTE

o For oil type refer to Allison Operation and Maintenance Manual and engine log book. o Shake oil cans before use in order to mix the anti-foam additives with the oil. If oil foaming occurs, refer to Allison CSL 1052.

a.

Fill oil tank (15) until oil level is atthe MAX marking (approx. 4.5 1) on the sight gauge placard.

b.

Install filler cap in filler neck.

c.

Enter oil type in engine log book.

BO 105 CHAPTER 63 Page 15

MAINTENANCE MANUAL 80105

EUROCOPTER

63 - 5

oi

63 - 6

Removal - oil cooler

c o o 1 e r

1

1. Remove No. 2 engine cowling (refer to Chapter 22). 2. Drain lubrication oil (refer to paragraph 63-4). 3. Loosen clamp (4, figure 63-5) and push back the rubber shroud. 4. Disconnect drain line (31) at engine deck. NOTE

Perform fol10wing step 5. only on helicopters S/N 160 and prior. On helicopters S/N 161 and subsq., the oil temperature transmitter (8) is installed on the main transmission (see figure 63-5).

5. Disconnect electrica1 connector from oi1 temperature transmitter (8). 6. Disconnect oi1 1ine (11) from the oil fi1ter (6) and oil 1ines (10 and 23) from oi1 coo1er (13). 7. Disconnect oi1 1ine (16) at frame 9. 8. Disconnect connecting 1ines (4 and 8, figure 63-4). 9. Cap or p1ug all open lines and ports.

10. Remove oi1 cooler (13, figure 63-5) from oi1 tank (15) as fo110ws:

* * * * * * * * * * * * * * * * * * * * * *

a.

b.

Oil coo1er configuration without mounting rack: 1)

Remove screw (1) together with nut and washers (2).

2)

Remove screws (12, fig. 63-4) together with nuts and washers (11), and remove filler caps (13).

3)

Remove oi1 coo1er and, if necessary, spacer tubes (22).

Oil coo1er configuration with mounting rack: 1)

Remove screw (1) together with washers and nut (2), and remove shim (37B, fig. 63-5).

2)

Remove screws (12, fig. 63-4) together with washers and nuts (11) •

3)

Remove screws (7) together with washers and nuts (9).

4)

Remove oil coo1er and retain washers (21) for reinstal1ation.

BO 105 CHAPTER 63 Page 16

Revision 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 63 - 7 1.

Cleaning - oil cooler

The oil cooler may be cleaned by various methods. The reasons for and the types and methods of cleaning are listed in Table 63-2. The procedure for each method is described instep 2.

Reason for cleaning

Type of cleaning

Method to be used 1, Ir, IIr or IV

Periodic inspection

Internal cleaning (oil passages) and external cleaning (air passages)

Method 1 or method 11 and method IV or method 111 and method IV

Chip indication in one or both engines on helicopters without scavenge oil filters. If uncertainty exists as to whether or not filter bypass has occurred on helicopters with scavenge oil filters. Chip indication in main transmission.

Internal cleaning

Method 11 or method 111 Flush oil cooler, oil tank and oil lines with cleaning agent

On helicopters with scavenge oil filters: When bypassindicator button has extended and uncertainty exists as to whether or not filter bypass has occurred.

Internal cleaning

Method 11 or method 111 Flush oil cooler, oil tank and oil lines with cleaning agent

Contaminated air passages

External cleaning

Method 1 (but with cooler ports tightly sealed) or method IV

Table 63-2

Cleaning the oil cooler

BO 105 CHAPTER 63 Page 17

- - - - - - - - - - - - ' - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Cleaning methods. a.

Method 1: (If the appropriate equipment is available, methods 11 and 111 shall be given preference) Submerge the oil cooler in trichloroethylene (CM 204) at approx. 85 oc or in tetrachloroethylene (CM 205) at approx. 110 oC, and soak for approx. 2 hours. At 20-minute intervals, remove oil cooler from the cleaning solvent, shake vigorously and allow the cleaning solvent to drain from the oil cooler. At end of the soaking period, blow dry with compressed air and flush with lubricating oil (CM 103) .

b.

Method 11: (A force flushing unit is required) Connect the inlet and outlet ports of each of the three cooler sections to the force flushing unit equipped with filter screen and flush each section in both directions. Flushing fluid:

Cleaning agent (CM 204 or CM 205) or oil carbon solvent (CM 210)

Flushing rate:

150 to 300 l/min

Flushing pressure:

approx. 3 bar

Flushing temp. :

approx. 60 oC with cleaning agent (CM 204 and CM 205); refer to manufacturer's instructions when using oil carbon solvent (CM 210) .

Flushing duration:

approx. 60 min.

Blow the oil cooler clean with compressed air and írnmediately flush with lubricating oil (CM 103); flushing with oil may be done manually. c.

Method 111: (Force flushing unit and ultrasonic unit required) Connect the inlet and outlet ports of each of the three cooler sections to the force flushing unit equipped with a microfilter (membrane filter). Expose the oil cooler to ultrasonic waves and then flush.in both directions. Repeat this procedure until no metal or carbon particles can be seen with the naked eye in a filtered sample of the cleaning agent. Ultrasonic frequency: 40 kHz Acoustic power:

250 VA

Duration of exposure: approx. 3 min. Flushing fluid:

oil carbon solvent (CM 210)

Flushing rate:

150 to 300 l/min

BO 105 CHAPTER 63 Page 18

MAINTENANCE MANUAL 80 105

EUROCOPTER

Flushing pressure:

approx. 3 bar

Flushing temperature: approx. 40 oC Flushing duration:

approx. 30 mino

Blow the oil cooler clean with compressed air and then irnmediately flush with lubricating oil (CM 103); flushing with oil may be done manually. d.

Method IV: External cleaning of minor contarnination: Blow oil cooler clean with compres sed air or with a strong jet of water. Spray water jet parallel to cooler fins to avoid bending them. External cleaning of oil and grease contamination: Blow oil cooler clean with steam jet blower. Add wetting agent (CM 225) to improve cleaning effect and then dry cooler fins with compressed airo

Revision 12

BO 105 CHAPTER 63 Page l8A

EUROCOPTER

63 - 8

MAINTENANCE MANUAL 80 105

Installation - oil cooler

NOTE Before installing oil cooler, check that the 3 locating pins attached under the interconnecting clamp to the housing circurnference of the mating oil cooler fan, are still in place, if this particular type of oil cooler fan is installed (refer to Chapter 11).

* * * * * * * * * * * * * * * * * * * * * * * * * * * *

lo

2.

Oil cooler configuration without mounting rack: a)

If previously removed, reinstall spacer tube (22, fig. 63-4) in oil tank (6).

b)

Place oil cooler (2) in mounting position above oil tank (6) and fasten to oil tank together with the retaining chains of filler caps (13), using screws (12) and nuts and washers (11).

c)

Attach oil cooler to oil cooler support bracket, using screw (1, fig. 63-5) and washer and nut (2).

Oil cooler configuration with mounting rack: NOTE To obtain stress-free installation of the oil cooler, washers (21, fig. 63-4) may be added unevenly or only on one side. Shim (37B, fig. 63-5) must be installed free from stress, therefore peel laminations off shirn as necessary to obtain correct shim thickness. a)

Place oil cooler (2, fig. 63-4) in mounting position above rack (5) and secure together with the retaining chains of filler caps (13), using screw and washer (12), washers (21) and nuts and washers (11).

b)

Install screws (7) together with nuts and washers (9).

c)

Attach oil cooler to oil cooler support bracket, using screw and washer (1, fig. 63-5), shim (37B) and nut and washer (2).

3. Remove the caps and plugs from lines and fittings.

4. Configuration 11:

Connect connecting lines (4, figure 63-4). Configuration 111 (after accomplishment of SB 60-58) : Connect connecting lines (8 and 10) . 5. Connect oil line (16, figure 63-5) at frame 9 (21) and lockwire the connections. 6. Connect oil lines (10 and 23) to oil cooler (13) and oil line (11) to oil filter (6).

BO 105 CHAPTER 63 Page 18B

Revision 12

EUROCOPTER

MAINTENANCE MANUAL 80 105

NOTE Perform the following step 7. on helicopters up to and ------ including S/N 160; on helicopters S/N 161 and subsq., the oil temperature transmitter (8) is installed on the main transmission (see figure 63-5). 7. Connect electrical connector to the oil temperature transmitter. 8. Connect drain line (31) to engine deck. 9. Fit rubber shroud over cooler fan mating flange on oi1 cooler and secure with clamp (4). 10. Service the oil tank (refer to paragraph 63-4). 11. Perform ground run and inspect oil system for leaks. 12. Install engine cowling (refer to Chapter 22).

Revision 12

BO 105 CHAPTER 63 Page 19

MAINTENANCE MANUAL 80105

EUROCOPTER

63 - 9

O i 1 tan k

63 - 10

Removal - oil tank

NOTE

To remove the oil tank it is necessary to remove the oil tank and the oil cooler as a unit.

1. Remove left and right engine cowlings (refer to Chapter 22) . 2. Drain lubrication oil (refer to paragraph 63-4). 3. Remove lockwires from the oil line connections (18 and 25, figure 63-5). 4. Disconnect oil lines (16, 18, 23 and 25) and vent lines (17 and 24) at frame 9 (21). 5. Remove hose clamps (20 and 26) from the engine deck. 6. Disconnect oil line (11) from the engine deck and detach clamp from rnain transmission support (9). 7. Disconnect oil line (10) from oil cooler (13) and disconnect drain line (31) at engine deck. If scavenge oil filters are installed, disconnect clamps (15, fig. 63-4) from engine deck. 8. Cap or p1ug open lines and fittings. 9. Loosen clamp (4, fig. 63-5) on cooler fan housing (3) and push back the rubber shroud. NOTE

Perforrn following step 10. on1y on helicopters S/N 160 and prior. On helicopters S/N 161 and subsq.¡ the oil temperature transmitter (8) is installed on the main transmission.

10. Remove electrical connector from the 011 temperature transmitter.

* 11. Remove screws (34) securing oi1 coo1er and record number and location of * shim (37A) and sealing washers (32) for reassembly at same position. * * 12. Remove screw (1) and nut and washers (2). If oH cooler configuration * with mounting rack, also remove shim (37B). Remove assembled oil cooler * and tank. 13. If required, remove oil cooler and oil lines from oil tank in accordance with figure 63-4.

BO 105 CHAPTER 63 Page 20

Revision 12

MAINTENANCE MANUAL

EUROCOPTER

63 - 11

eo 105

Cleaning - oil tank

1.

Subrnerge oil tank (15, figure 63-5) in trichloroethylene (CM 204) for approx. 20 minutes at approx. 85 oC.

2.

Flush oil tank and allow trichloroethylene to drain off. Blow oil tank clean with compressed air and then flush with lubricating oil (CM 103) .

63 - 12

Installation - oil tank

NOTE

Before installing the oil tank and cooler assembly check that the three locating pins attached under the interconnecting clamp to the housing circumference of mating oil cooler fan are still in place if this particular type of oil cooler fan is installed (refer to Chapter 11).

1.

If removed, install the oil cooler and oil lines on oil tank in accordance with figure 63-4.

2.

Locate oil tank and cooler assembly in position (refer to figure 63-5). NOTE

o Before securing the oil tank and oil cooler assembly to * the engine deck or rail (oil cooler configuration with * mounting rack) place a shim (37A) under the aft LH mount on * the bottom of the oil tank. * o When installing the rear LH screw (34), interpose a washer (33) and three sealing washers (32) between the screw head and the mount. Install each of the remaining screws together with washer (33) only.

* * *

* *

3.

Tighten screws (34) of lubrication system, taking care to tighten the rear LH screw only that amount of turns necessary to slightly deform the sealing washers.

4.

Attach oil cooler to oil cooler support bracket, using screw (1) and nut * and washers (2). If oil cooler configuration with mounting rack, also add * shim (37B). Peel laminations from shim as necessary to obtain stress-free * shim installation. For torque load, see fig. 63-5. *

5.

Fit rubber shroud over the oil cooler-to-cooler fan connection and secure with clamp (4).

6.

Remove caps and plugs from lines and ports.

7.

Connect oil line (10) and drain line (31) to oil cooler (13) and engine deck respectively. If scavenge oil filters are installed, secure clamps (15, figure 63-4) to engine deck.

8.

Connect oil line (11, figure 63-5) to the elbow union and secure to the transmission support strut with clamp.

Revision 12

BO 105 CHAPTER 63 Page 21

MAINTENANCE MANUAL 80105

EUROCOPTER

Configuration 1 2

13 ---f+-~.,.L-~

600079

1 Cooler duct 2 OH cooler 3 Vent lines - No. 1 and No. 2 engines 4 Connecting lines oil cooler - oil tank 5 Oil cooler rack 6 OH tank 7 Screw, washer 8 Connecting lines, upper oil cooler - oil tank 9 Nut, washer 10 Connecting lines, lower oil cooler - oil tank 11 Nut, washer 12 Screw 13 Filler cap 14 Oil line, scavenge filter - oil cooler 15 Clamp, screw, washer, spacer

Figure

63-4

16 17 18 19 20

* 21 * 22

Scavenge oil filterNo. 1 engine Scavenge oil filterNo. 2 engine Connecting line, oil cooler - oil tank Connecting line, oil cooler - oil tank Oil lineWasher Spacer tube

Oil cooler and oil tank - removal and installation

(1

of

2)

BO 105 CHAPTER 63

Page 22

Revision 12

MAINTENANCE MANUAL BO 105

EUROCOPTER

2

Configuration IV

Configuration IIr

Configuration II

2

2

~ 17 ---++-~.........4-1-

13

7

9

8 13

7

8&

13

I

12

12

11 12

21

20

3& &

10

18

3

4

10&

~-----5& 6

5

6 600232.1

3

16

& &

Standard on S/N 311 and subsq.

& On

helicopters rnodified by SB 60-58. Standard on S/N 651 and subsq.

Figure 63-4

Revision 12

&

14

&

3

4

~ On helicopters rnodified by SB 60-27.

19

Only if scavenge oil filter is installed

~ Scavenge oil filters are installed

oil cooler and oil tank - rernoval and installation

if the helicopter is equipped with the appropriate optional equiprnent

(2 of 2)

BO 105 CHAPTER 63 Page 23/24

5

6

15&

15&

~5-7N{

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 9. Connect oil lines (16, 18, 23 and 25) and vent lines (17 and 24) to fitting at frame 9 (21). 10. Secure oil and vent lines to the engine deck with the two hose clamps (20 and 26) . 11. Secure fittings of oil lines (18 and 25) with lockwire. NOTE

Perform the following step 12. only on helicopters S/N 160 and prior. On helicopters S/N 161 and subsq., the oil temperature transmitter (8) is installed on the main transmission.

12. Connect electrical connector to oil temperature"transmitter. 13. Service the oil tank (refer to paragraph 63-4). 14. Perform ground run and inspect oi! system for leaks. 15. Install engine cowlings (refer to Chapter 22) . 63 - 13

O i 1 a n d ven t

1 i n e s

63 - 14

Removal - oil and vent lines

l.

Remove left and right engine cowlings (refer to Chapter 22) .

2.

Drain lubrication oil (refer to paragraph 63-4). NOTE

For information on removing and installing the oil and vent lines at the engine end, refer to Chapter 61.

3.

Remove assembled oil tank and cooler in accordance with paragraph 63-10, steps 3. thru 12.

4.

Remove lockwires securing the fittings of oil lines (18 and 25, figure 63-5) and disconnect the oil lines at the oil cooler (15).

5.

Disconnect oil lines (7, 23 and 16), vent lines (17 and 24) and drain line (31) from oi! coo1er (13) and oi! tank (15). If scavenge oi! filters are installed, disconnect oil lines (16 and 42) from filter (39) and oil lines (23 and 41) from filter (38).

6.

Disconnect and remove oil lines (10, 29 and 30) from main transmission.

7.

Disconnect oi! line (14, figure 63-4) from fi!ter (16).

8.

Cap or plug all open lines and ports.

BO 105 CHAPTER 63 Page 25

- - - - - - - - - - - - - . MBB HEL1COPTERS - - - - - ' - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 63 - 15

Cleaning - oil and vent lines

Flush oil and vent lines with difluorodichloromethane (CM 201). Clear the lines with compressed air and then flush them with lubricating oil (CM 103) .

63 - 16 1.

1nstallation - oil and vent lines

Remove caps and plugs from lines and fittings. CAUTION

o REMOVED TEFLON HOSES WH1CH HAVE ASSUMED 1NSTALLAT10N CURVATURES MAY BE STRA1GHTENED BUT NOT BENT AGAINST THE CURVE DUR1NG RE1NSTALLATION. o WHEN 1NSTALLING THE 01L L1NES MAKE SURE THAT THE DIRECT10N-OF-FLOW ARROWS P01NT IN THE RIGHT D1RECTION.

2.

Connect oil lines (10, 29 and 30, figure 63-5) to the main transmission.

3.

Connect oil lines (7, 23, 16, 18 and 25) and vent lines (17 and 24) to the oil tank (15) and oil cooler (13). If scavenge oil filters are insta1led, connect oil lines (16 and 42) and (23 and 41) to filters (39) and (38) respectively.

4.

Secure fittings of oil lines (18 and 25) with lockwire.

5.

Install drain line (31) to oil cooler (13).

6.

Connect oil line (14, figure 63-4) to filter (16).

7.

Install oil tank and coo1er assembly as described in paragraph 63-12, steps 2. thru 12.

BO 105 CHAPTER 63 Page 26

EUROCOPTER

MAINTENANCE MANUAL 80 105 2

Configuration 1 S/N 7-160

15-6 Nm 1- 1

4---3

13

14 4 5

12 15

7 8

23

1

9 -r3:------..'. . 35

30

9

16

10

17

29

--=======:;J

11

28

34--~-~~

33 _ _

/.

27

./

/'

31 26-------~

600121.1 25 --------+.iJ.~;,;¡r

1 Screw, washer 2 Nut, washer 3 Fan housing 4 Clamp 5 Screw 6 Oi1 fi1ter for main transmission system 7 Oi1 line - main transmission 8 Oil temperature transmitter and electrical connector 9 Transmission support RH 10 Oil line main transmission 11 Oil line - main transmission 12 Main transmission 13 Oil cooler 14 Cooler duct 15 Oil tank 16 Oil line No. 2 engine 17 Vent line - No. 2 engine 18 Oil line No. 2 engine

-

-

Figure 63-5 Revision 12

.~.

/.

+--~~.r

I

19 Oil pressure transmittermain transmissi0n 20 Hose clamp 21 Frame 9 22 Oil pressure switch main transmissicn Oil line - No. 1 engine 23 24 Vent line - No. 1 engine 25 Oil line - No. 1 engine 26 Hose clamp 27 Oil line - main transmission 28 Fitting 29 Oil line - main transmission 30 Oil pressure sensing line main transmissicn 31 Drain line 32 Sealing washer (3 off) 33 Washer 34 Screw 35 Magnetic plug and self closing valve 36 Lockwire 37 Filler cap

Routeing of lines - lubrication system (1 of 3) BO 105 CHAPTER 63 Page 27/28

24 - - - - - - - + l 18 19

20 21 22

37A

137B

Shim Shim

;~

MAINTENANCE MANUAL

EUROCOPTER

ea 105

Configuratiom 11 and IlIon S/N 161 16 2

1

5 - 6 Nm

1-

13

--3

1

'--

4

"0-----5

~.).í~J~a~~1

7

I 10 ---'i-I---~ll I

Af----23

I

9

~

11----/-

I··rI35-====

30

I

1=S!':.::::::1~+---7

36

18

17

/' 21

"""---10 ......

----,..1"'-\ t+-----11

34--~:""'--......~

,.,

34.:--f

32-----"

'

...

"

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34 33

&32~

33----4-~~

'. " ,

r-,-- . ""'-',

" ....., ' ,.....

\

.

15

31-----""

. . .' . . . ,

, .........."

8

25

-'.....

;

I

~L.,

Item 32 (3 off) and item 37A at this location only.

Method of oil tank attachment on S/N 311 and subsq., and on S/N 310 and prior if SB 60-27 has been accomplished.

I Figure 63-5

Revision 12

Routeing of lines - lubrication system (2 of 3) BO 105 CHAPTER 63 Page 29/30

\

\, \

'\

, '.. . ,

\

\

' .... .....\

\

\

,

24

,

23

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\

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,...

, '...

,

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,,~ ~ ... '4'+...) ~~

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Ify~(

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,,/

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.." ..... i L , <" I .........,. \,/

'o ...

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¡

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...... , 600121

,

. . . \ \ ",.'..

\

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29

,

,

,

+,,&,

..

/'

>'

_ _ _ _ _ _ _ _ _ _ _ _ _ MBB HELICOE'TERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Configuration IV Installed only on helicopters equipped with scavenge oil filters

41

25

17

VIEW

A

600229

38 39

40 41 42

Figure 63-5

Scavenge oil filter (No. 1 engine) Scavenge oil filter (No. 2 engine) Connecting line, oil cooler - oil tan k Oil line Oil line

Routeing of lines - lubrication system (3 of 3) BO 105 CHAE'TER 63 E'age 31/32

24

23

21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

NOTE

When installing the oil lines, ensure that their bend radii are not less than the minimum values specified in the following tableo

Hose type (Aeroquip) Location (figure)

Hose, inner diameter

rmn

Hose, outer diameter

rmn

Minimum bend radius

rmn

inches inches inches

AE 566-4 30, Fig. 63...5

AE 566-8 7,11,16 17, 23, 24, 29, Fig. 63-5

AE 566-10 18, 25, Fig. 63-5

4.4 0.173

9.9 0.391

12.3 0.485

11.4 0.448

16.9 0.665

19.6 0.772

50.8 2.0

117.3 4.62

139.7 5.50

Hose type (Aeroquip) Location (figure) Including scavenge oil filter

AE 541-10 16,23,41,42, fig. 63-5 (3 of 3) 18,19, fig. 63-4 1,2,5,7, figure 63-9

Hose, inner diameter

rmn

15.2 0.600

Hose, outer diameter

rmn

Minirnum bend radius

rmn

inches inches inches Table 63-3

23.5 0.925 76.2 3.00 Minimum bend radii for oil lines

BO 105 CHAPTER 63 Page 33

- - - - - - - - - - - - ' - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 8. Service the oil tank (refer to paragraph 63-4). NOTE

Make certain that the oil supply lines froro the oil tank to the engine are filled with oil. When starting the engines the oil pressure must build up within a few seconds. If this is not the case, fill oil lines and filter casings in engines with oil.

9. Perform ground run and inspect oil system for leaks. 10. Install engine cowlings (refer to Chapter 22).

Ra m a i r

63 - 17

NOTE

d u c t

The ram air duct is installed on helicopters S/N 451 and subsq. and those modified by SB 60-37.

63 - 18

Removal - ram air duct

l.

Remove left and right engine cowlings (refer to Chapter 22) .

2.

Detach snow deflector (3, figure 63-6) after removing screws (2, 4, 6, 7 and 11) with washers and nuts (10, 12, 13 and 14) with washers.

3.

Remove hose (33) of differential pressure switch (34) from tube connector; remove electrical connector (35).

4.

Remove differential pressure switch (34) by removing screws (36).

5.

Detach rotor brake pressure line (39) from the transmission support struts by unscrewing and removing clamps (5 and 38) .

6.

Loosen clamp (22) and detach rubber shroud from ram air duct (1).

7.

Remove ram air duct as shown in figure 63-6, beginning with the ram air scoop (15).

BO 105 CHAPTER 63 Page 34

MAINTENANCE MANUAL 80 10S 63 - 19

Installation - ram air duct

1. Check for presence of edge protection pads on the ram air duct. Make sure, that the interface protection (adhesive tape (CM 614) or sealant (CM 662)) on the main transmission (37, fig. 63-6) is not missing, damaged or separated. If neccessary, install the interface protection as follows: a. Repair the interface protection with adhesive tape (CM 614) as follows:

NOTE

If the adhesive tape is missing: Install the ram air duct provisionally and mark the interface line on the main transmission with a 50ft pencil (e.g. 28). Remove the ram air duct for the installation of the interface protection.

1) Mark the position of the adhesive tape on the main transmission with a 50ft pencil (28). If the interface protection is installed for the first time, mark a 5. cm wide area left and right of the interface line on the main transmission. 2) Remove the adhesive tape, which is separated or damaged. Inspect the main transmission in this area in accordance with Chapter 11-3. 3) Clean the bonding area. Then degrease the bonding area with a lint-free cloth made damp with acetone (CM 203). Touch up damaged surface protection in accordance with Chapter 02 with twocomponent PUR lacquer (CM 437). 4) Install new adhesive tape (CM 614). b.

Interface protection with sealant (CM 662) (alternative to adhesive tape)

NOTE

If the interface protection is missing, or if the adhesive tape is to be repalced by sealant: Install the ram air duct provisionally and mark the interface line on the main transmission with a 50ft pencil (e.g. 2S). Remove the ram air duct for the installation of the interface protection.

NOTE

If the adhesive tape is replaced by sealant, the adhesive tape must be removed completely.

1) Mark the position of the interface protection with a 50ft pencil (28). If the interface protection is installed for the first time, mark a 5 cm wide area left and right of the interface line on the main transmission. 2) Remove the adhesive tape or the damaged or delaminated sealant. Make sure you do not damage the surface of the main transmission housing. Inspect the main transmission in this area in accordance with Chapter 11-3. 3) Clean the bonding area. Then degrease the bonding area with a lint-free cloth made damp with acetone (CM 203).Touch up damaged surface protection in accordance with Chapter 02 with twocomponent PUR lacquer (CM 437). 4) Apply masking tape (VM 609) around the marked area. 5) Apply sealant (CM 662) in a layer of appr. 2 mm to the marked area. Use a plastic scraper to smooth the surface of the sealant. Allow the sealant to dry.

6) Paint the interface protection with two-component PUR lacquer (CM 437) and allow to dry. 7) Remove the masking tape. Revision 23

CHAPTER 63 Page 35

Gteurocopter en EAOS Compeny

MAINTENANCE MANUAL BO 105

2.

Install ram air duct in reverse order of disassembly (refer to paragraph 63-18).

3.

Fit rubber shroud on ram air duct and secure with clamp (22).

4. Secure the rotor brake pressure line (39) to the main transmission support struts with clamps (5 and 38). 5.

Install differential pressure switch (34) on ram air duet with screws (36). Conneet hose (33) and electrical connector (35); take care that hose is not kinked, f1attened or twisted.

6.· Install snow deflector (3) as shown in figure 63-6. 7.

Installleft and right engine forward cowlings (refer to Chapter 22).

8. Test oil cooler fan failure warning light as follows: a. Connect and switch on external power source to helicopter (refer to Chapter 92). b. Ground run the helicopter; warning light Oll COOl (refer to figure 63-2) must 90 off at rotor speed in excess of 70% (refer to Chapter 105). c.

Switch off and disconnect external power source (refer to Chapter 92).

. CHAPTER 63 Page 36

Revision 23

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 1

Ram air duct

2 Screws, washers 3 Snow def lector 4 Screws, washers 5 Clamp 6 Screw, washer 7 Screw 8 Clamp 9 Washer 10 Nut 11 Screw 12 Nut, washer 13 Nut, washer 14 Nut, washer 15 Ram ai r scoop 16 Screw, washer 17 Screw, washer 18 Angle 19 Housing RH 20 Screw, washer 21 Ventilating duct, lower part 22 Clamp 23 Housing LH 24 Screw, washer 25 Nut, washer 26 Angle 27 Screw, washer 28 Clamp 29 Screw, washer 30 Air guide LH 31 Nut, washer 32 Screw 33 Hose 34 Pressure switch 35 Electrical connector 36 Screw, washer 37 Main transmission 38 Clamp 39 Pressure line - rotor brake

...----.

""r-----3 ~

39

19P---l1

7----.114'

.-\-:----- 5

-~:.--..

DETAlL

B 3---HI

/

6~

38--1--/

37---Il-"-7.~---15

30 - - - - - , r , { 28---~

29 ....,.-----lli:l..

25---26--_____, 16

36

~

1~/35

24

-=======~~

23

-------~I

~ ~'8

~'7

_.- _.~

;--------19

/ ...__-- 34

22---.¡¡¡

...--- 33

~'I"""':#'j~----==--20

-+------- 21 DETAlL

J----32

600078

Figure 63-6

8---_~~

Ram air duct - removal and installation BO 105 CHAPTER 63 Page 37/38

A

- - - - - - - - - - - - - - - M B B HELICOPTERS - - - - - . . . , . . . - - - - - - - MAINTENANCE MANUAL MBB - BO 105 63 - 20

NOTE

Oi 1 t e mp e r a t u r e

t r a n s m i t ter

Removal and installation procedures for the No. 1 and No. 2 engine oil temperature transmitters are identical.

63 - 21

Removal - oil temperature transmitter

1.

Remove right engine cowling (refer to Chapter 22).

2.

Disconnect electrical connector (1, figure 63-7) from oil temperature transmitter (2).

3.

Remove lockwire (5) from oil temperature transmitter (2).

4.

Unscrew oil temperature transmitter from fitting (4) and remove together with packing (3),

5.

Plug openings.

6.

Discard sealing ring (3).

63 - 22

Installation - oil temperature transmitter

1.

Remove plugs from openings.

2.

Screw oil temperature transmitter (2, figure 63-7) into fitting (4), together with packing (3).

3.

Secure oil temperature transmitter (2) with lockwire.

4.

Connect electrical connector (1) to oil temperature transmitter.

5.

Ground run the helicopter and check the oil temperature indication (refer to Chapter 105).

6.

Visually inspect oil temperature transmitter for evidence of leakage.

7.

Install right engine cowling (refer to Chapter 22).

BO 105 CHAPTER 63 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS

3

4

1 2 3 4

Electrical connector Oil temperature transmitter Packing Fitting S Lockwire

600199

Figure 63-7

63 - 23

Oil temperature transmitter - removal and installation

Oi 1 P r e s s u r e

NOTE

t r a n s m i t ter

Removal and installation procedures for the No. 1 and No. 2 engine oil pressure transmitters are identical.

63 - 24

Removal - oil pressure transmitter

1.

Remove right engine cowling (refer to Chapter 22).

2.

Disconnect electrical leads (4, figure 63-8) from oil pressure transmitter (3).

3.

Remove lockwire (5).

4.

Unscrew and remove oil pressure transmitter (3) from fitting (1), together with packing (2).

S.

Plug the openings.

6.

Discard sealing ring (2).

63 - 2S

Installation - oil pressure transmitter

1.

Unplug the openings.

2.

Screw oil pressure transmitter (3, figure 63-8) into fitting (1) together with packing (2).

BO lOS CHAPTER 63 Page 40

- - - - - - - - - - - - - . MBB HELICOPTERS ----~-------­ MAINTENANCE MANUAL MBB - BO lOS 3.

Secure oil pressure transmitter (3) with lockwire.

4.

Connect electrical leads (4) to oil pressure transmitter.

s.

Perform ground run and check oil pressure indication (refer to Chapter lOS).

6.

Inspect oil pressuretransmitter for leaks.

7.

Install right engine cowling (refer to Chapter 22).

Fitting 2 Packing 3 oil pressure transmitter 4 Electrical leads S Lockwire

1

Figure 63-8

63 - 26

oil pressure transmitter - removal and installation

M a 9 n e tic

d r a i n p 1 u 9

(indicating type)

The procedures for removing, installing and testing the magnetic drain plugs of both engines are described in the Allison Operation and Maintenance Manual.

BO lOS CHAPTER 63 Page 41

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 S e a ven g e

63 - 27

NOTE

o i 1

f i 1 ter

Paragraphs 63-27 thru 63-30 apply to lubrication systems in corporating scavenge oil filters.

63 - 28

Removal - scavenge oil filter

l.

Remove right engine cowling (refer to Chapter 22) .

2.

Remove baffle plate (8, figure 63-9) installed over upper scavenge oil filter (6).

3.

Remove lockwire securing oil lines (1, 7, 2 and 5) to scavenge oil filters (6 and 4). Disconnect oil lines from scavenge oil filters.

4.

Cap or plug open lines and scavenge oil filter ports.

5.

Remove the three mounting screws (15) and washers (14) from each scavenge oil filter (6 and 4) and remove scavenge oil filters.

63 - 29

NOTE

Installation - scavenge oil filter

Scavenge oil filters manufactured by either PALL or FACET may be installed. Both installed scavenge oil filters must be from the same manufacturer and must be attached by their own mounting supports. Intermixing is not permitted.

1.

Install scavenge oil filters (6 and 4, figure 63-9) with their respective three mounting screws (15) and washers (14).

2.

Remove plugs or caps from scavenge oil filter ports and oil lines.

3.

Connect oil lines (1, 7, 2 and 5) to scavenge oil filters (6 and 4) and secure with lockwire.

4.

Install baffle plate (8) over upper scavenge oil filter (6).

5.

Ground run helicopter (refer to Chapter 105). Visually inspect scavenge oil filters and lines for oil leaks.

6.

Install right engine cowling (refer to Chapter 22) .

BO 105 CHAPTER 63 Page 42

MAINTENANCE MANUAL 80105

3

4

2 15

11

10/

/

"'FACET

",1 ;1

12

13

12

'"

/.

PALL

a::

""""

~I '"o

o ID

1

onune

8

Baffleplate

14

2

onune

9

Oil cooler

15

Screw

3

on tank

10

Differential pressure indicator

16

O-ring

Washer

4

Scavage oil filter (No. 1 engine)

(filter bypass indication)

17

O-ring

5

onune

11

Filter head

18

O-ring

6

Scavage oil filter (No. 2 engine)

12

bowl

19

Ring

7

OilUne

13

Filter element

Figure 63-9 Revision 23

I

Scavenge oil filter CHAPTER 63 Page 43

O~~pter 63 - 30

MAINTENANCE MANUAL SO 105

Replacement of filter elements

1. Open RH forward access door.

r

Remove lockwire. Unscrew filter bowl (12, figure 63-9) from filter head and shake bowl from side to side until element (13) inside is freed. Remove filter bowl (12) and element (13). Remove filter element from filter bowl and discard filter element and O-rings.

3.

Clean filter bowl (12) and filter head (11).

4.

Depress differential pressure indicator button (10) if extended. Perform oil change according to para 63-4.

EFFECTIVITY 5.

1

Step 5. is valid for scavage oil filters FAMET.

Place new filter element (13) with O-ring (17) in bowl (12). Place O-ring (16) on top offilter element (13). Screw bowl (12) with O-ring(18), ring (19) and filterelement (13) intofilter head by hand. Secure with lockwire.

EFFECTIVITY

Step 6. is valid for scavage oil filters PALL.

Place new filter element (13) in bowl (12). Place O-ring (16) on top of filter element (13). Screw bowl (12) with O-ring (18) and filter element (13) into filter head by hand. Secure with lockwire. 7.

Perform ground run according to chapter 105 and visually check filter for leakage.

8.

Close RH forward access door.

CHAPTER 63 Page 44

Revision 23

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

64

F 1 R E WA L L S

Table of Contents

Page

Paragraph Title 64 - 1

DESCRIPTION - FlREWALLS

.....

3

64 - 2

INSPECTION FOR CONDITION - FlREWALLS

3

64 - 3

REPAIR - FlREWALLS .

.

3

64 - 4

Removal -' firewalls

4

64 - 5

Installation - firewalls

5

BO 105 CHAPTER 64 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 64 - 1

DESCRIPTION - FIREWALLS

The firewal1s (fig. 64-1 thru 64-4) separate both engine compartments and the transmission compartment from each other. They isolate the engines from the rest of the helicopter and prevent flames from spreading in the event of an engine fire. The firewalls are made of titanium sheetmetal with asbestos seals bonded to the edges and are secured to each other and to the engine deck with quick release fasteners. 64 - 2

INSPECTION FOR CONDITION - FlREWALLS

1.

Inspect firewalls (fig. 64-1 thru 64-4) for cracks, broken spotwelds, loose rivets and deformation. Refer to para 64-3 for repair procedure.

2.

Check quick release fasteners for security of installation and damage. If loose or damaged, replace according to Chapter 02.

3.

Check glass fiber seals skirting the firewalls for evidence of damage and separation. Replace any damaged seals and rebond detached ones in accordance with para 64-3.

4.

Check engine intake bellows (3 and 4) for cracks and inspect clamps (13) for security.

5.

a.

Replace torn bellows.

b.

Tighten loose clamps.

Inspect drive shaft casings (5 and 6) for cracks, breaks, and evidence of damage to the fire retardant paint coating. Repair casings in accordance with REM 201. Touch up damaged fire retardant paint coating as described in Chapter 22.

64 - 3

REPAIR - FIREWALLS

NOTE

Repair the firewalls according to FAA AC 43.13-1A, AIRCRAFT INSPECTION AND REPAIR and REM 201. Use LN9178 or LN9179 rivets.

1.

Drill out broken spotwelds and replace with appropriately sized rivets.

2.

Restore contour of deformed firewalls using plastic harnmer and suitable dressing tools.

3.

Rebond separated glass fabric seals with cement (CM 672) or silicone adhesive (CM 673) .

BO 105 CHAPTER 64 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4.

Stop-drill (3 mm dia.) cracks at both ends and rework cracks as necessary to eliminate chafing. a.

Fabricate doubler from titanium sheet of next gage thickness to cover damaged area.

b.

Brush mating surface of doubler with sealing compound (CM 635) and rivet to damaged area of firewall.

64 - 4

Removal - firewalls

1.

Remove engine and transmission cowlings (refer to Chapter 22).

2.

Remove forward firewalls (1 and 2, figs. 64-1 thru 64-4): CAUTION

TAKE CARE NOT TO DAMAGE THE DRIVE SHAFTS WHEN REMOVING THE FIREWALLS.

NOTE

For configuration 11 firewalls, remove drive shafts according to procedure in Chapter 11. For configuration 1, 111, IV firewalls, removal of the drive shafts is required only when the engine intake bellows are removed.

a.

If required, remove drive shaft in accordance with Chapter 11.

b.

Disconnect N2 Teleflex cable by opening the quick-disconnect at left forward firewall (2) and remove flanges from firewall passage (8). Repeat this procedure on the right firewall (1) of configuration 11 (fig. 64-2).

c.

Release the quick re1ease fasteners as necessary.

d.

If installed, remove the upper forward firewall (15, figs. 64-1 and 64-4) and upper plate (14). If required, unscrew clamps (13) and remove the right and left drive shaft casings (5 and 6). Remove the right and left forward firewalls (1 and 2), right and left drive shaft casings (5 and 6) and, for configuration 1, 111 and IV firewalls, remove bellows (3 and 4) .

e. f.

NOTE g.

Steps g. thru i. apply to configuration 1, 111 and IV firewalls.

Unscrew clamps (13, fig. 64-2) and remove right and left drive shaft casings (5 and 6) .

80 105 CHAPTER 64 Page 4

----------""-----MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

h.

If required, remove the drive shafts according to Chapter 11.

i.

Oisconnect the quick-disconnect of the N2 Teleflex cable before removing the right bellows.

j.

Release the quick release fasteners of the configuration 11 firewall, and remove engine intake bellows (3 and 4) .

Remove center firewall (9, figs. 64-1 thru 64-4) as follows: CAUTION

4.

a.

Release the quick release fasteners securing the tail rotor drive shaft shield (10) to the center firewalls and remove the shield.

b.

Release quick release fasteners that secure the center firewall (9) and carefully remove center firewall.

Remove right and left aft firewalls (11 and 12, figs. 64-1 thru 64-4) by releasing the quick release fasteners.

64 -5 1.

TAKE CARE NOT TO OAMAGE TAIL ROTOR ORIVE SHAFT WHEN REMOVING FIREWALLS.

Installation - firewalls

Install right and left forward firewalls (1 and 2, figs. 64-1 thru 64-4) as follows: CAUTION

TAKE CARE NOT TO OAMAGE THE ORIVE SHAFTS WHEN INSTALLING FIREWALLS.

a.

Install right and left forward firewalls (1 and 2), right and left drive shaft casings (5 and 6) and, for configuration 1, 111 and IV firewalls, install bellows (3 and 4); secure quick release fasteners.

b.

If required, install the drive shafts and drive shaft casings (5 and 6) according to Chapter 11.

c.

Install flanges on left firewall passage (8) for N2 Teleflex cable and close quick-disconnect.

BO 105 CHAPTER 64 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105

2.

Install center firewall (9, figs. 64-1 thru 64-4) as follows: CAUTION

TAKE CARE NOT TO OAMAGE TAIL ROTOR ORIVE SHAFT WHEN INSTALL1NG FIREWALLS.

a.

Carefully locate center firewall (9) in position and secure it to the engine deck and forward and aft firewalls with quick release fasteners.

b.

Secure tail rotor drive shaft shield (10) to the center wall with quick release fasteners.

3.

Install right and left aft firewalls (11 and 12, figs. 64-1 thru 64-4) with quick release fasteners.

4.

Inspect all firewalls for security of installation.

5.

Install engine and transmission cowlings (refer to Chapter 22). CAUTION

BO 105 CHAPTER 64 Page 6

CHECK TA1L ROTOR ORIVE SHAFT FOR FREEOOM OF MOVEMENT AT PLACES WHERE IT PASSES THROUGH THE F1REWALLS. MIN1MUM CLEARANCE OF 2.5 MM 1S REQU1REO BETWEEN SHAFT ANO FIREWALLS.

- - - - - - - - - - - - - . MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

12

13

600201

1 2 3 4 5 6 7 8

6

4

Right forward firewall Left forward firewall Right engine intake bellows Left engine intake bellows Right drive shaft casing Left drive shaft casing Lower forward firewall Passage for N2 Teleflex cable Figure 64-1 Firewalls

7

9 10 11 12 13 14 15

Center firewall Tail rotor drive shaft shield Right aft firewall Left aft firewall Clamp Upper plate Upper forward firewall

- Configuration 1 BO 105 CHAPTER 64 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3-....;H---f-

5 ----f-~('\

600203

1 2 3 4 5 6 7

Right forward firewall Left forward firewall Right engine intake bellows Left engine intake bellows Right drive shaft casing Left drive shaft casing Lower forward firewall Figure 64-2

BO 105 CHAPTER 64 Page 8

8 9 10 11 12 13

Passage for N2 Teleflex cable Center firewall Tail rotor drive shaft shield Right aft firewall Left aft firewall Clamp

Firewalls - Configuration 11

------------"--~MBB

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

& BO 105S only & Items 4

16

&

secured with only Same item

600204

~

1 2 3 4 5 6 7 8 9

6

Right forward firewall Left forward firewall Right engine intake bellows Left engine intake bellows Right drive shaft casing Left drive shaft casing Lower forward firewall Passage for N2 Teleflex cable Center firewall Figure 64-3

10 11

& &

12 13 14 15 16

Tail rotor drive shaft shield Right aft firewall Left aft firewall Clamp Upper plate Bellows frame with attached panel assembly Right aft firewall

Firewalls - Configuration 111 BO 105 CHAPTER 64 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

12

3

13

600202

1 2 3

4 5

6 7

8

6

4

Right forward firewall Left forward firewall Right engine intake bellows Left engine intake bellows Right drive shaft casing Left drive shaft casing Lower forward firewall Passage for N2 Teleflex cable Figure 64-4

BO 105 CHAPTER

Page 10

7

64

9 Center firewall 10 Tail rotor drive shaft shield 11 Right aft firewall 12 Left aft firewall 13 Clamp 14 Upper plate 15 Upper forward firewall

Firewalls - Configuration IV

Oeurocopter

MAINTENANCE MANUAL 80105

en EADS Oomplll1Y

65 ENGINE OPERATION AND CONTROL Table of Contents

Paragraph Title

Page

65-1

OESCRIPTION - ENGINE OPERATION ANO CONTROL

.

3

65-2

TROUBLESHOOTING - ENGINE OPERATION ANO CONTROL

.

4

65-3

INSPECTION - ENGINE OPERATION ANO CONTROL

.

7

65-4

N1 gas producer fuel control Iinkage

7

65-5

Checking and rigging - N1 gas producer fuel controllinkage

7

65-6

Removal - N1 gas producer fuel controllinkage

65-7

Inspection and repair - N1 gas producer fuel controllinkage

11

65-8

Installation - N1 gas producer fuel controllinkage

11

65-9

N2 Power turbine governor control Iinkage

16

65-10

Checking and rigging - N2 power turbine governor controllinkage

16

65 - 10A

CheCk~ng and r~gg~ng - N2-servomotor (P/N 1564 T1 00-5)

65 - 108

CheckJng and nggJng - N2-servomotor (P/N 02979-7-4, P/N 12.1.2100) .

65 - 10C

Checking and rigging - bearing distance N2-servomotor (P/N 02979-7-4, P/N 12.1.2100, P/N 1564 T100-5) 23E

65 -11

Setting lever pivot radii in accordance with the governor data sheets

24

65 -12

Setting the lever angle settings in accordance with the governor data sheets

28

65 -13

Removal - N2 power turbine governor control Iinkage . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

65 -13A

Removal - N2-servomotor (P/N 1564 T1 00-5, P/N 02979-7-4, P/N 12.1.2100) . . . . .

65 -14

Inspection and repair - N2 power turbine control linkage . . . . . . . . . . . . . . . . . . . . . . . . . .

33

65 -15

Installation - N2 power turbine governor controllinkage

33

65 -15A

Installation - N2-servomotor (P/N 1564 T1 00-5, P/N 02979-7-4, Tkz 12.1.2100)

65-16

Functional check - N2 actuators

35

65 -17

Operational check and operating range adjustment N2 governor controls (on the ground)

38

Adjustment - N2 governor controls (after test flight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

65-18

Revision 25

.

10

23A .

23C

I

32A.

35A.

CHAPTER 65 Page 1/2

- - - - - - - - - - - - - . MBB HELlCOPTERS - - - - - - - - - - - - MAlNTENANCE MANUAL MBB - BO 105 65 - 1

OESCRlPTlON - ENGlNE OPERATlON ANO CONTROL

1.

Engine power output is primarily a function of the gas producer speed N1, power turbine speed N2, cornpressor discharge pressure, and the fuel flow. Fuel flow is controlled by the engine fuel control systern .. Each engine is furnished with a gas producer fuel control N1 (right side) and a power turbine governor N2 (left side). A detailed description of the engine fuel control systern is contained in the ALLlSON OPERATlON & MAlNTENANCE MANUAL.

2.

The gas producer fuel controls N1 are operated through Teleflex cables frorn two engine power levers rnounted side-by-side on the cabin roof. The levers have three positions: OFF, lOLE, and FLlGHT. A power-lever detent in the lOLE position prevents the power levers frorn being inadvertantly shifted directly frorn OFF to FLlGHT, or vice versa. An additional detent in the OFF position is available as optional equiprnent.

3.

With the N2 governor lever in a given position, an increase in the load on the engines, i.e., by upward rnovernent of the collective pitch stick, would cause the N2 RPM and, therefore, the rotor RPM to droop; to rnaintain the rotor RPM, the pilot would have to reset the N2 governor lever each time the power requirernents of the rotor systern are changed. This situation is avoided by providing autornatic droop cornpensation, whereby rnovernent of the collective pitch stick is transrnitted via a lever on the hydraulic unit to the N2 governor levers on the engines. The rigging can be adjusted so that the rotor speed rernains relatively constant irrespective of the power output dernand on the engines. An electrically operated actuator, which varies, through changes in its length, the correlation between the collective pitch stick and the N2 governor levers, is installed in the rnechanical linkage of each engine. Extension or retraction of the actuators in the sarne direction causes the speed of both engines to change in unison within the perrnissible lirnits; rnovernent of the actuators in opposing directions enables the load on one engine to be increased with a proportional decrease in load on the other. The actuators are controlled by a four-way trim switch rnounted on the collective pitch stick. The three functions of the N2 governor controls are as follows: to cornpensate for N2 droop when power output dernand on the engines is increased to vary the power on both engines (torque rnatching) to govern N2 rprn at a different speed.

BO 105 CHAPTER 65 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 65 - 2

TROUBLESHOOTING - ENGINE OPERATION ANO CONTROL

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Power levers hard to move, or cannot be moved evenly

Broken or frayed Teleflex cable wires

Replace Teleflex cables (refer to para 65-6).

Deformed Teleflex tubes

Remove Teleflex tubes, calibrate tube diameters and reinstall tubes (refer to paras 65-6, 65-7 and 65-8). Replace defective tubes.

Power-lever disengage levers hard to move

Lubricate sliding surfaces of disengage levers with grease (CM 101) .

Binding NI fuel control shaft

Replace NI gas producer fuel control (refer to Chapter 61).

2

NI overspeed

Defective NI gas producer fuel control

Replace NI gas producer fuel control (refer to to Chapter 61).

3

N2 overspeed

NI gas producer fuel control defective

Rp.place NI gas producer fuel control (refer to Chapter 61).

N2 power turbine governor defective

Replace N2 governor (refer to Chapter 61) .

Table 65-1

BO 105 CHAPTER 65 Page 4

Troubleshooting

(1 of 3)

- - - - - - - - - - - - ' - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 TROOBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

4

Idle speed too high or too low

N1 gas ptoducer fuel control linkage incorrectly rigged

Check mechanical linkage between power lever and NI fuel control for correct rigging and readjust as necessary (see para 65-5).

Gas producer fuel control idle adjustment not properly set

Correct the idle adjustment setting on N1 fuel control (refer to ALLISON OPERATION ANO MAINTENANCE MANUAL) .

5

Engines track unevenly in torque (i.e. torque split) when slow power changes are made

.Malfunctioning tachometer generator

Replace tachometer generator (refer to Chapter 61, Engine dismantling /build-up) .

Malfunctioning tachometer indicator

Replace tachometer indicator (refer to Chapter

Binding in the N2 control linkage

Perform friction test (refer to para 65-15).

N2 control linkage incorrectly rigged

Check N2 control linkage for correct rigging and readjust as required (refer to pára 65-10) .

Power turbine governor incompatibilitYi adjustment of the lever pivot radii does not correct the condition

Replace one of the governors (refer to Chapter 61) . Its replacement shall be compatible with the retained governor.

Table 65-1

91) •

Troubleshooting

(2 of 3)

BO 105 CHAPTER 65 Page 5

- - - - - - ' - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

6

Engines track unevenly in torque (i.e. torque split) when rapid power changes are made at between 30% and 79% Q on group 1 helicopters and between 30% and 86% Q on group 11 helicopters (refer to Table 65-2)

Air trapped in torquemeter lines

Check whether an N1 split, or a change in the N1 split, also occurs during power changes. If both N1 rpm indications move synchronously during power changes, ventilate the torquemeter line of the instrument with the slower reading. Repeat check.

Malfunctioning compressor bleed control valve

Test bleed control valve on both engines or replace the bleed control valve in accordance with the ALLISON OPERATION ANO MAINTENANCE MANUAL.

Air leaks in the Isolate and eliminate pneumatic lines leaks. between the engine and N1 gas producer fuel control, and between the N1 gas producer fuel control and the N2 power turbine governor N2 control Check N2 control linkage linkage incorrectly for correct rigging and rigged readjust as required (refer to para 65-10). Power turbine governor incompatibility

Table 65-1

BO 105 CHAPTER 65 Page 6

Troubleshooting

If N1 split and torque split occur simultaneously and corrective action has not improved the condition. Replace the appropriate governor (refer to Chapter 61).

(3 of 3)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Model A Group 1 helicopters Group Ir helicopters

BO 105 A

Model D

Model C

Model S

BO 105 C23 BO 105 C-2 BO 105 CDN

BO 105 D BO 105 DS

BO 105 CS BO 105 CS-2

BO BO BO BO BO BO

BO BO BO BO

BO BO BO BO BO BO

105 105 105 105 105 105

CB CB-2 CDN-B CB-4 C/CB-4 CDN-B-4

105 105 105 105

DB DB-4 DBS DBS-4

105 105 105 105 105 105

CBS CBS-2 CON-BS CBS-4 S/CBS-4 CDN-BS-4

Table 65-2 ·Groupingof helicopters with reference to troubleshooting and adjustments

BO 105 CHAPTER 65 Page 6A/B

-eurocopter

MAINTENANCE MANUAL BO 105

. . en EAOO Comp8ny

INSPECTION - ENGINE OPERATION ANO CONTROL

65 - 3

1. Visually inspect N1 gas producer controls for general condition. 2.

Inspect engine power levers on the overhead console for ease of movement and correct engagement. Axial play must not exceed 0.25 mm.

3.

Press both power-Iever disengage levers (1, figure 65-1) on overhead console upward and check that the power levers are properly disengaged and that the disengage levers return automatically to their park positíons.

4.

Inspect visible sections of Teleflex cables in the N1 gas producer and N2 power turbine controllinkages for condition, secure attachment and ease of movement.

5.

a.

Ifthere is roughness or binding, remove N1Teleflex cables per paragraph 65-6 and inspect for condition per paragraph 65-7.

b.

Ifthere is roughness or binding, remove N2 Teleflex cables per paragraph 65-13 and inspect forcondition per paragraph 65-14.

Inspect quick-disconnects (52, Figure 65-3 and 17, Figure 65-8) of N1 gas producer fuel controllinkage and of N2 power turbine governor control linkage for condition, mechanical damage and wear and check Teflex cables in quick-disconnect for axial play. a.

Open quick-disconnect (bayonet socket).

b. Turn aside the two claws in quick-disconnect. c.

Vísually inspect quick-disconnect. If there is mechanical damage or wear, replace quick-disconnect La. w. Sectíon 65-6 and 65-8 or 65-13 and 65-15.

d.

Checkontheconnection point ofthetwo Teflex cables inthequick- disconnectwhetherthereisexcessive axial play. To do so, move the two Teflex cables back and forth in axial direction. Axial play on the connectíon point may not exceed 0.3 mm. Ifaxial play exceeds the permissible limit, replace Teflex cables i. a. w. Sectíon 65-6 and 65-8 or 65-13 and 65-15.

e.

Ifaxial play ofTeflex cables in the quick-disconnect is within the permissible limits and thequíck-disconnect shows no signs of damage, close claws and, while doing so, ensurethat claws tightly surround Teflex cable.

f.

Close quick-disconnect.

6.

Inspect spherical bearings in the trim actuator rod ends for roughness and evidence of corrosion.

7.

Functionally check tri m actuators (refer to paragraph 65-16).

8.

Inspect N1 and N2 controllinkages for wear, condition and secure attachment.

65 - 4

N1 GAS PROOUCER FUEL CONTROL LlNKAGE

65 - 5

CHECKING ANO RIGGING - N1 GAS PROOUCER FUEL CONTROL LlNKAGE

1. Remove left engine aft cowling (refer to Chapter 22) and open right engine access door.

NOTE

The N1 gas producer fuel control must be rígged in accordance with the Allison OPERATION AND MAINTENANCE MANUAL.

2.

Slowly return the engine power levers (2, figure 65-1 ) from the FLlGHT posítion to the IDLE detent position. With the power levers in the IDLE posítion, the pointers on the gas producer fuel control quadrants must be positioned exactly on the 30° mark. If a setting adjustment is requíred, remove cotter pin (10, figure 65-2) and nut (7) and detach the angle joint (3) from the gas producer fuel control lever.

3.

Back off jamnut (4) and rotate angle joint (3) one or more turns in the required direction (one turn is equivalent to approx. 1.3 mm) then reinstall angle joint.

Revision 25

CHAPTER 65 Page 7

•

• _

eurocopter

MAINTENANCE MANUAL BO 105

00 EA[E Company

4. The lever stop arm must bottom out on the maximum and minimum speed stops of the N1 fuel control when the power levers are moved to their respective end positions. In the end positions the inspection holes in the sliding sleeves must be blocked by the swivel assemblies within them. The power levers must be approximately parallel to each other in the OFF position.

VIEwA

2

1 2 3 4

Disengage levers Power levers Sliding sleeves Swivel assemblies

Figure 65-1

2

_.

Rigging - N1 gas producer fuel controllinkage (cabin roof)

CHAPTER 65 Page 8

Revision 24

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

8

600133

7

6

Detall

9

A

1 Nut . 2 N1 fuel control lever 3 Angle joint 4 Jamnut 5 Sliding sleeve 6 Pointer 7 Nut 8 Washer 9 Bushing 10 Cotter pin 11 Swivel assembly

Figure 65-2

~

Threads must be visible and block the inspection hole

~

With power lever in FLIGHT position, the inspection hole must be blocked by the swivel assembly

~

With·power lever in OFF position, there must be clearance between sliding sleeve and swivel assembly

Rigging - N1 gas producer fuel control linkage (at connection to engine) BO 105 CHAPTER 65 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 5.

If the angle joint cannot be adjusted sufficiently, loosen nut (1) on the throttle shaft until the NI gas producer lever (2) can be rotated. Move the lever one serration (150 spacing) in the desired direction, then tighten the nut. Correct excessive adjustment to either side by performing steps 2. and 3.

6.

Check the NI fuel control rigging for looseness. (The IDLE position must be correctly adjusted beforehand according to steps 2. and 3., and,if necessary, step 5.). Slowly raise the power levers from the OFF to the IDLE position. The gas producer fuel control pointer must not be more than 2 mm below the 30 0 mark. If this setting is exceeded, eliminate loosenessi replace Teleflex cable if necessary.

7.

Lubricate sliding surfaces with grease (CM 101).

8.

Install left engine cowling (refer to chapter 22) and close the right engine access door.

65 - 6

Removal - NI gas producer fuel control linkage

l.

Remove engine cowling (refer to Chapter 22) . Remove protective plate from the tandem hydraulic unit to obtain access to the left engine and remove the center and aft firewalls.

2.

Unscrew and remove hand knobs from the power levers and power-Iever disengange levers. Remove the fairing from the power lever assembly by opening the quick-release fasteners. Unscrew overhead panel and allow to fold down.

3.

Remove lockwire from collet (5, figure 65-3), then unscrew jamnut (4) and collet (5).

4.

Remove cotter pin (3) and withdraw bolt (11). Detach clevis (12) from power lever (1). Remove sliding sleeve (6) from Teleflex cable (18) by rotating the clevis (12) (LH thread) .

5.

Open quick-disconnect (52) and disengage Teleflex cables (18 and 55) from each other , then with draw Teleflex cable (18) from quick-disconnect.

6.

Unscrew clamping screw (68). Remove cotter pin (63), nut (62) and washer (64). Disconnect angle joint (67) from gas producer lever (66). Take care to retain bushing (65).

7.

Unscrew angle joint (67) together with sliding sleeve (69) from Teleflex cable (55) (LH thread). Pull Teleflex cable (55) out of quick-disconnect (52) .

8.

Remove lockwires from swivel assembly (61) and clamping nipples (56, 53). Unscrew and remove clamping nipples (56 and 53); remove Teleflex tube (54) .

9.

Remove jamnut (59); remove swivel assembly (61).

BO 105 CHAPTER 65 Page 10

EUROCOPTER

MAINTENANCE MANUAL BO 105

10. Remove flange (51) with seal (50) from firewall passage. 11. Remove screws (41, 34), washers (42,35), clamps (43, 36) and spacers (44, 37). On the left engine, remove screws (45, 34), washers (46, 35), clamps (47,36) and spacers (48,37). 12. Remove lockwire from tube connector (32). Unscrew and remove c1amping nipples (33 and 49) from tube connector (32) and quick-disconnect (52) respectively. Draw tube (38) forward and remove. . 13. Remove clamp (30) by unscrewing and removing screw (29), washer (40) and spacer (39) and detach tuba clamp (26) by removing screw (24) and washer (25). Unscrew tube clamp (26) halves only if Teleflex tube (22) is to be rep1aced with a new one. 14. Unscrew and remove tube connector (32) from c1amping nipple (31). Remove clamps (15) by unscrewing and removing screws (13) and spacers (14) or screws (13A) and washers (14A), as applicable. 15. Remove lockwire from tube connector (20). Unscrew and remove c1amping nipple (21) from tube conneclor and remove Teleflex tube (22). 16. Remove lockwire from c1amping nipple (16). Unscrew and remove cJamping nipple (16) from swivel assembly (9). Remove reinforcing plate from overhead panel and withdraw Teleflex tube (17).lf necessary, unscrew tube connector (20) from clamping nipple (19). 17. Remove lockwire from swivel assembly (9) and remove swivel assembly (9). 65-7

Inspection and repair - Ni gas producer fuel controllinkage

1. Remove grease from Teleflex cables, then inspect Teleflex cables for wear, broken or frayed wires, and corrosion. Replace damaged Teleflex cables. Lubricate reusable Teleflex cables with grease (CM 102) at installation. 2. Inspect Teleflex tubes for dents and kinks, replace deformed Teleflex tubes. 3. Inspect sliding sleeves and swivel assemblies for external damage and deformation, replace if damaged. 65-8

Installation - Ni gas producer fuel controllinkage

1. Install swivel assembly (9, figure 65-3), but do not tigllten screws (8) at this time. 2. Install Teleflex tube (17) with either screws (13) and spacers (14) or screws (13A) and washers (14A), as applicable, and clamps (15). Screw clamping nipples (16 or 19) into swivel assembly (9) and tube connector (20) respectively. Do not tighten screws and clamping nipples at this time.

Revision 18

CHAPTER 65 Page 11

I

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 14A 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Power levers Washer Cotter pin Jamnut Collet Sliding sleeve Washer Screw Swivel assembly Spacer Bolt Clevis Screw Screw Spacer Washer Clamp Clamping nipple Teleflex tube Teleflex cable Clamping nipple Tube connector Clamping nipple Teleflex tube Screw Screw Washer Tube clamp Washer Nut Screw Clamp Clamping nipple Tube connector Clamping nipple Screw Washer Clamp Spacer Teleflex tube Spacer Washer Screw Washer Clamp Spacer Screw Washer Clamp Spacer

Figure 65-3

BO 105 CHAPTER 65 Page 12

49 50 50A 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

Clamping nipple Seal Disk Flange Quick-disconnect Clamping nipple Teleflex tube Teleflex cable Clamping nipple Screw Washer Jamnut Screw Swivel assembly Nut Cotter pin Washer Bushing Gas producer lever Angle joint Clamping screw Sliding sleeve Bracket Nut

N1 gas producer fuel control linkage - removal and installation (1 of 2)

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

DETAlL

D 23--1

,..

.

11

26~~/~" ""-..~ i: '. ~ 2. ~~ ~ 2.1"

~

"-

(!!)----27 8 28

66 65 64

27~ 28 8 61

DETAlL

A

9

DETAlL 10

S 6 4

DETAlL

."'-.,.

" ," 7---~tJ.e::ll.

,,

E 40

DETAlL

I~,~~ B

11

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I

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~

/,-- \~/

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17

18

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DETAlL 30

G-32

/14A 13A '"

~~~'~-;~ :r-l I j <.../

56

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./

---IT~33 ~;~ ~V~

Conflg"atlon 1

"i/JII"-g I

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F

17

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I

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'~71

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DETAlL

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i

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I

i I

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51

~46

~-47

[J-48

49

34

3S

37

DETAlL 6S0001LS

Figure 65-3

~

S2

36

Configuration 11

NI gas producer fuel control linkage - removal and installation (2 of 2) BO 105 CHAPTER 65

Page 13/14

I

H

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3. Attach Teleflex tube (22) to cabin rear wall with screw (24), washer (25) and tube clamp (26) and with screw (29), washer (40), clamp (30) and spacer (39); hand-tighten screws". Screw clamping nipples (21 and 31) hand-tight into tube connectors (20 and 32) respectively. Seal tube clamp (26) and cabin rear wall with sealing compound (CM 661) . 4. Guide the Teleflex tube (38), with the clamping nipple (49) leading, through the firewall passage; slip flange (51) and seal (50) over it and screw the coupling half of the quick-disconnect (52) onto it. Tighten clamping nipple (49) and secure it with lockwire. 5. Install clamp (36) to cabin rear wall with screw (34), washer (35) and spacer (37); install clamp (43) on engine deck with screw (41), washer (42) and spacer (44). Install clamps (47) on engine deck of left engine with screws (45), washers (46) and spacers (48). 6. Secure flange (51) and seal (50) in place with screws (57) and washers (58) . 7. Screw the clamping nipples tightly into tube connectors (20, 32) and swivel assernbly (9). Tighten screws (8) in swivel assernbly (9) and safety with lockwire. Tighten the clamps.

8. Lubricate Teleflex cable (18) with grease (CM 102) and insert it through the open quick-disconnect (52). Thread sliding sleeve (6) onto Teleflex cable by rotating the clevis (12). Make certain that the Teleflex cable is visible in the inspection hole of the sliding sleeve (6). 9. Connect clevis (12) to power lever (1) with bolt cotter pino Move power levers to IDLE position.

"(11)

but do not insert

10. Install swivel assembly (61) on bracket (70) and secure with lockwire. 11. Connect Teleflex tube (54) to coupling half of quick-disconnect (52) and to swivel assernbly (61). Lubricate Teleflex cable (55) with grease (CM 102) and insert into the open quick-disconnect. Connect Teleflex cables together and close the quick-disconnect. 12. Screw angle joint (67) onto the Teleflex cable so that the pointer reaches the 30° mark when the angle joint is connected to the gas producer lever. 13. Rig NI fuel control linkage in accordance with paragraph 65-5. 14. Tighten clamping screw (68). Tighten nut (62) and secure with cotter pin (63) . 15. Tighten clamping nipples (53 and 56) and lockwire them.

BO 105 CHAPTER 65 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 16. Tighten collet (5) and jamnut (4) and secure with lockwire; secure bolt (11) with cotter pin (3). 17. Install reinforcing plate and fairing on power lever assembly. Fold up and secure overhead panel. Install the hand knobs on the engine power levers and power-lever disengage levers. 18. On completion of work on left engine, install the protective plate on the tandem hydraulic unit and install the center and aft firewalls (refer to Chapter 64). Install engine cowling (refer to Chapter 22) .

65 - 9

N2 Power turbinegovernor control linkage

65 - 10

Checking and rigging - N2 power turbine governor control linkage

Special tool: Hydraulic ground unit 1.

Remove engine cowling (refer to Chapter 22) .

2.

Ensure that hydraulic unit and flight controls are properly rigged before proceeding.

3.

Connect and switch on external power source (refer to Chapter 92).

4.

Connect hydraulic ground unit to system I and apply pressure.

5.

Move collective pitch stick to full down (flat pitch) position and engage stick detento

6.

If disconnected, connect rod ends (2, figure 65-5) to fork lever (1). Check for clearance of at least 1 mm between sliding sleeve and swivel assembly; if clearance is less, disconnect rod ends (2) from fork lever (1). Rig the Teleflex cables by adjusting the rod ends on the sliding sleeves (6). Connect rod ends to fork lever (1) but do not secure them at thiS time.

7.

Disengage collective pitch stick detent and slowly raise stick to full up position. While raising the stick, check for freedom of movement throughout the entire control linkage. The inspection holes in the sliding sleeves must be blocked by the swivel assemblies when the collective pitch stick is in full up position.

BO 105 CHAPTER 65 Page 16

- - - - - - - - - - - - - . MBB HELICOPTERS ----~-------­ MAINTENANCE MANUAL MBB - BO 105

1 2 3 4

Fork lever Spring Sliding sleeve Rod end

400106

4

" '.

DETAlLA

~

On group 11 helicopters (refer to table 65-2), connect the rod ends to the upper hole Figure 65-4

8.

3

N2 power turbine governor controls - connection to hydraulic unit

Make sure. that the N2 control linkage simultaneously follows collective pitch input s by slowly raising the collective pitch stick from the full down position. The N2 governor levers must begin to move before the boost piston in the hydraulic unit has travelled more than 5 mm. They must follow boost piston travel in either direction, with the return movement also setting in before boost piston travel exceeds 5 mm. However, the N2 governor levers are not slaved to the collective pitch stick over its entire travel range. Slaving ends when the boost piston is in approximately the upper third of its stroke.

BO 105 CHAPTER 65 Page 17

- - - - - - - - - - - - - M B 8 · HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL M88 - 80 105 If the N2 governor levers do not follow to the described extent, there is too much friction in the control linkage. In this case, inspect Teleflex cables for binding in accordance with para 65-15 and take remedial action as required. 9. Measure the travel of the Teleflex cables connected to the engine by moving the collective pitch stick from the full down to the full up position. Travel should be at least 29 mm (see figure 65-5). If less, check linkage for freedom of movement and Teleflex cables, bearings and bellcranks for play. Perform corrective action as necessary. 10. With the collective pitch stick full down, check that the inspection hole in Teleflex cable (21) is at least half covered. 11. If the inspection hole in Teleflex cable (21) is less than half covered, shorten the effective length of Teleflex cable (7) as follows: a.

Open quick-disconnect so that Teleflex cable (7) can be rotated.

b.

Disconnect rod ends (2) from fork lever (1).

c.

Loosen jamnut (4) and collet (5). Shorten Teleflex cable (7) by rotating it counterclockwise (one turn equals 2.5 mm) into the sliding sleeve. Retighten collet (5) and jamnut (4).

d.

Connect and secure rod ends (2) to fork lever (1).

12. 8ack off jamnut (20), then bend open tabwasher (23) and unscrew Teleflex cable (21) from rod end (19). Together with a new tabwasher, screw Teleflex cable (21) into rod end (19), but do not safety at this time. If necessary, rotate Teleflex cable (21) so that the claws smoothly engage in the quick-disconnect, ,then close latter. 13. Repeat step 10. check. 14. Move collective pitch stick to full down and lock in this position. Position the bellcranks on both engines as shown; dimension must equal to 15 + 0.2 mm, otherwise adjust rod end (19) as necessary. Tighten jamnut and screw with tabwasher (23). 15. Retract actuator by pressing pilot's four-way switch forward to INCR. 16. Check that center-to-center distance between actuator bearings corresponds to dimension shown in figure 65-5; adjust as necessary. Observe condition of inspection holes in adjusting spindle (17). 17. For Allison 250-C20/C20B series engines with Bendix power turbine governors: Set pivot radius (R) of governor lever (12) at 56 ± 0.5 mm. On group II helicopters (refer to table 65-2), set pivot radius (R) at 61 ± 1 mm. These radii are rough settings.

BO 105 CHAPTER 65 Page 18

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

8

DETAlLO

9

10

DETAlL

15

15

e DETAlL

1 Fork lever 2 Rod end 3 Jamnut (see figure 2 of 2) 4 Jamnut 5 Collet 6 Outer tube 6ASliding sleeve 7 Teleflex cable 8 N2- actuator 9 Governor lever, CECO 10 Double serrated washer 11 N2-governor, CECO 12 Governor lever, Bendix 13 N2-governor, Bendix 14 Stop arm with quadrant pointer 15 Washer 16 Rod end 17 Adjusting sPindle} 18 Bellcrank . (see figure 2 of 2) 19 Rod end 20 Jamnut 21 Teleflex cable 22 Quadrant and shaft assembly ~

-#----12

Setting the lever angle and lever pivot radius

~

16

8

1/

Dimensions in mm

.

\

~--13

14

Check for freedom of movement over entire range

Figure 65-5

E

600139.1

Rigging the N2 power turbine governor controls (1 of 2) BO 105 CHAPTER 65 Page 19/20

Actuator

~

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- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

l\

I 1

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Configuration I

A

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Fork lever Rod end Jamnut Jamnut Collet Outer tube Sliding sleeve Telef lex cable N2 actua tor Governor lever, CEca Double serrated washer N2 governor, CECO Governor lever, Bendix N2 governor, Bendix Stop arm with quadrant pointer Washer Rod end Spindle Bellcrank Rod end Jamnut Telef lex cable Quadrant and shaft assembly Tabwasher Rod ends ·rnust be screwed in far enough to block the inspection hole

~ Inspection hole covered by nut ~ At maximurn collective

Configuration Ir 6

. . . . .- ---5 "¡::'~1------4

'-'~-----3

7-----2

(see figure 1 of 2) Dimensions in mm Rigging adjustment at connection to hydraulic unit DetaU

B

Inspection hole

21

15.0 +0.2

23

I

(O/'· .:::;r !,l

~ Inspection hole in sliding sleeve must be at least half blocked. Inspection hole in rod end must be totally blocked. Both parts are shown in cross-section.

Rigging adjustment at connection to engine

. /

pitch the inspection holes rnust be blocked by the inner tubes Figure 65-5

6A

600129.2

Rigging the N2 power turbine governor controls (2 of 2) BO 105 CHAPTER 65 Page 21/22

"

I

! 20 23

i 19

17

8

el eurocopter lIfl EAOS

MAINTENANCE MANUAL 80 105

Cornpany

For Allison 250-C20/C20B series engines with CECa power turbine governors: Set pivot radius (R) of governor lever (9) at value determined using the power turbine governor data sheet (refer to paragraph 65-11). If the governor data sheet is not available, set pivot radius at 56 ± 0.5 mm. For Allison 250-C18 series engines: Set governor lever pivot radius at 56 ± 0.5 mm. 18. Set governor lever angle as follows: a.

For Allison 25O-C18 series engines: Position governor lever stop arm so that the pointer is centered between MIN and MAX. This is a preliminary setting which may have to be adjusted after ground check-running the engine (refer to paragraph 65-17). Obtain rough setting by making adjustments at the radial serrations on the governor lever shaft. A fine setting, which is usually required, is obtained by adjusting the thread engagement of rod end 16) and adjusting spindle (17). Observe condition of inspection holes in adjusting spindle (17).

b.

For 25O-C20/C20B series engines with CECO and Bendix govemors: The CECO governor (11) shaft and lever (9) have 25 and 24 radial serrations respectively. Accordingly, the double serrated washer (10) interposed between them has 24 radial serrations on the lever side and 25 on the governor shaft side. This arrangement permits the lever to be moved in O.6-degree increments relative to the shaft. The Bendix governor (13) shaft and lever (12) have 24 and 25 radial serrations respectively. The double serrated washer interposed between then is identical to the one on the CECO governor. Fine setting: rotate double serrated washer (10) relative to governor shaft and lever. With one serration equivalent to 0.6°, five serrations amount to a 3° change in angle, which is equivalent to approximately 1% change in N2 rpm.

c.

For 250-C20/C20B series engines with CECO governor: Set quadrant and shaft assembly (22) at 60° + 2° by adjusting the serrated washer (10), or Set at the value determined in accordance with paragraphs 65-11 and 65-12.

d.

For 25O-C20/C20B series engines with Bendix governor: Position lever stop arm (14) so that the pointer is centered between MIN and MAX. This is a preliminary setting which may have to be adjusted after ground check-running the engine (refer to paragraph 65-17).

19. Check for freedom of movement of N2 controllinkage as follows: Move collective pitch stick though the fu" range of travel with the N2 actuator fully retracted, then with the actuator fully extended. Make sure that the MAX and MIN stops are not contacted and that N2 actuator does not interfere with the N2 governor lever or with the lever shaft and surmounting nut. Do not set lever pivot radius at less than 39 mm, or at less than 45 mm on actuators with suppressor unit.

CHAPTER 65 Page 23

_~pter EFFECTIVITY

65 -10A

MAINTENANCE MANUAL 80 105

Applicable after ASB BO 105--60-106.

Checking and rigging - N2-servomotor (P/N 1564 nOO-5)

1.

Remove engine cowling (refer to Chapter 22).

2.

Remove center and aft firewalls as necessary (refer to Chapter 64).

3.

Ensure that flight controls are properly rigged before proceeding.

4.

Connect and switch on externaI power source (refer to Chapter 92).

5.

Move the pilot's four-way trim switch forward to INCR and hold. The servomotor (1, figure 65-5A) must retract and stop automatically in the end position (BEEP MAX POSITION). Release the four-way trim ~~h.

-

6. Verify that the distance between the center of the spherical bearing (7) and end of adjusting spindle (2) is 108.0 ± 0.5 mm, see figure 65-5A. 7.

If the measured value does not agree with the default value, push the four-way trim switch afterward to DECR so that the adjusting spindle (2) extends to full extent. Remove lockwire (5) and unscrew setscrews (3). Readjust the end position (BEEP MAX POSITION) with the adjusting screw (6), according to figure 65-5A. Verify the new end position and, if necessary, repeat the procedure until the default value is reached. If the default value is not attained, replace the servomotor (1) according to Chapters 65-13A and 65-15A.

8.

Move the pilot's four-way trim switch afterward to DECR and hold. The servomotor (1) must extend and stop automatically in the respective end position (BEEP MIN POSITION). Release the four-way trim switch.

9.

Check adjusting spindle (2) for max. 17 ± 2.0 mm travel, see figure 65-5A.

10. If the measured value does not agree with the default value, push the four-way trim switch forward to INCR so that the adjusting spindle (2) retracts completely. Adjust the end position (BEEP MIN POSITION) with the adjusting screw (4), according to figure 65-5A. Verify the new end position and, if necessary, repeat the procedure until the default value is reached. If the default value is not attained, replace the servomotor (1) according to Chapters 65-13A and 65-15A.

_

11. Tighten and secure the setscrews (3) with lockwire (5). 12. Switch off and disconnect external power source (refer to Chapter 92). 13. Install center and aft firewalls as prior removed (refer to Chapter 64). 14. Install engine cowling (refer to Chapter 22). 15. Perform ground run to verify Nradjustment (refer to Chapter 105-3). 16. Verify NZmin during functional test flight (refer to Chapter 105-3). 17. After the successful completion of the functional test f1ight, seal the adjusting screws (4) and (6) with sealing compound (CM 635). CHAPTER 65 Page 23A

Revision 25

-.

f»eurocopter lIIl

MAINTENANCE MANUAL BO 105

EAlJS CompDny

DETAlL

DETAlL

A

B

c~

108.0 ± 0.5

17.0 ± 2.0

e

DETAlL 90° rotated

& Retracted Position á BEEP MAX POSITION & Extended Position á BEEP MIN POSITION il, 1 complete turn á approx. 1 mm change in range of travel

7

1 Servomotor 2 Adjusting spindle 3 Setscrews il, 4 Adjusting screw "BEEP MIN POSITION" 5 Lockwire il, 6 Adjusting screw "BEEP MAX POSITION" 7 Spherical bearing Figure 65-5A Rigging - N2-servomotor (P/N 1564 T100-5)

Revision 25

CHAPTER 65 Page 23B

Oeurocopter lIIl

EFFECTIVITY

65 -108

MAINTENANCE MANUAL 80105

fA06 CompImy

Applicable after ASB BO 105-60-106.

Checking and rigging - N2-servomotor (P/N D2979-7-4 or P/N 12.1.2100)

1.

Remove engine cowling (refer to Chapter 22).

2.

Remove center and aft firewalls as necessary (refer to Chapter 64).

3.

Ensure that flight controls are properly rigged before proceeding.

4.

Connect and switch on externaI power source (refer to Chapter 92).

5.

Move the pilot's four-way trim switch forward to INCR and hold. The servomotor (1, figure 65-5A) must retract and stop automatically in the end position (BEEP MAX POSITION). Release the four-way trim switch.

6.

Verify that the distance between the center of the spherical bearing (5) and end of adjusting spindle (2) is 107.8 ± 0.5 mm, see figure 65-5B.

7.

If the measured value does not agree with the default value, push the four-way trim switch backward to DECR so that the adjusting spindle (2) extends completely. Adjust the end position (BEEP MAX POSITION) with the adjusting screw (4), according to figure 65-5B. Verify the new end position and, if necessary, repeat the procedure until the default value is reached. If the default value is not attained, replace the servomotor (1) according to Chapters 65-13A and 65-15A.

8.

Move the pilot's four-way trim switch afterward to DECR and hold. The servomotor (1) must extend and stop automatically in the respective end position (BEEP MIN POSITION). Release the four-way trim switch.

9.

Check adjusting spindle (2) for max. 17 ± 2.0 mm travel, see figure 65-5B.

10. If the measured value does not agree with the default value, push the four-way trim switch forward to INCR so that the adjusting spindle (2) retracts completely. Adjust the end position (BEEP MIN POSITION) with the adjusting screw (3), according to figure 65-5B. Verify the new end position and, if necessary, repeat the procedure until the default value is reached. If the default value is not attained, replace the servomotor (1) according to Chapters 65-13A and 65-15A. 11. Switch off and disconnect external power source (refer to Chapter 92). 12. Install center and aft firewalls as prior removed (refer to Chapter 64). 13. Install engine cowling (refer to Chapter 22). 14. Perform ground run to verify N2-adjustment (refer to Chapter 105-3). 15. Verify N2min during functional test flight (refer to Chapter 105-3). 16. After the successful completion of the functionai test flight, seal the adjusting screws (3) and (4) with sealing compound (CM 635). CHAPTER 65 Page 23C

Revision 25

-

_.

_eurocopter

MAINTENANCE MANUAL SO 10S

un EADS Comp6ny

DETAlL

DETAlL

B

A

&17.0 ± 2.0ffi

107.8 ± 0.5

~c

DETAlL

e

90° rotated

~2

4

---m

W~3

1 Servomotor 2 Adjusting spindle 3 Adjusting screw "BEEP MIN POSITION" 4 Adjusting screw "BEEP MAX POSITION" 5 Spherical bearing

ill Retracted Position á BEEP MAX POSITION .& Extended Position á BEEP MIN POSITION

Figure 65-5B Rigging - N2-servomotor (P/N D2979-7-4 or P/N 12.1.2100)

Revision 25

CHAPTER 65 Page 23D

Aeurocopter ~ en EAOO Compony

EFFECTIVITY

65 -10C

MAINTENANCE MANUAL BO 105

Applicable after AS8 80 105-60-106.

Check and adjustment - bearing distance N2-servomotor (P/N 02979-7-4, P/N 12.1.2100, P/N 1564 T100-5)

NOTE

Accomplish only if 8EEP MAX POSITION & (figure 65-5A or 65-58) was readjusted.

1.

Move the pilot's four-way trim switch forward to INCR and hold. The servomotor (2, figure 65-5C) must retract and stop automaticaliy in the end position 8EEP MAX POSITION & (figure 65-5A or 65-58). Release the four-way trim switch.

2.

Check that the distance between the center of the spherical bearing (3, figure 65-5C) and the rod end (4) is 145 ± 0.5 mm and readjust as necessary. Observe compliance with inspection hole requirements in spacer tube (1), see figure 65-5C.

CHAPTER 65 Page 23E

Revision 25

-

ct

euroeopter lIIl EAOS

MAINTENANCE MANUAL SO 105

C:lmpellY

DETAlL

DETAlL

A

B &, Rod end must be screwed in until it completely blocks the inspection hole

& Inspection hole covered by nut

&

Nominal dimension applies only when adjusting spindle is retracted

4

i----3 2

1 Spacer tube 2 Servomotor 3 Spherical bearing 4 Rod end Figure 65-5C Check and adjustment - N2-servomotor (P/N 02979-7-4, P/N 12.1.2100, P/N 1564 T100-5)

Revision 25

CHAPTER 65 Page 23F

Aeurocopter ~ en

MAl NTENANCE MAN UAL BO 105

EAOS Comparly

65 -11

Setting lever pivot radii in accordance with the governor data sheets

NOTE

Paragraph 65-11 applies only to the CECa governor.

1. To accomplish rough lever pivot radius settings on phase 1 N2 governors using the governor data sheets, proceed as follows: Phase 1 N2 governors CECa P/N 104100A1 104100A1 104100A2 104100A3 104100A3 104100A3 104100A3 104100A4 104100A5 a.

ALLlsaN P/N 6875654C 68756540 6876678A 6876798 6876798A 68767988 6876798C 6877543 6851387

-

Using the data from the Allison data sheet, determine the difference in speed (d) for the governor by subtracting the specified speed setting at 210 Ib/hr govemor fuel flow from the specified speed setting at 100 Ib/hr governor fuel flow. 4200 is the reference speed setting and is equivalent to 100% N2 RPM. For example, d = 150 RPM

b.

Refer to the data sheet for power lever (shaft) gain "g" (determines the effect of lever angle setting on N2 rpm) for the governor. For example, 9 = 16 RPM per degree of lever angle.

c.

Determine the lever pivot radius for the actuator-to-!ever connection on both engines, using the following formula:

xg ( ) R = d1000 + 126 mm 126 = known positive 3% advance in RPM from ground run at 20% torque to cruise at 75% torque. d. If one of the lever pivot radii obtained in step C. exceeds the maximum adjustable setting, then redetermine the lever prior radii using the following formula:

xg ( ) R = d1000 + 128 mm 168 = known positive 4% advance in RPM from ground run at 20% torque to cruise at 75% torque.

CHAPTER 65 Page 24

-,

- - - - - - - - - - - - - . MEB HELICOPTERS - - - - - - - , - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 e.

Set the lever pivot radii of both engines to the values determined in step c. or d .. Both radii must be determined using the same formula. NOTE

2.

The two lever pivot radii (for engines 1 and 2) are intended as rough settings prior to the test flight. Corrections must be made as necessary after the initial test flight.

To accomplish rough lever pivot radius settings on phase 11 N2 governors, proceed as follows: Phase 11 N2 governors

CECO

ALLISON

104500A3

6886410

a.

Determine the lever pivot radius using the data sheet values for N1DO and the values given in figure 65-6 for nPLG. The lever pivot radius limits for a 3% advance in RPM are shown in figure 65-6.

b.

The lever pivot radius limits for a 4% advance in RPM (max. allowable value is 96 to 100%) are shown in figure 65-7. If the lever pivot radius read from figure 65-6 is outside the established limits, it can then be determined from figure 65-7. However, it is important to obtain the lever pivot radii of both governors (No. 1 and No. 2 engines) from the same figure.

c.

Set N2 governor levers to the lever pivot radii determined in step b. NOTE

The lever pivot radii (for engines 1 und 2) are intended as rough settings prior to the test flight. Corrections must be made as necessary after the initial test flight.

BO 105 CHAPTER 65 Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

.• i ..

~

..

'or

t

••~

••

! ...

.. :- ....... - :-" t·......- .. " .-

n100 600081

Figure 65-6 BO 105 CHAPTER

Page 26

65

N2 Power lever pivot radius for 3% speed increase

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

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Sample Problem: "plg

=:

3690 rpm

R

=:

49mm

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.

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600082

Figure 65-7

N2 Power lever pivot radius for 4% speed increase BO 105 CHAPTER 65 Page 27

...•...

..-..

_~

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 65 - 12

Setting the lever angle settings in accordance with the governor data sheets

NOTE

Paragraph 65-12 applies only to the CECO governor.

If the governor data sheets are available, the following formula should be used to the determine the lever angle setting on phase 11 N2 governors: Bqovernor lever = BREP - 30

n100 - n210

- - - - - - t 2° 4200 - npLG

Symbol

Meaning

Reference point No. on governor data sheet

Bqovernor lever

Governor lever shaft angular setting for ground run N2 = 100 to 101.5%

CECO data sheet J1-1098 page 2

Allison data sheet J1-1092 page 2-3

2

2

BREP

Governor lever angular setting at reference point (remark: LOCK P/L)

n210

N2 RPM at 210 lb/hr fuel flow (remark: PTG gain)

4

5

n100

N2 RPM at 100 lb/hr fuel flow (remark: PTG gain)

6

12

npLG

N2 RPM at power lever angular setting BREP - 30°

9

17

PTG: PLG: REP:

POWER TURBINE GOVERNOR POWER LEVER GAIN REFERENCE POINT Table 65-3

BO 105 CHAPTER 65 Page 28

_eurocopter

MAINTENANCE MANUAL BO 105

un EAOS Cornpeny

65 - 13

Removal - N2 power turbine governor control Iinkage

1. Remove engine cowlings (refer to Chapter 22). Gain access to the right engine by removing the center and aft firewalls (refer to Chapter 64). 2.

Oisconnect rod ends (2, figure 65-8) from the fork lever (1) on the hydraulic unit.

3.

Remove lockwire from collet (5). Loosen jamnut (4) and collet (5). Remove sliding sleeve (6) from Teleflex cable (16) by rotating rod end (2), (LH thread).

4. Open quick-disconnect (17) and disengage Teleflex cables from each other. Withdraw Teleflex cable (14) from open quick-disconnect. 5.

Remove rod end (38) from bellcrank (40) and move actuator (28) to one side.

6.

Oisconnect rod end (42) from bellcrank (40). Oraw rod end (42) with Teleflex cable (22) aft and remove.

7.

Oisconnect electrical connector from actuator and remove bonding jumper (33); remove cable clamp. Remove actuator from governor lever (27).

8.

For AIIison 250-C20/C20B series engines with Bendix governors, unhook spring (25).

9.

If necessary, remove governor lever (27) from lever shaft (26).

10. Do not remove cotter pin (45), washer (46) and pin (47) to remove bellcrank (40) from engine flange unless necessary. 11. Repeat steps 3. thru 10. on the other engine.

NOTE

Steps 12. thru 15. apply only to the No. 1 engine and steps 16. and 17. only to the No. 2 engine.

12. Unscrew and remove clamp (15) from the transmission support strut. 13. Remove lockwire from c1amping nipple (12). Unscrew and remove clamping nipple (12); remove Teleflex tube (13) together with the coupling half. 14. Do not remove flange (18) and seal (19) from the firewall passage unless necessary. 15. Remove lockwire from swivel assembly (24). Loosen jam nut (23) and unscrew swivel assembly (24) from union (21). Remove swivel assembly (24) together with union (21) and coupling half. 16. Remove lockwire from clamping nipples (12 and 31). Unscrew c1amping nipples (12 and 31) from swivel assemblies (7 and 24). Remove Teleflex tube (30) together with coupling half. 17. Do not remove flange (18) and seal (19) from the firewall passage unless necessary, remove Teleflex tube (13). 18. Remove swivel assembly (7) from bracket (8). Revision 25

CHAPTER 65 Page 29

I

Aeurocopter ~lII\EAl:$~

Fork 2 3 4 5 6 6A 7 8 9 10 11 12 13 14 15 16 17 18 18A 19 20 21 22 23 24

lever Rod end Jamnut Jarnnut. Col.1et Outer tube Sliding sleeve Swivel assembly Bracket Bracket Tube clamp, upper half Tube clamp, lower half Clamping nipple Teleflex tube Teleflex cable Clamp CI·.ing nipple Quick-disconnect Flange Disk Seal Firewall Union Teleflex cable Jamnut Swivel assembly

MAINTENANCE MANUAL BO 105

25 26 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

Spring Levershatt Governor lever N2 actuator Clamping nipple Teleflex tube Claming nipple Washer Bonding jumper Adjusting spindle Jamnut Screw Washer Rod end Ring Bellcrank Cotter pin Rod end Washer Cotter pin Cotter pin Washer Pin Pin Tabwasher

-

-,

Figure 65-8 N2 power turbine governor controllinkage - removal and installation(1 of 2)

CHAPTER 65 Page 30

See N2 connectlon tO. 28) No. 1 englne (Items 24 Conllguratlon wlth Bendlx governor

25

32

27

~y~~1

27

~ ~j -' \'\~~ ~/

16

1\, \'1'

I '.¿' 32

N2 connectlon to No• 1 angine

32 DETAlL 5

D

32 Conflguratlon with govemor

6A

ceco

~-":"'-4

DETAlL

B

2

45 DETAlL

E

33

6 5 4

_3~.

~2

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2 \

t'j'r-j

1 ~L.J

DETAlL

\

\\

A 39

\

28

24 DETAlL

Figure 65-8

N2

- removal and installation BO 105 CHAPTER 65 Page 31/32

e

Seuroeopter l1li EAD5

EFFECTIVITY

65 - 13A

MAINTENANCE MANUAL SO 105

CornpImy

Applicable after ASB BO 105-60-106.

Removal - N2-servomotor (P/N 1564 T1 00-5, P/N D2979-7-4 and P/N 12.1.2100)

1. Remove engine cowling (refer to Chapter 22). 2.

Remove center and aft firewalls as necessary (refer to Chapter 64).

3.

Ensure that flight controls are properly rigged before proceeding.

4. Connect and switch on external power supply (refer to Chapter 92). 5.

Move the pilot's four-way trim switch forward to INCR and retract the servomotor (11, figure 86--8A) to fully extent.

6.

Disconnect electrical connector (12) from servomotor (11) and remove bonding jumper (10).

7.

Remove rod end (4) from lever (2) by removing split pin (1) and screw (5) with washers (3).

8. Remove nut (13) with washer (14) and detach servomotor (11) with washer (15) from special bolt (16). 9.

If the servomotor (11) will be replaced, back off nut (8) and unscrew spacer tube (7) from spindle of the servomotor (11).

Revision 25

CHAPTER 65 Page 32A

-eurocopter •

MAINTENANCE MANUAL BO 105

an EAOO Compeny

DETAlL

A

-

B ~

& Torque 3.6 Nm &, Torque 1.8 Nm Torque 6.4 Nm

L1 L1 DETAlL

Torque 32 Nm

B 13 14

15

1 Split pin 2 Lever 3 Washer 4 Rod end 5 Screw 6 Nut 7 Spacer tub 8 Nut 9 Washer

10 Bonding jumper 11 Servomotor 12 Electrical connector 13 Nut 14 Washer 15 Washer 16 Special bolt

Figure 65-8A Removal and instaliation - N2-servomotor (P/N 1564 T100-5, P/N D2979-7-4 and P/N 12.1.2100)

CHAPTER 65 Page 32B

Revision 25

-.

MAINTENANCE MANUAL 80 105

EUROCOPTER

17. Do not remove flange (18) and seal (19) from the firewall passage unless necessary, remove Teleflex tube (13). 18. Remove swivel assembly (7) from bracket (8).

65 -14

Inspection and repair - N2 power turbine controllinkage

1. Remove grease from Teleflex cables, then inspect Teleflex cables for wear, broken or frayed wires, and corrosion. Replace damaged Teleflex cables. Lubricate reusable Teleflex cables with grease (CM 102) at installation.

2. Inspect Teleflex tubes for dents and kinks. Replace deformed tubes. 3. Inspect sliding sleeves and swivel assemblies for external damage and deformation. Replace if deformed or damaged. 4. Inspect bellcrank for play, mechanical damage and corrosion.

a. Polish out mechanical damage and corrosion using No. 600 grit abrasive cloth. Reworked area must not exceed 0.15 mm in depth. b. Replace bellcrank if play is presento

5. Inspect rod end bearings and actuator bearings for play, rough operation and corrosion. If bearings are damaged, or axial play exceeds 0.1 mm, replace affected rod end or actuator. 65 -15

Installation - N2 power turbine governor controllinkage

1. Install swivel assemblies (7, figure 65-8) on bracket (8).

NOTE

Steps 2. and 3. apply only to the right engine and steps 4. and 5. only to the left engine.

2. Connect Teleflex tube (13) to coupling half. Insert Teleflex tube (13), and screw clamping nipple (12) into the swivel assembly (7). Install flange (18) and seal (19) on the firewall passage.

Revision 18

CHAPTER 65 Page 33

I

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

3. Install swivel assembly (24) if previosly removed. Connect Teleflex tube (30) to coupling half. Insert Teleflex tube (30) and screw clamping nipple (31) into swivel assembly (24). 4. Connect union (21) to coupling half if disconnected. Insert swivel assembly (24) and screw home jamnut (23) without tightening at this time. Insert union (21) and screw swivel assembly and union together. Tighten jamnut (23). Install flange (18) and seal (19) on the firewall passage. 5. If disconnected, connect Teleflex tube (13) to coupling half. Insert Teleflex tube (13) and screw clamping nipple (12) into swivel assembly (7). Fit clamp (15) on transmission support strut. 6. Apply a thin coat of grease (CM 101) to pin (47). Install bellcrank (40) on engine flange with pin (47), washer (46), and cotter pin (45). 7. Install governor lever (27) on lever shaft (26). 8. Apply a thin coat of grease (CM 102) to Teleflex cable (14) and insert it in the open quick-disconnect. Thread sliding sleeve (6) onto Teleflex cable (14) by rotating rod.end (2, LH thread). The Teleflex cable must be visible in the inspection hole in the sliding sleeve (6A, fig. 65-5). Tighten up collet (5) and jamnut (4). 9. If disassembled, screw rod end (42, fig. 65-8) onto Teleflex cable (22). Lubricate Teleflex cable tube (22) with grease (CM 102) and insert in swivel assembly (24). Connect Teleflex cables (14 and 22) together and close the quick-disconnect. 10. Connect rod ends (2) to fork lever (1) without installing cotter pins. 11. Connect rod end (42) to bellcrank (40). Set bellcrank (40) in accordance with paragraph 65-10. 12. Rig actuator to dimensions specified in paragraph 65-10 and connect to the governor lever (27) and bellcrank (40). Install washer (32) with the flat edge against the actuator housing. Connect electrical connector and bonding jumper (33). Secure the cable clamp. 13. Attach spring (25) on Allison 250-C20/c20B series engines fitted with Bendix governors. 14. Repeat steps 6. thru 9. and steps 11. thru 13. on the other engine. 15. Check N2 control rigging in accordance with paragraph 65-10 and adjust as necessary.

BO 105 CHAPTER 65 Page 34

Oeurocopter lIIl EAOS

MAINTENANCE MANUAL 80 105

Compony

16. If the Teleflex cables do not operate smoothly, check cable friction as follows: a.

Disconnect Teleflex cables at the hydraulic unit end. On Allison 250 C20/C20B series engines fitted with Bendix governors, unhook spring (25). Attach a spring scale to the actuator-to-governor lever connecting bolt. Holding spring scale parallel to actuator axis, puJl spring scale aft until the Teleflex cable begins to move.

b. The force required to move the Teleflex cables should not exceed 35 N. Take friction measurements with the collective pitch lever in mínimum pitch position and in cruise position (Le., lever level with center console) respectively. c.

If the force required to move the cable exceeds 35 N, isolate and, if possible, eliminate the cause of the excessive friction in the N2 controllinkage as follows: 1) Check the Teleflex tubes for kinks and unacceptable bend radiL Inspect position of quick-disconnects. Teleflex tubes must have straight runs of approx. 50 mm before and after each connecting and disconnecting point. If necessary, reroute the Teleflex tubes. 2) Check the sliding sleeves and swivel assemblies for smooth operation. If necessary, lubricate with grease (CM 101). 3) For Bendix governors only: check the torque on the governor lever shaft (refer to Allison CEB 1106). If necessary, replace governor. 4) Calibrate inner diameter of Teleflex tubes by removing the Teleflex cables and pulling the test cable, TLN 288/105, 1500 mm long, through the tubes.

17. Repeat steps a. thru

C.

on the other engine.

18. Install remaining locking hardware. 19. Install center and aft firewalls (refer to Chapter 64). Install engine cowling (refer to Chapter 22).

CHAPTER 65 Page 35

Aeurocopter ~ en

MAINTENANCE MANUAL BO 105

EA06 Oompany

EFFECTIVITY

65-15A

-.

Applicable after A8B BO 105-60-106.

Installation - N2-servomotor (P/N 1564 T10~5, P/N 02979-7-4 and P/N 12.1.2100)

1. If prior removed, screw spacer tube (7, figure 86-8A) with tab washer (9) into the new servomotor (11). 2. Adjust distance between the center of spherical bearing and the rod end (4) of the retracted servomotor (11) to 145 ± 0.5 mm according to figure 65-5C and secure with nut (8, figure 86-8A). 3. Connect rod end (4) with screw (5) and washers (3) to lever (2) and secure with split pin (1). 4. Install electrical connector (12) and bonding jumper (10) on servomotor (11). 5. Check and rig N2-servomotor (refer to Chapters 65-10A and 65-1 OB).

CHAPTER 65 Page 35A

-

Revision 25

Aeurocopter en EAOO ~

MAINTENANCE MANUAL BO 105

Compony

BLANK PAGE

CHAPTER 65 Page 358

-eurocopter •

8Il

MAINTENANCE MANUAL BO 105

EAOO Compeny

65-16

Functional check - N2 actuators

NOTE

Two different types of N2 actuator circuit exist, Le. types 1. and 2. In circuit type 1. both N2 actuators move in opposite directions when the four-way trim switch is set to "L+" and "R+". In circuit type 2. one N2 actuator remains in position while the other one moves the N2 lever towards MAX. Steps 2. thru 10. apply to helicopters with N2 actuator circuit type

1. 1. Connect and switch on external power supply (refer to chapter 92). Close circuit breaker N2 CONT. 2.

Move pilot's four-way trim switch forward to "INCR" and hold in this position. 80th actuators must retract and stop automatically in their respective end positions; both governor levers must move to MAX. Release four-way trim switch.

3.

Move pilot's four-way trim switch aft to "DECR" and hold in this position. 80th actuators must extend and stop automatically in their respective end positions; both governor levers must move to MIN. Release fourway trim switch.

4.

Move pilot's four-way trim switch left to "L+" and hold in this position. The No. 1 engine actuator must retract and the No. 2 engine actuator must extend; the No. 1 engine governor lever must move to MAX and the No. 2 engine governor lever must move to MIN. 80th actuators must stop automatically in their end positions. Release four-way trim switch.

5.

Move pilot's four-way trim switch right to "R+" and hold in this position. The No. 1 engine actuator must extend and the No. 2 engine actuator must retract; the No. 1 engine governor lever must move to MIN and the No. 2 engine governor lever must move to MAX. Release four-way trim switch.

6.

Repeat functional check (steps 2. thru 5.) using copilot's four-way trim switch. Actuator response must be identical.

NOTE

The pilot's trim controls have priority status. The pilot can override the copilot's inputs.

7.

Move pilot's four-way trim switch forward to "INCR" and hold in this position. 80th actuators must retracto While the actuators are retracting, move the copilot's four-way trim switch aft to "DECR" and hold in this position. The actuators must continue to retract and then stop automatically in their respective end positions.

8.

Repeat step 7. for the other trim switch settings. Actuator movement initiated by the pilot must remain unaffected by copilot's inputs.

9. Move copilot's four-way trim switch forward to "INCR" and hold in this position. 80th actuators must retract. While the actuators are retracting, move the pilot's four-way trim switch aft to "DECR" and hold in this position. The actuators must change their direction of travel. Release both four-way trim switches.

10. Repeat step 9. for the other trim switch settings. The pilot's trim inputs must override those of the copilot and cause the actuators to reverse their direction of movement.

NOTE

CHAPTER 65 Page 36

The following steps 11. thru 18. apply to helicopters with N2 actuator circuit type 2. When the four-way switch in circuit type 2. is moved to "L+" and "R+", one N2 actuator remains in position while the other one moves the N2 lever towards MAX. Revision 25

-

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 11. Test actuators in accordance with steps 2. and 3. 12. Move pilot's four-way trirn switch left to "L+" and hold switch in this position. The No. 1 engine actuator rnust retract with the No. 2 engine actuator not changing its position. No. 1 engine actuator rnust stop autornatically in its end position. Release four-way trirn switch. 13. Move pilot's four-way trirn switch right to "R+" and hold switch in this position. The No. 2 engine actuator rnust retract with the No. 1 engine actuator not changing its position. No. 1 engine actuator rnust stop autornatically in its end position. Release four-way trirn switch. 14. Repeat functional check using the copilot's four-way trirn switch. Actuator response to the respective switch settings rnust be as described in steps 11. thru 13. NOTE

Check the override capability of the pilot's four-way trirn switch over the copilot's trirn switch in accordance with steps 15. thru 18.

15. Move copilot's four-way trirn switch forward to "INCR" and hold in this position. Both actuators rnust retracto While the actuators are retracting, rnove the pilot's four-way trirn switch aft to IIDECR" and hold in this position. Both actuators rnust reverse their direction of rnovernent, i.e., extend and then stop autornatically in their end positions. Release both four-way trirn actuators. 16. Move copilot's four-way trirn switch aft to "DECR" and hold in this position. Both actuators rnust extend. While the actuators are extending, rnove the pilot's four-way trirn switch forward to "INCR II and hold in this position. Both actuators rnust reverse their direction of rnovernent, i.e., retract and then stop autornatically in their end positions. Release both four-way trirn switches. 17. Move copilot's four-way trirn switch left to IIL+" and hold in this position. The No. 1 engine actuator rnust retract with the No. 2 engine actuator not changing its position. While No. 1 engine actuator is retracting, rnove the pilot's four-way trirn switch right to IIR+" and hold in this position. The No. 1 engine actuator rnust stop and No. 2 engine actuator rnust retract and stop autornatically in its end position. Release both four-way trirn switches. 18. Move copilot's four-way trirn switch right to "R+" and hold in this position. The No. 2 engine actuator rnust retract with No. 1 engine actuator not changing its position. While No. 2 engine actuator is retracting, rnove the pilot's four-way trirn switch left to "L+" and hold in this position. The No. 2 engine actuator must stop and the No. 1 engine actuator rnust retract and stop autornatically in its end position. Release both four-way trirn switches. 19. Open circuit breaker N2 .CONT. Switch off and disconnect external power supply (refer to chapter 92).

80 105 CHAPTER 65 Page 37

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 65 - 17

NOTE

Operatiorial check and operating range adjustment N2 governor controls (on the ground) o Ground run shall be performed by authorized personnel only. o Bench rnatching of the governors must already be accomplished. o Two different types of N2 actuator circuits exist, i.e. types 1. and 2. In circuit type 1. both N2 actuators move in opposite directions when the four-way trirn switch is set to "Lt" and "Rt". In circuit type 2. one N2 actuator rernains in position while the other one rnoves the N2 lever towards MAX. Torque and N2 speed rnust increase. Steps 1.a. thru d. apply to helicopters with N2 actuator circuit type 1.

1.

Close circuit breaker N2 CONT and operate the collective-rnounted four-way trirn switch as follows: a.

Forward "INCR":

N2 speed of both engines must increase

b.

Aft "DECR":

N2 speed of both engines must decrease

c.

Left "Lt":

Torque and N2 speed of No. 1 engine must increase Torque and N2 speed of No. 2 engine rnust decrease

d.

Right "Rt":

Torque and N2· speed of No. 2 engine rnust increase Torque and N2 speed of No. 1 engine must decrease

NOTE

2.

Steps 1.e. thru h. apply to helicopters with circuit type 2.

e.

Forward "INCR":

N2 speed of both engines must increase

f.

Aft "DECR":

N2 speed of both engines must decrease

g.

Left "Lt":

Torque and N2 speed of No. 1 engine must increase Torque and N2 speed of No. 2 engine rernain unchanged

Right "R+":

Torque and N2 speed of No. 2 engine rnust increase Torque and N2 speed of No. 1 engine rernain unchanged

The N2 operating range is set during the ground run at flat pitch by operating both engines together or separately. Twin-engine ground runo a.

Set rotor rprn NR at 100% + 1% with equal torque on both engines. If 100% rotor rprn cannot be achieved, set NR at rnax. possible speed with equal torque on both engines.

BO 105 CHAPTER 65 Page 38

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Shut down the engines without altering the actuator trim positions. Mark or record the lever angle settings on the quadrants of both governors. Use a felt-tip peno

c.

Press four-way trim switch forward to fully retract N2 actuators if they are still extended.

d.

If 100% NR was achieved in step a., adjust the lever angles to the settings obtained in step b. by repositioning the serrated washers (with N2 actuators retracted).

e.

If the NR achieved in step a. was less than 100%, add 3 0 for each percent deviation from 100% NR to the lever angle settings recorded in step b. This gives the lever angle settings for 100% NR. Set the levers to the corrected angles by adjusting the serrated washers.

f.

If a setting adjustment has been made on an N2 governor, check the governor to ensure that the MAX stop screw is not contacted when the N2 actuator is retracted fully at maximum collective pitch. AIso check that the MIN stop screw is not contacted when the N2 actuator is extended fully at minimum collective pitch. Perform this check with the hydraulic system pressurized. If hydraulic pressure cannot be applied, check the stop screws as follows:

Collective pitch

N2 actuator

Clearance between quadrant and stop screws

Maximum (Stick full up)

Fully retracted

Contact between quadrant and stop screw not allowed

Minimum (Stick full down)

Fully extended

3 mm clearance

g.

For 250-C20/c20B series engines with Bendix governors, check for contact with stop screws using hydraulic pressure. Contact is most likely at mínimum pitch with the N2 actuator fully extended. In this case, unscrew the MIN stop screw until there is a clearance of 0.1 mm between the stop lever and the governor housing. If there is still no clearance, rework is required in accordance with figure 65-9.

h.

Check N2 operating range. Adjust twin-engine power to produce max. possible NR. Nominal value: NR = 100 to 101.5% with equal torque on both engines. Torque split must not exceed 10%. If necessary, repeat steps a. thru g. to reset lever angle.

BO 105 CHAPTER 65 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Single-engine ground runo NOTE

o The following steps are required only if the twin-engine ground run has not been performed. o The engine not being tested can be retarded to idle to avoid a restart.

a.

Set the rotor speed NR to 98 to 99% on each engine. If this speed cannot be achieved, adjust engine to give the max. possible NR.

b.

Shut down the engine without changing the actuator trim position. Mark or record the lever angle setting on the quadrant. Use a felt -tip pen.

c.

Retract N2 actuator if still extended.

d.

If 98% NR was achieved in step a., set the lever angle setting recorded in step b. on both engines. If necessary, adjust the serrated washer (with actuator fully retracted) to aid in obtaining the setting.

e.

If less than 98% NR was achieved in step a., add 3° for each percent of deviation from 98% NR to the lever angle recorded in step b. This gives the lever angle setting for 98% NR. Adjust the serrated washer on each engine to obtain the corrected lever angle setting.

f.

Check N2 governor stop screws for contact (refer to twin-engine ground run, steps f. and g.).

g.

Start the engines.

h.

Check N2 operating range. Set the max. single engine NR for each engine. Nominal value:

NR = 98.5% to 99.5%

Set the max. twin-engine NR. Nominal value:

NR

=

100% to 101.5%

If necessary, repeat steps a. thru f. to reset lever angle.

BO 105 CHAPTER 65 Page 40

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Governor lever not shown Measure rework dlmenslon (5.5) here

Mln. stop screw backed off so that end Is flush wlth flange surface

Dlmenslons In mm

L....J...---Min S.S

Rework step lever so that strlklng surface Is paraller to flange surface

600138

Figure 65-9 65 -18

Reworking the N2 governor stop lever (Bendix governor)

Adjustment - N2 governor controls (after test flight)

If readjustment is required after the test flight, note the following basic data: 1.

On the engine showing slowest increase in torque reduce the governor lever pivot radius by up to two serrations for each percent torque split, or, alternatively, increase the lever pivot radius on the other engine by the same amount. Note that the rpm should increase between 2% and 3% from ground run at flat pitch (collective pitch stick full down) to hover flight. If the rpm increase is less than 2% or exceeds 3%, the applicable lever pivot radius must be decreased or increased, respectively.

2.

If an N2 governor has been readjusted, check the following: a.

N2 governor stop screws (refer to paragraph 65-17).

b.

Angle between the N2 governor lever and actuator axis; ang1e must be greater than 30°. (See figure 65-10).

c.

N2 trim ranges (refer to para 65-17).

BO 105 CHAPTER 65 Page 41

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

I

I

/

!

600137.2

1 Governor lever 2 Actuator

~

The angle between the governor lever and the end-to-end axis of the extended actuator must be greater than 30° (collective pitch lever full down)

Figure 65-10

BO 105 CHAPTER

Page 42

65

Checking the angle between actuator and governor lever

-------------'----'--MBB HELICOPTERS - - - . . , . . - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

700

S T A N DAR D E Q u 1 P M E N T

Tab1e of Contents

Chapter

Title

701

P 1 L OT AND COP 1 L OT S E AT S

702

C A B 1 N E Q u 1 P ME N T

703

1 N TER 1 O R P A N E L L 1 N G

704

CAB 1 N VE NT S YS T E M

705

MA S T MO M E N T 1 N D 1 C A T O R S Y S T E M

BO 105 CHAPTER 700 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 701

P I L OT AND COP I L OT S E AT S

Table of Contents

Page

Paragraph

Title

701 - 1

DESCRIPTION - PILOT ANO COPILOT SEATS

701 - 2

INSPECTION FOR CONDITION - PILOT

701- 3

REMOVAL - PILOT AND COPILOT SEATS

5

701 - 4

INSTALLATION - PILOT

5

701 - 5

Removal - Seat Rails

5

701 - 6

Installation - Seat Rails

5

ANO

ANO

3

COPILOT SEATS

COPILOT SEATS

4

BO 105 CHAPTER 701 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 701 - 1

DESCRIPTION - PILOT ANO COPILOT SEATS

The pilot and copilot seats are positioned between frames 3 is mounted on two longitudinal seat rails (9 and 11, figure fixed to the cabin floor. Stop bolts (13) hold the seats on travel adjustment handle (18) is pressed inwards, it allows slid forwards or rearwards in the seat rails.

5

1--_ _ 6

-=f:jt!-l-i...L. J

3

----¡-:::-2====~~

2

----'~

and 4. Each seat 701-1) which are the rails. If the the seat to be

Seat turned by 180 0

........

.<~ 8

~

~hmJ .~

?1

9

10

14

11

15

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17

13

18

12

19

Seat substructure Bucket seat Seat cushioning Lap belt Shoulder belt Fairing Back cushioning Fitting Seat rail, right Backing Seat rail, left Backing Stop bolt Washer Nut Screw Screw Travel adjustment handle Disengaging shaft

700010LS

Figure 701-1

Pilot and Copilot Seat BO 105 CHAPTER 701 Page 3

EUROCOPTER

MAINTENANCE MANUAL BO 105

The seat has the following parts: Seat substructure (1) with bucket seat (2) and fairing (6). Seat cushioning (3) and back cushioning (7). Lap belt (4) and shoulder belt (5). Fittings (8) for securing lap belt to floor. Seat rails (9 and 11) with stop bolts (13).

701 - 2

INSPECTION - PILOT AND COPILOT SEATS

1. Inspect seat substructure (1, figure 701-1) for deformation and riveted connections for condition. a. Change seat substructure if deformed. b. 2.

Replace loose rivets.

Inspect seat and back cushioning covers for damage. Change or repair cushioning if damaged.

3. Check that disengaging shaft (19) operates freely and easily. If stiffness is evident, clean handle (18) mechanism with dry cleaning solvent (CM 202) and lubricate with oil (CM 103). 4. Inspect fairing (6) for damage. Replace fairing if damaged (cracked). 5. Inspect shoulder belts (5) and lap belts (4) for damage, contamination and dampness. a.

If there is evidence of broken stitching, tears, chafing, and other impairing marks, replace the belts or repair in accordance with manufacturer's instructions (refer to Autoflug Component Maintenance Manual).

b. Clean dirty belt with water and mild soap (e. g. Nislin 4M). c. •

Dry damp belt straps either in the open or in a well-ventilated room away from direct sunlight.

6. Inspect lap bett lock for condition (refer to Autoflug Component Maintenance Manual). 7. Check belt locking action for correct functioning. Refer to Optional Equipment, Chapter 801-5. 8.

Unlock seat and push it forwards and rearwards. If stiff to move, remove seat and clean seat rails and rollers with dry cleaning solvent (CM 202).

CHAPTER 701 Page4

Revision 18

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 701 - 3

Removal - Pilot and Copilot Seats

1.

Separate lap belt (4, figure 701-1) from fittings (8).

2.

Remove stop bolts (13) with washers (14) and nuts (15).

3.

Press handle (18) inwards and push seat rearwards out of the seat rails (9 and 11) .

701 - 4

Installation - Pilot and Copilot Seats

1.

Insert seat into the rear of the seat rails (9 and 11, figure 701-1) and push it forwards, at the same time press handle (18) inwards and lock seat.

2.

Install stop screws (13) with washers (14) and nuts (15).

3.

Secure lap belt (4) to fitting (8).

701 - 5

Removal - Seat Rails

1.

Remove pilot/copilot seat, as required (refer to paragraph 701-3) .

2.

Remove screws (16 and 17, figure 701-1) and take out seat rail (9 or 11).

701 - 6

NOTE

Installation - Seat Rails All helicopters specified as follows must be fitted with guide rails 105-82518 or 105-82520 (also refer to IPC). - Helicopters with an extended C.G. envelope (refer to Chapter 849 and SB 80-67) - Helicopters with cross mass 2.5 t.

1.

Secure seat rail (9 or 11, figure 701-1) to floor with screws (16 and 17) .

2.

Install pilot/copilot seat, as required (refer to paragraph 701-4) ..

BO 105 CHAPTER 701 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 702

C A B 1 N E Q U 1 P ME N T

Table of Contents

Paragraph

Title

702 - 1

DESCRIPTION - CABIN EQUIPMENT

3

702 - 2

INSPECTION FOR CONDITION - CABIN EQUIPMENT

4

702 - 3

REMOVAL - C!illIN EQUIPMENT

4

702 - 4

INSTALLATION - CABIN EQUIPMENT

5

Page

BO 105 CHAPTER 702 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 DESCRIPTION - CABIN EQUIPMENT

702 - 1

The cabin equipment consists of a fire extinguisher, hand lamp andmedical kit. The fire extinguisher (1, figure 702-1) is secured in a clamping retainer to the pilot or copilot seat. The contents are indicated by a pressure gauge. If correctly filled the pointer of the pressure gauge will be in the green zone. The hand lamp (10) is secured in a clip (13) next to the pilot seat. The medical kit (16) is secured in a bracket (18) to the right of the copilot seat.

10

DETAlL DETAlL

B

A

9

15

13

1 Fire extinguisher Clamping retainer 3 Screw 4 Washer 5 Nut 6 Washer 7 Screw 8 Nut 9 Fitting 10 Hand lamp 11 Screw 12 Washer 13 Clip 14 Rubber strap 15 Locking clip 16 Medical kit 17 Screw 18 Bracket

14

2

DETAlL

e 16

700009.1

Figure 702-1

Cabin Equipment BO 105 CHAPTER 702 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 702 - 2 1.

2.

3.

Inspect fire extinguisher for damage, security of installation and for correct filling. a.

Return the fire extinguisher to manufacturer if damaged (for example: glass of pressure gauge broken, carrying handle not movable) .

b.

If lead seal is missing but fire extinguisher is correctly filled, fit a new lead seal.

c.

If pointer of pressure gauge is not in green zone, return fire extinguisher to manufacturero

Check hand lamp for correct functioning and security of installation. a.

Replace defective hand lamp or change defective item.

b.

Replace defective clip, tighten loose screws.

Inspect bracket of medical kid for obvious damage and security of installation. a.

Replace or repair bracket in care of damage.

b.

Re-tighten loose screws.

702 - 3 1.

INSPECTION FOR CONDITION - CABIN EQUIPMENT

REMOVAL - CABIN EQUIPMENT

Removal - Fire extinguisher a.

Remove fire extinguisher (1, figure 702-1) from clamping retainer (2) •

b.

Remove screws (7) with washers (6) and nuts (5) and take out fitting (9) •

c. 2.

3.

Remove screws (3) with washers (4) and nuts (8) and remove clamping retainer (2) from fitting (9).

Removal - Hand lamp a.

Remove hand lamp (10) from clip (13).

b.

Remove screws (11) with washers (12) and remove clip (13) from floor.

Removal - Medical kit and bracket a.

Open locking clip (15) and remove medical kit.

b.

Remove screws (17) and take out bracket (18).

BO 105 CHAPTER 702 Page 4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 702 - 4

1.

INSTALLATION - CABIN EQUIPMENT

Installation - Fire extinguisher a.

Secure clamping retainer (2) with screws (3), washers(4) and nuts (8) to fitting (9).

b.

Secure fitting (9) in position with screws (7), washers (6) and nuts (5) •

c. 2.

3.

Place fire extinguisher (1) in clamping retainer (2).

Installation - Hand lamp a.

Secure clip (13) to floor with screws (11) and washers (12).

b.

Place hand lamp (10) in clip (13).

Installation - Medical kit and bracket a.

Secure bracket (18) to floor with screws (17).

b.

Place medical kit (16) in bracket (18) and close locking clip (15) on rubber strap (14).

BO 105 CHAPTER 702 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 703

I N TER I O R P A N E L L I N G

Table of Contents

Page

Paragraph

Title

703 - 1

DESCRIPTION - INTERIOR PANELLING

3

703 - 2

INSPECTION FOR CONDITION - INTERIOR PANELLING

8

703 - 3

REMOVAL - INTERIOR PANELLING

8

703 - 4

INSTALLATION - INTERIOR PANELLING

8

703 - 5

Removal - Instrument Panel Fairing

9

703 - 6

Installation - Instrument Panel Fairing

9

BO 105 CHAPTER 703 Page 1/2

- - - - - - - - - - - - - . MEB HELICOPTERS ---.......,...--------MAINTENANCE MANUAL MEB - BO 105 703 - 1

DESCRIPTION - INTERIOR PANELLING

The interior panelling is manufactured from glass-fibre reinforced plastics (GRP), polycarbonate (PC) or from quilted matting. The interior panelling consists essentially of the followingpanels which are attached by means of screws, studs, press fasteners and hook- and - pile tape. Cabin structure panelling Cabin roof panelling Cabin rear wall panelling Cargo compartment panelling Rear panelling Instrument panel fairing

DETAlL

A

DETAlL

B

4

DETAlL

e

700013

Cabin structure panelling Flap 3 Cabin roof- and rear wall panelling

1 2

Figure 703-1

4 Cargo compartment panelling

Rear panelling 6 Screws 7 Profile

5

Cabin Interior Pane1ling, Cargo Compartment and Rear Panelling (Configuration 1) BO 105 CHAPTER 703 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

10

~

+

6 5

. ..

9

700002.1

Figure 703-2 BO 105 CHAPTER 703 Page 4

8 9

10 11 12 13

Cabin rear wall Cabin rear wall Stud screw Locking pin Cabin rear wall Cabin rear wall

.

.'W···' ;

,

1 Cabin structure panelling 2 Cabin roof panelling, right 3 Cabin roof panelling, left 4 Cabin roof panelling, rear 5 Hook tape 6 Pile tube '7 Flap

.

,

,

panelling, upper panelling, lower panelling, upper panelling, upper

Cabin Interior Panelling (Configuration 11)

---------~~~E,N.

MBB HELICOPTERS_ BO 105 MAINTENANCE MANUAL MBB

1 2 3 4 5

Cargo lower Cargo lower C over Cargo upp er Cargo upper

comPartmen t Panelling, right t panel1ing, compartmen left , comPartmen t panelllng, rightartmen t panelling, com P left

Figure 703-3

6 Cargo comPartment panelling, forward Handhole 87 Cargo comPp~~fment panelling, upper rearll'ng Pane 1 , 9 Rear anelling, 10 Rear Pane1ling, 11 12 Rear Rear ppane lling,

right le ft upper (BO 1055) upper

Cargo Compartmen t and Rear Panelling (Con figuration II) BO 105 CHAPTER 703 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

7

700012

Cabin roof panelling, right Cabin rear wall panelling Cover, right Cargo compartment panelling, right 5 Cargo compartment panelling, upper

1 2 3 4

Figure 703-4

BO 105 CHAPTER 703 Page 6

6 Cover, upper 7

Ventilation

8 Cargo compartment panelling, left 9 Cover, left

10 11

Cabin roof panelling, left Cabin structure panelling

Cabin Interior Panelling and Cargo Compartment (Configuration 111)

- - - . . . : . . . . - - - - - - - - - . M B B HELICOPTERS ---~------,.~---­ MAINTENANCE MANUAL MBB - BO 105

8

12 4

6 - -'L

7 700004.1

1 2 3 4

Stud Sleeve Light shield Side shield, left

5 6 7 8

Cover, left Side fairing, left Side fairing, r-ight Side shield, right

Figure 703-5

9 10 11 12 13

Screw Washer Cover, right Cover, rear Cover, upper

Instrument Panel Fairing 105 703 Page 7

BO CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS ~~~~~~~~~~~~~ MAINTENANCE MANUAL MBB - BO 105 703 - 2

1.

2.

INSPECTION FOR CONDITION - INTERIOR PANELLING

Inspect interior panelling (cabin structure panelling, cabin roof panelling, cargo compartment panelling, instrurnent panel fairing etc.) for security and damage. a.

Remove the any damaged part and either repair or replace.

b.

Retighten loose retaining items.

Check that all retaining items are fitted. Replace missing retaining items (locking pins, screws, press buttons, hook tapes a.s.o.).

703 - 3

REMOVAL - INTERIOR PANELLING

1.

Configurations 1 and 11 (figure 703-1, 703-2 and 703-3) : Remove or loosen retaining items (screws, locking pins, studs) of respective interior panelling component and remove panelling.

2.

Configuration 111 (figure 703-4): Loosen hook tapes and press buttons of respective interior panelling component and remove panelling.

703 - 4

INSTALLATION - INTERIOR PANELLING

1.

Configurations 1 and 11 (figure 703-1, 703-2 and 703-3) : Secure respective interior panelling component, using retaining items (screws, locking pins, studs).

2.

Configuration 111 (figure 703-4): Secure respective interior panelling component, using press buttons and hook tape.

BO 105 CHAPTER 703 Page 8

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 703 - 5

Removal - Instrument Panel Fairing

1.

Loosen studs (1, figure 703-5) and take out light shield (3) and side shields (4 and 8) .

2.

Loosen studs (1) and take out side fairings (6 and 7) and covers (5, 11 and 12) .

3.

Remove screws (9) with washers (10) and take out upper cover (13).

703 - 6

Installation - Instrument Panel Fairing

1.

Secure upper cover (13, figure 703-5) with screws (9) and washers (10).

2.

Secure side fairings (6 and 7) and covers (5, 11 and 12) with studs (1).

3.

Secure side shields (4 and 8) and light shield (3) with studs (1).

BO 105 CHAPTER 703 Page 9/10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

704

CAB 1 N VE NT S YS T E M

Table of Contents

Page

Paragraph

Title

704 - 1

DESCRIPTION - CABIN VENT SYSTEM

704 - 2

INSPECTION FOR CONDITION - CABIN VENT SYSTEM

3

704 - 3

Removal - Actuating Device

3

704 - 4

Installation - Actuating Device

4

704 - 5

Removal - Vent Box

4

704 - 6

Installation - Vent Box

4

....

3

BO 105 CHAPTER 704 Page 1/2

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

704 - 1

DISCRIPTION - CABIN VENT SYSTEM

The cabin vent system consists of vent boxes, spring wires and actuating devices. It is installed in the cabin on the left- and right-hand side of the instrument panel. The flow of fresh air into the cabin is regulated by means of levers (2, figure 704-1) which are connected to flaps (12) in the vent boxes (13) by means of the spring wires. 704 - 2

INSPECTION FOR CONDITION - CABIN VENT SYSTEM

1.

Inspect the actuating devices and vent boxes for damage and security. Change damaged parts. Tighten loose threaded connections.

2.

Check that the function of the actuating devices is correct and free. If there is too much friction, loosen nuts (4 and 25, figure 704-1), remove spring wire (26) and wash with dry cleaning solvent (CM 202). Lightly lubricate the bearings of levers (2 and 22) with lubricating oil (CM 103). Install spring wire (26) (refer to paragraph 704-4).

704 - 3

Removal - Actuating Device

1.

Remove instrument panel fairings as far as necessary (refer to Chapter 703) .

2.

Loosen nut (4, figure 704-1) and allow spring wire (26) to hang free.

3.

Remove actuating device (30 or 31) together with screws (29) and washers (28) •

4.

If necessary: remove screw (7) and washers (6) and take out lever (2).

5.

If necessary: remove screws (8) and washers (9) and take out rope sleeving (27), spring wire (26) and pipe clamps (10).

BO 105 CHAPTER 704 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS ------------~ MAINTENANCE ~ruAL MBB - BO 105 704 - 4

Installation - Actuating Device

1.

If removed: secure rope sleeving (27, figure 704-1), spring wire (26) and pipe clamps (10) with washers (9) and screws (8) to the instrument panel.

2.

If removed: lightly lubricate bearing pivot of base plate(l) with grease (CM 101) and secure lever (2) with screw (7) and washer (6).

3.

Install actuating device (30 or 31) with screws (29) and washers (28).

4.

Place spring wire (26) in bushing (3) and screw (23) and secure with nuts (4 and 25) .

5.

Adjust lever (2) and flap (12) as follows:

6.

a.

Move lever (2) forward to position "2 V".

b.

Loosen nut (25), secure flap (12) in closed position and tighten nut (25) .

c.

Move lever (2) and check function. Repeat adjustment if necessary.

Install ínstrument panel fairings (refer to Chapter 703) .

704 - 5

Removal - Vent Box

1.

Remove instrument panel fairings as far as necessary (refer to Chapter 703) .

2.

Loosen nut (25) and allow spring wire (26) to hang free.

3.

Remove screws (20) with washers (21).

4.

Lift vent box (13) 3nd loosen clamp (14). Remove hose (15) and take out vent box (13).

704 - 6

Installation - Vent Box

1.

Place vent box (13) in installation position and secure hose (15) to vent box (13) with clamp (14).

2.

Secure vent box (13) to instrument panel and cabin frame with screws (20) and washers (21).

3.

Attach spring wire (26) to lever (22) and secure with nut (25). Adjust flap (12) as described in paragraph 704-4, step 5.

4.

Install instrument panel fairings.

BO 105 CHAPTER 704 Page 4

MAINTEN~:

~~~~-------­

HELICOPTERS MANUAL MBB - BO 105

1 Base plate 2 Lever 3 Bushing 4 Nut 5 Screw 6 Washer 7 Screw 8 Screw 9 Washer 10 Pipe clamp 11 Rubber gasket 12 Flap 13 Vent bax 14 Clamp 15 Hose 16 Screw 17 Washer 18 Screw 19 Cover 20 Screw 21 Washer 22 Lever 23 Screw 24 Washer 25 Nut . wire 26 S prlng 27 Rape sleevin 9 28 Washer 29 Screw 30 Actuating device, left 31 Actuating device, right

10

10

19--' 17 _ _

~

12

13

DETAlL

14

700014

Figure 704-1

Cabin Vent System BO 105 CHAPTER 704

Page 5/6

10

18

B

9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 705

M A S T MO M E N T I N D I C A T O R S Y S T E M

Table of Contents

Paragraph

Title

705 - 1

DESCRIPTION - MAST MOMENT INDICATOR SYSTEM

3

705 - 2

SPECIAL TOOLS ANO TEST EQUIPMENT

5

705 - 3

TROUBLESHOOTING - MAST MOMENT INDICATOR SYSTEM

7

705 - 4

INSPECTION - MAST MOMENT INDICATOR SYSTEM

9

705 - 5

Ma s t

705 - 6

Removal - mast moment indicator

11

705 - 7

Installation - mast moment indicator

12

705 - 8

Ro t a r y

12

705 - 9

BALANCING - MAST MOMENT INDICATOR/ROTARY TRANSMITTER

13

705 - 10

S t r a i n g a u g e (D M S) (b r i d g e) ....

21

Page

mo me n t

i n die a t o r

11

t r a n s m i t ter

mo u n t i n g p 1 a t e

705 - 11

Removal - strain gauge mounting plate (bridge)

21

705 - 12

Installation - strain gauge mounting plate (bridge)

23

705 - 13

ZERO BALANCING - STRAIN GAUGE BRIDGE

30

705 - 14

CALIBRATION - STRAIN GAUGE BRIDGE

33

705 - 15

SAMPLE FORM OF TEST RECORD

36

BO 105 CHAPTER 705 Page 1/2

- - - - - - - - - - - - - . M B B HELICOPTERS - - - - . , - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 705 - 1 l.

DESCRIPTION - MAST MOMENT INDICATOR SYSTEM

General The rnast moment indicator is used to measure and transmitthe bending moments occurring at the main rotor masto The system consists of the following parts: 1 2 3 4 5

Mast moment indicator Rotary transmitter Strain gauge bridge (DMS bridge) Fuse or circuit breaker (according to configuration) Cables

3------

~~,

1 --!";4-~+_al~: 4 --,~~"_+_'~rl"I"P~

Figure 705-1

General View - mast moment indicator system BO 105 CHAPTER 705 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Operation Four strain gauges ("DMS") which are bonded to the upper section of the rotor mast and combined to form a bridge circuit (3, figure 705-1) supp1y measured values resu1ting from the bending moment of the rotor masto These values are transmitted via the inductive rotary transmitter (2) to the mast moment indicator (1) and indicated on the analog display. The scale is divided into several ranges. These ranges are color-coded as follows: - green is

normal operating range

- yellow is

caution range

- red mark

maximum (permissible bending moment is exceeded)

The system is supp1ied with current from the main bus PP21. EFFECTIVITY

705 - 2

o o

S/N 7-160 - the circuit breaker 1WM S/N 161 and up - the fuse 1WM

SPECIAL TOOLS ANO TEST EQUIPMENT

Special tools and test equipment can be replaced by tools and equipment of equivalent standard. The tools and test equipment for which a Part Number is given can be obtained from MBB. Tool No.

Part No.

Designation

1

ET BO 105 MAST MOMENT

MM replacement package repair kit

Replacement of strain gauges (DMS)

MBB

2

DMD 20

Digital strain gauge

Zero balancing and calibration of the strain gauge bridge

Hottinger Baldwin MeBtechnik GmbH Box 4235 6100 Darmstadt 1 West Germany

3

10S-94S64'W1

Balancer

Balancing of rotary transmitter/ MM indicator

MBB

BO 105 CHAPTER 705 Page 4

Use

Manufacturer

MBB HELICOPTERS MAINTENANCE MANUAL MBB - BO 105 Tool No.

Part No.

Designation

Use

Manufacturer

4

Ohrnmeter/ mu1timeter

Resistance and insulatíon measurement

Cornmercial

5

Soldering iron

Soldering of resistors

Cornmercial

6

Hot-air blower

Cornmercial Detachment of adhesive joints and shrinking-on of heat shrink sleeves

7

1x56 136 848

Bonding device

Bonding of strain gauges

ZF

8

1x56 136 905

Holding and fixing device

Bonding of mounting plate for plug-type connector in rotor mast

ZF

9

1x56 136 910

Multi-purpose bar

Preparation of bonding surfaces

ZF

10

105-13101 W5

Calibration device

Calibration of strain gauge bridge

MBB

11

1x56 136 906

Fixture

Soldering of resistors

ZF

12

1x56 136 909

Protractor

Marking of bonding surfaces

ZF

Connecting cable

Connection of digital strain gauge (DMD 20)

MBB

13

BO 105 CHAPTER 705 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 705-3 TROUBLESHOOTING-MAST MOMENT INDICATOR SYSTEM

A Replace wiring r------l harness and

assembly system Check fusl 1 WM or circuit bruker

Check ltl'll balance 01 strain gauge bridge. lolerlnc:e· -100 Ihru +1001'11/..

..¡

~N~o~

Replace or circuitfuse No

breaker Yes

Yes

No

Replace MM indicator

Mount calibration device 10S-13101WS

Adjust MM indicator for balance

No

Determine calibration value. tolerance 870 - 89S ".,./10

Replace cables

Remove rolary Iransmitter and connect lo cables luding lo MM indicafor

No Yes

Check balance

Replace rotary transmitter

No

Removl! main rotor head and inspect wiring hamess 13VB

e

A

o

E

700035

Figure 705-2

Adjust for balance

Troubleshooting - rnast rnornent indicator systern

BO 105 CHAPTER 705 Page 7/8

F

G

O~~Pter 705 - 4

MAINTENANCE MANUAL 80105

INSPECTION - MAST MOMENT INDICATOR SYSTEM

1. Functional test with stationary rotor a. Connect external power unit. b. According to configuration, push the MAST MOMENT circuit breaker (4, figure 705-1) or insert fuse 1WM. The L1MITwarning light maythen iIIuminate. In this case, press TEST push-button approximately 2 sec., release TEST push-button, pointer must return to home position until warning light extinguishes. c.

d.

Press TEST push-button (8, figure 705-7) on the mast moment indicator. -

The pointer must move to the white mark (full-scale deflection 10). If the pointer does not reach the white mark, or goes beyond it, adjust full-scale deflection using the calibrating screw "CAL" (7).

-

The L1MIT warning Iight (9) must illuminate.

Release TEST push-button. -

The warning Iight must extinguish. Pointer must return to home position.

e.

Pull MAST MOMENT circuit breaker or remove fuse 1WM.

1.

Disconnect external power unit.

2. Functional test with rotating rotor WARNING

• THIS TEST MUST BE PERFORMED BY AN AUTHORIZED PERSONo • THE COLLECTIVE PITCH STICK MUST BE IN THE LOCKED POSITION. • THE WIND SPEED MUST NOT EXCEED 10 kts AND THE HELlCOPTER MUST BE HEADED INTO THE WIND.

a. According to configuration, push MAST MOMENT circuit breaker or insert fuse 1WM (4, figure 705-1). b.

Connect external power unit.

c.

Start engines and set rotor speed to 97% nRO The pointer of the MM indicator must come to rest at a value around the "O" mark at the beginning of the green range.

CHAPTER 705 Page 9

MAINTENANCE MANUAL BO 105

d. Unlock cyclic stick and slowly push forwards. For HC model CB-S, CBS-S and DBS-S (70 mm), for al! other HC models (7S mm), measured from center of cyclic stick grip. 1) The pointer of the MM indicator must advance up to the junction of the green and yellow ranges and must remain within 4 mm of the junction in either range.

3.

e.

Return cyclic stick to neutral position and lock.

f.

Shutdown engines and disconnect external powerunit. According to configuration, pull MAST MOMENT circuit breaker or remove fuse 1 WM.

Check of the resistance values (strain gauge bridge).

NOTE

This test is only to be performed if malfunctions occur in the mast moment indicator systemo

a. Remove rotary transmitter (refer to chapter 11). b. Using ohmmeter (tool no. 4), checkthe resistance values ofthe strain gauge bridge at connector 4WMb. c.

If one or several of the measured values are outside the tolerances specified in figure 70S-3, replace strain gauge bridge (referto paragraph 70S-11). 1) At "oc;" resistance, replace wiring harness. Strain Gauge

Strain Gauge Bridge

'-3-'-'l (22 (0 .

I

I

I Frontview Connector, 4WMb

I

•

=Pin

I L.

O

= Socket

I

I I Connecting wire

Resistance beween wires 3 and 2 and 3 and 2 and 1 und 1 und

4 1 2 4 4 3

=114 to =114 to = 84 to = 84 to = 84 to = 84 to

Tolerance± Figure 70S-3

CHAPTER 70S Page 10

1260 1260 960 960 960 960

t measured at connector 4WMb

-

t

-,- I

2 1

Connector, 4WMb

1% Measurement of the resistance of the strain gauge bridge

Revision 24

-eurocopter

MAINTENANCE MANUAL BO 105

. . lIIIEAlll Compeny

705 - 5

705 - 6

Mast moment indicator

Removal - mast moment indicator

1. Disconnect power supply. 2.

Remove screws (4, figure 70S-4) attaching the Iight stop (S). Electric wire (3) may remain on the light stop (S).

3.

Disconnect connectors 2WMa, 2WMb (1) and protect with caps.

4. According to configuration, loosen tightening clamp screws (6), or remove attaching screws ofthe MM indicator. S.

Pul! out MM indicator (2) backwards from the instrument panel and protect wiring connectors with caps. 1

6----------, 9---------, 6----+-4-"''''''''' 8----l-

~----2

1 2 3 4 S 6

Connectors 2WMa, 2WMb MM indicator Electric wire Attaching screw Light stop Tightening clamp screws/ attaching screws 7 Tightening clamp 8 Instrument panel 9 Light stop bracket

7---+---H-I¡"...o

6 -------4JO"l' 6--------l,----'G

Figure 70S-4

Mast moment indicator

CHAPTER 70S Page 11

Seurocopter

MAINTENANCE MANUAL BO 105

"" EAOO CIlmp8ny

I

705 -7

Installation - mast moment indicator

AN INDIVIDUAL REPLACEMENT OF THE MAST MOMENT INDICATOR OR OF THE ROTORY TRANSMITTER IS NOT ALLOWED. MAST MOMENT INDICATOR AND ROTORY TRANSMITTER CAN ONLY BE REPLACED BY TWO OTHERS WITH IDENTICAL SERIAL NUMBERS. MAST MOMENT INDICATOR AND ROTORY TRANSMITTER MUST BE ALlGNED (SEE SI-B0105-22 REVISION 2).

CAvnON

1. Balance mast moment indicator if necessary (refer to paragraph 705-9). 2.

Install MM indicator (2, figure 705-4) on instrument panel (8), align and, according to configuration, secure by tíghteníng the tíghteníng clamp screws (6) or ínsertíng and tíghteníng the attachíng screws.

3.

Remove caps and plug in electrical connectors (1).

4.

Installlight stop (5) with attaching screws on light stop bracket (9).

5.

Perform functional test (refer to paragraph 705-4).

705 - 8

Rotary transmitter

Removal and installation of rotary transmitter (refer to chapter 11).

CHAPTER 705 Page 12

Revision 25

Oeurocopter

MAINTENANCE MANUAL SO 105

en EA!E t::ompsny

705 - 9

BALANCING - MA5T MOMENT INDICATOR / ROTARY TRAN5MITTER

A balancing of the mast moment indicator to the rotary transmitter has to be performed by the manufacturer (see 81-B0105-22 Revision 2). If balanci ng is necessary, mast mome nt ind icatar and rotary transmitter have to be sent together to the manufacturer. Mast moment indicators and rotary transmitters which have been repaired by the manufacturer are balanced. The existing tools can be used for troubleshooting. 8teps 1 until 36 deleted. Pages 14 until18 are blank pages.

~I ~I

<:

~I U')

o

~

Figure 705-5

1 Connector 4WMa 2 Receptacle 4WMB

Rotary transmitter

Figure deleted

Figure 705-6 Revision 25

Mast moment indicator CHAPTER 705 Page 13

-eurocopter •

MAINTENANCE MANUAL SO 105

en EAffi CompMy

.-.

BLANK PAGE

-

CHAPTER 705 Paga 14

MAINTENANCE MANUAL SO 105

CSeUDCOPter en EAOO Com;leny

BLANK PAGE

CHAPTER 705 Page 15

-eurocopter •

8Il EAOO

MAINTENANCE MANUAL BO 105

Comp8ny

-

BLANK PAGE

CHAPTER 705 Page 16

Seurocopter lIll

MAINTENANCE MANUAL SO 105

EAOO Com;I8ny

BLANK PAGE

CHAPTER 705 Page 17

aeurocopter •

8ft EAnS

MAINTENANCE MANUAL BO 105

Qlmpllny

BLANK PAGE

...-....-

CHAPTER 705 Page 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

s maln bus PP2'l 21Vgreen

MIl /r~+'I-----i1- 6

MM-BALANCER

51 525354

~~~'---~10

All switches in depressed "OPEN" switch position for normal operation

1)5-94564W1 ..

~--kPM-""';""4

7

2 A

•

900489

1 2 3

4 3

5

6 7 8

9 10 11

12 13 14 15 16 17

8

Comparators plug-in card

9

Toggle switch Tuning potentiometer Balancer Rotary transmitter Circuit braker or fuse Scale's initial value "O" CAL-potentiometer TEST push-button LIMIT warning light Full-scale deflection Red mark Potentiometer R99 Potentiometer R107 Potentiometer R43 Potentiometer R54 Potentiometer R31 Potentiometer R10

15---4....

'.

14---'+"'/

General view of plug-in cards and connection of balancer - mast moment indicator BO 105 705 Page 19/20

CHAPTER

• ~ Secure screw with locking adhesive

Carrier repeater plug-in card

Figure 705-7

Memory plug-in card

Base plate

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 705 - 10

St r a i n g a u g e

(DMS)

mo u n t i n g p 1 a t e

(b r i d g e)

705 - 11

Removal - strain gauge mounting plate (bridge)

1.

Remove main rotor head (refer to chapter 13).

2.

Remove rotary transmitter (refer to chapter 11).

3.

Release wiring harness (1, figure 70S-S). For this purpose, remove clamp (S) •

CONFIGURATION 11

CONFIGURATION 1

-------6 -------7

11 7

------8

........- - 2

~./I.--

5

10 9

3

Figure 70S-S

1 Wiring harness 2 Retaining disc 3 Tubing (upper half) 4 Connector 52Wa 5 Mounting plate with connector assy 52W 6 Screw 7 Washer S Clamp 9 Rotor mast 10 Nut (2 piece) 11 Nut 12 Tubing assy

Removal of wiring harness and mounting plate (bridge) BO 105 CHAPTER 705 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB'- BO 105

4. Carefully pull wiring harness (1) upwards. 5. Remove retaining disc (2) from rotor mast (9). 6. Loosen nuts (10), disconnect connector (4) from the mounting plate (5) and remove wiring harness (1). 7. According to configuration, remove upper half of the tubing (3) or tubing assy (12) from rotor masto CAUTION

BEFORE TAKlNG FURTHER MEASURES, INSTALL SUlTABLE CATCHING DEVICE (E.G. CARDBOARO DISC) IN THE ROTOR MAST BENEATH THE STRAIN GAUGES TO PREVENT THE INGRESS OF FOREIGN OBJECTS INTO THE MAIN TRANSMISSION.

8. Remove nuts (1, figure 705-9) with washers (8)and remove circuit board (2) from mounting plate (3). 9. Knock off mounting plate with flat plastic chisel (7). 10. Cut leads leading to strain gauges (4) and remove mounting plate (3) from rotor masto

11. Heat strain gauges using hot-air blower (tool no. 6) and detach together with the leads. 12. Insert a suitable light source in rotor masto 13. Carefully remove adhesive residues from the rotor mast's inner wall,' taking care to avoid scores and scratches.

BO 105 CHAPTER 705 Page 22

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 7-----~

2

r--~---:,.-"""'_I_~

3

r-+--+--t-+---I~

8

-_y-t-+---5

..........- -+--+---- 4 _~~!__---4

900050

1 Nut (2 piece) 2 Circuit board 3 Mounting p1ate 4 Strain gauges (DMS) Figure 705-9 705 - 12 1.

5 6 7 8

Bonding surfa ce Catching device Plastic chisel Washers (2 piece)

Removal of strain gauge bridge

Installation - strain gauge mounting plate (bridge)

Bonding of the strain gauges CAUTION

CARRY OUT BONDING OF THE STRAIN GAUGES IMMEDIATELY AFTER COMPLETION OF THE CLEANING PROCESS.

a.

Clean flange surface of the rotor mast and the surface in the rotor mast to be bonded, including the surrounding areas, with Acetone (CM 203) .

b.

Mark bonding surfaces (3 and 4, figure 705-10) using protractor (tool no. 12). For ·this purpose, insert the bonding device in the bore holes (1), press pressure pad against inner side of the rotor mast using lever and mark contour of the pressure pad.

BO 105 CHAPTER 705 Page 23

- - - - - - - - - - - - - M B B HELlCOPTERS - - - - - - - - - - - - MAlNTENANCE MANUAL MBB - BO 105 c.

Remove bonding tool.

d.

Prepare strain gauges for bonding: 1)

Remove 1ever from the bonding tool and clamp it in a vice. CAUTlON

2)

DURlNG THE FOLLOWlNG WORK STEP, THE BONDlNG SURFACES OF THE STRAlN GAUGES MUST NOT BE TOUCHED ANO SOlLED ANO THE SOLDER CONNECTlONS MUST NOT BE DAMAGED.

Fasten strain gauge pair 3-1 (wire colors brown, red, orange, yellow) to the lever using adhesive tape, as shown in figure 705-11.

e.

Clean marked bonding surfaces with Acetone (CM 203) and threat with abrasive cloth 180 and polishing cloth 400 using the multi-purpose bar (tool no. 9). Then thoroughly clean with cleaning tissue, lint-free cotton cloth or cleaning pad and Acetone (CM 203) .

f.

Repeat cleaning process several times until it is certain that the bonding surfaces are completely free from grease and clean. 7

6 3

5

4

2

1 Bore holes 2 Bore holes 3 Bonding surface of strain gauge pair 3-1 4 Bonding surface of strain gauge pair 4-2 Figure 705-10 BO 105 CHAP'rER 705 Page 24

5 Mounting plate 6 Bonding surface of strain gauge leads 7 Bonding surface of mounting plate 8 Rotor mast

Bonding surfaces in the rotor mast

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2-V)

4

I >-:""""""'~--------6

~~---6

5 - - - - - - - - " '....

900492

1 Pressure pad of the bonding device 2 Strain gauge bonding surface 3 Lever of the bonding device Figure 705-11

4 Strain gauge pair assy 5 Parting film 6 Adhesive tape, adhesive side

Installation of the strain gauges

g.

Clean bonding surfaces of the strain gauges (2) with cleaning tissue and Acetone (CM 203) .

h.

Brush-coat bonding surfaces with adhesive X60 (quick-cure adhesive, supplier: Hottinger Baldwin MeBtechnik GrnbH), irnmediately insert the lever of the bonding device with the strain gauges into the bonding device, mount bonding device on the rotor mast flange and press the strain gauges against the inner wall of the rotor mast until the adhesive has set (approx. 3 minutes at room temperature) . CAUT10N

i.

DO NOT REMOVE EXCESS ADHES1VE, AS THERE 1S THE DANGER OF WEAKEN1NG THE ADHES10N OF THE J01NT.

Allow adhesive to cure (approx. 20~30 minutes at 20 OC). Then detach film strip, remove bonding device and take off adhesive tape. BO 105 CHAPTER 705 Page 25

- - - - - - - - - - - - - MEB HEL1COPTERS - - - - - : . - - - - - - - - - - MA1NTENANCE MANUAL MEB - BO 105

2.

j.

Bond second strain gauge pair in the rotor mast in the same way, locating it at 180 0 relative to the first pairo

k.

Route cable of the strain gauges horizontally below the bonding surface of the mounting plate, bond with adhesive X60 (quick-cure adhesive, supplier: Hottinger Baldwin Meatechnik GmbH) "and press against the inner wall of the rotor mast using the multi-purpose bar (tool no. 9) (see figure 705-9) .

l.

After completion of bonding, apply an approx. 0.5-mm-thick protective coating of Terostat to the strain gauge bridge and its leads. Extend protective coating 3 to 5 mm beyond the cable area. Allow to cure for the period of time specified by the manufacturero

Bonding of the mounting plate CAUT10N

o CARRY OUT BOND1NG OF THE MOUNTING PLATE 1MMED1ATELY AFTER COMPLET10N OF THE CLEAN1NG PROCESS. o PROTECT1VE COAT1NG OF THE STRA1N GAUGES ANO LEADS MUST NOT COME 1NTO CONTACT W1TH ACETONE.

a.

Mark bonding surfaces (6 and 7, figure 705-10) using protractor (tool no. 12).

b.

Clean bonding surfaces with Acetone" (CM 203) and treat with abrasive cloth 180 and polishing cloth 400 using the multi-purpose bar (tool no. 9). Then thoroughly clean with cleaning tissue, lint-free cotton cloth or cleaning pad and Acetone (CM 203) .

c.

Repeat cleaning process several times until it is certain that the bonding surfaces are completely free from grease and clean.

d.

Route the ends of the strain gauge leads from below through the heat-shrink sleeve (5, figure 705-12) .

e.

Brush-coat bonding surfaces of the mounting plate (8) with adhesive X60 (quick-cure adhesive, supplier: Hottinger Baldwin Meatechnik GmbH) and, using the holding and fixing device (tool no. 8), press mounting plate with connector assy (4) against the inner wall of the rotor mast until the adhesive has set (approx. 3 minutes at room temperature) . CAUT10N

f.

DO NOT REMOVE EXCESS ADHESlVE, AS THERE 1S THE DANSER OF WEAKENING THE ADHES10N OF THE J01NT.

Allow adhesive to cure (approx. 20-30 minutes at 20 OC).

BO 105 CHAPTER 705 Page 26

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - : - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 g.

Warm up heat-shrink sleeve (5) using hot-air blower (tool no. 6). Do not overheat heat-shrink sleeve, as otherwise the insulation of the strain gauge bridges will be destroyed.

h.

Solder strain gauge bridge leads to the circuit board (see figure 705-13) .

3. Perform insulation test CAUTION a.

THE TEST VOLTAGE MUST NOT EXCEED 60V.

Connect ohmrneter (tool no. 4) successively between the individual pins of the connector 52VV (3) and a point without paint on the rotor masto In the maximum measurement range, the measured resistance value must not' fall below 100 M n . If resistance value is lower, replace strain gauge bridge.

4. Perform zero balancing (refer to paragraph 705-13). 5. Calibrate strain gauge bridge (refer to paragraph 705-14) . 6. Assemble circuit board (3, figure 705-12) with connector (4) in the rotor masto 7. Remove dirt, foreign matter and other residues from the rotor mast and take the catching device located below the strain gauges out of the rotor masto 8. According to configuration, insert upper half of the tubing (3, figure 705-8) or tubing assy (12) into the rotor mast and route wiring harness (1) downwards through the retaining disc and the tubing. 9. Plug in connectors (4, 5), tighten nuts (10) and secure with locking adhesive (CM 623) . 10. Insert retaining disc (2) into rotor mast (9) and attach wiring harness 'with clamp (8). 11. Install rotary transmitter (refer to chapter 11). 12. Install main rotor head (refer to chapter 13) . 13. Perform functional test (refer to paragraph 705-4) .

BO 105 CHAPTER 705 Page 27

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

3 --------'''\..

4-----\Q

8-----1-5-----~

DETAlLA

7

4----+-

+4-+-+----:::_ 6

900496

1 Nut (2 piece) 2 Washer (2 piece) 3 Circuit board

Figure 705-12 80 105 CHAPTER 705 Page 28

4 5 6 7 8

Mounting plate with connector Heat-shrink sleeve Strain gauge Rotor rnast Bonding surface of rnounting plate

Installation position of the rnounting plate and circuit board

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DMS

CD ®

,

CD ®

~

l

r--t--+--+--+- . -

-

"""'"'i--"~

DMS

14

i"-t--,

-.;----2

900052

~

tj -

• t----

1 2 3 4 r------3 Terminal lead colors BR1 BR2 BR3 BR4

brown, green red, blue orange, violet yellow, green

1 Strain gauges (DMS) 2 Circuit board 3 Connector S2VV Figure 705-13

Wiring diagram of the strain gauge bridge (DMS) 105 705 Page 29

BO CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 705 -13

NOTE

ZERO BALANCING - STRAIN GAUGE BRIDGE

The following description is applicable for the calibration by rneans of the digital strain gauge DMD 20. Other devices of equivalent standard can also be used. The operating instructions for the rneasuring instrurnent used rnust be observed. All values rneasured rnust be docurnented in a test record.

1. Connect DMD 20 (tool no. 2) to connector 52VV (3, figure 705-13). 2. Set bridge selector switch to Graetz bridge position. 3. Set gauge factor (K-factor) selector switch to 02.00.

4. Set cornpensation switch to + OO. 5. Set switch of zero balancing potentiorneter to OFF position.

6. Check state of charge of the rneasuring instrurnent's battery as follows: a.

Set operating rnode selector switch to BATT. CONTROL position and read off operating voltage on the digital indicator.

b.

If the reading is below 10 V, replace battery.

7. Set operating rnode selector switch to "Measure" position and read off the balance val~e of the strain gauge bridge on the digital indicator.

8. Using the rneasured value, deterrnine the resistor R4 or Rs frorn figure 705-14.

9. Rernove circuit board (3, figure 705-12) frorn the rnounting plate (4) and insert it in fixture (tool no. 11). Insert fixture in rotor rnast flange. 10. Solder selected resistor R4 or Rs on the circuit board using refined solder (see figure 705-15), pinch off protruding leads of the resistor and clean soldered joint with spirit. 11. Check zero error of the strain gauge bridge (refer to step 7). Perrnissible range: - 100 to + 100 ~rn/rn. 12. Rernove DMD 20 (tool no. 2) and connecting cable. 13. Rernove fixture (tool no. 11) and ternporarily install circuit board (3, figure 705-12) on rnounting plate (4). 14. Carry out calibration of the strain gauge bridge (refer to paragraph 705-14) .

BO 105 CHAPTER 705 Page 30

.....

p::;~.':¡<~';::! :)::¡::: ::=:!/"_~<:

o o o

'"'J

o - B&1anc1ng rniator all th. tunctton ot brld,e tunln,. ::'.':':'

.... ....

1-'-

lO

e

R ( Q)

pm/m

R ( D)

1 H

60 66 73 80 88 97 107 118 128 140 154 167 182 200 222 250 273

180 160 150 130 120 110 100 91 82 75 68 62

11 m/ m

-

t;

ro -.J D

910 820 750 680 620 560 510 470 430 390 360 330 300 270 240 220

(JI

I t-'

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ro t-' ro o

rT

1-'-

o

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1-'-

llJ lO t;

llJ

S

llJ

::l OrT llJ

t::r

:::·.i

"7"""1

--~

k k k k k k k k k k k k k k k k

k k k k k k k k le k k k

334 375 400 462 500 545 600 660 732 800 882 968

!:.:::':::: ::.::".:

{::: •

. : . : . ::.: :::.:!:::.:

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Z

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en

00

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':.

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5<XlO

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

@-RJ-~

R4-IJ @ O ::::"R5-& -IJ

I~I@@) -R2 -RI

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I()\St1tSrrSrl Sr2@) Sr'

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o

SI'

SIl

o

900495

Figure 705-15

BO 105 CHAPTER

Page 32

705

Soldering of resistors R1

-

Rs

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 CALIBRATION - STRAIN GAUGE BRIDGE

705 - 14

The following description is applicable for the calibration by means of the digital strain gauge DMD 20. Other devices of equivalent standard can also be used. The operating instructions for the measuring instrument used must be observed. All values measured must be documented in a test record.

NOTE

1.

Mount bar of the calibration device (tool no. 10) on rotor mast (for direction of installation see figure 705-16) and connect strain gauge DMD 20 (1) to connector (6).

5 ------?:~)IO~ 6 ---::f~1IL -l--I-::-tt-

DETAlL

.. A

3

A

900032.1

Strain gauge DMD 20 Strain gauges 3 Bar of the calibration device

1 2

Figure 705-16

4 Weights of the calibration

device (981 N) Rotor mast 6 Connector 52VV

5

Calibration device BO 105 CHAPTER 705 Page 33

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

2.

Set switch of zero balancing potentiorneter to "ON" position.

3.

Adjust digital indicator to "O" using zero balancing potentiorneter.

4.

Attach weights (4, figure 705-16) to bar (3).

S.

Read off first calibration value on the digital indicator and enter it in the test record.

6.

Based on the calibration value read on the indicator, take the corresponding resistance values for R1 through R3 from table 70S-l.

Calibration value

873

-

891

~~ 890

(Kn)

R2

(Q)

R3

(Q)

O

O

O

- 910

6.2

2.4

O

911

-

927

3.0

2.7

2.4

928

- 947

2.0

3.9

3.6

948

967

1.S

S.l

S.l

968

-

990

1.2

6.8

6.2

991

- 1012

1.0

8.2

8.2

1013

- 1037

8.82

10

10

1038

- 1062

0.7S

12

11

1063

- 1090

0.68

13

13

Table 70S-1

BO lOS CHAPTER 70S Page 34

R1

Selection of the calibration resistors

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - , - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 7. Removecircuit board (3, figure 705-12) from connector and mounting plate (4) and insert in fixture (tool no. 11). 8. Solder resistor R1 through R3 on the circuit board using refined solder (see figure 705-15), pinch off protruding leads of the resistors and clean soldered joints with spirit. 9. Read off calibration value on the digital indicator and enter it in the test record. Permissible tolerance: 873 - 890 ~m/m. 10. Remove DMD 20 (tool no. 2) and connecting cable. 11. Apply an approx. 3-rnm-thick protective coating of silicone rubber (CM 612) to both sides of the circuit board. 12. Remove fixture and place circuit board (3, figure 705-12) on the connector and mounting plate (4). NOTE

Use a suitable spacer to ensure that the connector S2VVa is held at the distance necessary for its connection.

13. Install circuit board (3) with washers (2) and nuts (1) and handtighten nuts. 14. After the protective coating has cured, remove the spacer. 15. For further assembly refer to paragraph 705-12, steps 9 through 13.

BO 105 CHAPTER 705 Page 35

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 705 - 15

SAMPLE FORM OF TEST RECORD

MBB

Mast Moment Indicator System Test Record Zero Balancing / Calibration'

1.

Zero balancing lrefer to paragraph 705-13) .

1.1

Balance value:

1.2

R4

1.3

Actual value after balancing

•••••••••

~m/m

or Rs

=

, (values from figure 705-14) .

(permissible range: - 100 + 100

~m/m)

2.

Calibration (refer to paragraph 705-14)

2.1

First calibration value:

2.2

Resistance value from table 705-1: R¡

= ••.•••• Kn;

2.3

Check calibration

2.4

Calibration value

R2

.

n; R3

= ••••••••

(permissible range: 873 - 890

~m/m)

Inspection:

.

BO 105 CHAPTER 705 Page 36

Date: Department: Page: of

= •..•..••••.••.

Signature:

n;

'

_eurocopter

800

MAINTENANCE MANUAL MBB - BO 105

O P T ION A L E Q U 1 P M E N T Table of Contents

Chapter

Title

801

SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

802

ELECTRICAL HEATING AND VENTILATION SYSTEM 4kW/3+1kW

803

WINDSHIELD WIPER SYSTEM

804

DUAL WINDSHIELD WIPER SYSTEM

805

WINDSHIELD WIPER AND WASHER SYSTEM

806

SPLIT BENCH SEAT

807

BENCH SEAT (PLATE-SUPPORTED)

808

BENCH SEAT (STRUT-SUPPORTED)

809

4-SEAT BACK-TO-BACK BENCH

810

RETRACTABLE LANDING LIGHT - FORWARD ACCESS DOOR

811

RETRACTABLE LANDING LIGHT - CROSSTUBE

812

SEARCH AND LANDING LIGHT

813

SEARCHLIGHT SX-16 - without infrared filter - with infrared filter

814

MEDICAL EQUIPMENT MOUNTING PLATE

815

WALL CABINET ASSEMBLY

816

SUCTION BOTTLE HOLDER

817

OXYGEN BOTTLE HOLDER

818

INFUSION BOTTLE SUSPENSION HOOK

819

MEDICAL ATTENDANT'S SEAT

Revision 8

BO 105 CHAPTER 800 Page 1

_eurocopter

MAINTENANCE MANUAL M88 - 80 105

Chapter

Title

820

CONVERTED COPILOT SEAT

821

LITTER RETENTION SYSTEM

822

CARGO HOOK SYSTEM

823

ANTlSETTLlNG SHOES

824

SNOW SKIDS

825

EMERGENCY FLOTATlON SYSTEM

826

FUEL JETTlSON SYSTEM

827

FUEL JETTlSON SYSTEM (76 mm OlA.)

828

FUEL MlCROFlLTER SYSTEM

829

CROSS FEED LlNES

830

SELF SEALlNG FUEL TANKS

831

LONG RANGE FUEL TANK

832

FUEL SYSTEM WITH DlVlDED SUPPLY TANK

833

EXTERNAL LOUDSPEAKER SYSTEM

834

EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

835

WlNCH OPERATOR'S SAFETY HARNESS

836

RESCUE WlNCH

837

EXTERNAL REARVlEW MlRROR

838

HlGH LANDlNG GEAR

839

SERVlCE HOUR METER

840

LlGHTNING PROTECTOR

841

ENGlNE AlR CLEANER

842

ENGlNE AlR CLEANER (WlTHBLEED AlR SHUTOFF)

843

ENGlNE lNLET SCREEN

BO 105 CHAPTER 800 Page 2

EUROCOPTER

Chapter

Title

844

PENDULUM ABSORBERS

845

CHIP WARNING INDICATION

846

STABILlTY AUGMENTATION SYSTEM

847

FOLLOW-UP TRIM

848

SPERRY-HELlPILOT

849

EXTENSION OF C. G. ENVELOPE 50 mm

851

SEARCH- ANO LANDING-L1GHT 450 W

852

COMPRESSOR RINSING EQUIPMENT

853

FIRE EXTINGUISHING SYSTEM

854

MAIN ROTOR BLADE FOLDING SYSTEM

855

GROSS MASS 2,500 kg

856

ATTACH FITTINGS - MULTIPURPOSE PYLON

857

CONTINUOUS IGNITION SYSTEM

858

YAW BRAKE

859

WIRE STRIKE PROTECTION SYSTEM (WSPS)

860

ENGINE AIR CLEANER - BLOWER PURGE

861

EMERGENCY FLOTATION SYSTEM (F105 - 85189)

862

WEATHER RADAR SYSTEM

863

FLlR SYSTEM

864

FREE

865

FREE

866

FREE

867

CARTRIDGE - TYPE FUEL PUMP

Revision 19

MAINTENANCE MANUAL BO 105

fij

1".•

CHAPTER 800 Page3

EUROCOPTER

MAINTENANCE MANUAL 80 105

..

BLANK PAGE

CHAPTER 800

Page4

Revision 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

801

SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

Table of Contents

Paragraph

Title

801 - 1

DESCRIPTION - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

3

801 - 2

TROUBLESHOOTING - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL o o o o o o o o o o o o o o o o o o o o o o

3

INSPECTION SCHEDULE - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL o o o o o o o o o o o o o o

4

INSPECTION FOR CONDITION - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL o o o o o o o o o o o o o

5

FUNCTIONAL TEST - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL o o o o o o o o o o o o o o o o o

5

801 - 6

REMOVAL - SHOULDER HARNESS WITH AUTOMATIC INERTIA REELo

6

801 - 7

INSTALLATION - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL o o o o o o o o o o o o o o o o o . o o o o o .

6

801 - 3 801 - 4 801 - 5

Page

BO 105 CHAPTER 801 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 801 - 1

DESCRIPTION - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

The automatic inertia reel on the pilot and copilot seats consists of a control mechanism housing (15, fig. 801-1) and an inertia reel (5) which are located on the left side and back of the seat respectively. Both components are connected together by means of a control cable (10). The shoulder harness (1) is attached to the inertia reel. The control lever (12) can be moved to three operating positions: 1

Automatic locking: the strap can be extended and retracts automatically. At accelerations of between 20 and 30 m/s 2 , the reel locks and prevents further extension of the strap.

11

Manual locking. The strap is locked.

111 -

Unlocking: as long as the control lever is held in this position, the strap can be extended and automatically retracts without locking at the specified accelerations.

A detailed description of the construction and operation of the automatic inertia reel is contained in the Autoflug Component Maintenance Manual. 801 - 2

TROUBLESHOOTING - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

Troubleshooting instructions are contained in the Autoflug Component Maintenance Manual (AFG-GH-06-34-00-00-00).

BO 105 CHAPTER 801 Page 3

EUROCOPTER

• 801 - 3

MAINTENANCE MANUAL 80105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 801 Page 4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 801 - 4

INSPECTION FOR CONDITON - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

Inspect shoulder harness for damage, contamination and dampness.

l.

a.

If there is evidence of broken stitching, tears, chafing, and other impairing marks, replace the harness or repair in accordance with manufacturer's instructions (refer to Autoflug Component Maintenance Manual) .

b.

Clean dirty harnesses with water and rnild soap (e.g. Nislin 4M).

c.

Dry damp harness straps either in the open or in well-ventilated rooms, away from direct sunlight.

2.

Without applying too much force, check that the screws of the harness buckle are seated tightly. Inspect buckle components parts for corrosion, wear and flaking chrOme plating; if necessaryreplace buckle.

3.

Inspect inertia reel (5, fig. 801-1) for damage and security of installation. Replace inertia reel if damaged; tighten lock screws attaching inertia reel to mounting plateo

4.

Inspect control mechanism housing (15) for damage and security of installation. Check control lever (12) for proper functioning. Tighten loose attaching screws; replace damaged or rnalfunctioning reel control housing.

5.

Check that union nuts (9 and 14) are seated tightly; tighten loose union nuts.

801 - 5

FUNCTIONAL TEST - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

l.

Move control lever to position 111 (unlocking) and then release control lever. It must automatically return to position 1 (automatic locking).

2.

Lean body -forward in the seat, then back again; the inertia reel strap must reel out and in =espectively.

3.

Give inertia reel strap a sudden pull; the strap must lock.

4.

Move control lever to position 111 (unlocking) and hold in this position; the strap must reel out and then retract again with no restrictions.

5.

Move control lever to position 11 (locking); the reel prevents extension of a strap.

6.

Return control lever to position 111 (unlocking), then release control lever.

BO 105 CHAPTER 801 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 801 - 6

REMOVAL - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

l.

Unscrew union nut (14, fig. 801-1) and disconnect control cable (10) from control mechanism housing (15):

2.

Remove screws (13), nuts (18) and washers (17); remove control mechanism housing from bracket (16).

3.

Remove seat fairing assembly from seat structure (hook and pile tape attachment) .

4.

Unscrew union nut (9) and disconnect control cable from inertia reel (5). NOTE

Restrain inertia reel strap from fully retracting into the inertia reel housing during the next step in the disassembly.

5.

Disconnect shoulder harness (1) from inertia reel strap by unscrewing the interconnecting bolts of the shackle on the end of the harness straps. Insert a screwdriver through the loop of the inertia reel strap to prevent it from fully retracting into the inertia reel housing when the bolts are withdrawn.

6.

Remove inertia reel from mounting plate (11) by removing attaching screws (6, 2), nuts (S, 4) and washers (7, 3).

SOl - 7 l.

INSTALLATION - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL

Connect control cable (10, fig. SOl-l) to inertia reel with union nut (9) •

2.

Mount inertia reel on mounting plate (11) with screws (6, 2), nuts (8, 4) and washers (7, 3).

3.

Guide free end of control cable through the relevant hole in the seat structure.

4.

Mount control mechanism housing to bracket (16) with screws (13), washers (17) and nuts (18); connect control cable to control mechanism housing with union nut (14).

5.

Perform functional test in accordance with para SOl-S.

6.

Attach seat fairing to seat structure with hook and pile tape.

BO 105 CHAPTER 801 Page 6

MBB HELICOPTERS - - - - - - - - - - - =.MAINTENANCE MANUAL MBB - BO 105

~." ,.! .

15

2

13

I /~

~" 14 4

DETAlL

e

\ \

11

\

VIEW

......... _-

1 Shoulder harnes s 2 Screw 3 Washer 4 Nut 5 Inertía reel 6 Screw 7 Washer 8 Nut 9 Uníon nut 10 Control cable 11 Mountíng plate 12 control lever 13 Screw 14 Uníon nut 15 Control mechanism housíng 16 Bracket 17 Washer 18 Nut 800348

301-1

Shoulder harness with inertia reel BO 105 CHAPTER 801 Paae 7/8

7

DETAlL

8

A

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

a02

ELECTRICAL HEATING AND VENTlLATION SYSTEM 4kW/3+1kW

Table of Contents

Page

Paragraph

Title

a02 - 1

DESCRIPTION - ELECTRICAL HEATING ANO VENTlLATION SYSTEM 4kW/3+1kW .

3

TROUBLESHOOTING - ELECTRICAL HEATING ANO VENTlLATION SYSTEM 4kW/3+1kW . . . . . . . . . . . . . . . .

4

INSPECTION SCHEDULE - ELECTRICAL HEATING AND VENTlLATION SYSTEM 4kW/3+1kW . . . . . . . . . . . . . . . . . .

7

INSPECTION FOR CONDITION - ELECTRICAL HEATING ANO VENTlLATION SYSTEM 4kW/3+1kw . . . . ..

a

FUNCTIONAL CHECK - ELECTRICAL HEATING ANO VENTlLATION SYSTEM 4kW/3+1kW

8

a02 - 6

Removal - vent nozzles

9

a02 - 7

Installation - vent nozzles

10

802 - a

Removal - heating cartridge

10

a02 - 9

Installation - heating cartridge

11

802 - 10

Removal - axial fan

11

a02 - 11

Installation - axial fan

12

a02 - 12

Replacement - carbon brushes (axial fan)

12

a02 -13

Removal - control unit

13

802 - 14

Installation - control unit

13

a02 - 15

Replacement - flexible hoses

13

a02 - 16

Removal - heater blower

13

802 - 17

Installation - heater blower

14

a02 - la

Removal - auxiliary control unit

14

a02 - 19

Installation - auxiliary control unit

14

802 - 2 802 - 3 a02 - 4 a02 - 5

BO 105 CHAPTER 802 Page 1/2

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DESCRIPTION - ELECTRICAL HEATING ANO VENTlLATION SYSTEM 4kW/3+1kW

l. General The system, controlled through a switch mounted on the overhead console, provides cockpit air conditioning (4kW configuration) and cargo compartment heating (3+1kW cOnfiguration); preselected temperatures and air supply are maintained at a constant level. The heating system operates only when the engines are running or an external power unit is connected. 2. Description The electrical heating and ventilation system consists of heating, circuit protection, and control components, together with an air flow distribution system comprised of flexible hoses (see fig. S02-1 and S02-2) . 3. Operation

NOTE

a.

If the rescue hoist is installed, the heating and ventilation system can only be operated with the hoist master switch at OFF. Heating Setting the overhead console-mounted switch BLOWER-OFF-HEATING 3HA to HEATING activates the axial fan SHA, which supplies the distribution system with either fresh (outside) air or cabin air, depending on the position of the air-intake lever in the ribbed cover of the air intake. Turning the rotary control knob TEMP CONT SHA on the overhead console clockwise activates the centrally mounted 1kW heating cartridges 18HA and 19HA through relay 9HA, and the laterally mounted 1kW heating cartridges 20HA and 21HA in the 4kW configuration, through relay 10HA (see fig. 802-3). In the 3+1kW configuration, the heating cartridge 20HA in the 4kW configuration is replaced by a heater blower 22HA which is controlled through the auxiliary control unit 31HA by toggle switch CARGO COM HEATING 30HA located on the overhead console. In the ON position, cargo compartment heating is provided, the temperature of which cannot be regulated (see fig. S02-4). The lamps of the four-light annunciator HEATING 7HA located in the bottom left hand corner of the overhead console, light up when their respective heating cartridge is energized.

BO 105 CHAPTER 802 Page 3

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS All the heating cartridges are protected against overheating (approx. 63 OC) by thermal switches. Additional thermal switches in the center heating cartridges interrupt the power supply as soon as the air flow temperature exceeds approx. 30 OC. b.

Ventilation Setting the overhead console-mounted switch BLOWER-OFF-HEATING 3HA to BLOWER provides the axial fan 8HA with power from the main bus PP2l, while closing the power path to the four heating cartridges in the 4kW configuration (see fig. 802-3) via blocking diodes llHA and l2HA (see fig. 802-3). with the two switch settings of toggle switch CARGO COM HEATING 30HA, the 3+lkW configuration can provide heating of the cargo compartment. In position ON, the heater blower 22HA operates in conjunction with the axial fan. In position OFF, both cargo compartment heating and ventilation are shut down (see fig. 802-4).

802 - 2

TROUBLESHOOTING - ELECTRICAL HEATING ANO VENTILATION SYSTEM 4kW/3+lkW

General Perform troubleshooting with wiring diagrams 802-1 and 802-2 in the Wiring Diagram Manual (WDM). If reseue hoist is installed, set its master switch WINCH to OFF. Check all associated switches and circuit breakers for unimpaired mechanical function. Check that all associated electrical connections are tight and secure. Troubleshoot using either external or generator power only. Depress all system circuit breakers: On instrument panel: IHA and 2HA On overhead console: l3HA, l4HA, ISHA, I6HA and I7HA Functionally check all four heating cartridges by momentarily pressing the four-light annunciator 7HA in the overhead console.

BO 105 CHAPTER 802 Page 4

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No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Axial fan 8RA inoperative in position BLOWER

Faulty axial fan

Measure applied voltage. Check for shorted coil. Replace axial fan as required

Faulty toggle switch 3RA or wiring/insulation between circuit breaker 1RA and axial fan

Check per wiring diagram. Repair as required and replace defective parts

Faulty axial fan

See above

Faulty toggle switch 3RA

Check continuity of switch and replace if necessary

Faulty control unit 19VE

Check per wiring diagram. Inspect electrical connections and ground connections. Replace control unit as required

Faulty temperature control circuit board 4RA

Check per wiring diagram. Inspect electrical connections. Replace circuit board as required

Faulty temperature control SRA

Inspect rheostat for proper function. Replace temperature control as required.

Heating cartridges do not get hot when the axial fan is operating

Faulty control unit 19VE

Check per wiring diagram. Inspect electrical and ground connections. Replace control unit as necessary

One heating cartridge fails

Faulty heating cartridge

Check heating cartridge for continuity and replace as necessary

2

3

Axial fan 8RA inoperative in position HEATING

Table 802-1

Troubleshooting (1 of 2)

BO 105 CRAPTER 802 Page 5

- - - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO lOS"

NOTE

Item 6 of the following table applies to the 3+1kW configuration only.

TROUBLESHOOTING (continued) No.

4

TROUBLE SYMPTOM

Smell of burning in cockpit

PROBABLE CAUSE

CORRECTlVE ACTION

Applicable circuit breaker in control unit is faulty

Check circuit breaker for continuity and replace as necessary

Burned winding in axial fan 8HA

Replace axial fan

Heating cartridges do not shut off

Check heating cartridges and thermoswitches; replace faulty parts

5

Temperature cannot be regulated

Temperature control circuit board 4HA faulty; faulty temperature control

Check per wiring diagram. Replace rheostat SHA or circuit board 4HA

6

Heater blower 22HA (cargo compartment heating system) inoperative

Faulty heater blower

Measure voltage. Replace heater blower as required.

Faulty wiring or insulation between toggle switch 3HA and fan heater 22HA

Check per wiring diagram. Repair wiring or insulation and replace faulty parts

Faulty auxiliary control unit

Remove control unit and check per wiring diagram. Replace faulty parts

Faulty toggle switch 3HA or 30HA

Perform functional check and replace as necessary

Table 802-1

BO 105 CHAPTER 802 Page 6

Troubleshooting (2 of 2)

EUROCOPTER

802 - 3

Revision 18

MAINTENANCE MANUAL 80 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 802 Page7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 802 - 4

INSPECTION FOR CONDITION - ELECTRICAL HEATING ANO VENTILATION SYSTEM 4kW/3+1kW

General Inspection items 1. thru 4. require prior removal of the nose door. Inspection item 8. applies to the 3+lkW configuration only. 1. Inspect axial fan SHA for external damage and security of attachment. Ensure that bonding jumper connection has a good contacto 2. Inspect manifold and elbows for security of attachment; tighten attaching hardware as necessary. 3. Inspect flexible hoses between manifold and floor passage for damage and security of attachment. Replace damaged hoses and tighten loose clamps. 4. Inspect control unit 19VE and associated wiring harness for external damage and security of attachment. 5. Inspect air intake for security of attachment and ensure air-intake lever functions properly. 6. Inspect flexible hoses in the feet area for chafe marks and breaks, and replace it necessary. Tighten loose clamps. 7. Inspect heating cartridges and vent nozzles for external damage and associated support brackets for security of attachment. 8. Inspect heater blower 22HA, auxiliary control unit 31HA and wiring harness for external damage and security of attachment.

802 - 5

FUNCTIONAL CHECK - ELECTRICAL HEATING AND VENTILATION SYSTEM 4kW/3+1kW

The system shall be functionally checked not only at the specified time intervals but also after replacement of electrical components. The functional check shall only be performed using an external power supply or with engines running and generators operating. If rescue hoist is installed, set hoist master switch WINCH to OFF. Depress following circuit breakers: On the instrument panel: 1HA and 2HA On the overhead console: 13HA, 14HA, lSHA, 16HA and 17HA

BO 105 CHAPTER 802 Page 8

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 l. Functional test - heating a.

Engage external power supply or start engines in turn and activate both generators. NOTE

If only one generator is activated or serviceable, the heating system is designed to remain OFF.

b.

Momentarily press four-light annunciator: Serviceability is indicated by lights illuminating.

c.

Set toggle switch 3RA to HEATING; turn TEMP CONT SRA full clockwise.

d.

Ensure entire heating system is operating properly.

2. Functional test - temperature control a.

Close cockpit doors.

b.

Set toggle switch 3RA to HEATING; move air-intake lever to CABIN AIR; turn TEMP CONT SRA full clockwise.

c.

Ensure entire heating system is operating properly.

d.

Turn TEMP CONT SRA counterclockwise to the point where the cabin heating is turned off (the heater blower in the cargo compartment continues to operate) .

e.

Start the cabin heating again by turning the temperature control knob clockwise. If the cabin temperature rises above or falls below the preselected temperature, the heating system will turn off or on respectively (does not apply to the cargo compartment) .

3. Functional test - ventilation a.

Set toggle switch 3RA to BLOWER.

b.

Ensure axial fan 8RA is operating properly.

802 - 6

Removal - vent nozzles

l. Side vent nozzles: Loosen clamp (16, fig. 802-5) and detach vent nozzle from adapter (17). 2. Center vent nozzles: a.

Remove screws (27) and washers (26) and detach heating cartridge from bracket (25).

BO 105 CRAPTER 802 Page 9

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Remove screws (24) and remove cover of heating cartridge electrical terminal box; disconnect electrical lead (13).

c.

Loosen clamp (16) and detach vent nozzle from adapter (17).

802 - 7

Installation - vent nozzles

l. Side vent nozzles: Install and align vent nozzle on adapter and secure with clamp (16, fig.802-5). 2. Center vent nozzles: a.

Install vent nozzle on adapter, but do not tighten clamp (16) at this time.

b.

Connect electrical lead (13) and secure cover of heating cartridge electrical terminal box with screws (24).

c.

Secure heating cartridge to bracket (25) with screws (27) and washers (26); align vent nozzle on adapter and tighten clamp (16).

802 - 8

Removal - heating cartridges

l. Side heating cartridge: a.

Remove screws (24, fig. 802-5) and detach cover of heating cartridge electricál terminal box; disconnect electrical lead (22).

b.

Loosen clamp (21); remove screws (27) and washers (26) and pull heating cartridge out of flexible hose.

c.

Loosen clamp (16) and remove attaching hardware (18, 19 and 20) . Remove assembled vent nozzle and adapter from heating cartridge.

2. Center heating cartridge: a.

Loosen clamp (21); remove screws (27) and washers (26) and pull heating cartridge out of flexible hose.

b.

Remove screws (24) and detach cover of heating cartridge electrical terminal box; disconnect electrical leads (13 and 22) .

c.

Loosen clamp (16) and remove attaching hardware (18, 19 and 20); remove assembled vent nozzle and adapter from heating cartridge.

BO 105 CHAPTER 802 Page 10

- - - - - - - - - - - - - M E B HELICOPTERS -~-----:---------­ MAINTENANCE MANUAL MEB - BO 105 802 - 9

Installation - heating cartridges

l. Side heating cartridge a.

Secure assembled vent nozzle and adapter to heating cartridge with screws (18, fig. 802-5), washers (19) and nuts (20).

b.

Secure heating cartridge to bracket (25) with screws (27) and washers (26). Connect loose end of hose to heating cartridge adapter and secure with clamp (21).

c.

Connect e1ectrical lead (22) and install cover of heating-cartridge junction box with screws (24).

d.

Align vent nozzle on adapter and secure with clamp (16).

e.

Perform functional check (refer to para 802-5) .

2. Center heating cartridge a.

Secure assembled vent nozzle and adapter to heating cartridge with screws (18), washers (19) and nuts (20).

b.

Connect electrical leads (13, 22) and install cover of heating cartridge junction box with screws (24).

c.

Se cure heating cartridge on bracket (25) with screws (27) and washers (26). Connect loose end of hose to heating cartridge adapter and secure with clamp (21).

d.

Align vent nozzle on adapter and secure with clamp (16).

e.

Perform functional check (refer to para 802-5) .

802 - 10

NOTE

Removal - axial fan

Removal of the axial fan requires prior removal of the nose door.

1. Remove screws (8, fig. 802-5) from support brackets (6, 9) and remove bonding jumper (10). 2. Withdraw axial fan (3). 3. Loosen screws (11) and detach cover of junction box (7). 4. Identify electrical wiring to aid reconnecting and disconnect electrical wiring from junction box.

BO 105 CHAPTER 802 Page 11

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Installation - axial fan

802 - 11

NOTE

Arrow on axial fan housing points left.

l. Connect electrical wiring to junction box (7, fig. 802-5).

2. Install cover of junction box with screws (11). 3. Fit axial fan (3) between support brackets (6 and 9). Install manifold and elbow mounting flange on support brackets (6 and 9) respectively with screws. 4. Install bonding jumper (10). 5. Perform functional check (refer to para 802-5) . 802 - 12

Replacement - carbon brushes (axial fan)

l. Remove axial fan (refer to para 802-10) . 2. Remove screw (35, fig. 802-5) and remove cover (36).

3. Remove screws (37) and washers (38) and rernove carbon brushes (39) from the holders. 4. Insert carbon brushes in the holders and secure with screws and washers.

5. Fit cover and secure with screw. 6. Connect axial fan to 28 VDC supply and to ground.

NOTE

If using new unlapped carbon brushes, the axial fan must be operated for 12 hours in order te lap them.

7. Install axial fan (refer te para 802-11).

BO 105 CHAPTER 802 Page 12

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 802 - 13

Removal - control unit

l. Identify electrical wiring to aid reconnection and disconnect from control

unit (12, fig. 802-5); disconnect bonding jumper. 2. Remove screws (5) and withdraw control unit. 802 - 14

Installation - control unit

l. Install control unit (12, fig. 802-5) with screws (5). 2. Connect electrical wiring and bonding jumper. 3. Perform functional check (refer to para 802-5). 802 - 15

Replacement - flexible hoses

l. Loosen all clamps and carefully withdraw old flexible hose.

2. Route new hose through the floor panel from below and attach to heating cartridge hose adapter with clamp. 3. Slide clamps onto free end of hose, position hose as instructed, and tighten clamps.

CAUTION

802 - 16

TAKE CARE THAT THERE IS NO INTERFERENCE WITH THE BELLCRANK OF THE RUDDER CONTROLS. Removal - heater blower

l. Remove screws (30, fig. 802-5) and washers (31) and remove heater blower from bracket (32).

2. Remove junction box cover. 3. Disconnect electrical wiring.

BO 105 CHAPTER 802 Page 13

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 802 - 17

Installation - heater blower

l. Connect electrical wiring. 2. Attach junction box cover. 3. Position heater blower (29, fig. 802-5) in bracket (32) and secure with screws (30) and washers (31). 4. Perform functional check (see para 802-5) . 802 - 18

Removal - auxiliary control unit

l. Open and secure rear clamshell doors.

2. Remove fairing from the canted frame on the aft right hand side of the helicopter. The auxiliary control unit (33, fig. 802-5) is attached to the forward side of the canted frame. 3. Remove electrical connector (34). 4. Remove screws (28) and withdraw auxiliary control unit.

802 - 19

Installation - auxiliary control unit

l. Install auxiliary control unit (33, fig. 802-5) to canted frame with screws (28). 2. Connect electrical connector (34). 3. Install fairing on canted frame and close rear clamshell doors.

4. Perform functional check (refer to para 802-5).

BO 105 CHAPTER 802 Page 14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

5

VIEW

B ....'"rr--

3

'3 -----#-------+--i

2

12 ----f.---1--i

VIEW

A

--+----10

~8~ I

11

~DDl(@) 11

I

cQ;cQ;cQ;cQ;OO

I I

I

~cQ;~ooo

1

I

2 ®

3 4

5 6

9

B

7

7 8 9 10 11

800343

12 13 Fig. 802-1

Heating cartridge 18HA Heating cartridge 19HA Heating cartridge 20HA Heating cartridge 21HA Axial fan 8HA Control unit 19VE Temperature control SHA Toggle switch 3HA 7HA Annunicator panel Circuit board 4HA 1VE Main relay box Circuit breaker 1HA 2HA Circuit breaker

Electrical heating and ventilation system 4kW control elements BO 105 CHAPTER 802 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

12 A----4

6---\'4IIír1

/'---- 2

VIEW

VIEW

B

A

15

10---!--

--~---!'-{ MEA11NG

11

9 800344

Fig. 802-2 BO 105 CHAPTER 802 Page 16

8

7

Heating cartridge 18HA Heating cartridge 19HA Heating cartridge 21HA Axial fan 8HA 19VE Control unit 22HA 6 Heater blower 7 Temperature control SHA 3HA 8 Toggle switch 9 Four -light 7HA annunciator 10 Circuit board 4HA 11 Toggle switch 30HA 12 Auxiliary control unit 31HA 1VE 13 Main relay box 14 Circuit breaker 1HA 15 Circuit breaker 2HA 1 2 3 4 5

Electrical heating and ventilation system 3+1kW control elements

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 AUXILlARY BUS

WINCH MASTER SWITCH 4MF

r-- ~-9\-k-~-Ñ---OFF

:

¡ L

L

::

_____ 3HA

OHEATING • OFF •

BLOWER

CIRCUIT BOARD TEMPERATURE CONTROL4HA

......;;;;.--11· BLOWER 8HA 7HA

5HA

-_.----.

.

I

r-;=---HEA'T"ER·21HA

1I

I

I

I

I

. OUTER RIGHT

-r

~~.19'

10HA

~ J INNER AIGHT

INNER LEFT

26HA I

9HA ~

"0'--"-', I

CONTROL UNIT 19 VE

--_._-.-_.

~

800345

Fig. 802-3

If rescue hoist is installed, circuit is energized through hoist master switch

Electrical heating and ventilation system 4kW - schematic diagram BO 105

CHAPTER 802 Page 17

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 WINCH MASTER SWITCH 4MF

~-~-9\-k-~---';"~~-OFF : ! L l

...-

---, CARGO COMPARTMENT HEATING 3DHA

,

.-.

';l

- - - ~.

__O!i..¡ OFF

::

_____ 3HA

o

°HEATI~G O~F

BlOWER

CIRCUIT BOARD TEMPERATURE CONTROl4HA

l-...t'~)--II~ 11 33HA

HEATER/BlOWER UNIT 22HA

--_._.

L --....

,"L ~

-~---+--

·l

HEATER

_ _ , 19H'±;

.....

I

-l+OIIIlI(}~>-- . ....,l

-

1DHA

L .1--l--. .-cr--c~-...

'-.- ; - . , . . . . - -.....

I·-~· - - - + - '

L.--±HEATER 18HA

1

CONTROL UNIT 19 VE

L-...:.

.__ . _ .

BLOWER 8HA

-800346

Fig. 802-4 BO 105 CHAPTER 802 Page 18

~

If rescue hoist is installed, circuit is energized through hoist master switch

Eleetrical heating and ventilation system 3+lkw - Sehematie diagram

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

E

VIEW

O

12 DETAlL

36

35

8

i

5~ \----14

-----39 13--~'~--'

o.

_------38

~

:

------37 6

7

8

9

3 800347

VIEwA

1 Air intake 2 Air intake lever 3 Axial fan 8RA 4 Fresh-air inlet 5 Screw 6 Support bracket 7 Junction box 8 . Screw 9 Support bracket 10 Bonding jumper 11 Screw 12 Control unit 19VE 13 Electrical lead 14 Vent nozzle, center 15 Vent nozzle, side 16 Clamp 17 Adapter 18 Screw 19 Washer 20 Nut

Fig. 802-5

21 Clamp 22 Electrical lead 23 Heating cartridge 24 Screw 25 Bracket 26 í'1asher 27 Screw 28 Screw 29 Heater blower 22HA 30 Screw 31 Washer 32 Bracket 33 Auxiliary control unit 31HA 34 Electrical connector 35 Screw 36 Cover 37 Scre\.¡ 38 Washer 39 Carbon brush

___- ~ - - 2

17

\

I I

25---t

{

/ 24 ---.JW

~-----21

Electrical heating and ventilation system 4kW/3+1kW BO 105 CHAPTER 802 Page 19/20

4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 803

WINDSHIELD WIPER SYSTEM

Table of Contents

Paragraph

Title

Page

803 - 1

DESCRIPTION - WINDSHIELD WIPER SYSTEM

3

803 - 2

TROUBLESHOOTING - WINDSHIELD WIPER SYSTEM

4

803 - 3

INSPECTION SCHEDULE - WINDSHIELD WIPER SYSTEM

7

803 - 4

INSPECTION FOR CONDITION - WINDSHIELD WIPER SYSTEM

8

803 - 5

FUNCTIONAL TEST - WINDSHIELD WIPER SYSTEM

8

803 - 6

Removal - motor .

9

803 - 7

Installation - motor

10

803 - 8

Removal - converter

10

803 - 9

Installation - converter

11

803 - 10

Replacement - wiper blade

12

803 - 11

Replacement - flexible drive shaft

12

803 - 12

Adjustment - pressure of blade on windshield

12

BO 105 CHAPTER 803 Page 1/2

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - , - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 803 - 1 l.

DESCRIPTION - WINDSHIELD WIPER SYSTEM

General The purpose of the windshield wiper system is to maintain good forward visibility for the pilot during inclement weather. The system is operated by the 2ME WIPER toggle switch which can be positioned to ON, OFF, and PARK. There are two configurations which differ in the way they are grounded. In configuration 1, the motor 4ME is grounded directly to the fuselage, while configuration 11 has the motor connected to ground via dropping resistor 3ME. Operation of both circuits is identical. Configuration 1: S/N 6 thru 160 (fig. 803-1) Configuration 11: S/N 161 and subsq. (fig. 803-2).

2.

Description The windshield wiper comprises a motor which is screwed to the underside of the front floor plate in the cockpit, and a converter which is attached with a bracket to the center post of the windshield. A flexible drive shaft connects the motor to the converter. Power from the PP22 auxiliary bus is supplied to the 4ME motor through the 1ME circuit breaker, 2ME wiper switch, and the 3ME dropping resistor. An automatic reset thermal protector breaks the motor circuit when the temperature of the motor casing exceeds 90 oC, and makes the circuit again automatically when the casing has cooled sufficiently.

3.

Operation The wiper system is operational when the wiper circuit breaker is depressed and power is supplied to the PP22 auxiliary bus. When the WIPER toggle switch is set to 1 (ON), power is supplied to the motor which drives the converter through the flexible drive shaft, causing the wiper arm to sweep back and forth across the windshield with a stroke angle of 90°. When the wiper moves into the stow (PARK) position, a limit switch in the motor is actuated causing the circuit to short and the motor to shut down. Because the wiper switch is spring-loaded in P (Park), it returns automatically to O (Off) when released. The 3ME dropping resistor limits current consumption when the 2ME wiper switch is in the position P (Park) .

BO 105 CHAPTER 803 Page 3

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TROUBLESHOOTING - WINDSHIELD WIPER SYSTEM

General Use the following wiring diagrams in the Wiring Diagram Manual (WDM) for troubleshooting the system: Configuration I: Configuration II:

803-1 803-2

Inspect all associated electrical connections for security. Check all associated switches and circuit breakers for unimpaired mechanical functioning. Engage external power supply. (16P battery switch on instrument panel in BAT OFF / EPU ON position) . Depress 1ME circuit breaker on instrument panel. No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

4ME motor defective

Check 4MEa connector for voltage; check electrical connections for good contact: Check voltage across motor using wiring diagram for the appropriate configuration. Replace motor if defective; refer to paras 803-6 and 803-7

Bonding jumper connecting 4ME motor to fuselage loose and without contact

Check bonding jumper for continuity; establish contact and tighten screw/bolt connection

Activated or defective thermal protector in 4ME motor

Inspect motor casing for excessive overheating. If motor does not automatically restart after cooling down, replace motor in accordance with paras 803-6 and 803-7

Motor 4ME fails to start when supplied with power (wiper switch in ON position)

Table 803-1 BO 105 CHAPTER 803 Page 4

Troubleshooting (1 of 3)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 TROUBLESHOOTING (continued) No. TROUBLE SYMPTOM

2

Motor runs but wiper arm does not move

PROBABLE CAUSE

CORRECTIVE ACTION

Defective 1ME circuit breaker or 2ME wiper switch

Check continuity of circuit breaker and wiper switch; check connections for good contacto Replace defective switch/circuit breaker

Defective electrical wiring

Check wiring for continuity using applicable wiring diagram. Replace faulty wiring.

Defective 3ME resistor

Measure resistance. Replace defective resistor

Configuration 11 only: Bonding jumper on 2ME wiper switch is loose and without contact

Check for continuity of bonding jumper. Establish contact and tighten screw/bolt connection

Defective converter

Replace converter in accordance with paras 803-8 and 803-9

Defective flexible drive shaft

Replace flexible drive shaft in accordance with para 803-11

3

Wiper arm oscillates too slowly

Excessive current consumption when motor opera tes under full load; brushes probably worn

Replace motor in accordance with paras 803-6 and 803-7

4

Wiper fails to stop in stow position even with toggle switch in PARK

Cam assembly/limit switch in motor defective

Replace motor in accordance with paras 803-6 and 803-7

Table 803-1

Troubleshooting (2 of 3)

BO 105 CHAPTER 803 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

5

Defective 2ME wiper switch

Check continuity of wiper switch; replace defective wiper switch

Configuration 1 only: Bonding jumper on 2ME wiper switch is loose and without contacto

Check continuity of bonding jumper; establish control and tighten screw/bolt connections

Defective electrical wiring

Check continuity of wiring using applicable wiring diagram; replace faulty wiring

Wiper does not return to stow position although wiper switch is set to PARK

. Defective thermal protector 6

Wiper blades do not provide a élear windshield

Replace motor in accordance with paras 803-6 and 803-7

Damaged or deteriorated wiper blades

Replace wiper blades in accordance with para 803-10

Tension on wiper blades too low

Adjust pressure of blade on windshield in accordance with para 803-12

Table 803-1 Troubleshooting (3 of 3)

80 105 CHAPTER 803 Page 6

EUROCOPTER

803 - 3

Revision 18

MAINTENANCE MANUAL 80 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 803

Page7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSPECTION FOR CONDITION - WINDSHIELD WIPER SYSTEM

803 - 4 1.

Inspect wiper blade for security, condition, and wear. Replace damaged and deteriorated blades.

2.

Inspect wiper arm for security and condition. If wiper arm is loose, remove lockwire from clamping SCrew¡ tighten clamping screw and secure with new lockwire.

3.

Check pressure of wiper blade on windshield¡ adjust tension in accordance with para 803-12.

4.

Check stow position of wiper blade. In the stow position the wiper blade must rest parallel to the center post of the cabin structure. The clearance between blade and center post must be approx. 30 mm. If necessary, correct stow position by relocating the wiper arm on the wiper shaft or by rotating the wiper blade.

5.

Inspect converter housing for cracks and loss of grease in vicinity of the wiper shaft, worm and housing assembly, and cover plateo Replace converter as necessary.

6.

Inspect motor and converter for security. If necessary, remove lockwire from attaching screws, tighten attaching screws, and secure with new lockwire.

7.

Inspect motor, converter, and bracket for corros ion and damaged surface protection. Touch up corroded areas and damaged surface protection as necessary.

8.

Inspect flexible drive shaft for external damage and check that both union nuts are properly lockwired.

9.

Inspect electrical connections for mechanical security and condition.

803 - 5

FUNCTIONAL TEST - WINDSHIELD WIPER SYSTEM

General - To ensure smooth operation of the wiper during the functional test, continuously spray the windshield with water or lift wiper arm clear of windshield. - Engage external power supply. Place battery switch 16P located on the right side of instrument panel in BAT OFF/EPU ON position. - Depress 1ME WIPER circuit breaker on instrument panel.

BO 105 CHAPTER 803 Page 8

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Place 2ME wiper switch in ON position. The wiper must sweep across the entire cleaning area without interruption.

2.

Place 2ME wiper switch in mid-position. The wiper must stop where it is. CAUTION

DO NOT HOLD THE 2ME WIPERSWITCH IN THE PARK POSITION FOR MORE THAN 3 SECONDS OVER A lO-MINUTE PERIOD BECAUSE THE 3ME DROPPING RESISTOR WILL OVERHEAT.

3.

Place and hold 2ME wiper switch in the PARK position. The wiper must move to the stow position parallel to the center post and come to rest there.

4.

Release 2ME wiper switch and pull out 1ME circuit breaker.

5.

Remove external power supply from helicopter.

S03 - 6

Removal - motor

1.

Make sure the wiper arm is in the stow position, then pull out the lME circuit breaker.

2.

Remove forward access door.

3.

Remove flooring material on copilot's side.

4.

Disconnect flexible drive shaft (10, fig. S03-3) from motor by unscrewing and removing union nut (26).

5.

Disconnect bonding jumper (24) from motor.

6.

Remove screws (2S) while assistant supports the motor.

7.

Remove electrical connector (27) from motor.

BO 105 CHAPTER S03 Page 9

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Installation - motor

1.

Engage external power supply (refer to Chapter 900) .

2.

Install connector(27, fig. 803-3) and lockwire.

3.

Have the assistant support the motor in its mounting position on the underside of the front floor plate; secure it with screws (28) and install lockwire.

4.

Connect bonding jumper (24).

5.

Depress 1ME circuit breaker. Move 2ME wiper switch to PARK position and hold it there until motor shuts down.

6.

Connect flexible drive shaft (10) to motor with union nut (26) and secure with lockwire.

7.

Perform functional test in accordance with para 803-5.

8.

Replace flooring material; install forward access door.

803 - 8

Removal - converter

1.

Remove instrument panel fairing, asrequired.

2.

Loosen clamping screw (18, fig. 803-3) and remove bolt (19) with washer (20) .

3.

Remove wiper arm (22) from wiper shaft.

4.

Unscrew and remove union nut to disconnect flexible drive shaft (10) from converter (11).

5.

With the assistant holding the journal box (17), unscrew nut (13) from the journal box. Remove journal box and outer rubber spacer (15).

6.

Remove screws (5) with washers (6, 7), and screws (8) with washers (6) from center post, and remove bracket (12) together with converter.

7.

Remove inner rubber spacer (15), tab washer (14), and nut (13) from wiper shaft .

8.

Remove screws (9) with washers (6) and detach converter from bracket.

BO 105 CHAPTER 803 Page 10

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803 - 9

Installation - converter

1.

Turn converter drive shaft to locate converter in stow position.

2.

Depress 1MEcircuit breaker. Hold 2ME wiper switch in PARK position until motor stops.

3.

Secure converter to bracket (12, fig. 803-3) with screws (9) and washers (6) .

4.

Install nut (13), new tab washer (14) and inner rubber spacer (15) on wiper shaft.

5.

Secure converter assembly to the windshield center post with screws ( S, 8) and washers (6, 7).

6.

Install journal box (17) and outer rubber spacer (15) on wiper shaft. With the assistant holding the journal box, screw nut (13) against the journal box; bend tab washer (14).

7.

Seal joint between the journal box and shaft sleeve with sealing compound (CM 662) .

8.

Loosen nut (1) and adjust wiper blade so that the stow position is parallel to and approx. 30 mm from the center post. Locate wiper arm on wiper shaft and tighten clamping screw (18) and nut (1).

9.

Install washer (20) and bolt (19).

10. Connect flexible drive shaft (10) to converter and secure with lockwire. 11. Perform functional test in accordance with para 803-5. 12. Check pressure of wiper blade on windshield; if necessary, adjust pressure in accordance with para 803-12. 13. Install lockwire on clamping screw (18) and bolt (19).

BO 105 CHAPTER 803 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Replacement - wiper plade

803 - 10 1.

Lift wiper arm (22, fig. 803-3) from its stow position and hold it clear of windshield by inserting a pin (2.5 mm diameter) in borehole (23) in the arm channel.

2.

Remove nut (1) with washer (2) and detach wiper blade.

3.

Install new wiper blade and align with the windshield center post.

4.

Secure wiper blade to wiper arm with nut (1) and washer (2).

5.

Remove pin and lower the wiper blade onto windshield. Verify that the wiper blade is parallel to the windshield center post; adjust blade position as necessary. Replacement - flexible drive shaft

803 - 11

NOTE

Replace flexible drive shaft with windshield wiper in the stow position.

1.

Remove instrument panel fairing as required, and remove forward access door.

2.

Disconnect the flexible drive shaft (10, fig. 803-3) from motor and from converter by unscrewing union nuts.

3.

Connect and secure new flexible drive shaft.

4.

Perform functional test with wiper arm held clear of the windshield (refer to para 803-5).

803 - 12

Adjustment - pressure of blade on windshield

1.

Attach spring scale to the measuring point (fig. 803-3) on wiper armo

2.

The wiper blade must detach from the windshield with pulling force of 15-17 N. If necessary adjust the pressure of the blade on the windshield as follows: - To decrease tension on blade, turn pressure adjusting screw (21) clockwise. - To increase tension on blade, turn pressure adjusting screw (21) counterclockwise.

3.

Operate wiper for one minute on wet windshield and then check blade tension; readjust blade tension as necessary.

BO 105 CHAPTER 803 Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2VE

-PP22

l

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2ME

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1. 2VEd

3 ME

800349

Fig. 803-1

Windshield wiper system - wiring schematic configuration 1 105 803 Page 13

BO CHAPTER

_ _ _ _ _ _ _ _ _ _ _ _ _ MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSTRUMENT PANEL 2VE PP22

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10 A

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4MEa

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------I.~ WIPER MOTOR 800350

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Wiper switch shown in stow position Fig. 803-2

BO 105 CHAPTER 803 Page 14

Windshield wiper system - wiring schematic Configuration Ir

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

+---22

21---

~---23

DETAlL

B

800351

6:. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

B1ade pressure measuring point Nut Washer free Wiper blade Screw Washer Washer Screw Screw Flexible drive shaft Converter Bracket Nut Tab washer Rubber spacer

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

18

Windshield Journal box Clamping screw Bolt Washer Pressure adjusting screw Wiper arm Bore Bonding jumper Motor Union nut Electrical connector Screw Front floor plate Protective resistor

16

11

10

Fig. 803-3

Windshield wiper system BO 105 CHAPTER 803 Page 15/16

6

9

-

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 804

DUAL WINDSHIELD WIPER SYSTEM

Tab1e of Contents

Paragraph

Title

Page

804 - 1

DESCRIPTION - DUAL WINDSHIELD WIPER SYSTEM

3

804 - 2

TROUBLESHOOTING - DUAL WINDSHIELD WIPER SYSTEM

4

804 - 3

INSPECTION SCHEDULE - DUAL WINDSHIELD WIPER SYSTEM

6

804 - 4

INSPECTION FOR CONDITION - DUAL WINDSHIELD WIPER SYSTEM

7

804 - 5

FUNCTIONAL TEST - DUAL WINDSHIELD WIPER SYSTEM

7

804 - 6

REMOVAL - DUAL WINDSHIELD WIPER SYSTEM

. .

8

804 - 7

INSTALLATION - DUAL WINDSHIELD WIPER SYSTEM

9

804 - 8

Replacement - wiper blades

11

804 - 9

Adjustment - pressure of blade on windshield

12

BO 105 CHAPTER 804 Page 1/2

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DESCRIPTION - DUAL WINDSHIELD WIPER SYSTEM

General The purpose of the dual windshield wiper system is to maintain good forward visibility for the pilot in inclement weather. The system is operated by the wiper switch WIPER located on the instrument panel. ON, OFF and PARK positions can be selected by the WIPER switch.

2.

Description The windshield wiper unit consists of two converters (22, fig. 804-2) and a motor (19). It is attached by a supporting frame (24) to the center post and horizontal frame of the cabin structure. Two converters, each connected to the motor by a coupling, convert the rotary motion of the motor to synchronous oscillating movements of the wiper arms, with the wiper arms moving in opposite directions. A cam driven by the motor drive shaft via a special gear train, regularly operates a microswitch which is also installed in the motor. The gear reduction in this cam drive is identical to that in the wiper converters. During normal operation, i.e., with the wiper switch in ON, this regular, automatic actuation of the microswitch does not affect motor operation. with the wiper switch in PARK and the 3ME dropping resistor now connected in series with the motor, the voltage applied to the motor is decreased so that the motor slows down and, after the microswitch actuates, stops. The wipers come to rest in the stow position (see fig. 804-1).

3.

Operation The system is operational when the PP22 auxiliary bus is supplied with power and the WIPER circuit breaker is depressed. With the wiper switch in the ON position, power is supplied to the 4ME motor (see fig. 804-1). The motor drives the wiper through both converters. The wiper is switched off when the wiper switch is set to OFF: Pressing and holding the wiper switch in the PARK position causes the wiper to come to rest in the stow position. The WIPER switch must not be held in PARK for more than 3 seconds over a lO-minute period because the 3ME dropping resistor will overheat.

BO 105 CHAPTER 804 Page 3

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TROUBLESHOOTING - DUAL WINDSHIELD WIPER SYSTEM

General Use wlrlng diagram 804-1 in the Wiring Diagram Manual (WDM) fer treubleshooting the system. Perform troubleshooting using external power unit. (Battery switch en instrument panel in BAT OFF/EPU ON position) Check all circuit breakers and switches for unimpaired mechanical functioning; check electrical cennection for security. Depress 1ME circuit breaker on instrument panel. If parts of the motor are damaged, the entire motor may be exchanged, or repaired in accordance with the manufacturer's instructions.

No. TROUBLE SYMPTOM

PROBABLE CAUSE

1

Defective 4ME motor

Measure voltage; check motor for continuity. Replace defective motor in accordance with paras 804-6 and 804-7

2ME wiper switch or 1ME circuit breaker defective

Check wiper switch and circuit breaker for continuity and replace if defective

Faulty wiring between 2ME wiper switch, 1ME circuit breaker, and ground (boH on instrument panel)

Check continuity of wiring. Replace faulty wiring

Converter/coupling defective

Replace converter/coupling in accordance with paras 804-6 and 804-7

2

Dual wiper system fails to start when power is applied to electrical system and 2ME wiper switch is in ON position

Motor runs but wiper arms do not move

Table 804-1

BO 105 CHAPTER 804 Page 4

. CORRECTIVE ACTION

Troubleshooting (1 of 2)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

3

Wipers fail to stop in the stow position although wiper switch is in PARK

Cam assembly/park limit switch defective

Replace motor in accordance with paras 804-6 and 804-7

4

Wipers do not return to stow position although wiper switch is in PARK

Defective 2ME wiper switch

Check wiper switch for continuity¡ replace is defective

Defective 3ME dropping resistor

Measure resistance¡ replace if defective

Worn brushes in 4ME motor

Replace motor in accordance with paras 804-6 and 804-7

Defective bonding jumper

Reestablish ground connection

Excessive current consumption with motor operating under full loa

Worn brushes in motor¡ replace motor in accordance with paras 804-6 and 804-7

5

Wiper arms oscillate too slowly

Defective coupling Replace coupling in accordance with paras 804-6 and 804-7 6

Motor operates noisily

Motor- and converter axes not aligned

Align axes in accordance with para 804-7

7

Wiper blades do not clear the windshield

Wiper blades deteriorated or damaged

Replace wiper blades in accordance with para 804-8

Tension on wiper blade too low

Adjust pressure of blade on windshield in accordance with para 804-9

Table 804-1

Troubleshooting (2 of 2)

BO 105 CHAPTER 804 Page 5

EUROCOPTER

• 804 - 3

MAINTENANCE MANUAL 80 10S

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 804 Page6

Revision 18

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INSPECT FOR CONDITION - DUAL WINDSHIELD WIPER SYSTEM

1.

Inspect wiper blades for security, condition and wear. Replace worn or damaged wiper blades.

2.

Inspect wiper arms for security and condition. If wiper arms are loose, remove lockwire from clamping screws. Tighten up and lockwire clamping screws.

3.

Check pressure of wiper blade on windshield. If necessary, adjust blade tension in accordance with para 804-9.

4.

Check stow position of wiper blades. In the stow position the wiper blades must rest parallel to the center post of the cabin structure. The clearance between each blade and the center post should be approx. 30 mm. If necessary, correct the stow position by relocating the wiper arms on their respective wiper shafts.

5.

Inspect the casing of both converters for cracks and loss of grease around thewiper shaft, worm and housing assembly and cover plateo Replace converters as necessary.

6.

Inspect wiper drive unit for security, corrosion, distortion and damaged surface protection. Replace damaged attaching hardware. Touch up damaged surface protection and corroded areas.

7.

Inspect electrical connections for security and condition.

804 - 5

FUNCTIONAL TEST - DUAL WINDSHIELD WIPER SYSTEM

General CAUTION

TAKE CARE THAT PILOT AND COPILOT DOORS ARE CLOSED DURING WIPER OPERATION WITH THE BLADES CLEAR OF WINDSHIELD.

To ensure smooth operation of wiper during functional test, continuously spray windshield with water, or lift wiper arm clear of windshield. Connect external power supply. Place battery switch on instrument panel in BAT OFF/EPU ON position. Depress 1ME WIPER circuit breaker on instrument panel. 1.

Place 2ME WIPER switch in ON position; both wipers oscillate synchronously in opposite directions. Stop wiper by moving wiper switch to OFF.

BO 105 CHAPTER 804 Page 7

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CAUTION

DO NOT HOLD THE 2ME WIPER SWITCH IN THE PARK POSITION FOR MORE THAN 3 SECONDS OVER A la-MINUTE PERIOD BECAUSE THE 3ME DROPPING RESISTOR WILL OVERHEAT.

2.

Continue to hold wiper switch in PARK position until the wiper gradually approaches stow position and the motor stops suddenly at the inboard end of the stroke.

3.

Verify that both wiper blades are parallel to the center post. Remove external power supply.

4.

Move battery switch to BAT ON. If the 2ME wiper switch is now positioned to ON, the wiper will not respond because in normal system operation it will only receive power when both generators are operating.

5.

Switch off dual wiper system and place battery switch to BAT OFF.

804 - 6 1.

2.

REMOVAL - DUAL WINDSHIELD WIPER SYSTEM

Wiper arm a.

Lift wiper arms (13, fig. 804-2) far enough away from the windshield for a pin (2.5 mm diameter) to be inserted into the borehole (12) in each arm channel to hold them clear of the windshield. Operate wiper to stow position.

b.

After removing the lockwire, unscrew and remove screw (9) with washer (10) from each wiper arm and unscrew the respective clamping screw (7); detach wiper arms from wiper shafts.

Wiper drive unit a.

Pull out 1ME circuit breaker on instrument panel.

b.

Remove instrument panel fairing as far as necessary.

c.

Disconnect electrical connector (23) and bonding jumper (3 and 20) .

d.

Remove screws (1,17) from the center post and horizontal frame and carefully withdraw the drive unit with the wiper shafts from the lead-throughs in the windshield.

e.

If required, remove the components of both windshield lead-throughs as follows: Unscrew and remove screws (4) and washers (5). This releases two washers (25), two rubber discs (26) and one retaining ring (27). Remove the four distance sleeves (6) from the boreholes around the lead-through. (Installation requires help from an assistant) .

BO 105 CHAPTER 804 Page 8

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Motor and converters a.

Remove screws (3, fig. 804-3) with nuts (1) and washers (2) and remove screws (14) with nuts (16) and washers (15).

b.

Disconnect both converters from the motor.

c.

Carefully remove couplings with spring clips (6) from the connector sleeves (7).

d.

Remove screws (11) and washers (10); remove bracket (12) from motor (5).

804 - 7 1.

2.

INSTALLATION - DUAL WINDSHIELD WIPER SYSTEM

Initial setting of motor and converters. a.

Engage external power supply.

b.

Connect electrical connector (9, fig. electrical bonding connection.

c.

Hold motor so that its weight is not supported by wiring harness and bonding jumper (8); now depress 1ME circuit breaker on instrument panel and then hold WIPER toggle switch on instrument panel in PARK position until the motor stops in the stow position.

d.

To proceed.with installation, again disconnect electrical connector and bonding jumper from motor.

e.

Now adjust both converters to their respective stow positions by rotating the converter drive shafts until the wiper arms reach the inboard end of their strokes. (Note that wiper shafts oscillate in opposite directions) .

804~3)

to motor (5) and make

Assembling the motor and converters. a.

Install new O-rings in the connector sleeves (7, fig. 804-3).

b.

Lubricate right and left couplings and associated spring clips (6) with grease (CM 102), and carefully install the couplings on their respective converter drive shafts.

c.

To avoid damaging the O-rings, carefully connect the converters to the right and left motor shafts via the couplings.

BO 105 CHAPTER 804 Page 9

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NOTE

3.

For a good ground connection, the following mating surfaces must be free from non-conductive finishes: Wiper motor - bracket Converter - supporting frame Bracket - supporting frame

d.

Attach bracket (12) loosely to supporting frame (13) with screws (14), washers (15) and nuts (16).

e.

Fit motor and converters in supporting frame; attach converters to supporting frame with screws (3), washers (2) and nuts (1); attach motor to bracket with screws (11) and washers (10).

f.

Make absolutely sure that the axes of the motor and converters are aligned when tightening the screws installed in steps d. and e.

g.

Connect electrical connector and bonding jumper to motor; position WIPER switch to ON and check that motor runs smoothly. If motor is rough-running, realign motor and converters.

h.

Disconnect electrical connector and bonding jumper again; apply lacquer to any exposed bare metal surfaces.

i.

Replace removed lockwires.

Installation of wiper drive unit a.

If removed, re-install lead-through components by inserting the four distance sleeves (6, fig. 804-2) first. Then hold rubber disc (26) and washer (25) correctly aligned on the outer surface of the windshield and, with the assistant doing likewise with rubber disc (26), washer (25) and retaining ring (27) on the inner surface, install and handtighten the four screws (4) and washers (5).

b.

Back off two screws (18) and four screws (21) only enough turns to allow displacement of the retaining bracket. Carefully insert wiper shafts through the windshield lead-throughs.

c.

Loosely attach support structure to center post and horizontal structure with screws (17), washers and nuts, and screws (1), two washers and nuts, respectively; align support structure so that wiper shafts are concentric with the lead-though and provide a tight seal with the rubber discs (26).

d.

Tighten screw connections (1, 17, 18, 21).

BO 105 CHAPTER 804 Page 10

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4.

5.

e.

Connect bonding jumpers (3, 20) with screws, washers, spring washers, and nuts.

f.

Connect electrical connector (23) and install lockwire.

Installing the wiper arms. a.

Temporarily install and hold left wiper arm (13, fig. 804-2) on wiper shaft; after removing the retaining pin from borehole (12) in the arm channel, lower the wiper arm with blade onto the windshield so that the wiper blade is parallel to and approx. 30 mm away from the center post.

b.

If necessary, adjust stow position of wiper blade by loosening nut (16) and repositioning the wiper arm to give the specified clearance. Tighten nut (16) and clamping screw (7). Install screw (9) with washer (10).

c.

Repeat steps a. and b. for the right wiper armo

Concluding work. a.

Check pressure of blade on windshield; if necessary, adjust tension on wiper blade (refer to para 804-9).

b.

Perform functional test (refer to para 804-5).

c.

Lockwire screw (9) to clamping screw (7).

d.

Install' instrument panel fairing.

804 - 8 l.

Replacement - wiper blades

Lift wiper arms (13, fig. 804-2) from their stow positions and ho1d them , clear of windshield by inserting a pin (2.5 mm diameter) in borehole (12) in each arm channel.

2.

Remove nut (16) with washer and detach wiper blade.

3.

Insert new wiper blade and position it parallel to and approx. 30 mm away from the center post.

4.

Secure wiper blade to wiper arm with nut and washer (16).

5.

Remove pin and lower the wiper blade onto the windshield; realign wiper blade if it is not parallel to the center PQst.

BO 105 CHAPTER 804 Page 11

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804 - 9

Adjustment - pressure of blade on windshield

l.

Attach spring scale to measuring point (fig. 804-2) on wiper armo

2.

The wiper blade must detach from the windshield with a pulling force of 15-17 N. If necessary, adjust pressure of blade on windshield as follows: - To decrease tension on blade, turn pressure adjusting screw (11) clockwise. - To increase tension on blade, turn pressure adjusting screw (11) counterclockwise.

3.

Operate wiper for one minute on a wet windshield and then check blade tension; readjust blade tension as necessary.

BO 105 CHAPTER 804

Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

0

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Figo 804-1

Dual windshield wiper system - Wiring Diagram

BO 105 CHAPTER 804 Page 13/14

-<>-1

- - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

VIEwA

VIEW

....'...,........

B

...

,'"

~

""

14 - - - , . . , -

'" ........

14

13-_-..'

6-7 Nm

11

I 6- 7 Nm I 9. 10 8 2.6-3.2 Nm I 7

6-7 Nm

~ Blade pressure measuring point 1 2

3 4 5 6

7 8 9 10 11

12 13 14

Screw Center post Bonding jumper Screw Washer Distance sleeve Clamping screw Lockwire Screw Washer Pressure adjusting screw Borehole Wiper arIO Wiper blade

15 16 17 18 19 20 21 22 23 24 25 26 27

free Nut, washer Screw Screw Motor Bonding jumper Screw Converter Electrical connector Supporting frame Washer Rubber disc Retaining ring

+/----19

3---1I-i-./

20

I 2.6-3.2

Nm

I 25

I 6-7 Nm

26

25

27

11 I

~

DETAlL 800353

7

Fig. 804-2

26

Dual windshield wiper system BO 105 CHAPTER 804 Page 15/16

e

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

.~3 "r---- 4 ~---5

7

·1

6-7 Nm

~----10

1 - - - - 1 1 110-11 Nm

I

12

~---13

1 2

3 4 5 6 7

8

Nut Washer Screw Converter Motor Coupling with spring clip Connector sleeve Bonding jumper Fig. 804-3

9

10 11

12 13 14 15 16

Electrical connector Washer Screw Bracket Supporting frame Screw Washer Nut

Windshield wiper aggregate BO 105 CHAPTER 804 Page 17/18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 805

WINDSHIELD WIPER ANO WASHER SYSTEM

Tab1e of Contents Paragraph Title

Page

805 - 1

DESCRIPTION - WINDSHIELD WIPER AND WASHER SYSTEM

3

805 - 2

TROUBLESHOOTING - WINDSHIELD WIPER ANO WASHER SYSTEM

3

805 - 3

INSPECTION FOR CONDITION - WINDSHIELD WIPER ANO WASHER SYSTEM .

7

805 - 4

FUNCTIONAL TEST - WINDSHIELD WIPER ANO WASHER SYSTEM

8

805 - 5

REMOVAL AND INSTALLATION - WINDSHIELD WIPER ANO WASHER SYSTEM .

9

805 - 6

ADJUSTMENT - WINDSHIELD WIPER ANO WASHER SYSTEM

14

805 - 7

INSPECTION SCHEDULE - WINDSHIELD WIPER ANO WASHER SYSTEM . . . . . . . . . . . . . . . . .

15

BO 105 CHAPTER 805 Page 1/2

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 805 - 1

DESCRIPTION - WINDSHIELD WIPER ANO WASHER SYSTEM

In conjunction with the dual windshield wiper system (refer to chapter 804) the windshield wiper and washer system is provided to clean the windshield on the pilot's and copilot's sides. The system consists of the spray-nozzle (22, fig. 805-1) mounted onto the wiper blades, the reservoir (6) with the electrical motor pump (8) and the hose lines. The reservoir (contents: approx. 6 litres) is installed on the inside of the left cargo compartment door (5). The system is supplied with power from main bus NON ESS BUS PP22 via circuit breakers WIPER (4) and WASH (3) in the instrument panel (2). The system is controlled by means of the toggle switch WIPER (1) on the instrument panel. It can be set to positions OFF, WIPER and WASH. When set to spring-loaded position WASH, washing fluid is sprayed onto the windshield and after a short delay the wiper starts one complete cycle operating, and returns to its endposition activated by relay 8ME in control box 92VE (23) .The control box is located below the floor and installed on frame 2, fwd, LH. 805 - 2

TROUBLESHOOTING - WINDSHIELD WIPER ANO WASHER SYSTEM

General Troubleshooting procedure only applies to the washer system. Troubleshoot dual windshield wiper system in accordance with chapter 804. Use wiring diagram "Windshield Wiper and Washer" of the wiring diagram manual (WDM) . Troubleshooting is performed with EPU connected to the helicopter. Circuit breakers WASH and WIPER (instrument panel) must be depressed. -

Close pilot's and copilot's doors. To prevent the wiper blades·from contacting the windshield when operated for test purposes, lift off wiper arms and secure them by inserting metal pins into the respective holes.

BO 105 CHAPTER 805 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 TROUBLESHOOTING (continued)

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Water is not sprayed onto windshield with toggle switch set to WASH

No washing fluid in reservoir

Fill reservoir with washing fluid

Motor pump not supplied with power

Check complete electric system of windshield wiper and washer system in accordance with wiring diagram. Replace defective parts

Motor pump defective

Check motor for function (audible sound), replace if necessary (refer to 805-5)

Pump intake clogged

Remove motor pump (refer to 805-5) and clean intake

Check valve in hose Une binding or defective

Replace check valve (refer to 805-5)

Hose lines clogged, kinked or squeezed

Clean or re-route hose Unes

Incorrect adjustment of delay circuit

Check adjustment, re-adjust if necessary (refer to 805-6)

2

Washing fluid is sprayed onto windshield only after wipers started operating

Table 805-1

BO 105 CHAPTER 80S Page 4

Troubleshooting

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

B

DETAlLA

:,&----22 4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Toggle switch Instrument panel (control panel) Circuit breaker Circuit breaker Cargo compartment door Reservoir Strap Motor pump Support Fitting Clamp Hose line Clamp Hose line Check valve Electric wiring Tee Union 20 Screwed joint Hose line Hose line Spray-nozzle Control box 92VE

Figure 805-1

3

2

-':"'---5 4-"';"'--6

N-+.....:--~'---I---7

8 9 18

17

ATH.709.2.1

Windshield wiper and washer system

BO 105 CHAPTER 805 Page 5/6

DETAlLe

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 805 - 3

INSPECTION FOR CONDITION - WINDSHIELD WIPER AND WASHER SYSTEM

This inspection for condition only applies to the washer system. For conditional inspection of dual windhsield wiper system refer to chapter 804. l. Inspect hose lines and reservoir as follows: a.

Check fluid level of reservoir; if necessary fill reservoir with washing fluid. Mixing ratio of antifreezing or cleaning is indicated on the reservoir.

b.

Inspect reservoir for general condition, secure fit and contamination. If necessary, replace, fasten or clean reservoir.

c.

Inspect visible sections of hose lines for secure fit of connections, for chafing, porosity and leaks. - If necessary replace hose lines or re-tighten leaking hose connections.

2. Inspect spray-nozzles for damage, clogging and secure fit. - If necessary clean nozzles or replace wiper blades together with nozzle assembly. 3. Inspect electrical system as follows: a.

Inspect circuit breakers, toggle switches and push bottons for general condition, secure fit and mechanical operation. - If necessary fasten or replace switches.

b.

Inspect motor pump for general condition and secure fit. - If necessary fasten or replace motor pump.

c.

Inspectvisible sections of electric wiring for chafing. - If necessary repair or replace wiring.

d.

Inspect electric connections for secure fit and corrosion. - If necessary, re-tighten connection, remove corros ion or replace plug or receptacle.

e.

Inspect control box 92VE for secure fit and general condition. - If necessary fas ten control box, replace damaged parts or control box completely.

SO 105 CHAPTER 805 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4. Inspect dacals for presence, separation and legibility. - If necessary fasten or replace decals. 805 - 4

FUNCTIONAL TEST - WINOSHIELD WIPER ANO WASHER SYSTEM

CAUTION

TAKE CAR THAT PILOT ANO COPILOT DOORS ARE CLOSED DURING WIPER OPERATION WITH THE BLADES CLEAR OF WINDSHIELD

l. To prevent the wiper blades from contacting the windshield, lift off wiper

arms and secure them by inserting metal pins into the respective holes. 2. Connect external power supply (refer to chapter 92) and depress circuit breakers WIPER and WASH on instrument panel.

CAUTION

o MAXIMUM OPERATION TIME MUST NOT EXCEED 10 SECONDS ALLOW SYSTEM SEVERAL MINUTES TO COOL DOWN AFTERWARDS. o IN NORMAL OPERATION, A MAXIMUM OF 10 WASHER-WIPER CYCLES WITH 2 SECONOS OPERATION AND 2 SECONDS STANDSTILL IS PERMISSIBLE. ALLOW SYSTEM SEVERAL MINUTES TO COOL DOWN AFTERWARDS.

3. Set toggle switch WIPER in the control panel to WIPER. - The wiper arms shall synchronously swivel into opposing directions. 4. Set toggle switch to OFF. - Motor continues running and must then stop abruptly. - Wiper blades must be in a parallel position to the center spar. 5. Set toggle switch WIPER to WASH position and release.

- Washing fluid must be sprayed onto the windshield. After 2.5 s the spray procedure must be finished and one wiper cycle must be triggered. 6. Pull circuit breakers WIPER and WASH and disconnect EPU.

BO 105 CHAPTER 805 Page 8

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 805 - 5

REMOVAL AND INSTALLATION - WINDSHIELD WIPER AND WASHER SYSTEM

For removal and installation procedures of the dual windshield wiper system refer to chapter 804. l. Removal and installation - control box 92VE (3, fig. 805-2). a.

Switch off power supply.

b.

Remove nose access door.

c.

Disconnect electric connector 92VEA/a (1) and protect connector and receptacle with caps.

d.

Remove bolted joints (2) and remove control box from frame 2.

e.

Install control box in reverse order of removal, then perform functional test (refer to paragraph 805-4) .

Frame 2

Floor forward

j

'mE r'4kE I cmm

I

'!S&F

l1láííF I

o ATH.109.1.1

2

3

2

1 Electric connector 2 Bolted joint 3 Control box

Figure 805-2

Removal and installation - control box 92VE BO 105 CHAPTER 805 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2. Removal and installation - relay 6ME, 7ME, 8ME (1, fig. 805-3). a.

Remove capacitor 13ME (12) out of its support to perform removal of relays 7ME and 8ME (refer to step 3.b.). Do not unsolder electric wiring.

b.

If relay 8ME has been removed, the delay must be adjusted after installation (refer to paragraph 805-6) .

c.

Remove nuts and remove the respective relay (1) out of socket (2).

3. Removal and installation - capacitor 13ME (12). a.

Remove shrinkable sleeves from capacitor and unsolder electric wiring.

b.

Loosen nut (13) of capacitor and remvoe capacitor out of its support (11) •

CAUTION

IN ORDER TO INSULATE THE CAPACITOR AND THE CONTROL BOX HOUSING FROM EACH OTHER, SLIDE TRANSPARENT SLEEVE OVER CAPACITOR BODY PRIOR TO INSTALLATING A NEW CAPACITOR.

c.

Fasten capacitor to support, using nut. Secure nut with securing compound (CM 620) .

d.

Slide appropriate shrinkable sleeves over electric wiring and solder electric wiring to capacitor in accordance with the wiring diagram (refer to WDM) .

e.

Slide shrinkeable sleeves onto soldering joints.

4. Removal and installation - control relay 9ME (4). a.

Remove shrinkable sleeves from electric connections of the control relay and unsolder electric wiring.

b.

Loosen clamp (3) and draw out control relay.

c.

Slide appropriate shrinkable sleeves over electric wiring prior to installation.

d.

Install control relay in control box, using clamp and solder on electric wiring in accordance with-wiring diagram (refer to WDM).

e.

Slide shrinkable sleeves onto soldering joints.

BO 105 CHAPTER 805 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 5. Removal and installation - diodes lsME, 16ME, 17ME (7, 6, 10) and resistor 14ME (9). a.

Loosen screws (8) and remove respective diode (6, 7, 10) or resistor (9) from terminal junction box (5).

b.

Fit new part with appropriate insulated terminals prior to installation. Slide transparent shrinkable sleeve over diodes.

c.

Install diode or resistor to terminal junction box with screws; proceed in accordance with wiring diagram (refer to WDM) .

3

2

4

o 13 _ _

o o 9 ME o

12 ----iH~~A

o 11

10

9

8

7

6

5

ATH.709.3.1

1 Relay 2 Socket 3 Clamp 4 Control relay 5 Terminal junction box 6 Diode 16ME

Figure 805-3

7 Diode lsME 8 Screw 9 Resistor 10 Diode 17ME 11 Support 12 Capacitor 13 Nut

Removal and installation - components of control box 92VE

80 105 CHAPTER 805 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 6. Removal and installation - resistor 18ME and 19ME (4, fig. 805-4). a.

Remove nuts (1) and electric wiring (2).

b.

Loosen bolted joints (3) and remove resistor (4).

c.

Installation is performed in reverse order of removal. Connect electric wiring in accordance with wiring diagram (refer to WDM) .

ATH.709.4.1

1 Nut 2 Electric wlrlng 3 Bolted joint

Figure 805-4

BO 105 CHAPTER 805 Page 12

4 Resistor 5 Control box 92VE

Removal and installation - resistors 18ME and 19ME

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 7. Removal and installation - reservoir (6, fig. 805-1). a.

Disconnect electric connectors 986VF and 29AT from frame SP10.

b.

Remove clamp for the electric wiring of the motor pump.

c.

Remove lockwire and loosen bolted joint of strap.

d.

Withdraw reservoir out of support (9) far enough to gain access to the hose connection of the motor pump (8).

e.

Loosen hose clamp (11) and slide aft over hose line (12).

f.

Remove hose line from fitting (10) of motor pump (8). Use suitable container to catch spilled fluid.

g.

Remove reservoir out of support.

h.

Installation is performed in reverse order of removal. Secure bolted joint of strap with lockwire, then perform functional test (refer to paragraph 805-4) and visually check system for leaks.

8. Removal and installation - motor pump (8, fig. 805-1). a.

Remove reservoir (refer to step 7.).

b.

Remove lacing twine from the electric wiring (16) of the motor pump.

NOTE

Seals are fitted at the locations where motor pump and reservoir are jointed. The motor pump is additionally fixed of a clamping device.

c.

Remove motor pump from reservoir (6).

d.

Remove shrinkable sleeve from electric connector and push pins out of connector.

e.

Installation of the motor pump is performed in reverse order of removal. Crimp terminals on electric wiring and slide shrinkable sleeve on electric wiring prior to installation. Insert contacts into connector in accordance with wiring diagram (refer to WDM) and shrink sleeve on connector.

BO 105 CHAPTER 805 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 9. Removal and installation - check valve (15, fig. 805-1). a.

Loosen clamps (13) on check valve fittings and remove hose lines (12, 14) .

b.

Slide hose lines over fittings of replacement check valve and fasten with clamps. Make sure that the check valve is installed in the correct position.

805 - 6

ADJUSTMENT - WINDSHIELD WIPER ANO WASHER SYSTEM

If the delay between washer and wiper cycle is not equal to 2.5 s, the period can be adjusted with the adjustment screw (2, fig. 805-5) of relay 8ME (1). Adjustment is also required after replacement of relay 8ME (1). The adjusting screw can be turned by means of a screw driver which has to be inserted into bore (3) of control box 92VE (4). 1. Remove nose access door. 2. Perform functional test in accordance with paragraph 805-4 and measure the delay between washer and wiper cycle, using a stop watch. 3. If the measured value is much greater than 2,5 s, the adjusting screw (2) of relay 8ME (1) must be turned to the left. If the period is much less than 2,5 s, the adjusting screw must be turned to the right. 4. Repeat steps 2. and 3. until the deleay approximately equals 2.5 s. 5. Install nose access door.

4

3

2

1 2 3 4

Figure 805-5 Bo 105 CHAPTER 805 Page 14

Adjusting the delay

Relay 8 ME Adjusting screw Bore Control box 92VE

EUROCOPTER

805 - 7

Revision 18

MAINTENANCE MANUAL 80 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 805 Page 15

EUROCOPTER

MAINTENANCE MANUAL 80105

BLANK PAGE

CHAPTER 805 Page 16

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

806

SPLIT BENCH SEAT

Table of Contents

Paragraph

Title

806 - 1

DESCRIPTION - SPLIT BENCH SEAT

3

806 - 2

INSPECTION SCHEDULE - SPLIT BENCH SEAT

4

806 - 3

INSPECTION FOR CONDITION - SPLIT BENCH SEAT

5

806 - 4

REMOVAL - SPLIT BENCH SEAT

5

806 - 5

INSTALLATION - SPLIT BENCH SEAT

6

Page

BO 105 CHAPTER 806 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

806 - 1

DESCRIPTION - SPLIT BENCH SEAT

The bench frame (1, fig. 806-1) is a tubular construction providing seating for three people. The bench frame is attached to the cabin floor and fuselage at frame 7 by stud fittings (9) and quick-release pins (19) respectively. A quick-release pin (17) connects strut (15) with support tube (16), which is fastened to the lateral spar of the cabin rear wall by an additional stud and pan fitting. The two seat bottoms (2 and 7) consist of flame-resistant fabric and have back cushions sewn on them. These two back cushions and the cornrnon back cushion (3) above them are attached to the cabin rear wall by studs (24). On S/N 50 and subsq., the back cushions are replacedby overall cushioning of cabin rear wall. The three lap-safety belts (manufactured by Autoflug GrnbH) are attached to rings (18) and fittings (20) on frame 7. The two-man seat or the entire bench can be folded up against the back cushion.

BO 105 CHAPTER 806 Page 3

EUROCOPTER

• 806 - 2

MAINTENANCE MANUAL BO 10S

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 806 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSPECTION FOR CONDITION - SPLIT BENCH SEAT

806 - 3

1. Inspect bench frame (1, fig. 806-1) for distortion and damage. Replace any defective structural member. 2. Inspect stud fasteners (21 and 24) and quick-release pins (14 and 19) for condition and correct locking and release action. Remove damaged or poorly functioning stud fasteners and quick-release pins.

3. Inspect stud fittings (9) for security and correct locking and release action. If necessary, tighten hardware attaching stud fittings to bench legs; replace poorly functioning tube fittings. 4. Inspect fabric seats (2 and 7) and back cushion (3) for damage. Replace if

damaged. 5. Inspect lacing cords securing the fabric seats to the bench frame.

a.

Tighten loose cords.

b.

Replace worn or overstretched cords.

6. Inspect lap-safety belts for security and condition. If required, tighten attaching hardware of rings (18) and fittings (20) or replace lap-safety belts if damaged. 806 - 4

NOTE

REMOVAL - SPLIT BENCH SEAT

The two-man seat can be removed separately.

l. Remove stud fasteners (24, fig. 806-1), eyelets (25) and locking washers (26) and remove back cushion (3) from the cabin rear wall. 2. Detach lap-safety belts (8) from rings (18) and fittings (20) on frame 7. 3. Unlace cords attaching fabric seats (2 and 7) to bench frame. 4. Remove stud fasteners (21), eyelets (22) and locking washers (23) and remove fabric sets. 5. Remove quick-release pins (19) and tension strap (6).

6. Remove bench frame as follows: a.

Remove quick-release pins (17).

b.

Depress sleeve locks (10) on the stud fittings and pull sleeves (11) back over the sleeve locks so that jaws (12) disengage from studs (13) in the pan fittings.

c.

Withdraw bench frame and assembled tube fittings. BO 105 CHAPTER 806 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 806 - 5

INSTALLATION - SPLIT BENCH SEAT

l. Install bench frame as follows: a.

Locate bench frame in installed position.

b.

Depress sleeve locks (10, fig. 806-1) and pull sleeves (11) back over the sleeve locks. Position stud fittings (9) in bench legs and rear strut over the corresponding studs (13) in the cabin floor and lateral spar of the cabin rear wall respectively.

c.

Depress sleeves back over the sleeve locks so that jaws (12) grip the studs (13).

d.

Install

quick~release

pins (17) in support tube (16) and strut (15).

2. Secure bench frame to frame 7 with quick-release pins (19) and install tension strap (6). 3. Attach back cushion of fabric seats (2 and 7) to the cabin rear wall with stud fasteners (21), eyelets (22) and locking washers (23).

4. Lace the cords of fabric seats to bench frame. 5. Attach back cushion (3) to cabin rear wall with studs (24), eyelets (25) and locking washers (26). 6. Hook the lap-safety belts (S) into rings (lS) and fittings (20) on frame 7.

BO 105 CHAPTER S06 Page 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

7

2

DETAlL

A

3

DETAlL

E

, I

I

1

II

10'

"'.:---;.,1 ... ."

..,

c:::.

= ::::J 1l~-+--12

---13

2 11

.-.----4

------5 DETAlLe

,--¡......+---- 6

DETAlL

F

16-------+

~'l----17

'"--I----S

15----..L

~~:!1!!:.---1S

800355

:'....

DETAILB

1 2 3 4 5 6 7 8 9 10 11

12 13

Bench frame Fabric seat, small Back cushion Hook tape Pile tape Tension strap Fabric seat, large Lap-saftety belt 12-jaw stud fitting Sleeve lock Sleeve Jaws Stud (pan fitting)

14 15 16 17 18 19 20 21 22 23 24 25 26

Fig. 806-1

Quick-release pin Strut Support tube Quick-release pin Lap-belt attaching ring Quick-release pin Fitting Stud fastener Eyelet Locking washer Stud fastener Eyelet Locking washer

Split bench seat

DETAlLO

20-~1

14 14

BO 105 CHAPTER 806 Page 7/8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

807

BENCH SEAT (PLATE-SUPPORTED)

Table of Contents

Page

Paragraph Title

.. . . . . . .

807 - 1

DESCRIPTION - BENCH SEAT

807 - 2

INSPECTION SCHEDULE - BENCH SEAT

4

807 - 3

INSPECTION FOR CONDITION - BENCH SEAT

5

807 - 4

REMOVAL - BENCH SEAT

5

807 - 5

INSTALLATION - BENCH SEAT

6

807 - 6

STOWAGE - BENCH SEAT

..

6

3

BO 105 CHAPTER 807 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 DESCRIPTION - BENCH SEAT

807 - 1

The bench seat consists of a plate strut (9, fig. 807-1) and seat bottom and seat back plates (5 and 3) with removable cushions (1 and 2) . Three lap-safety belts (manufactured by Autoflug GmbH) are attached to frame 7 of the fuselage and to fittings on the seat back plateo If required, the seat bottom can be folded against the seat back. DETAlL

A

DETAlL

B

4

DETAlL

D

3 l·

·1

4--'

ti t

DETAlL

~

3·

e 3 ~~;...---

5

:"iIIIIG----- 6 ~---7

~c:::S¿

1/'"-----

1 8

2

---..------ 9

3

4

800356

5

6 7

8 9 10

Fig. 807-1

Seat bottom cushion Seat back cushion Seat back plate Quick-release pin Seat bottom plate Screw Washer Attach bracket Plate strut Lap-safety belt

Bench seat - removal and installation BO 105 CHAPTER 807 Page 3

EUROCOPTER

• 807 - 2

MAINTENANCE MANUAL 80 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 807 Page4

Revision 18

----,-----------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 807 - 3

INSPECTION FOR CONDITION - BENCH SEAT

1. Inspect seat bottom and seat back cushions (1 and 2, fig. 807-1) for damage. RepIace damaged cushions. 2. Inspect pIate strut, seat bottom and seat back pIates (9, 5 and 3) for distortion and condition. RepIace distorted or damaged pIates. 3. Inspect brackets (8) of pIate strut and seat back pIate for security and condition. RepIace damaged brackets and quick-reIease pins (4), and tighten Ioose attaching hardware. 4. Inspect brackets attaching pIate strut to seat bottom pIate and seat bottom pIate to seat back pIate for security and condition. RepIace damaged brackets, and tighten Ioose attaching hardware. 5. Inspect Iap-safety beIts for security and condition. Tighten Ioose attach fittings, and repIace damaged Iap-safety belts. 807 - 4

REMOVAL - BENCH SEAT

1. Remove seat bottom and seat back cushions (1 and 2, fig. 807-1) and unhook and remove the three Iap-safety beIts. 2. Remove hardware attaching pIate strut brackets (8) to cabin floor. Each

bracket is attached by two screws, washers and square spacers. 3. Fold plate strut up against the underside of the seat bottom pIate and fasten to the brackets on seat bottom plate, using the screws, washers and spacers previously removed (see detail C, fig. 807-1). 4. Remove quick-release pins (4) from the brackets on the seat back plate and

remove bench seat from the cabin.

BO 105 CHAPTER 807 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS --------......;...---MAINTENANCE MANUAL MBB - BO lOS 807 - S

INSTALLATION - BENCH SEAT

1. Attach seat back plate (3, fig. 807-1) by quick-release pins (4).

2. Remove hardware attaching plate strut to the seat bottom plate; swing the plate strut down and install to cabin floor using the same attaching hardware. The square spacers must be interposed between the bracket and cabin floor. 3. Install seat bottom and seat back cushions. Replace hook and pile tape with poor fastening quality or if damaged. 4. Hook lap-safety belts into their attachment fittings.

807 - 6

STOWAGE - BENCH SEAT

1. Remove hardware attaching brackets (8, fig. 807-1) to the cabin floor. Each bracket is attached by two screws, washers and square spacers. 2. Fold plate strut against the underside of the seat bottom plate and fasten

to brackets on seat bottom plate using the attaching hardware previously removed (see detail C, fig. 807-1). 3. Remove seat back cushion and lay it on the seat bottom cushion. 4. Fold the seat bottom plate and cushions against the seat back plate and secure in this position with the stowage loops.

NOTE

BO lOS CHAPTER 807 Page 6

The bench seat is unstowed in reverse sequence.

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

808

BENCH SEAT (STRUT-SUPPORTED)

Table of Contents

Paragraph Title

Page

808 - 1

DESCRIPTION - BENCH SEAT

3

808 - 2

INSPECTION SCHEDULE - BENCH SEAT

4

808 - 3

INSPECTION FOR CONDITION - BENCH SEAT

5

808 - 4

REMOVAL - BENCH SEAT

5

808 - 5

INSTALLATION - BENCH SEAT

5

808 - 6

STOWAGE - BENCH SEAT

.

6

BO 105 CHAPTER 808 Page 1/2

MAINTENANCE MANUAL MBB.,. BO 105

808 - 1

DESCRIPTION - BENCH SEAT

The seat structure, consisting of a seat bottom plate and a seat back plate (both alurninum sandwich), is attached to the cabin floor by means of struts mounted on the underside of the seat bottom plateo The seat back plate is attached to frame 7 and the cabin rear wall by brackets and quick-release pins respectively. The seat bottom and seat back plates are each provided with a 3-piece cushion. The bench seat is equipped with lap-safety belts only or with lap-safety belts and shoulder harnesses (all manufactured by Autoflug GmbH) . The lap-safety belts are attached via fittings to the seat back plate and to fralne 7 of the fuselage. The shoulder harnesses, if installed, are attached at their upper end to the cabin rear wall and at their lower end to the respective lap-safety belts.

Revision 8

BO 105 CHAPTER 808 Page 3

* * * * * *

EUROCOPTER

• SOS - 2

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 808

Page4

MAINTENANCE MANUAL BO 105

Revision 18

_eurocopter 808 - 3

MAINTENANCE MANUAL MBB - BO 105

INSPECTION FOR CONDITION - BENCH SEAT

l. Inspect struts (6, fig. 808-1), seat bottorn plate (8) and seat back plate (3) for distortion and condition. Replace distorted or darnaged parts. 2. Inspect seat back plate attachrnent provisions for security and condition. Replace darnaged brackets and quick-release pins, and tighten loose attaching hardware. 3. Inspect rnounting brackets of struts (6) on underside of seat bottorn plate

for security. If necessary, tighten attaching hardware. 4. Inspect stud fittings (10) for security and correct locking and release action. If necessary, tighten' hardware attaching the stud fittings to the bench legs and replace poorly functioning stud fittings.

*

*

5. Inspect seat cushions for darnage; replace darnaged cushions.

6. Inspect lap-safety belts or lap-safety belts and shoulder harness attachrnent * fittings for security. If necessary, tighten attachrnent fitting rnounting * hardware. * 7. Inspect lap-safety belts or lap-safety belts and shoulder harnesses for

darnage and replace as necessary. 808 - 4 l.

* * *

REMOVAL - BENCH SEAT

Unlook lap-safety belts or safety belts and shoulder harnesses frorn their attachrnent fittings and rernove seat bottorn and seat back cushions.

* *

2. Rernove seat structure as follows:

a.

Depress sleeve locks (11, fig. 808-1) on the stud fittings and pull sleeves (12) back over the sleeve locks so that the jaws (13) disengage frorn the pan fitting studs (14).

b.

Fold struts upward into the stowage clips (7) installed on underside of the seat bottom plateo

c.

Rernove quick-release pins (4) frorn the,brackets on the seat back plate and rernove seat structure frorn the cabin. INSTALLATION - BENCH SEAT

808 - 5

l. Install seat structure as follows:

a.

Place seat structure in installed position.

b.

Attach seat back plate with quick-release pins (4, fig. 808-1).

Revision 8

BO 105 CHAPTER 808 Page 5

* *

cteurocopter

MAINTENANCE MANUAL MBB - BO 105

c.

Swing tne struts (6) down from the seat bottom. Depress the sleeve locks (11) and push the sleeves back up the sleeve locks. Position the stud fittings over the studs (14) of the pan fittings in the cabin floor.

d.

Press the sleeves down over the sleeve locks so that jaws (13) grip the studs in the pan fittings.

2. Install the seat bottom and seat back cushions. Replace hook and pile tape with poor fastening quality or if damaged.

* 3. Hook lap-safety belts or lap-safety belts and shoulder harnesses into their attachment fittings. * 808 - 6

STOWAGE - BENCH SEAT

1. Depress the sleeve locks (11, fig. 808-1) on stud fittings and pull the sleeves (12) up over the sleeve locks so that the jaws (13) disengage from the pan fitting studs. 2. Fold struts (6) upward into the stowage clips (7) on the underside of the seat bottom plateo 3. Remove seat back cushion and lay it on seat bottom cushion. 4. Fold bench seat upward to the stowed position and secure it there by means of the seat stowage loops (5) installed between frame 6a and 7.

NOTE

BO 105 CHAPTER 808 Page 6

The bench seat is unstowed in the reverse sequence.

Revision 8

MAINTENANCE MANUAL MBB - BO 105

DETAlL

E

DETAlL

O

DETAlLe

3--~ '.

""

I

I

10 I

I 1 I

4

-

l,,-- --.J , '.,.,/

... -_ ....... c ··_··....,

..N-"""""" 13

~-14

12 DETAlL

8 4

1 Seat bottom cushion

8 Seat bottom plate

2 Seat back cushion 3 Seat back plate

9 Lap-safety belt

4 Quick-release pin 5 Seat stowage loop 6 Strut 7 Strut stowage clip

10 11 12 13 14

12-jaw stud fitting Sleeve lock Sleeve Jaws Stud (pan fitting)

5

DETAlLA 800357

* *

Fig. 808-1

Revision 8

Bench seat - removal and installation (1 of 2) (Lap-safety belt configuration) BO 105 CHAPTER 808 Page 7/8

MAINTENANCE MANUAL Mee· eo 105

DETAlLe

DETAlLE

3---::'4

I

I tI

O

I II

_.... _........ 1,,---J , '

..

~

... "

,-

DETAlL

D

.. "

11

1---14

/

12

DETAlL

B

9 4

1 Seat bottom cushion

2 3 4 5

Seat back cushion Seat back plate Quick-release pin Seat stowage loop 6 Strut 7 Strut stowage clip 8 Seat bottom plate

9 Lap-safety belt 10 12-jaw stud fitting 11 Sleeve lock 12 Sleeve 13 Jaws 14 Stud (pan fitting) 15 Shoulder harness DETAlLA

E800392

Fig. 808-1

Revision 8

Bench seat - removal and installation (2 of 2) (Lap-safety belt and shoulder harness configuration) BO 105 CHAPTER 808 Page 9/10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

809

4-SEAT BACK-TO-BACK BENCH

Table oí Contents

Paragraph

Title

809 - 1

DESCRIPTION - 4-SEAT BACK-TO-BACK BENCH . . . .

3

809 - 2

INSPECTION SCHEDULE - 4-SEAT BACK-TO-BACK BENCH

4

809 - 3

INSPECTION FOR CONDITION - 4-SEAT BACK-TO-BACK BENCH

5

809 - 4

REMOVAL - 4-SEAT BACK-TO-BACK BENCH

5

809 - 5

INSTALLATION - 4-SEAT BACK-TO-BACK BENCH

6

Page

BO 105 CHAPTER 809 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

809 - 1

DESCRIPTION - 4-SEAT BACK-TO-BACK BENCH

The 4-seat back-to-back bench consists of a welded tubular frame with a eanvas seat bottom and is attaehed to the eabin floor by means of stud and pan fittings. The plastic seat back is equipped with seat belts and can be removed by lifting straight up.

DETAlL

A

3

I

10

I

I 1

",

,.~

I I ~----,1 .......... ...".""'''''

c::.-='::::J DETAlL

5

B

8---800196.1

6

Fig. 809-1

1 2 3 4 5 6 7 8

Seat baek Safety belt Canvas seat bottom Stud fitting Sleeve loek Sleeve Jaws S~ud (pan fitting)

4-seat baek-to-baek beneh BO 105 CHAPTER 809 Page 3

EUROCOPTER

• 809 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (reter to Chapter 101)

CHAPTER 809 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSPECTION FOR CONDITION - 4-SEAT BACK-TO-BACK BENCH

809 - 3 1.

Inspect bench frame and seat back (1, fig. 809-1) for condition. Replace damaged parts.

2.

Inspect stud fittings (4) for security of installation and correct locking and release action. If required, tighten hardware attaching stud fittings to bench legs and replace poorly functioning stud fittings.

3.

Inspect canvas seat bottom (3) for security of installation and condition.

4.

Inspect safety belts for damage, contamination and dampness.

5.

a.

If there is evidence of broken stitching, tears, chafing, and other impairing marks, replace the safety belts or repair in accordance with manufacturer's instructions (refer to Autoflug Component Maintenance Manual) .

b.

Clean dirty safety belts with water and mild soap (e.g. Nislin 4M).

c.

Dry damp safety belts either in the open or in well-ventilated rooms, away from direct sunlight.

If protective padding is installed on overhead panel frame: a.

Inspect for security of installation and condition.

b.

Bond separated protective padding onto overhead panel frame, using contact adhesive (CM 605).

c.

Replace damaged protective padding as follows:

809 - 4

1)

Remove protective padding.

2)

Clean overhead panel frame with acetone (CM 203)' and allow to dry.

3)

Apply contact adhesive (CM 605) to ptotective padding and bond onto overhead panel frame. REMOVAL - 4-SEAT BACK-TO-BACK BENCH

1.

Remove copilot's seat.

2.

Depress sleeve locks (5), pull sleeves (6) upward over the sleeve locks, and lift and remove bench from cabin.

BO 105 CHAPTER 809 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 809 - 5

INSTALLATION - 4-SEAT BACK-TO-BACK BENCH

WARNING

INSTALL DOUBLE BENCH SEAT SO THAT UPPER SHOULDER BELT FASTENING FACES FORWARD IN DIRECTION OF FLIGHT.

l.

Place bench in installed position.

2.

Depress sleeve locks (5), pull sleeves (6) up, position bench over the studs (8) in the cabin floor, and press bench down so that the stud fittings (4) are over the stud.

3.

Depress sleeves (6) so that the jaws (7) of the stud fittings grip the studs.

4.

Install copilot's seat.

BO 105 CHAPTER 809 Page 6

EUROCOPTER

MAINTENANCE MANUAL BO 105

810 RETRACTABLE LANDING LIGHT - MOUNTED ON FORWARD ACCESS DOOR Table o, Contents

Paragraph Title

Page

810-1

DESCRIPTION - RETRACTABLE LANDING LIGHT SYSTEM

•....••....•.•..••...

3

810-2

TROUBLESHOOTING - RETRACTABLE LANDING LIGHT SYSTEM •.••.•....•.•••

4

810-3

INSPECTION SCHEDULE - RETRACTABLE LANDING LIGHT SYSTEM .•.....•..•

6

810-4

INSPECTION FOR CONDITION - RETRACTABLE LANDING LIGHT SYSTEM

.

7

810-5

FUNCTIONAL TEST - RETRACTABLE LANDING L1GHT SYSTEM

..•.•.•....•.••.

8

810- 6

Removal - retractable landing light

.

9

810-7

Installation - retractable landing light

.

9

810- 8

Replacement - quartz-iodine lamp

.

9

Revision 18

CHAPTER 810 Paga 1

EUROCOPTER

MAINTENANCE MANUAL 80 105

BLANK PAGE

CHAPTER 810

Page2

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 810 - 1

DESCRIPTION - RETRACTABLE LANDING LIGHT SYSTEM

The purpose of the retractable landing light is to illuminate part of the pilot's field of view in darkness. It is flush-mounted in the center of the forward access doo~ and can be extended electrically to approx. 73° from the flush position. System components and their locations: Retractable landing light with drive assembly 8LA

- forward access door

Circuit breaker 3LA

- instrument panel 2VE (horizontal section)

Rocker switch 20LA Relay 18LA

- control unit on collective pitch stick - relay box 10VE

CONFIGURATION I Diodes 22LA, 23LA

- relay box 10VE

CONFIGURATION II Slide switch 24LA

- control unit on collective pitch stick

Diodes 22LA, 23LA Relay 2sLA Distributor 17VV

- diode plate 10KA in relay box 10VE - relay box 10VE - relay box 10VE

CONFIGURATION I The system is supplied with power from the main bus PP21 thru the LANDING LIGHT circuit breaker. Extension and retraction of the landing light is controlled by LANDING LIGHT rocker switch (4, fig. 810-1). The landing light is automatically turned on at an extension angle of approx. 15° from the flush position. When retracted to below this angle, it is automatically turned off. CONFIGURATION II The system is supplied with power from the emergency bus PP20, if the latter is installed, otherwise from main bus PP21 as in configuration l. In addition, the landing light can be switched on and off in the extended position via LANDING LIGHT slide switch (5). If the helicopter has dual controls, the same switches can be installed in the control unit on the copilot's collective pitch stick. In this case, the pilot's collective-mounted rocker switch (4) for extending and retracting the landing light has override status.

BO 105 CHAPTER 810 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 810 - 2

TROUBLESHOOTING -

RETRACT~LE

LANDING LIGHT

General Troubleshooting shall be performed using external power. Refer to wiring diagrams in the Wiring Diagram Manual (WDM). No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Faulty landing light assembly 8LA

Check 8LAa connector for voltage at contact B. If voltage is present, replace landing light

Faulty 18LA relay

Check relay and replace as necessary

Faulty 20LA rocker switch

Check rocker switch and replace as necessary

Faulty 23LA diode

Check diode and replace as necessary

Faulty electrical wiring

Check wiring against wiring diagram. Repair or replace wiring as necessary

Loose or faulty ground connection on 8LAa connector

Tighten or remake ground connection

Faulty 3LA circuit breaker

Check circuit breaker and replace as necessary

2

Landing light does not extend

Landing light does not come on

Faulty quarz-iodine Check 8LAa connector for voltage at contact C. If lamp voltage is present, remove lamp and check for voltage at lamp connections. If voltage is present, replace lampo If there is no voltage, the landing light assembly is faulty. Replace latter as necessary. Faulty electrical wiring

Table 810-1 BO 105 CHAPTER 810 Page 4

Check wiring against wiring diagram. Repair or replace wiring as necessary.

Troubleshooting (1 of 2)

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

CONFIGURATION II

3

Landing light does not retract

Faulty 24LA slide switch

Check slide switch and replace as nescessary

Faulty 25LA relay

Check relay and replace as necessary

Faulty electrical wiring

Check wiring against w~r~ng diagram. Repair or replace wiring as necessary

Faulty landing Check 8LAa connector for light assembly 8LA voltage at contact A. If voltage is present/ replace landing light Faulty l8LA relay

Check relay and replace as necessary

Faulty 22LA diode

Check diode and replace as necessary

Faulty 20LA rocker switch

Check iocker switch and replace as necessary

Table 810-1

Troubleshooting (2 of 2)

BO 105 CHAPTER 810 Page 5

EUROCOPTER

• 810 - 3

MAINTENANCE MANUAL 80 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 810 Page6

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 810 - 4

INSPECTION FOR CONDITION - RETRACTABLE LANDING LIGHT SYSTEM

1.

Extend landing light (3, fig. 810-1).

2.

Inspect landing light for evidence of dirt. clean outer canopy (11) with clean water or a suitable solvento

3.

Inspect outer canopy for damage and corrosion. remove corrosion. replace landing light.

4.

Inspect quarz-iodine lamp (10) for damage. replace quarz-iodine lampo

5.

Check screws (9) connecting landing light to forward access door for tightness. tighten screws.

6.

Check retaining ring (8) of quarz-iodine lamp for secure fit and damage. replace retaining ringo

7.

Check all accessible plug-in connections for tightness. tighten plug-in connections

8.

Check rocker switch (4) and slide switch (5) for proper functioning and damage. replace switches.

9.

Inspect visible lengths of electrical wiring for broken and chafed wires, and for correct routeing. repair, replace or reroute wires.

10. Inspect labels on switches for presence, legibility and damage. replace labels.

BO 105 CHAPTER 810 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 810 - 5

FUNCTIONAL TEST - RETRACTABLE LANDING LIGHT SYSTEM

lo

Connect external power supply (refer to chapter 92).

2.

Depress 3LA circuit breaker LANDING LIGHT on instrument panel. NOTE

Steps 3. and 6. apply to CONFIGURATION 11 only.

3.

Select pilot's collective-mounted LAND LIGHT slide switch (5, Fig. 810-1) to ON.

4.

Press pilot's collective-mounted LANDING LIGHT rocker switch (4) to EXT hold in this position. landing light must extend. landing light must automatically come on when extended beyond an extension angle of approx. 15°. landing light motor must shut down when the landing light reaches an extension angle of approx. 73°.

5.

Release rocker switch (4).

6.

Select LAND LIGHT slide switch (5) to OFF, then return it to ON. landing light must go out, then come on again.

7.

Press rocker switch (4) to RETR and hold in this position. landing light must retracto landing light must automatically go out when retracted below an extension angle of 15°. landing light motor must shut down when landing light is in fully retracted positon.

8.

Release rocker switch (4).

9.

If landing light switches are mounted on the copilot's collective pitch stick, repeat steps 3. thru 8. on these switches. NOTE

The override status of the pilot's collective-mounted rocker switch need not be checked because its authority is ensured if the switch functions correctly.

10. Pull 3LA circuit breaker. 11. Disconnect external power supply.

BO 105 CHAPTER 810 Page 8

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 810 - 6

Removal - retractable landing light

1.

Remove all power from helicopter electrical system.

2.

Remove forward access door (15, fig. 810-1).

3.

Remove lockwire of connector (7), then pull out connector and fit with a protective cap.

4.

Remove screws(9) and withdraw landing light from the forward access door together with mounting ring (16).

810 - 7

Installation - retractable landing light

1.

Insert landing light (3) in forward access door (15) and secure to door with screws (9) and mounting ring (16).

2.

Plug connector (7) into receptacle (6) and secure with lockwire.

3.

Install forward access door.

4.

Functionally test landing light (refer to para 810-5).

810 - 8

Replacement - quartz-iodine lamp

1.

Remove all power from the aircraft electrical system.

2.

Remove retaining ring (8, fig.810-1) and carefully pull quartz-iodine lamp (10) from outercanopy (11).

3.

Disconnect electrical leads (12) from quartz-iodine lamp by removing attaching screws (identify leads first), then remove lampo

4.

Connect electrical leads (12) to new

c:

Fit quartz-iodine lamp in outer canopy (11) so that key on lamp seats in corresponding groove in outer canopy.

6.

Secure quartz-iodine lamp in outer canopy with retaining ring (8).

7.

Functionally test landing light (refer to para 810-5) .

oJ.

quartz-iodin~

lampo

BO 105 CHAPTER 810 Page 9/10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

15

14

DETAlL

e 14

13

1 2 3 4

11

u-i---10

65

6 7 S 9

/ 8

10 11

12 DETAlL

A

DETAlL

B

14 15 16

6

800358

Fig. 810-1

13

Retractable landing light - mounted on forward access door BO 105 CHAPTER 810

Page 11/12

Circuit breaker 3LA Relay box laVE Landing light SLA Rocker switch 20LA Slide switch 24LA Receptacle 8LAA Electrical connector 8LAa Lampretaining ring Screw Quartz-iodine lamp Outer canopy Electrical lead Motor assembly Drive assembly Forward access door Mounting ring

CONFIGURATION II only

EUROCOPTER

MAINTENANCE MANUAL 80105

811 RETRACTABLE LANDING LlGHT - MOUNTED ON CROSSTUBE Table o, Contents

Paragraph Title

Page

811-1

DESCRIPTION - RETRACTABLE LANDING LIGHT SYSTEM

811-2

TROUBLESHOOTING - RETRACTABLE LANDING L1GHT SYSTEM •.••••••..••.•.

4 •

811-3

INSPECTION SCHEDULE - RETRACTABLE LANDING L1GHT SYSTEM ••.•.••••••

6

811-4

INSPECTION FOR CONDITION - RETRACTABLE LANDING L1GHT SYSTEM ••••••

7

811- 5

FUNCTIONAL TEST - RETRACTABLE LANDING LIGHT SYSTEM .••••••••••.••••

8

811 - 6

Removal - retractable landing light

.

9

811 -7

Installation - retractable landing Iight

.

9

811 - 8

Replacement - quartz-iodine lamp

Revision 18

o

.••••••.•••••••••••••

••••••••••••••••••••••••••••••••••••••••••••••

3

10

CHAPTER 811 Paga 1

MAINTENANCE MANUAL BO 105

EUROCOPTER

BLANK PAGE

CHAPTER 811 Page2

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 811 - 1

DESCRIPTION - RETRACTABLE LANDING LIGHT SYSTEM

The purpose of the retractable landing light is to illuminate part of the pilot's field of view in darkness. It is installed in a separate housing (5) which is mounted on the step (13) on the left side of the front crosstube (25). The landing light can be extended electrically to approx. 73° from the flush position. System components and their locations: Retractable landing light with drive assembly 8LA Circuit breaker 3LA Rocker switch 20LA Slide switch Diodes 22LA, 23LA . Relay l8LA Relay 2SLA Distributor l7VV

- forward crosstube, left side -

instrument panel 2VE (horizontal section) control unit on collective pitch stick control unit on collective pitch stick diode plate lORA in relay box laVE relay box laVE relay box laVE relay box laVE

The systern is supplied with power through the 3LAcircuit breaker (1) frorn either the main bus PP2l or frorn the ernergency bus PP20, if the latter is installed. The landing light can be extended and retracted by operating the LANDING LIGHT rocker switch (6). It is turned on and off via the LANDING LIGHT slide switch (7). However, it will not come on until it has been extended beyond an extension angle of approx. 15°, and will go out upon retraction to below this angle, even with the slide switch in the ON position. If the helicopter has dual controls, the same switches can be installed in the control unit on the copilot's collective pitch stick. In this case, the pilot's collective-mounted rocker switch (6) for extending and retracting the landing light has override status.

BO 105 CHAPTER 811 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 811 - 2

TROUBLESHOOTING - RETRACTABLE LANDING LIGHT SYSTEM

General Troubleshooting shall be performed using external power. Refer to wiring diagrams in the Wlring Diagram Manual (WDM). No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Faulty landing light assembly 8LA

Check 8LAa connector for voltage at contact B. If voltage is present, replace landing light.

Faulty 18LA relay

Check relay and replace as necessary.

Faulty 20LA rocker switch

Check rocker switch and replace as necessary.

Faulty 23LA diode

Check diode and replace as necessary.

Faulty electrical wiring

Check wiring against wiring diagram. Repair or replace wiring as necessary.

Loose or faulty ground connection on 8LAa connector

Tighten or remake ground connection.

Faulty 3LA circuit breaker

Check circuit breaker and replace as necessary.

Faulty quartziodine lamp

Check 8LAa connector for voltage at contact C. If voltage is present, remove lamp and check for voltage at lamp connections. If voltage is present, replace lampo If there is no voltage, the landing light assembly is faulty. Replace latter as necessary.

Faulty electrical wiring

Check wiring against wiring diagram. Repair or replace wiring as necessary.

2

Landing light does not extend

Landing light does not come on

Table 811-1 BO 105 CHAPTER 811 Page 4

Troubleshooting (1 of 2)

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 TROUBLESHOOTING (continued) No. TROUBLE SYMPTOM

3

Landing light does not retract

PROBABLE CAUSE

CORRECTlVE ACTION

Faulty 24LA slide switch

Check slide switch and replace as necessary.

Faulty 2SLA relay

Check relay and replace as necessary.

Faulty landing Check 8LAa connector for light assembly 8LA voltage at contact A. If voltage is present, replace landing light. Faulty 18LA relay

Check relay and replace as necessary.

Faulty 22LA diode

Check diode and replace as necessary.

Faulty 20LA rocker switch

Check rocker switch and replace as necessary.

Table 811-1

Troubleshooting (2 of 2)

BO 105 CHAPTER 811 Page 5

EUROCOPTER

• 811 - 3

INSPECTION SCHEDULE (reter to Chapter 101)

CHAPTER 811

Page6

MAINTENANCE MANUAL BO 105

Revisior. 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 811 - 4

INSPECTION FOR CONDITION - RETRACTABLE LANDING LIGHT SYSTEM

l.

Extend landing light (4, fig. 811-1).

2.

Inspect landing light assembly on crosstube for dirt, corrosion, damage and secure attachment. clean dirty parts with clean water or a suitable solvento remove corrosion. replace damaged parts. tighten loose parts.

3.

Check screws (16) attaching landing light to base plate (23) for tightness. tighten screws (16).

4.

Check retaining ring (19) of quarz-iodine lamp for tight seat and damage. replace retaining ringo

5.

Check all accessible plug-in connections for tightness. tighten plug-in connections.

6.

Check rocker switch (6) and slide switch (7) proper functioning and damage. replace switches.

7.

Inspect visible lengths of electrical wiring for broken and chafed wires, and for correct routeing. repair, replace or reroute wires.

8.

Inspect label~ on switches for legibility, presence and damage. replace labels.

BO 105 CHAPTER 811 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 811 - 5

FUNCTIONAL TEST - RETRACTABLE LANDING LIGHT SYSTEM

1.

Connect external power supply (refer to chapter 92).

2.

Depress 3LA circuit breaker LANDING LIGHT on instrument panel.

3.

Select pilot's collective-mounted LAND. LIGHT slide switch (7, fig. 811-1) to ON.

4.

Press pilot's collective-mounted LANDING LIGHT rocker switch (6) to EXT and hold in this position. landing light must extend. landing light must automatically come on when extended beyond an extension angle of approx. 15°. landing light motor must shut down when landing light reaches an extension angle of approx. 73°.

5.

Release rocker switch (6).

6.

Select LAND LIGHT slide switch (7) to OFF, then return it to ON. landing light must go out, then come on again.

7. Press rocker switch (6) to RETR and hold in this position. landing light must retracto landing light must automatically go out when retracted below an extension angle of 15°. landing light motor must shut down when landing light is in fully retracted position. 8.

Release rocker switch (6).

9.

If landing light switches are mounted on copilot's collective pitch stick, repeat steps 3. thru 8. on these switches. NOTE

The override status of the pilot's collective - mounted rocker switch need not be checked because its authority is ensured if the switch functions correctly.

10. Pull 3LA circuit breaker. 11. Disconnect external power supply.

BO 105 CHAPTER 811 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

811 - 6

l.

Removal - retractable landing light

Removal of housing (5, fig. 811-1) together with attached landing light (4) •

a.

Remove all power from aircraft electrical system.

b.

Pull electrical connector (3) from landing light receptacle and blank off latter with protective cap from dummy receptacle (8); install protective cap on connector.

c.

Remove nut with washer (10) and swing support tube (11) forward slightly.

d.

Remove screws with washers (9) and carefully detach housing (5) from step (13).

e.

If necessary. remove clamps-with-support plate (12) from crosstube (25) •

2.

Removal of landing light (4) from housing (5). a.

Remove screws (16) and withdraw landing light (4) from housing (5).

b.

Unplug connector (17) and remove landing light (4); blank off connector with protective cap.

811 - 7 l.

2.

Installation - retractable landing light

Installation of landing light (4, fig. 811-1) in housing (5). a.

Plug electrical connector (17) into landing light (4) receptacle.

b.

Insert landing light in housing and secure landing light to cover plate (23) with screws (16).

Installation of assembled housing (5) and landing light (4) to left side of forward crosstube. a.

Secure housing (5) to step (13) with screws and washers (9).

b.

If removed, secure clamps-with-support plate (12) to crosstube so that support tube (11) can be attached to stud on support plateo

c.

Secure support tube to stud on support plate with screw and washer (12) .

d.

Remove protective cap from receptacle and reinstall it on dummy receptacle.

e.

Plug electrical connector (3) in receptacle.

f.

Perform functional test (refer to para 811-5) . BO 105 CHAPTER 811

Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

Replacement - quartz-iodine lamp

811 - 8

1.

Remove all power froro helicopter electrical system.

2.

Reroove lamp retaining ring (19, fig. 811-1) and carefully pull with draw quartz-iodine lamp (18) froro housing (15).

3.

Disconnect electrical leads (20) froro quartz-iodine lamp by rerooving attaching screws (identify leads first), then remove lampo

4.

Connect electrical leads (20) to new quartz-iodine lampo

5.

Fit quartz-iodine lamp in outer canopy (15) so that key on lamp seats in corresponding groove in outer canopy.

6.

Secure quartz-iodine lamp in outer canopy with retaining ring (19).

7.

Perform functional test (refer to para 811-5).

BO 105 CHAPTER

Page 10

811

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

B

DETAlL 3

8

9

10

11

12

23-_____

. . . . . ..

14-----+-

5----7--

24---../

23----'

-t---25

4-------\'4

DETAlL 12

8

DETAlL DETAlL

11

13

D

25,

e

A

t - - - - " - . - - 14

"

3

17

800200

Fig. 811-1

.. D

Retractable landing light - mounted on crosstube BO 105 CHAPTER 811 Page 11/12

15

1 2 3 4 5 6 7 8 9 10 11 12 13

Circuit breaker 3LA Relay box 10VE Electrical connector 149VVa Landing light 8LA Housing Rocker switch 20LA Slide switch 24LA Dummy receptacle with cap Screw with washer Nut with washer Support tube Clamps with support plate Step

14 15 16 17 18 19 20 21 22 23 24 25

Attach plate Housing (Landing light) Screw Electrical connector 8LAa Quartz-iodine lamp Retaining ring Electrical lead Motor assembly Orive assembly Cover plate Screw Forward crosstube, leftside

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

812

SEARCH AND LANDING LIGHT

Table of Contents

Paragraph

Title

812 - 1

DESCRIPTION - SEARCH AND LANDING LIGHT

3

812 - 2

TROUBLESHOOTING - SEARCH AND LANDING LIGHT

5

812 - 3

INSPECTION SCHEDULE - SEARCH AND LANDING LIGHT

7

812 - 4

INSPECTION FOR CONDITION - SEARCH AND LANDING LIGHT

8

812 - 5

FUNCTIONAL TEST - SEARCH AND LANDING LIGHT

8

812 - 6

REMOVAL - SEARCH AND LANDING LIGHT

10

812 - 7

INSTALLATION - SEARCH AND LANDING LIGHT

10

812 - 8

Lamp replacement

10

Page

BO 105 CHAPTER 812 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 812 - 1

DESCRIPTION - SEARCH ANO LANOING LIGHT

1. General The search and landing light is situated in the nose shell irnmediately below the battery compartment. It is retractable and can be rotated in any extended position. 2. Description The light is extended/retracted and rotated by two dc motors with reduction gears. Limit switches are used in stopping the light in the fully extended and retracted positions. The light is tutned on with the LANO LIGHT toggle switch. Directional control, i.e., extension, retraction and rotation, is via either the pilot's or copilot's collective-mounted 4-position switch, depending on the PIL/COP selector switch setting on the overhead panel. The ON and STOWED ANO LOCKED segments of the split caption indicate that the light is on and that it is fully retracted.and locked, respectively. Two SEARCHLIGHT circuit breakers are located in the instrument panel. The SA circuit breaker (400 LA) protects the control circuits, while the lOA circuit breaker (3 LA) protects the motor circuits and the light circuito AII the circuits are supplied with power from the PP21 main bus. 3. Operation To operate the search and landing light, both SEARCHLIGHT circuit breakers must be pressed. Select light operating controls by moving selector switch PIL/COP to desired position. If PIL is selected, the pilot's collective-mounted controls are energized. with LAND LIGHT toggle switch selected to ON, the light control relay energizes and turns on the search and landing light, and the ON caption' illuminates. If the 4-position switch is selected to OUT and kept in this position, drive voltage flows through the EXT limit switch to the excitation winding of the extend relay, which is energized and closes the circuit to the extend winding of' the motor. The motordrives the search and landing light in the extend direction until the OUT switch position is deselected or maximum extension travel of approx. 110 0 has been reached (EXT limit switch opens to break the extend relay exciter circuit) .

BO 105 CHAPTER 812 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The search and landing light can be rotated in either direction (left or right) up to 360° when in any extend or retracted position, except when fully retracted, by selecting L or R with the 4-position switch and holding it in this position. The control relay associated with the selected position energizes and applies power to the corresponding motor winding. When the 4-position switch is selected to IN, the exciter circuit of the extend relay is completed through the closed contacts of the RETR limit switch. The extend relay completes the circuit to the retract winding of the motor, which then drives the search and landing light in the retract direction, irrespective of its direction of rotation. At full retraction, the RETR limit switch breaks the relay exciter circuit, causing the motor to turn off. The open RETR limit switch applies voltage to the contacts of the CENTER (0°) limit switch. If the light is retracted and locked in its centered condition, the drive voltage is routed to the STOWED AND LOCKED caption, which illuminates for as long as the 4-position switch position is maintained. If the light is not centered, the control voltage is routed through the CENTER limit switch to the excitation winding of the RIGHT control relay. This relay completes the circuit to the RIGHT winding of the rotation motor. The motor rotates the search and landing light to the right until it is centered at 0° rotation (CENTER limit switch breaks the RIGHT relay control circuit and routes the voltage to the STOWED AND LOCKED caption which illuminates). . NOTE

The search and landing light does not turn off automatically; it must be turned off manually. Observe ON caption.

BO 105 CHAPTER 812 Page 4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 812 - 2

TROUBLESHOOTING - SEARCH AND LANDING LIGHT

General -

Refer to wiring diagram 812-1 in the Wiring Diagram Manual (WDM) . Check that all associated electrical connections are tight and secure. Check associated collective-mounted switches and both circuit breakers in instrument panel for unimpaired mechanical functioning. Connect external power supply (EPU) (Battery switch 16p in instrument panel selected BATT OFF/EPU ON) . Depress circuit breaker 400LA and 3LA.

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Lamp does not il1uminate

Defective lamp

Check for voltage on lamp¡ replace lamp as necessary

Faulty wiring

Check for continuity of wiring using applicable wiring diagram¡ replace faulty wiring

Defective circuit breaker

Check continuity of circuit breakers¡ replace defective circuit breaker

Defective 24LA toggle switch

Check switch for continuity¡ replace defective switch

Defective relay

Remove search and landing light (refer to para 812-6)¡ check relay¡ replace as necessary

Defective 3LA and/or 400LA circuit breaker

Check continuity of circuit breakers¡ replace as necessary

Defective selector switch PIL/COP 401LA in overhead panel

Check selector switch for continuity in each position in turn¡ replace defective switch

2

Lamp does not move to the desired position

Table 812-1

Troubleshooting (1 of 2) BO 105 CHAPTER 812 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued)

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

Defective 4-position switch

Check continuity of 4-position switch¡ replace as necessary

Faulty wiring

Check continuity of wiring¡ replace faulty wiring

Defective motor relay

Remove search and landing light (refer to para 812-6); check motor relay¡ replace as necessary

Defective extend/retract or rotation motor

Remove search and landing light (refer to para 812-6); apply voltage to motor; replace defective motor

Defective limit switches

Replace search and landing light

Table 812-1

BO 105 CHAPTER 812 Page 6

Troubleshooting (2 of 2)

EUROCOPTER

812 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 812 Page7

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 812 - 4 NOTE

INSPECTION FOR CONDITION

~

SEARCH ANO LANDING LIGHT

Inspect search and landing light in the extended condition.

1. Inspect search and landing light housing for secure mounting to nose shell. Tighten loose hardware and repair damaged seals and adhesive bonded connections. 2. Inspect housing and search and landing light for contamination; if necessary, clean with water and a soft cloth. 3. Inspect base plate for secure mounting to housing; tighten loose attaching hardware as necessary.

4. Where possible, inspect the extend/retract and rotation motors for security and condition. 5. Inspect lamp for condition. If there is a mist on the inner surface of the lens, replace lamp (refer to para 812-8). 812 - 5

FUNCTIONAL TEST - SEARCH ANO LANDING LIGHT

General -

Normally the functional test is performed using external power. If exceptional circumstances require the functional test to be performed with the engines operating, run them at ground idle speed of approx. 62% N1 and 100% N2.

-

Depress SEARCHLIGHT circuit breakerson instrument panel.

1. Move selector switch PIL/COP on overhead panel to PIL. 2. Select pilot's collective-mounted 4-position switch SEARCHLIGHT to OUT and hold in this position. The light must extend and automatically stop in the fully extended position. Release 4-position switch. 3. Select pilot's collective-mounted LAND LIGHT toggle switch to ON. The search and landing light and the ON segment of the split caption in the overhead panel must illuminate.

BO 105 CHAPTER 812 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4.

Select 4-position switch SEARCHLIGHT to R and hold in this position. The light shall rotate a full 360° to the right. Release switch.

5.

Select 4-positon switch SEARCHLIGHT to L and hold in this position. The light shall rotate a full 360° to the left. Release switch.

6.

Select 4-position switch SEARCHLIGHT to IN and hold in this position. The light must retract and automatically stop in the stowed (0°) position. The STOWED ANO LOCKED segment of the split caption in the overhead panel must illuminate. Release switch. The STOWED ANO LOCKED segment must extinguish. NOTE

To obtain a longer lamp life and peak lighting performance, a search and landing light that has been switched on must not be switched off again before being allowed to reach its full light intensity (after approx. 15 secs). Conversely, a light that has just been switched off must be allowed to cool for between 30 secs and 1 mino before being switched on again.

7.

Select LANO LIGHT toggle switch to OFF. The search and landing light and the ON segment of the split caption must extinguish.

8.

Repeat the switch positions described in steps 4. thru 7. using the copilot's collective-mounted 4-position switch SEARCHLIGHT and toggle switch LAND LIGHT. The light must not respond to any of the copilot's directional inputs and the associated captions must remain off.

9.

Move selector switch PIL/COP to COP: Repeat the switch positions described in step 4. thru 7. using the copilot's collective-mounted 4-position SEARCHLIGHT switch and toggle switch LAND LIGHT. The control responses must correspond to those described in steps 4. thru 7.

10.

Move selector switch PIL/COP to PIL. If the functional checks are completed, disconnect external power from the helicopter electrical system.

BO 105 CHAPTER 812 Page 9

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - 80 lOS

-------------MBB

812 - 6

REMOVAL - SEARCH ANO LANOING LIGHT

1. Detach base plate (2, fig. 812-2) with assembled search and landing light (4) from housing (1) by removing screws and washers (3). 2. Carefully withdraw assembled base plate and search and landing light downward from the housing. 3. Tag and disconnect electrical wiring. 4. Remove screws attaching search and landing light to the base plateo 812 - 7

INSTALLATION - SEARCH ANO LANOING LIGHT

1. Mount search and landing light on base plate (2, fig. 812-2). 2. Connect electrical wiring. 3. Carefully insert assembled base"plate and search and landing light into housing (1) and secure to housing with screws and washers (3). 812 - 8

Lamp replacement

1. Remove screws (20, fig. 812-2) and detach lamp retaining ring (19). 2. Carefully remove lamp (18) from canopy (12) and disconnect electrical wire (21).

3. Connect electrical wire (21) to new lampo 4. Place lamp in lamp canopy so that the projections on the rim of lamp mate with the corresponding slots in the canopy. S. Install lamp retaining ring (19) on lamp canopy with screws (20).

80 105

CHAPTER 812 Page 10

- - - - - - - - - -...........- -MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 MAIN BUS BAR PP21

OVERHEAD PANEL

28V'-

w~ ~I---_---"

P

LOe,,"

I L.

OH

SEARCHLlGHT

I

I

LAND L1GHT

---;\

j

OFF

r----~-----ON r I I

I I

OFF

COP.PIL.

ON

F~ ~I~

SWIT;; ; ; COLL. PITCH LEVER COPILOT

I

FOUR POStTION SWITCH ON COLL. PITCH LEVER PILOT

I

I I I

111...------_

1,

OUT

I

LAND L1GHT

OUT

L

I I

L

I

I

I

r

----

~~

L1MIT SWITCH RETRACTED EXTENDED

I

-----

I

I I I

@-----

EXT.lRETR.-MOTOR

I I

ROTATION MOTOR

=

oS

"

~---

1

"

RETR.

¡L

EX'.

rü

LHS

:

~r-

1

I

-,

L1MIT SWITCH CENTRING

----
I I

I

J

---------

I

I I

I

IN

I I

RHS

"

~

I

:

~

800359

Fig. 812-1

I

Electrical Schematic - Search and Landing Light BO 105 CHAPTER 812 Page 11/12

MAINTEN~~ MANUAL HELICOPTERS --;~~---------­ MBB - BO 105

DETAlL

12

D

13

14

VIEW

B

7--......l...-

8

VIEWC /.::::::;----5

•

6

A

16 15

DETAlL

b 8 Circuit Coll ,reaker 3LA ectlve lever 9 10 ~~9gI7 ~witch 401LA posltlon swit h 11 19

21

18

800360

1

2

43 5 6 7

Lamp housing Base plate Srew a n d washer Search and l 404LA Selector Swi~n~ing light Spli t capt' c PIL/COP Circuit b reaker ~on 402LA 400LA

Fig. 812-2

12 13 14 15 16 17 18 19 20 21

Lamp canopy c 403LA Rotation motor Relay box Lamp terminal Extend/retract Control unit motor Lamp Lamp ret a~nlng ' , r' Screw lng Electrical w'l re

Search and La nd'lng Light BO 105 CHAPTER 812 Page 13/14

4 11

I,

10

9

A

_eurocopter .

813

MAINTENANCE MANUAL MBB';' 80 105

S E A R C H L 1 G H T S X - 16 - without infrared filter - with infrared filter

* * *

Table of Contents Paragraph

Title

Page

813 - 1

DESCRIPTION - SEARCHLIGHT

3

813 - 2

TROUBLESHOOTING - SEARCHLIGHT

5

813 - 3

INSPECTION SCHEDULE - SEARCHLIGHT

7

813 - 4

INSPECTION FOR CONDITION - SEARCHLIGHT

8

813 - 5

FUNCTIONAL TEST - SEARCHLIGHT

9

813 - 6

REMOVAL - SEARCHLIGHT

12

813 - 7

INSTALLATION - SEARCHLIGHT

12

813 - 8

Removal - motor and gearbox

13

813 - 9

Installation - motor and gearbox

13

813 - 10

Removal - focusing

14

813 - 11

Installation - focusing motor

mot~r

14

813 - 12

Removal - window lens and frame assembly

15

813 - 13

Installation - window lens and frame assembly

15

813 - 14

Removal - xenon arc lamp

16

813 - 15

Installation - xenon arc lamp

17

813 - 16

Removal - IR-filter

18

813 - 17

Installation - IR-filter

18

813 - 18

Cleaning - foam filter element

19

813 - 19

Cleaning - reflector

19

813 - 20

Cleaning - IR-filter

20

Revision 8

BO 105 CHAPTER 813 Page 1/2

* * * * * * * * * *

*

*

* * * * *

* * *

* * *

* * *

* * *

_eurocopter 813 - 1

MAINTENANCE MANUAL MBB - BO 105

DESCRIPTION - SEARCHLIGHT

l. General The searchlight serves to make out objects in darkness. It is mounted on the nose of the helicopter and can be rotated through horizontal and vertical arcs. If equipped with an Infrared-IFCO-filter assembly, the searchlight can also be used as an infrared light source (IFCO = In Flight Change Over) .

* * *

2. Description The searchlight is attached to the gimbal support (1, fig. 813-1) consisting of two struts and a plateo The gimbal frame is connected to airframe-mounted brackets (2 and 3) with quick-release pins (4). Mounted on the gimbal assembly (11) are two drive units for moving the searchlight in azimuth and elevation. Each drive unit consists of a motor, a friction clutch, and a gearbox. When the searchlight reaches a limit of travel in any direction, the respective motor continues to rotate with the motor torque being absorbed by the friction clutch. Mounted within the searchlight housing are the xenon arc lamp, the reflector, the focusing motor, and various electrical components of the lamp starting circuito The xenon arc lamp is supported within the searchlight by its end terminals. The rear (anode) terminal end of the lamp is mounted in a spring-loaded stationary plate, while the front (cathode) terminal end is supported by a radial arrangement of rods called a spider (front support) behind the glass window. The xenon lamp is surrounded by a bell-shaped reflector which is attached to a ring supported by three rods fastened to a triangularplate (rear support). These rods slide through bushings in the stationary plates. Movement of the reflector toward the light source and front window is accomplished by the focusing motor which drives a rotating cam acting upon the back support. The rods are spring-loaded in one direction so that as the cam rotates to the lower position, the springs return the reflector toward the rear position, farther from the light source and lens. When the searchlight beam is being focused, the reflector moves either toward the back of the housing, away from the light source, or toward the light source in the opposite direction. If installed, the IR filter (35) is attached by a hinged mounting (34) to the front end of searchlight (33). A motor (36) equipped with a friction clutch and a gearbox rotates the IR filter down over the window lens (19) of the searchlight. Limit switches deenergize the motor when it has driven the IR filter to the full down and full up position.

Revision 8

BO 105 CHAPTER 813 Page 3

* * * * *

C/teurocopter

MAINTENANCE MANUAL Mee - eo 105

Configuration 1: . Movement of the searchlight is controlled via the remote control unit (detail D, fig. 813-2) located on the copilot's side of the cockpit. The junction box (detail C) containing the CB1 and CB2 circuit breakers (6, 7) is situated under the rear bench seat. Configuration 11: The control unit (detail B) is integrated in the instrument panel and can be operated by either the pilot or copiloto The searchlight can also be controlled by a 4-way directional switch (13) mounted on the pilot's collective lever. The junction box (detail C) containing the CB2 circuit breaker (14) is located in the cargo compartment. * If the searchlight is equipped with an IR filter, the control unit shal1 be * modified to include the IR filter controls. 3. Operation Starting the searchlight requires the SRCH LT circuit breaker (1, fig. 813-2) and either both PUSH TO RESET circuit breakers (6 and 7, configuration 1) or the PUSH TO RESET circuit breaker (14, configuration 11) to be depressed, and MASTER power on/off switch selected to ON. Selecting the MASTER switch to ON reduces the cabin heating performance by half, via control unit 19VE, and starts the searchlight cooling fan.

CAUTION

HOLDING THE START SWITCH DEPRESSED AFTER THE LAMP HAS IGNITED CAN DESTROY THE LAMP.

The xenon are lamp is ignited by pressing and holding the momentary contact type START switch. The START switch must be released irnmediately after ignition (takes approx. 5 secs). The movement of the searchlight in azimuth and elevation is controlled by the 4-way directional switch on the remote control unit or on the pilot's collective lever. In the switch positions UP, DOWN, LEFT and RIGHT, the searchlight beam is moved up, down, left and right, respectively. The momentary contact type FOCUS switch operates the focusing motor, which drives the reflector. If the switch isheld down in the closed position, the reflector will travel through the entire focus range, changing the diameter and intensity of the light beam.

* * *

* *

The motor of the IR filter (if installed) is controlled via the twoposition togg1e switch, labelled IR ON/IR OFF. When the IR filter is in the full down position, the IR ON caption (18) located on the control unit (15) will also be lit up by the lower limit switch. Brightness of the caption is controlled by togg1e switch (16), labelled BRIGHT/DIM.

BO 105 CHAPTER 813 Page 4

Revision 8

MAINTENANCE MANUAL MBB - BO 105

813 - 2

TROUBLESHOOTING - SEARCHLIGHT

General Refer to wiring diagrams 813-1, 813-2 (configuration 1) and 813-3 (configuration 11) in the wiring diagram manual (WDM). Inspect all associated electrical connections for tight and secure fit. Inspect all associated switches in control unit and all associated circuit breakers in instrument panel and junction box for proper mechanical functioning. Connect external power supply (EPU) and select 16P battery switch on instrument panel to BATT OFF / EPU ON. Press circuit breakers.

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Searchlight does not illuminate

Defective lamp

Check for voltage on lamp; replace lamp as necessary (refer to para 813-14)

Defective circuit breaker

Check circuit breaker for continuity; replace as necessary

Defective MASTER switch

Check switch for continuity; replace as necessary

Defective wiring

Check wiring for continuity using wiring diagram; replace defective wiring

Table 813-1

Revision 8

Troubleshooting (1 of 2)

BO 105 CHAPTER 813 Page 5

fteurocopter

MAINTENANCE MANUAL Maa - 80 105

TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

2

Spot size of searchIight beam cannot be changed

Defective FOCUS switch

Check switch for continuity; repIace as necessary

Defective focusing mechanism in searchlight

Inspect focusing mechanism fer free movement; repIace focusing motor as necessary (refer to para 813-10)

Defective wiring

Check wiring for continuity, using wiring diagram; repIace defective wiring

Defective 4-way directional switch

Check switch for continuity; repIace as necessary

Defective wiring

Check wiring for continuity using wiring diagrams; repIace defective wiring

Defective azimuth and/or eIevation motor

Check motor; repIace as necessary (refer to para 813-8)

IR switch defective

Check continuity of switch and repIace as necessary.

*

EIectrical wiring defective

* * * *

Check continuity of wiring per wiring diagram and repIace as necessary.

Motor defective

Check motor and repIace as necessary (ref. to paras 813-16 and 813-17.

3

* 4 * * *

Searchlight does not meve in azimuth and/or eIevation

IR filter (if instaIIed) cannot be rotated

* *

* TabIe 813-1 BO 105 CHAPTER 813 Page 6

Troubleshooting (2 of 2)

Revision 8

EUROCOPTER

813 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (reter to Chapter 101)

CHAPTER 813 Page7

cteuracopter 813 - 4

MAINTENANCE MANUAL Mee - 80 105

INSPECTION FOR CONDITION - SEARCHLIGHT

l. Inspect search1ight (17, fig. 813-1) for general condition and security. Replace damaged searchlight if inoperative (refer to para 813-6). 2. Inspect searchlight for contamination; clean as necessary. a.

Remove loose dirt from gimbal, gimbal support, searchlight housing and electrical connections with a soft brush.

b.

Remove mud spatters or similar spattering with a moist, lint-free cloth.

3. Visually inspect searchlight window lens (19) for contamination and damage. Clean dirty window lens; replace damaged window lens (refer to para 813-12) . 4. Inspect electrical connectors (5, 6 and 23) for condition and tight and secure fit. Replace damaged lockwires. 5. Inspect visible parts of electrical cables for condition. Replace damaged cables. 6. Inspect gimbal (11) for condition, security, and deformation. a.

Polish out mechanical damage, such as scratches, nicks, scores, and corros ion, using abrasive cloth.

b.

Touch up surface protection with single-layer lacquer (CM 407) .

c.

Tighten loose screws (25) and replace lockwire.

d.

Replace gimbal if deformed or cracked.

7. Inspect gimbal support (1) for condition and security. a.

Tighten loose bracket (2 and 3) attaching hardware.

b.

Replace damaged quick-release pins

c.

Replace damaged support components.

d.

Touch up surface protection with single-layer lacquer (CM 421) .

(~).

8. Inspect roll pins limiting searchlight movement for condition and tightness. a.

Replace damaged roll pins.

b.

Replace gearbox (9) or gimbal (11) with elongated holes.

BO 105 CHAl-'TER 813 Page 8

Revision 8

MAINTENANCE MANUAL MBB - BO 105

9.

Inspect motors (7 and 12) and gearboxes (9 and 14) for security; tighten attaching hardware and replace lockwire as necessary.

10.

Inspect control unit in cockpit and junction box under rear bench seat (configuration 1) or in cargo compartment (configuration Ir) for security; tighten mounting bracket attaching hardware as necessary. NOTE

The following steps shall only be performed if an IR filter is installed.

11.

Inspect mounting (34) and motor (36) of IR filter for general condition and security. Replace or tighten as necessary.

12.

Inspect IR filter (35) for dirt and damage. Clean or replace as necessary.

13.

Inspect electrical connector and wlrlng harness (37) for condition and security. Tighten or replace wiring harness in its entirety as applicable.

813 - 5

FUNCTIONAL TEST - SEARCHLIGHT

General Do not proceed with the functional test before checking the cables and connections. Perform functional test using either external or generator power (before switching on the generators, slightly increase engine idle speed) . If the 4kW heating system is installed, press 1HA, 2HA, 13HA, 14HA, lSHA, 16HA and 17HA circuit breakers and switch the heating system on (refer to chapter 802). Press CB1 and CB2 circuit breakers (configuration 1) or CB1 circuit breaker (configuration 11) on junction box, and press SRCH LT circuit breaker on instrument panel. l.

Select MASTER switch on control unit to ON. This must activate the searchlight blower and switch off the left and right side heating cartridges of the 4kW heating system. NOTE

2.

Searchlight movement in elevation is not limited by stops.

Select 4-way directional switch on control unit to UP and hold in this position. The searchlight must rotate upward. When it has covered an upward arc of approx. 10°, release switch.

Revision 8

BO 105 CHAPTER 813 Page 9

* * * * * * * * * * * * *

_eurocopter 3.

MAINTENANCE MANUAL Mee - eo 105

Select 4-way directional switch to DOWN and hold in this position. The searchlight must rotate downward. Release switch when the searchlight has covered a downward arc of 70°. NOTE

Movement of the searchlight in azimuth is limited by stops. After a travel limit has been reached, motor torque is absorbed by a friction clutch.

4.

Select 4-way directional switch to RIGHT. The searchlight must rotate to the right. Release switch when limit of travel has been reached.

5.

Select 4-way directional switch to LEFT and hold in this position. The searchlight must rotate to the left. Release switch when searchlight has reached the limit of travel.

* * * *

WARNING

WHEN ON THE GROUND AND TURNED ON, THE SEARCHLIGHT MAY IGNITE DRY VEGETATION OR OTHER FLAMMABLE MATERIAL WITHIN 50 FEET. AVOID FIXED FOCUSING AT OBJECTS WHILE ON THE GROUND. DO NOT AIM THE BEAM TOWARDS PEOPLE, AIRCFAFT OR VEHICLES AT CLOSE RANGE DUE TO TEMPORARY BLINDING EFFECTS.

CAUTION

DO NOT CONTINUE PRESSING THE START SWITCH ON THE CONTROL UNIT AFTER THE LAMP HAS IGNITED AS THIS WILL SERIOUSLY DAMAGE THE LAMP. AFTER SWITCHING OFF THE LAMP, ALLOW IT TO COOL DOWN FOR APPROX. 1 MINUTE BEFORE IGNITING IT AGAIN.

*

*

6.

Depress START switch on control unit until the lamp ignites, then release START switch. Ignition takes approx. 5 seconds. NOTE

Perform steps 7. and 8. for configuration 11 only.

7.

Perform functional test according to steps 5. thru 8. using the pilot's collective-mounted 4-way directional switch.

8.

Check for override control of pilot's collective-mounted 4-way directional switch over corresponding switch on the control unit as follows: Select one of the directional switch positions on the control unit, then select a different directional switch position on the pilot's collective; the searchlight must move in the direction selected by the pilot's collective-mounted directional switch.

BO 105 CHAPTER 813 Page 10

Revision 8

MAINTENANCE MANUAL MBB - BO 105

9.

Press and hold FOCUS switch on control unit. The searchlight beam will continually cycle from large to small to large again until the switch is released.

10.

Select MASTER switch to OFF. The lamp must go out and the blower must stop working. Both left and right side heating cartridges of the 4kW heating system must start working again.

* * * * Select IR switch on control unit to ON. The IR filter rotates down over * the window lens of the searchlight in approx. 20 seconds. When the IR fil- * ter is in the full down position, the IR ON caption on the control unit * NOTE

11.

The following steps shall only be performed if an IR filter is installed and intended for use.

must light up. WARNING

THE IR LIGHT BEAM CANNOT BE SEEN AND IS HAZARDOUS TO THE EYES AND SKIN. IF REQUIRED FOR OPERATION, THE IR IFCO TEST SHOULD BE PERFORMED VERY CAREFULLY. DO NOT AIM THE SEARCHLIGHT TOWARDS PEOPLE, AIRCRAFT OR VEHICLES. DUE TO THE POTENTIAL HAZARDS, DO NOT LOOK DIRECTLY AT ANY SEARCHLIGHT WITHIN 150 METER (500 FEET), WHICH MAY BE OPERATING IN THE IR MODE.

* * * * * *

* *

* * * * CAUTION o THE LIGHT LEAKAGE TEST SHOULD BE PERFORMED IN A DARK * ENVIRONMENT WITH DARK-ADAPTED EYES. IT SHOULD BE PERFORMED * FROM THE REAR OF THE SEARCHLIGHT. * * o ALLOW SEARCHLIGHT TO COOL FOR ONE MINUTE BEFORE RESTARTING * THE LAMP. * * o DO NOT CONTINUE PRESSING THE START SWITCH ON THE CONTROL UNTT * AFTER THE LAMP HAS IGNITED AS THIS WILL SERIOUSLY DAMAGE THE * LAMP. AFTER SWITCHING OFF THE LAMP, ALLOW IT TO COOL DOWN FOR * APPROX. 1 MINUTE BEFORE IGNITING IT AGAIN. * * 12. Switch on searchlight per steps 1 thru 6 and carefully inspect for light * leaks from around the filter gasket, rear cover, and the air inlet of * the searchlight. * * 13. Switch off searchlight per step 10. * * 14. Select IR switch to OFF. The IR filter will rotate back to the up * position and the IR ON caption will go out. * 15.

Switch off external power and pull circuit breakers.

Revision 8

*

BO 105 CHAPTER 813 Page 11

MAINTENANCE MANUAL MBB - BO 105

REMOVAL - SEARCHLIGHT

813 - 6

l. Select MASTER switch to OFF and pull SRCH LT circuit breaker on the instrument panel. 2. Disconnect electrical connectors (23 and 6, fig. 813-1) from the searchlight. 3. Detach safety cable (22); support searchlight to prevent it from falling, and remove pip pins (16). 4. Carefully remove searchlight from gimbal (11). 5. If required, disassemble gimbal (11) from giffibal support (1) as follows: a.

Pull electrical connector (5) out of receptacle.

b.

Remove screws (25) and washers (24) and detach gimbal from gimbal support.

c.

Remove quick-release pins (4) from brackets (3 and 2) and remove gimbal support.

813 - 7

INSTALLATION - SEARCHLIGHT

l. Attach gimbal support (1, fig. 813-1) to brackets (2 and 3) with quick-release pins (4). Adjust gimbal support via setscrew on right strut. 2. Place searchlight in gimbal and install pip pins (16). 3. Mount gimbal to the gimbal support plate with screws (25) and washers (24), and install lockwires. 4. Install safety cable (22) and plug in the electrical connectors (5, 6 and 23). Secure connector (5) with lockwire.

80 105 CHAPTER 813 Page 12

Revision 8

MAINTENANCE MANUAL Maa - 80 105

Removal - motor and gearbox

813 - 8

NOTE

'The removal procedure for the elevation and azimuth motors are identical.

1. Remove searchlight (17, fig. 813-1) and gimbal (11) from the gimbal support (1) as follows: a.

Pull out electrical connectors (6 and 23) and remove safety cable (22) .

b.

Unscrew and remove pip pins (16) and remove searchlight from gimbal.

c.

Remove screws (25) and washers (24) and detach gimbal from gimbal support.

2. Pull rubber boot off azimuth and/or elevation motor; tag and disconnect electrical wires. 3. Remove screws (8 and/or 15) and detach azimuth and/or elevation motor

and attached gearbox from gimbal. 4. Remove screws (10 and/or 13) and separate azimuth and/or elevation motor

from its respective gearbox. 813 - 9 NOTE

Installation - motor and gearbox When installing the azimuth gearbox, insert the stop pins for limiting searchlight rotation to the left and to the right in the appropriate holes in the azimuth gearbox housing.

l. Attach azimuth and/or elevation motor to its respective gearbox with

screws (8 and/or 13, fig. 813-1). Before assembling, apply a thin coat of lubricating oil to the cardan joint of the motor. 2. Mount assembled gearbox and motor to the gimbal with screws (8 and/or 15) . 3. Connect electrical wires and slide rubber boot over motor. 4. Position searchlight in gimbal and secure with pip pins.

5. Install assembled searchlight and gimbal on gimbal support as follows:

a.

Attach gimbal to gimbal support with screws (25) and washers (24) and install lockwires.

b.

Plug in electrical connectors (6 and 23) and install safety cable (22) .

6. Perform functional test (refer to para 813-5).

Revision 8

BO 105 CHAPTER 813 Page 13

_eurocopter 813 - 10

MAINTENANCE MANUAL MBB - BO 105

Removal - focusing motor

l. Remove back housing cover (26, fig. 813-1) by removing screws (27) together with washers from housing. 2. Disconnect electrical connector and set aside housing cover. 3. Remove eccentric disk from motor. 4. Tag and disconnect wires from motor termina1s. 5. Remove four screws, washers and nuts, and detach motor from its support.

813 - 11

Insta1lation - focusing motor

l. Mount motor on its support using four screws, washers and nuts. 2. Connect wiring to motor. 3. Place eccentric disk on motor axis and secure in place. 4. Place back housing cover in position and connect the electrical connector. 5. Secure housing cover to housing with screws and washers. 6. Perform functional test (refer to para 813-5).

BO 105

CHAPTER 813 Page 14

Revision 8

_eurocopter

MAINTENANCE MANUAL MBB - BO 105

813 - 12

Removal - window lens and frame assembly

WARNING

O

ALLOW WINDOW LENS TO COOL UNTIL IT CAN BE REMOVED SAFELY.

o WHEN WORK ON THE SEARCHLIGHT REQUIRES THE WINDOW LENS TO BE REMOVED, PROTECTIVE CLOTHING (i.e., FACE MASK, GLOVES AND LEATHER JACKET) MUST BE WORN BY PERSONNEL TO SHIELD THEM FROM FLYING GLASS SHOULD THE LAMP EXPLODE. l. Remove the three pan-head screws and washers securing the window lens and frame assembly. 2. Carefully remove window lens and frame assembly.

3. Install a protective cover over the opening in the housing to shield the reflector and lamp from damage and dirt.

813 - 13

Installation - window lens and frame assembly

WARNING

PERSONNEL WORKING ON THE SEARCHLIGHT WITH THE WINDOW LENS REMOVED MUST WEAR PROTECTIVE CLOTHING (i.e., FACE MASK, GLOVES AND LEATHER JACKET) TO SHIELD THEM FROM FLYING GLASS SHOULD THE LAMP EXPLODE.

l. Remove protective cover from housing.

2. Examine interior of housing for foreign objects.

3. Clean window lens before inserting it in housing. 4. Place window lens and frame assembly in position. 5. Carefully place window lens and frame assembly on housing and secure with screws and washers.

6. Perform functional test (refer to para 813-5).

Revision 8

BO 105 CHAPTER 813 Page 15

cteurocopter

MAINTENANCE MANUAL MBB - 80 105

813 - 14

Removal - xenon arc lamp

CAUTION

o ALLOW WINDOW LENS TO COOL UNTIL IT CAN BE REMOVED SAFELY.

o WHEN WORK ON THE SEARCHLIGHT REMOVED, PROTECTIVE CLOTHING LEATHER JACKET) MUST BE WORN FLYING GLASS SHOULD THE LAMP

REQUIRES THE WINDOW LENS TO BE (i.e., FACE MASK, GLOVES AND BY PERSONNEL TO SHIELD THEM FROM EXPLODE.

1. Remove window lens (19, fig. 813-1). Refer to.para 813-12. CAUTION

DO NOT TOUCH THE LAMP WITH BARE

H&~DS.

_

2. Remove bonding jumper from spider (20). 3. Remove cap screws, washers and nuts securing the spider to the searchlight housing. WARNING

THE FOLLOWING WORK STEPS MUST BE PERFORMED WITH THE UTMOST CARE.

4. Support lamp with gloved hand and remove screws fastening the spider to the lamp shield on front of lampo 5. Remove spider from searchlight housing. 6. Remove lamp shield from front of lampo 7. Wrap a plastic or fabric cover around the lamp and with a slow, steady forward pull, withdraw the lamp from the rear socket. 8. IrnmediatelY place the lamp in a safe container away from the work area.

BO 105 CHAPTER 813 Page 16

Revision 8

fteurocopter

MAINTENANCE MANUAL MBB - BO 105

813 - 15

Installation - xenon arc lamp

WARNING

PERSONNEL WORKING ON THE SEARCHLIGHT WITH THE WINDOW LENS REMOVED MUST WEAR PROTECTIVE CLOTHING (i.e., FACE MASK GLOVES AND LEATHER JACKET) TO SHIELD THEM FROM FLYING GLASS SHOULD THE LAMP EXPLODE.

CAUTION

DO NOT TOUCH THE LAMP WITH BARE HANDS.

l.

Holding the lamp still wrapped in the plastic or fabric cloth, move it in position.

WARNING

THE FOLLOWING WORK STEPS MUST BE PERFORMED WITH THE UTMOST CARE.

2.

Rotate the lamp until the three anode pins are aligned with their respective holes in the rear socket.

3.

Push the lamp steadily into socket.

4.

Push forward socket on cathode terminal of lampo

5.

Rotate spider (20, fig. 813-1) until nutplates on 1egs alignwith housing attachment screw holes; install attaching screws, washers and nuts.

6.

Support lamp with gloved hand and rotate the 1amp shield on front of lamp until ho1es align with spider attachment screw holes. Ensure that lamp shield is seated correctly on lampo

7.

Secure spider to lamp shield with screws.

8.

Secure bonding jumper to spider.

9.

Instal1 window lens (19) and frame assembly (refer to para 813-13).

10.

Perform functional test (refer to para 813-5).

Revision 8

BO 105 CHAPTER 813 Page 17

MAINTENANCE MANUAL MBB - BO 105

* * * * * * * * * * * * * * * *

813 - 16

Removal - IR filter (if installed)

1.

Remove electrical plug from motor of IR filter and fit with protective cap. If searchlight is to remain installed on helicopter protect and secure cable and connector, do not allow cable to impede movement of searchlight.

2.

Remove IR filter by removing screws, washers, ano spacers at each mounting point. Protect and store filter carefully.

3.

Remove left end plate by removing hinge boit.

4.

Remove lower limit switch cover and lower limit switch.

5.

Remove four screws fastening upper limit switch mount and switch to the searchlight.

* * 6. *

Remove right hinge bolt and IFCO filter drive assembly.

* * 813 - 17

Installation - IR filter

* * 1.

Install IFCO filter drive assembly and right hand hinge bolt.

* * 2. *

Install upper limit switch mount and switch, secure to searchlight with four countersunk screws.

* 3.

Install lower limit switch and switch cover.

*

* 4.

Install left end plate with hinge bolt.

* * 5. *

Install IR filter, spacers, washers, and screws. Lockwire screws.

*

6.

* * 7. * *

Connect electrical connector to motor. Verify adjustment of upper and lower limit switches and adjust as required. Refer to SX-16 Nightsun Operation and Maintenance Addendum for IR-IFCO filter.

BO 105 CHAPTER 813 Page 18

Revision 8

MAINTENANCE MANUAL MBB - BO 105

813 - 18

Cleaning - foam filter element

l. Remove screws (32, fig. 813-1) and spacer sleeves (30) and remove filter cover (31).

* * *

2. Remove frame (28) and remove foam filter element (29) from frame. 3. Rinse foam filter element in clean water and shake dry. 4. Attach foam filter element to back cover of searchlight housing with a clamping strip and install filter cover to back cover with screws and spacer sleeves.

*

813 - 19

Cleaning - reflector

NOTE

Make sure that searchlight has not been used for at least one hour and has cooled down.

WARNING

PERSONNEL MUST WEAR PROTECTIVE CLOTHING (FACE MASK, GLOVES AND LEATHER JACKET) WHEN REMOVING AND INSTALLING THE SEARCHLIGHT TO SHIELD THEM FROM FLYING GLASS SHOULD THE LAMP EXPLODE.

* *

l. Remove xenon arc 1amp (refer to para 813-14). 2. Tilt searchlight down at approx. 45° so that no cleaning liquid can enter the interior of the searchlight. 3. Clean the reflector as follows: a.

Using a piece of surgical cotton that has been saturated in alcohol, remove contaminating film in reflector by working from inside to outside of reflector.

b.

Prepare a solution of cleaning solvent (CM 218) and distilled water, and, using a piece of surgical cotton that has been saturated in this solution, clean the reflector again by working from inside to outside.

c.

Remove cleaning solvent with surgical cotton and distilled water.

4. Remove cleaning solvent from searchlight housing. 5. Install xenon arc lamp (refer to para 813-15).

Revision 8

80 105 CHAPTER 813 Page 19

MAINTENANCE MANUAL MBB - BO 105

* * * * * * * * * * * *

813 - 20 NOTE

Cleaning - IR filter (if installed) Make certain that the searchlight has not been used for at least 1 hour and has cooled down.

l.

The IR filter must be in the up position.

2.

Using a soft cloth and soap solution, remove dirt from both sides of the IR filter.

3.

Rinse with clear water and wipe dry using a soft cloth.

BO 105 CHAPTER 813 Page 20

Revision 8

MAINTENANCE MANUAL MBB - BO 105

DETAlL -<"X.~~--

2

/

I

B

/

I

28

I

\,

~\

\\

\ 31

DETAlL

A

f------:_-_- - - _

3

I'J

---

1..oIIlIii'-__00L7'

II ~

26

J

32 25 -----\04--11 2 4

36 ----.,1-- 33

'-----6

"'---------10

. - . - - - - - - - 11

34 ~-------12

:&-------- 16 21

---I---.J

14 13 E800361

19---~"""

17 18

Fig. 813-1 Revision 8

Searchlight

BO 105 CHAPTER 813 Page 21/22

1 2 3 4 5 6 7 8 9

Gimbal s upport Bracket Br acket Quick release pin Electr ical connector Electrical connector Az imuth motor Screw Azimuth gearbox la Screw 11 Gimbal 12 Elevation motor 13 Screw 14 Elevation gearbox 15 Screw 16 Pip pin 17 Searchlight 18 Window frame 19 Window lens

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Spider (front support) Lamp shield Safety cable Electrical connector Washer Screw Housing cover, back Screw Filter frame Foam filter element Spacer sleeve Filter cover Screw Searchlight with IR-Filter IR-Filter mounting IR-Filter IR-Filter motor Wiring harness

MAINTENANCE MANUAL MBB - BO 105

ANSICHT

ANSICHT

17

BRIGHT

~ 1

~

{

18

IRON

13 - - 1 - -

MASTER

Configuration 1: 2 MASTER switch 3 START S\Ú tch 4 FOCUS switch 5 4-way switch 6 Ci rcui t breaker 7 Circui t breaker Configuration 11: 8 4-way switch 9 MASTER switch 10 START switch 11 FOCUS swi tch 12 Collective lever 13 4-way switch 14 Circuit breaker lS Control p.anel 1R-filter 16 Toggle switch 17 Toggle switch 18 Annunciator

B

16

15

1 Circui t breaker

A

FOCUS

QN

~

~, I

OFF

SEARCHLIGHT

12----18

9

10

11 MASTER

DETAlL

e

DETAlL

(t)

6

e

5TART

FOCUS

(t)

+

3

'''"'@ e PUSH 10 nESEl

@1)--4--14

2

@

GIMBAL

LEF~

0

~

6

BO 105 CHAPTER 813 Page 23/24

e

(t)

RIGHT

UP

@

Searchlight - controls

5

DOWN

PU:;H TO RESEl

E;800362

Revision 8

D 4

Only installed if search light equipped with infrared filter.

Fig. 813-2

DETAlL

7

~

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 814

MEDICAL EQUIPMENT MOUNTING PLATE

Table of Contents

Page

Paragraph

Title

814 - 1

DESCRIPTION - MEDICAL EQUIPMENT MOUNTING PLATE

3

814 - 2

INSPECTION SCHEDULE - MEDICAL EQUIPMENT MOUNTING PLATE

4

814 - 3

INSPECTION FOR CONDITION - MEDICAL EQUIPMENT MOUNTING PLATE . . . . . . . . . . . . . .

5

814 - 4

REMOVAL - MEDICAL EQUIPMENT MOUNTING PLATE

5

814 - 5

INSTALLATION

5

~

MEDICAL EQUIPMENT MOUNTING PLATE

BO 105 CHAPTER 814 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

814 - 1

DESCRIPTION - MEDICAL EQUIPMENT MOUNTING PLATE

The medical equipment mounting plate (2, fig. 814-1) is located on the cabin rear wall. The cabin rear wall(S) is reinforced with two A-profiles (4) and is supported at the back by two struts fitted to the floor of the engine compartment .

..

~~~

DETAlL

~.

B

L·Ji.~1

10-¡~ ~_!_'0

. I I I. ~[jl I 1I f~-. I .

" t

~.

9

I

8

2

11

I 1~

13

~¡---II---

4

+---5

1

DETAlL

A

2 3 4 5

6 7 800363

8 9 10 11 12 13

Screw Mounting plate -Panel A-profile Cabin rear wall Strut Washer Lug Screw Washer Cotter pin Nut Washer

Fig. 814-1 Medical equipment mounting plate BO 105 CHAPTER 814 Page 3

EUROCOPTER

• 814- 2

MAINTENANCE MANUAL 80 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 814 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 814 - 3 1.

2.

INSPECTION FOR CONDITION - MEDICAL EQUIPMENT MOUNTING PLATE

Inspect mounting plate (2, fig. 814-1) for damage and security of attachment. a.

Replace mounting plate if damaged.

b.

Tighten any loose screws (1).

Inspect struts (6) for damage, deformation and securitYi replace any damaged or deformed struts and replace attaching hardware.

814 - 4

REMOVAL - MEDICAL EQUIPMENT MOUNTING PLATE

1.

Remove wall cabinet assembly. (Refer to chapter 815-4) .

2.

Remove mounting plate attaching screws (1, fig. 814-1) . Remove mounting plateo

3.

Remove cabin rear wall panel (3) .

4.

Remove bolts

5.

Pull back the struts (6) for enough to allow the washers (10) to be removed.

6.

Pull out struts into the cabin.

814 - 5

(9) ,

nuts (12) and washers

(13) •

INSTALLATION - MEDICAL EQUIPMENT MOUNTING PLATE

1.

Insert the struts (6) through the A-profiles (4) and the cabin rear wall into the engine compartment and secure their clevis ends to the lugs (8) in the floor of the engine compartment.

2.

Install the cabin rear wall panelling.

3.

Bond the washers (7) to the mounting holes on the back of the mounting plateo

4.

Install the mounting plate with screws (1).

5.

Install the wall cabinet assembly (refer to chapter 815-5) .

BO 105 CHAPTER 814 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 815

WALL CABINET ASSEMBLY

Table of Contents

Page

Paragraph

Title

815 - 1

DESCRIPTION - WALL CABINET ASSEMBLY

3

815 - 2

INSPECTION SCHEDULE - WALL CABINET ASSEMBLY

4

815 - 3

INSPECTION FOR CONDITION - WALL CABINET ASSEMBLY

5

815 - 4

REMOVAL - WALL CABINET ASSEMBLY . . .

5

815 - 5

INSTALLATION - WALL CABINET ASSEMBLY

5

BO 105 CHAPTER 815 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

815 - 1

DESCRIPTION - WALL CABINET ASSEMBLY

The wall cabinet assembly consists of two identical rectangular cabinets which are mounted on the medical equipment plateo

VIEW

A 2

3---H..,;

4---H-t

5

6

1 2 3 4 5 6 Fig.

815-1

Cabinet Screw, washer Pawl latch Flap support Hinged flap Hinge

Wall cabinet BO 105 CHAPTER 815 Page 3

EUROCOPTER

• 815 - 2

MAINTENANCE MANUAL SO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 815 Page4

Revision 18

- - - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 815 - 3

INSPECTION FOR CONDITION - WALL CABINET ASSEMELY

1.

Inspect wall cabinet assernbly; replace damaged cabinets.

2.

Inspect cabinets for secure attachment to the medical equipment mounting plate; tighten screws (2, fig. 815-1) as necessary.

3.

Inspect pawl latches (3), flap supports (4) and hinge (6) for proper function; replace cabinets as necessary.

815 - 4

REMOVAL - WALL CABINET ASSEMBLY

1.

Open hinged flap; remove screw and washers (2) from the cabinet rear wall.

2.

Remove cabinet from the medical equiment mounting plateo

815 - 5

INSTALLATION - WALL CABINET ASSEMBLY

Working through the open flap, mount cabinet on medical equipment mounting plate with four screws and washers (2).

BO 105 CHAPTER 815 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 816

SUCTION BOTTLE HOLDER

Tab1e of Contents

Paragraph

Title

816 - 1

DESCRIPTION - SUCTION BOTTLE HOLDER . . . .

. 3

816 - 2

INSPECTION SCHEDULE - SUCTION BOTTLE HOLDER

4

816 - 3

INSPECTION FOR CONDITION - SUCTION BOTTLE HOLDER

5

816 - 4

REMOVAL - SUCTION BOTTLE HOLDER . . .

5

816 - 5

INSTALLATION - SUCTION BOTTLE HOLDER

5

Page

BO 105 CHAPTER 816 Page 1/2

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

-------------MBB

816 - 1

DESCRIPTION - SUCTION BOTTLE HOLDER

The suction bottle holder is mounted on the medical equipment mounting plateo It comprises two fittings (1, 3, fig. 816-1). The lower fitting is the socket on which the suction bottle rests while the upper fitting has a clamping strap which holds the suction bottle in place.

VIEW

A 2

o

o

4

3-----++

800365

1 2 3 4 Fig.

816-1

Fitting, upper Screw, washer Fitting, lower Screw, washer

Suction bottle 'holder BO 105 CHAPTER 816 Page 3

EUROCOPTER

• 816 - 2

MAINTENANCE MANUAL 80105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 816 Page 4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 816 - 3 1.

2.

INSPECTION FOR CONDITION - SUCTION BOTTLE HOLDER

Inspect upper and lower fittings (1 and 3, fig. 816-1) for damage and security. a.

Replace damaged fittings.

b.

Tighten loose screws.

Inspect snap fastener on the upper fitting for positive locking. Replace fitting if necessary.

816 - 4

REMOVAL - SUCTION BOTTLE HOLDER

Remove screws and washers (2 and 4) and remove fittings.

816 - 5

INSTALLATION - SUCTION BOTTLE HOLDER

Align the fittings on the medical equipment mounting plate and secure each with two screws and washers (2 and 4) .

BO 105 CHAPTER 816 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 817

OXYGEN BOTTLE HOLDER

TabIe oi Contents

Page

Paragraph

TitIe

817 - 1

DESCRIPTION - OXYGEN BOTTLE HOLDER

3

817 - 2

INSPECTION SCHEDULE - OXYGEN BOTTLE HOLDER

4

817 - 3

INSPECTION FOR CONDITION - OXYGEN BOTTLE HOLDER

5

817 - 4

REMOVAL - OXYGEN BOTTLE HOLDER

. .

5

817 - 5

INSTALLATION - OXYGEN BOTTLE HOLDER

5

BO 105 CHAPTER 817 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 817 - 1

DESCRIPTION - OXYGEN BOTTLE HOLDER

The oxygen bottle holder is installed on the medical equipment mounting plateo It consists of two mounting brackets (1 and 4, fig. 817-1) and two clamps (2 and 3) for holding the oxygen bottle in the mounting brackets.

VIEW

A

~

,

1\

t I

\

~

3

I

I I I

)

800366

Mounting bracket, upper Clamp Clamp 4 Mounting bracket, lower

1 2 3

Fig.

817-1

Oxygen bottle holder BO 105 CHAPTER 817 Page 3

EUROCOPTER

• 817 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 817 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 817 - 3

l.

INSPECTION FOR CONDITION - OXYGEN BOTTLE HOLDER

Inspect mounting bracket (1 and 4, fig. 817-1) for damage and security. a.

Replace damaged mounting brackets.

b.

Tighten loose screws attaching mounting brackets to the medical equipment mounting plateo

2.

Inspect the clamps (2 and 3) for positive locking; if necessary, replace clamps.

3.

Inspect clamps for security; tighten attaching screws as necessary.

817 - 4

REMOVAL - OXYGEN BOTTLE HOLDER

Remove screws and washers attaching mounting bracket and/or clamp to medical equipment mounting plate and remove bracket and/or clamp.

817 - 5

INSTALLATION - OXYGEN BOTTLE HOLDER

Install bracket and/or clamp on the medical equipment mounting plate with screws and washers. Make sure that the clamp latches are located en the righthand side when viewed frem the frente

BO 105 CHAPTER 817 Page 5/6

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 818

INFUSION BOTTLE SUSPENSION HOOK

Table oi Contents Page

Paragraph Title 818 - 1

DESCRIPTION - INFUSION BOTTLE SUSPENSION HOOK . . . .

3

818 - 2

INSPECTION SCHEDULE - INFUSION BOTTLE SUSPENSION HOOK

4

818 - 3

INSPECTION FOR CONDITION - INFUSION BOTTLE SUSPENSION HOOK

5

818 - 4

REMOVAL - INFUSION BOTTLE SUSPENSION HOOK . . .

5

818 - 5

INSTALLATION - INFUSION BOTTLE SUSPENSION HOOK

5

BO 105 CHAPTER 818 Page 1/2

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 818 - 1

DESCRIPTION - INFUSION BOTTLE SUSPENSION HOOK

The two infusion bottle suspension hooks are located on frame 4b of the cabin roof.

7

6

3

1 2 ·3

4 5

¡F=b:::==== :-=:_==-~===:::::=

6 7

Frame 4b Infusion bottle Screw Washer Hook Washer Blind-rivet nut

5

B00367

Fig. 818-1

Infusion bottle suspension hook BO 105 CHAPTER 818 Page 3

EUROCOPTER

• 818 - 2

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 818

Page4

MAINTENANCE MANUAL 80105

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

818 - 3

INSPECTION FOR CONDITION - INFUSION BOTTLE SUSPENSION HOOK

Inspect hook (5, fig. 818-1) for condition and tight attachment to frame 4b (1). Replace damaged hook; tighten loose screw (3). 818 - 4

REMOVAL - INFUSION BOTTLE SUSPENSION HOOK

Remove screw (3, fig. 818-1) and washers (4 and 6) and detach hook. 818 - 5

INSTALLATION - INFUSION BOTTLE SUSPENSION HOOK

Install hook on frame 4b with screw (3) and two washers (4 and 6) .

BO 105 CHAPTER 818 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 819

MEDICAL ATTENDANT'S SEAT

Table of Contents

Paragraph

Title

819 - 1

DESCRIPTION - MEDICAL ATTENDANT'S SEAT

3

819 - 2

INSPECTION SCHEDULE - MEDICAL ATTENDANT'S SEAT

4

819 - 3

INSPECTION FOR CONDITION - MEDICAL ATTENDANT'S SEAT

5

819 - 4

REMOVAL - MEDICAL ATTENDANT'S SEAT

5

819 - 5

INSTALLATION - MEDICAL ATTENDANT'S SEAT

5

Page

BO 105 CHAPTER 819 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 819 - 1

DESCRIPTION - MEDICAL ATTENDANT'S SEAT

The medical attendant's seat with lap belt is located behind the pilot seat and faces inward. A forehead protection is provided on the back of the pilot seat to protect against head injuries.

DETAlL

A

3---0-

-----=----2

4

1

800368

5

6

8

7

Fig.

819-1

2 3 4 5 6 7 8

Medical attendant's seat Seat cushion Back cushion Lap belt Lap belt fitting Seat raíl LH Release pin Seat raíl RH

Medical attendant's seat BO 105 CHAPTER 819 Page 3

EUROCOPTER

• 819 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 819 Page4

Revision 18

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 819 - 3

INSPECTION FOR CONDITION - MEDICAL ATTENDANT'S SEAT

1.

Inspect seat cushion (2, fig. 819-1) and back cushion (3) for damage; replace damaged cushion.

2.

Inspect lap belt for damage and secure attachment to the lap belt fittings (5). a.

Perform inspection of lap belt in accordance with manufacturer' s instructions (i. e., Autoflug GmbH). Replace damaged lap belt.

b.

Tighten any loose screws attaching the lap be1t fitting to the cabin floor.

3.

Inspect seat rai1s (6 and 8) for damage and securitiy of installation. Replace damaged seat rails; tighten loose attaching screws.

4.

Inspect release pins (7) for positive lockingand security.

5.

a.

Replace seat rails or rnedical attendant's seat with elongated holes.

b.

Replace defective release pins.

Inspect lap belt lock for damage and positive locking. If necessary, replace lap belt.

819 - 4

REMOVAL - MEDICAL ATTENDANT' S SEAT

1.

Disconnect lap belt (4, fig. 819-1) frorn the lap be1t fittings (5) on each side of the seat.

2.

Pull out release pins (7) and lift rnedical attendant's ·seat (1) off the rails.

3.

Rernove screws attaching lap belt fittings (5) and seat rails (6 and 8) to cabin floor.

819 - 5

INSTALLATION - MEDICAL ATTENDANT'S SEAT

1.

Secure the lap belt fitting (5, fig. 819-1) and seat rails (6 and 8) to the cabin floor with screws.

2.

position rnedical attendant's seat (1) in the seat rails and secure with release pins (7).

3.

Connect lap belt to lap belt fittings (5).

BO 105 CHAPTER 819 Page 5/6

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANSE MANUAL MBB - BO 105

820

CONVERTED COPILOT SEAT

Table oí Contents

Paragraph

Title

820 - 1

DESCRIPTION - CONVERTED COPILOT SEAT

3

820 - 2

INSPECTION SCHEDULE - CONVERTED COPILOT SEAT

4

820 - 3

INSPECTION FOR CONDITION - CONVERTED COPILOT SEAT

5

820 - 4

CONVERSION - COPILOT SEAT

5

820 - 5

REMOVAL - CONVERTED COPILOT SEAT

6

820 - 6

INSTALLATION - CONVERTED COPILOT SEAT

7

820 - 7

Removal - seat rails

7

820 - 8

Installation - seat rails

8

Page

BO 105 CHAPTER 820 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

820 - 1

DESCRIPTION - CONVERTED COPILOT SEAT

The copilot's seat can be removed from and reinstalled back to front in the seat rails for use as a doctor's seat. Configuration 1 (fig. 820-1): The copilot seat is installed in the seat rails and secured with quick release pins. Configuration 11 (fig. 820-2): The horizontally adjustable copilot seat is installed on rollers in the seat rails. The adjustment mechanism comprises travel adjustment handle (8), disengage shaft (6) and splined bar (7). When converted, the copilot seat cannot be adjusted fore and aft due to lack of room.

BO 105 CHAPTER 820 Page 3

EUROCOPTER

• 820 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 820 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 820 - 3

INSPECTION FOR CONDITION - CONVERTED COPILOT SEAT

1. Inspect seat bottom framework for deformation and condition of riveting.

a.

Replace seat bottom framework if deformed.

b.

Replace loose rivets.

2. Inspect seat bottom and back cushions for damage. Repair or replace damaged cushions. 3. Inspect seat rails for damage and security. Replace damaged rails; tighten loose attaching hardware.

4. Inspect seat back fairing for damage. Replace fairing if damaged (e.g. cracks) . 5. Inspect lap belt and lock, and shoulder harness for condition. Proceed according to manufacturer's instructions. 6. Functionally check inertia reel. Proceed according to manufacturer's instructions. 7. Functionally check quick-release pins and inspect them for security. If mating holes are elongated, replace seat bottom framework or seat rails as necessary; replace defective quick-release pins.

Additional procedure for configuration 11: 8. Inspect disengage shaft (6, fig. 820-2) for free movement and proper operation. If free movement is impaired, clean the pivot points of adjustment handle (8) with dry cleaning solvent (CM 202) and lubricate with oil (CM 101) . 9. Disengage seat lock and slide seat back and forth in the rails. If there is binding, clean the seat rails and rollers with dry cleaning solvent (CM 202) .

820 - 4 NOTE

CONVERSION - COPILOT SEAT If dual controls are installed, the left cyclic stick must be removed prior to converting the copilot seat. Unscrew and remove locking handle on cyclic stick, and disconnect electrical connector. Remove cyclic stick by pulling upward. Cap electrical connector on cabin floor.

1. Disconnect lap belt from attach fittings. 2. Unscrew and remove lap belt fittings from aft mounting holes and transfer them to the forward mounting holes.

BO 105 CHAPTER 820 Page 5

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3. Install headrest. a.

Remove fairing from back of copilot seat.

b.

Remove existing rest from top of seat and replace it with headrest, using screws, washers and nuts.

c.

Reinstall fairing.

4. Configuration I:

Remove quick-release pins (6, fig. 820-1) and lift copilot seat out of the rails. Turn seat through 180 0 and reinstall back to front in the rails, using quick-release pins. 5. Configuration II: NOTE

In its normal position facing forward, the copilot seat is not secured by quick-release pin (19, fig. 820-2), and screws (13) function as travel stops when the seat is pushed forward.

a.

Remove quick-release pins (18) and remove copilot seat from the rails.

b.

Turn copilot seat through 180 0 and reinstall back to front in the rails.

c.

Install quick-release pins (18 and 19) . NOTE

The converted copilot seat cannot be horizontally adjusted due to lack of room.

6. Connect lap belt to attach fittings.

820 - 5

REMOVAL - CONVERTED COPILOT SEAT

Configuration I 1. Disconnect lap belt (5, fig. 820-1) from its attach fittings (3 and 4) . 2. Remove quick-release pins (6) and remove copilot seat from rails.

BO 105 CHAPTER 820 Page 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Configuration Ir 1. Disconnect lap belt (5, fig. 820-2) from its attach fittings (3 and 4). 2. Remove quick-release pins (18 and 19) . 3. Press travel adjustment handle (8) inward and slide seat aft until it clears the rails (9 and 11) . 820 - 6

INSTALLATION - CONVERTED COPILOT SEAT

Configuration I 1. position copilot seat in the rails (7 and 9, fig. 820-1) and lock in place with quick~release pins (6). 2. Connect lap belt to its attach fittings (3 and 4). Configuration Ir 1. Position seat on aft end of rails (9 and 11, fig. 820-2) and then slide it forward while pressing the travel adjustment handle (8) inward; lock seat in place. 2. Install quick-release pins (18 and 19). 3. Connect lap belt (5) to its attach fittings (3 and 4) . 820 - 7

Removal - seat rails

1. Remove copilot seat (refer to para 820-5). 2. Remove seat rails as follows: Configuration I: Remove screws (12 and 13, fig. 820-1) together with reinforcements (11) and remove seat rails (7 and 9) together with backing strips (8 and 10) . Configuration II: Remove screws (16 and 17, fig. 820-2) and remove seat rails (9 and 11) together with backing strips (10 and 12) .

BO 105 CHAPTER 820 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

820 - 8

Installation - seat rails

1. Install seat rails as follows: Configuration 1: Align seat rails (7 and 9, fig. 820-1) and backing strips (8 and 10) with mounting screw holes in the cabin floor and secure with screws (12 and 13) and reinforcements (11). Configuration 11: Align seat rails (9 and 11, fig. 820-2) and backing strips (10 and 12) with mounting screw holes in the cabin floor and secure with screws (16 and 17) . 2. Install copilot seat (refer to para 820-6).

BO 105 CHAPTER

Page 8

820

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A

-4----2

5-----,1F-

~¡.'-----4

6

DETAlL

B 1 Converted copilot seat 2 Headrest 3 Lap belt fitting 4 Lap belt fitting 5 Lap belt 6 Quick-release pin 7 RH seat rail 8 Backing strip 9 LH seat rail 10 Backing strip 11 Reinforcement 12 Screw 13 Screw

7---l-F

8--""",-"

10-------1

Fig. 820-1

Converted copilot seat (configuration 1) BO 105 CHAPTER 820 Page 9/10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2----_+_

~~o----8 fII"jJ,~:__----7

----6

L4'~..........

~"----- 3 ~,.........-----5

800370

1 2 3 4 5

6 7 8 9

10 11 12 13 14 15 16 17

18 19

Fig. 820-2

Headrest Converted copi1ot Lap belt fitting Lap belt fitting Lap belt Disengage shaft Splined bar Travel adjustrnent handle RH seat rail Backing strip LH seat rail Backing strip Screw Washer Nut Screw Screw Quick-release pin Quick-release pin

Converted copilot seat (Configuration 11) BO 105 CHAPTER 820 Page 11/12

~

'. . . . . ¡,. I

--------16

....

~~)(" ".........

"~---18

9----1Kil~

11 -----'------~~

----------19 13----_

12

__ 14

---:.------------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

821

LITTER RETENTION SYSTEM

Table of Contents

Paragraph Title

Page

.

821 - 1

DESCRIPTION - LITTER RETENTION SYSTEM

821 - 2

INSPECTION SCHEDULE - LITTER RETENTION SYSTEM

4

821 - 3

INSPECTION FOR CONDITION - LITTER RETENTION SYSTEM

5

821 - 4

REMOVAL - LITTER RETENTION SYSTEM

6

821 - 5

REPAIR - LITTER RETENTION SYSTEM

7

821 - 6

INSTALLATION - LITTER RETENTION SYSTEM

8

3

so 105 CHAPTER 821 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 821 - 1

DESCRIPTION - LITTER RETENTION SYSTEM

Differing types of litter retention are available and are described in the following. Configuration 1 (fig. 821-1) The left and right litter retainers each consist of two litter rails (3 and 5) which are screwed to the floor of the cargo compartment. The litters are rigidly attached to two cross supports (8). Each cross support comprises a bridge and two slides (15). To eliminate binding between the slides and the litter rails, the slides are so connected to the bridge that they can still move slightly. The litters are secured at the forward end of the rails ·by the slides which engage two retaining bars (25). The litters are secured aft with release pins (16) or locking mechanisms (26). Configuration 11 (fig. 821-2) The left and right litter retainers each consist of two litter rails which are screwed to the floor of the cargo compartment. The spring-loades detent levers (32) of the rail locking devices (30) prevent the litters from lifting off the rails and allow free movement of the litters in both directions. The snap locks (35) prevent the litters from sliding back and forth in the nuts by the engagement of two spring-loaded pins in the rail bores. The two forward litter snap tanks operate as stops. To slide the litters in and out of the cargo compartment, the aft snap locks must be removed first. The following interior configurations are possible: 1. Left and right litters installed. The copilot's seat can be turned to face

rearward. The space behind the pilot's seat can accomodate either medical equipment or a medical attendant's seat. 2. A long-range fuel tank with special rails in place of right litter. The litter rails must be removed first. 3. The right seat of the three-seat bench in place of the medical attendant's seat. If the long-range fuel tank is not installed, the right litter rails need not be removed, although the litter itself cannot be installed in the rails.

BO 105 CHAPTER 821 Page 3

EUROCOPTER

• 821 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 821 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 821 - 3

INSPECTION FOR CONDITION - LITTER RETENTION SYSTEM

Configuration 1 (fig. 821-1) 1. Inspect aft locking mechanism (26) for correct functioning, mechanical damage and damage to surface protection. a.

Perform functional check as follows: - Operate ratchet lever (27) several times. The locking pin must be free to move; lubricate with oil (CM 103) as necessary. - Press ratchet lever inwards and lock it with pawl (28). The locking pin must not engage.

b.

Replace locking mechanism if mechanical damage impairs function.

c.

Touch up damaged surface protection with two-component PUR topcoat (CM 426) .

2. Pull litter out of litter rails; do not cant the cross support slides (15) . 3. Inspect litter rails for damage to polyamide runners. Replace chipped, worn or cracked runners (see Chapter 821-5) . 4. Check that forward retaining bars (25) are tightly secured with the release pins. Litter rails or retaining bars with elongated boreholes must be replaced. 5. Inspect litter rails for mechanical damage, damaged surface protection and tight fit to cabin floor. 6. Inspect litter for secure attachment to the cross supports; tighten hand knob (21) or replace damaged parts, as necessary.

Configuration

11

(fig. 821-2)

l. Inspect snap locks (35) for damage; inspect pin (36) for freedom of

movement. a.

Polish out damaged areas on the litter snap locks using 400 grit abrasive cloth; rep1ace locks as necessary.

b.

Touch up damaged surface protection with two-component PUR topcoat (CM 426) .

c.

Clean binding pins with dry cleaning solvent (CM 202) and lubricate with lubricating oil (CM 103) .

BO 105 CHAPTER 821 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2. Inspect rail locking device (30) and detent lever (32) for condition and function.

a.

Replace any worn parts.

b.

If detentlever binds, clean rail locking device with dry cleaning solvent (CM 202) and lubricate with oil (CM 103) .

3. Inspect litter rails for damage to runners. Replace runners if chipped, worn or cracked (see para 821-5). 4. Inspect rivets attaching base plates (10, 28, 29) to litter rails for looseness. Renew loose rivets. 5. Inspect screws securing litter rails to compartment floor for tight fit. Tighten loose screws. 821 - 4

REMOVAL - LITTER RETENTION SYSTEM

Configuration 1: NOTE

The left and right litter retainers are syrnrnetrically constructed.

1. Open rear clam-shell doors and secure in the open position. 2. Remove release pins (16, fig. 821-1) or locking mechanism (26) and pull litter out of the litter rails. 3. Remove release pins from the forward retaining bar (25) and remove retaining bar.

4. Remove screws (12) with washers (2); remove guide plate (13) together with base plate (14). 5. Remove screws (11) with washers (2); remove litter rails (3, 10) together with base plates (4, 9). 6. Remove screws (1, 7) with washers (2); remove litter rails (3, 5) together with base plates (4, 6). 7. Detach litter from cross supports. a.

Unscrew and remove hand knobs (21).

b.

Remove release pin (17) and remove locking hinge (20).

80 105 CHAPTER 821 Page 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Configuration 11: l. Open and secure rear clam-shell doors.

2. Disengage and remove aft snap locks (35, fig. 821-2). Pull litter out of the litter rails. 3. Disengage and remove forward snap locks. 4. Remove screws (5) and washers (19) securing litter platform (20); remove litter platform.

5. Remove screws (11, 13) and washers (6) securing litter rails (15, 16) and litter rails (21, 22); remove litter rails. 6. Remove screws (1, 3) and washers (2, 4) and screws (5) and washers (6); remove litter rail (9).

7. Remove screws (24, 25, 26, 3) and washers (2) and screws (5) and washers (6) and remove litter rail (27). 821 - 5

REPAIR - LITTER RETENTION SYSTEM

Configuration 1: Replacing rail runners: l. Strip runner from litter rail. 2. Scrape off residual adhesive in the rail with a spatula and then clean bonding surface with toluene (CM 219) .

3. Mix adhesive (CM 606) and hardener (CMN 607) and bond new runner to rail with the adhesive mixture. 4. Insert a piece of squared wood along the entire lenth of the litter rail and clamp it tightly against the runner until the adhesive has cured.

Configuration II: l. Replacing rail runners

NOTE

Prior to drilling and installation, irnmerse new runners in water for approx. 3 hours. The material will absorb water and swell, thus making it easier to work with.

a. Drill out tubular rivet and remove rail runner.

BO 105 CHAPTER 821 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Insert and align new runner in the rail.

c.

Drill holes in the runner to match the hole pattern in the rail. Countersink holes in the runner and install tubular rivets to secure the runner to the rail.

2. Replacing torsion spring (33, fig. 821-2) on locking device (30).

a.

Remove locking washer (34), pin (31), and torsion spring.

b.

Insert new torsion spring together with pin and secure with bushing.

c.

Set detent lever (32) perpendicular to litter rail by rebending torsion spring as necessary.

3. Replacing pin (36) and compression spring (37):

a.

Drill off rivet securing grip (38) to pin (36). Remove pin and compression spring.

b.

Clean housing, replacement pin, and compression spring with dry cleaning solvent (CM 202) .

c.

Lubricate pin and compression spring with lubricating oil (CM 103) prior to installation.

d.

Insert compression spring and pin in housing and rivet grip to pino

e.

Press in the pin and inspect pin for ease of movement. If there is evidence of binding, rework riveting. INSTALLATION - LITTER RETENTION SYSTEM

821 - 6

Configuration I NOTE

The left and right hand litter retainer are constructed symmetrically.

1. Position litter rails (3, 5, 10, fig. 821-1), guide plate (13), and base plates (4, 6, 9, 14) on compartment floor and secure them to the floor with screws (1, 7, 11, 12) and washers (2). 2. Position litter on cross supports. Secure litter to the cross supports with the locking hinge (20) and release pins (17). Tighten hand knob (21). 3. Position forward retaining bars (25) in the litter rails (3) and lock each retaining bar with two release pins. 4. Push litter along the rails and inspect aft locking mechanism (26) for function (refer to para 821-3).

BO 105 CHAPTER 821 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Configuration 11: 1. Seeure litter rails and litter platform to the eompartment floor with serews and washers (see fig. 821-2). 2. Install snap loeks (35) in the rails.

3. Slide the litter through its full range of travel, forward and then aft. The litter must pass through the loeking deviees (30) in both direetions with no restrietions. 4. Slide the litter forward and install the aft litter rail loeks. The rail loek pins (36) must loek into the rail without interferenee. 5. Pull up on the litter. The loeking deviees (30) must hold the litter on the rails.

BO 105 CHAPTER 821 Page 9/10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

O

DETAlL

A

13

28

Locking mechanism shown in unlocked condition 21 DETAlL

1 2 3 4

S 6 7

8 9

10 11

12 13

14

Screw Washer Rail, forward section Base plate Rail, aft section Base plate Screw Cross support Base plate Rail Screw Screw Guide plate Base plate

15 16 17

18 19 20

21 22 23 24 25

26 27 28

Slide Release pin Release pin Screw Bushing Locking hinge Hand knob Cotter pin Nut Washer Retaining bar, forward Locking mechanism, aft Ratchet lever Pawl

B

DETAlL \ ' - - _ - - . - -_ _1 I

25 800371

Fig. 821-1

Litter retention system (Configuration I) BO 105

CHAPTER 821 Page 11/12

e

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

e DETAlL

A

35-

DETAlL

B

, .................n.-_ 32

30

800372

10-~

1 2 3

4 5 6 7 8

9

10 11

12 13 14

15 16 17 18 19

Screw Washer Screw Washer Screw Washer Runner Screw Rail, outer (right litter) Base plate Screw Runner Screw Runner Rail, inner aft (right litter) Rail, inner forward (right litter) Runner Runner Washer

Fig. 821-2

20 21 22 23

24 25 26 27

28 29 30 31 32 33

34 35

36

37 38 39

Litter platform Rail, inner aft (left litter) Rail, inner forward (left litter) Runner Screw Screw Screw Rail, outer (left litter) Base plate Base plate Locking device Pin Detent lever Torsion spring Locking washer Snap lock Pin Compression spring Grip Shackle

Litter retention system (Configuration 11)

BO 105 CHAPTER 821 Page 13/14

5 1&--19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

822

CARGO HOOK SYSTEM

TabIe of Contents

Paragraph Title

Page

822 - 1

DESCRIPTION - CARGO HOOK SYSTEM

3

822 - 2

TROUBLESHOOTING - CARGO HOOK SYSTEM

7

822 - 3

INSPECTION SCHEDULE - CARGO HOOK SYSTEM

13

822 - 4

INSPECTION FOR CONDITION - CARGO HOOK SYSTEM

14

822 - 5

FUNCTIONAL TEST - CARGO HOOK SYSTEM

15

822 - 6

Removal - cable assembly

17

822 - 7

Installation - cable assembly

18

822 - 8

Removal - cargo hook

20

822 - 9

Installation - cargo hook

20

822 - 10

Removal - cross tube fittings

25

822 - 11

Installation - cross tube fittings

25

822 - 12

Removal - buffer plate

28

822 - 13

Installation - buffer plate

28

822 - 14

Removal - hook retainer (snap hook or sling)

28

822 - 15

Installation - hook retainer (snap hook or sling)

28

822 - 16

Adjustment - Bowdenflex cable of cargo hook configuration 1

30

822 - 17

Adjustment - Bowdenflex cable of cargo hook configuration 11

31

BO 105 CHAPTER 822 Page 1/2

EUROCOPTER

822 - 1

MAINTENANCE MANUAL 80 105

DESCRIPTION - CARGO HOOK SYSTEM

1. General The cargo hook system is designed for loads up to 900kg and 1200kg. It consists of fixed mounting provisions and a detachable cable assembly. 2.

Description The cargo hook (8, Fig. 822-1) is suspended centerline below the fuselage by four cables which attach via quick-release pins to fittings (6) on the forward and aft cross tubes. The 1200kg cargo hook type is additionally configured with shackles between the links and the hook suspension cables (see fig. 822-2, 2 of 2). In the event of an emergency, the load can be released by the pilot or copilot mechanically, using the emergency release control (1). Emergency release is also possible electrically through switch LOAD HOOK on the pilot's or copilot's collective pitch stick. Electrical release is controlled through the relay contained in relay box 10VE (11) (on SIN 101 and subsq.). When not in use, the cargo hook is stowed by attaching it to a hook retainer (5) installed on the left side of the fuselage. The buffer plate (7) prevents the cargo hook from damaging the fuselage skin in the stowed position. In the event that the helicopter is operated La.w. Flight Manual Supplement 10-53, reinforcing plates are installed on the fuselage in the area of the fuselage mounts.

I I

Two cargo hook configurations are available. They differ in the following: -

cargo hook type hook retainer type procedure for adjusting the Bowdenflex cable of the mechanical emergency release control.

Configuration 1: The SIREN A90B type cargo hook must be c10sed manually after the load is attached. The hook retainer is a snap hook. The indicator light on the instrument panel (2) illuminates when the hook is open. The Bowdenflex cable of the mechanical emergency release control is adjusted by adding or removing shims between the nipple and support bracket (refer to para 822-16). Configuration 11: With the 81REN cargo hook types 81609-2-1051 -1 OSAI -1061 -1 06A and S1609.1.118A, the hook closes automatically after the load has been attached. The hook retainer is a sling. The indicator Iight comes on after the load has been released (the hook suspending freely without load). The Bowdenflex cable of the mechanical emergency release control is adjusted by adding or removing shims between the nipple and nipple support or by rotating the cable guide (refer to para 822-17).

Revision 17

CHAPTER 822 Page 3

I

EUROCOPTER

MAINTENANCE MANUAL 80 105

The configuration 11 cargo hook types difter from each other as follows: Remarks

Part Number ECO

SIREN S1609-2-105

105-80339

Part numbers are applicable if cargo hook has not been modified by an S8 or AS8

S1609-2-106

105-80327

Part numbers are applicable if cargo hook has been modified by M88 S8-801 05-80-81 or Siren S8 No. 10A

105-803.26

Part number is applicable if cargo hook héis been modified by M88 AS8-801 05-80-1 07

The 80wdenflex cable of the mechanical emergency release control is adjusted by adding or removing shims between the nipple and the support bracket (refer to para 822-17)

Remarks

Part Number SIREN S1609-2-105A

S1609-2-106A

I

&, S1609-1-118A --

ECO 105-80339 V001

Part numbers are applicable if cargo hook has not been modified by an S8 or AS8

105-80328

Part numbers are applicable if cargo hook has been modified by M88 S8-80105-80-81 or Siren S8 No. 10A

105-80331

Part number is applicable if cargo hook has been modified by M88 ASB-801 05-80-1 07

117-80126

&,

Part number is applicable if cargo hook has been modified by Siren S8 No. 10A --

The 80wdenflex cable is adjusted by altering the depth of cable guide thread engagement (refer to para 822-17)

-_.._ - - - - - - - - - - _ . _ - - -

CHAPTER 822 Page 4

Revision 17

EUROCOPTER

MAINTENANCE MANUAL 80 105

3. Operation a.

Helicopter S/N 11 thru 100 With circuit breaker CARGO HOOK 1MD depressed and switch CARGO HOOK 2MD in OPEN, the cargo hook is opened by a solenoid. At the same time the yellow indicator light 3MD is energized through a switch within the cargo hook. The cable hook is closed by setting switch CARGO HOOK 2MD to CLOSE and by pressing the trigger on the cargo hook. The indicator light 3MD will go out. On helicopters with dual controls, the copilot can also open the cargo hook by operating the LOAD HOOK 2MD switch mounted on his collective pitch stick.

b.

Helicopter S/N 101 and subsq., configuration 1: With circuit breaker HOOK 1MD depressed and pilot's collective-mounted switch LOAD HOOK 2MD in OPEN, the solenoid of cargo hook 4MD is energized through the contacts of relays 7MD and 6MD and the cargo hook opens. At the same time, relay 6MD is energized through a switch within the cargo hook. Indicator light HOOK 3MD is illuminated through a 6MD relay contact and the solenoid is de-energized. When the pilot's collective-mounted switch LOAD HOOK 2MD is returned to CLOSED, the cargo hook can be closed by pressing the trigger on the cargo hook. Indicator light HOOK 3MD goes out. On helicopters with dual controls, the copilot can also open the cargo hook by operating the switch LOAD HOOK 2MD mounted on his collective pitch stick. With this switch in OPEN, relay 7MD is energized and power is routed through the contacts of relays 7MD and 6MD to energize the solenoid in cargo hook 4MD.

c.

Helicopter S/N 101 and subsq., configuration 11: With circuit breakers HOOK 1MD depressed and pilot's collective-mounted switch LOAD HOOK 2MD in OPEN, the solenoid of cargo hook 4MD is energized through the contacts of relays 7MD and 6MD, and the cargo hook opens. The load is released and the cargo hook locks automatically. The load on the hook now less than SON and relay 6MD is energized. This completes the circuit to indicator light HOOK 3MD, which illuminates, and breaks the circuit to the solenoid in the cargo hook. On helicopters with dual controls, the copilot can also open the cargo hook through the switch LOAD HOOK 2MD mounted on his collective pitch stick. With this switch in OPEN, relay 7MD is energized and power is routed through the contacts ofrelays 7MD and 6MD to energize the solenoid in the cargo hook 4MD.

BO 105 CHAPTER 822 Page 5

EUROCOPTER

MAINTENANCE MANUAL 80105

800286

12

* *

*

11

10

9 6

8

7

6

1 Ernergency release control 2 Instrument panel (circuit breakers, indicator lights) 3 Collective pitch stick 4 Cargo hook placard 5 Hook retainer Configuration 1: snap hook Configuration 11: sling 6 Cross tube fitting 7 Buffer plate 8 Cargo hook Configuration 1: SIREN A90B Configuration 11: 5IREN 51609-2-105/ -10SA/ -106/ -106A/ 51609.1.118A 9 Receptacle SMDA 10 Wiring harness 3VB 11 Relay box 10VE 12 Wiring harness 9VB Fig. 822-1

BO 105 CHAPTER 822 Page 6

Cargo hook systern

Revision 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 822 - 2

TROUBLESHOOTING - CARGO HOOK SYSTEM

General -

Use wiring diagrams 822-1 and 822-2 in the Wiring Diagram Manual (WDM) to troubleshoot the system.

-

Check electrical connections for security and switch LOAD HOOK 2MD for proper function.

-

Depress indicator light HOOK 3MD to test the lamp (refer to para 822-5).

-

Depress circuit breaker HOOK 1MD.

1. Troubleshooting of configuration I No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Circuit breaker 1MD defective

Check circuit breaker for continuity and replace as necessary

Connectors 2VEE/2VEe SMDA/SMDa, 4MDA/4MDa corroded; poor contact

Measure voltage at connectors and remove corrosion

Switch 2MD defective

Check switch for continuity in both operating positions and replace as necessary

Poor electrical bonding

Inspect bonding jumpers. Remove corros ion from terminal connections and replace bonding jumpers as necessary

Cargo hook defective

Check cargo hook solenoid for continuity and replace as necessary

Trouble syrnptoms No. 1 thru 4 apply to helicopters S/N 11-100 only 1

Cargo hook does not open

Table 822-1

Troubleshooting (1 of 6)

BO 105 CHAPTER 822 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Troubleshooting of configuration 1 (continued) No.

TROUBLE SYMPTOM

2

Cargo hook does Cargo hook defective not close although the trigger has been pressed and switch 2MD is in CLOSED

Replace cargo hook

3

Indicator light 3MD illuminates when tested, but remains off when the hook is open

Check wiring for continuity and replace as necessary

4

Indicator light 3MD Microswitch in cargo illuminates when hook defective cargo hook is closed

PROBABLE CAUSE

Faulty wiring between cargo hook and indicator light

CORRECTlVE ACTION

Check microswitch and replace as necessary

The following trouble symptoms apply to helicopters S/N 101 and subsq. 5

Cargo hook does not open

Circuit breaker 1MD defective

Check circuit breaker for continuity and replace defective circuit breaker

Switch 2MD defective

Check switch for continuity in both operating positions and replace as necessary

Relay 6MD or 7MD defective

Inspect relays and replace as necessary

Poor electrical bonding

Inspect bonding jumpers. Remove corros ion from terminal connections and replace bonding jumpers as necessary

Cargo hook defective

Check solenoid and switch for continuity and replace cargo hook as necessary

Table 822-1

BO 105 CHAPTER 822 Page 8

Troubleshooting (2 of 6)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Troubleshooting of configuration 1 (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

6

Cargo hook does not close although trigger has been pressed and switch 2MD in CLOSED

Cargo hook defective

Replace cargo hook

7

Indicator light 3MD fails to illuminate when hook is open

Relay 6MD defective

Inspect relay 6MD and replace as necessary

Circuit breaker 1MD defective

Check circuit breaker for continuity and replace if defective

Switch in cargo hook defective

Check switch for continuity in both operating positions and replace as necessary

Indicator light 3MD defective

Check indicator light and replace if defective

Relais 6MD defective

Check relay 6MD and replace as necessary

Microswitch in cargo hook defective

Check microswitch and replace microswitch or cargo hook as necessary

8

Indicator light 3MD remains on when hook is closed

Table 822-1

Troubleshooting (3 of 6)

BO 105 CHAPTER 822 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2. Troubleshooting of configuration 11 No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Circuit breaker 1MD defective

Check circuit breaker for continuity and repIace as necessary

Connectors 2VEE/2VEe SMDA/SMDa, 4MDA/4MDa corroded¡ poor contact

Measure voltage at connectors and remove corrosion

Switch 2MD defective

Check switch for continuity in both operating positions and repIace as necessary

Poor eIectrical bonding

Inspect bonding jumpers. Remove corrosion from terminal connections and repIace bonding jumpers as necessary

Cargo hook defective

Check cargo hook solenoid for continuity . and repIace as necessary

Trouble Syrnptoms No. 1 thru 4 appIy to heIicopters S/N 11-100 only 1

2

Cargo hook does not open

Cargo hook does Cargo hook defective not cIose aIthough the trigger has been pressed and switch 2MD is in CLOSED

TabIe 822-1

BO 105 CHAPTER 822 Page 10

RepIace cargo hook

Troubleshooting (4 of 6)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS Troubleshooting of configuration 11 (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTI0N

3

Indicator light 3MD illurninates when tested, but rernains off when the hook is open

Faulty wiring between cargo hook and indicator light

Check wiring for continuity and replace as necessary

4

Indicator light 3MD Microswitch in cargo illurninates when hook defective cargo hook is closed

Check rnicroswitch and replace as necessary

The following trouble syrnptorns apply to helicopters S/N 101 and subsq.: 5

6

Cargo hook does not open

Cargo hook does not close

Circuit breaker 1MD defective

Check circuit breaker for continuity and replace defective circuit breaker

Switch 2MD defective

Check switch for continuity in both operating positions and replace as necessary

Relay 6MD or 7MD defective

Inspect relays and replace as necessary

Poor electrical bonding

Inspect bonding jumpers. Rernove corrosion frorn terminal connections and replace bonding jurnpers as necessary

Cargo hook defective

Check solenoid and switch for continuity and replace cargo hook as necessary

Locking rnechanisrn defective

Replace cargo hook

Table 822-1

Troubleshooting (5 of 6)

BO 105 CHAPTER 822 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 Troubleshooting of configuration 11 (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECT1VE ACT10N

7

1ndicator light 3MD fails to illuminate when hook is open

Relay 6MD defective

1nspect relay 6MD and replace as necessary

Circuit breaker 1MD defective

Check circuit breaker for continuity and replace if defective

Switch in cargo hook defective

Check switch for continuity in both operating positions and replace as necessary

1ndicator light 3MD defective

Check indicator light and replace if defective

Relais 6MD defective

Check relay 6MD and replace as necessary

Microswitch in cargo hook defective

Check microswitch and replace microswitch or cargo hook as necessary

8

1ndicator light 3MD remains on when hook is closed

Table 822-1

BO 105 CHAPTER 822 Page 12

Troubleshooting (6 of 6)

EUROCOPTER

822 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (reter to Chapter 101)

CHAPTER 822 Page 13

EUROCOPTER

822 - 4

MAINTENANCE MANUAL 60 105

INSPECTION fOR CONDITION - CARGO HOOK SYSTEM

1. Inspect cross tube fittings (5, fig. 822-2) for mechanical damage, corrosion and security of installation. a.

Polish out mechanical damage and corrosion to depth not exceeding 0.5 mm, using 400 grit abrasive cloth.

b. Applychromate conversion coating (CM 316) to reworked area. Then applytwo-componentwash primer (CM 423) and single-Iayer lacquer (CM 407). c.

If required according to inspection schedule, penetrant-inspect cross tube fittings for cracks in accordance with MIL-STD-6866, and replace as necessary.

d. Tighten loose attaching hardware to torque values shown in fig. 822-4. 2.

Inspect protective blank (14, fig. 822-2) of dummy receptacle (13) for condition and secure installation. Tighten loose protective blank and replace if damaged.

3.

Inspect cargo hook retainer (11, fig. 822-5) and fitting (14) for mechanical damage, corrosion and security of installation. a.

Polish out mechanical damage and corrosion to a depth not exceeding 0.2 mm, using 400 grit abrasive cloth.

b. Apply chromate conversion coating (CM 316) to reworked area. Then apply two-component zinc chromate primer (CM 456) and single-Iayer lacquer (CM 407). c.

Tighten loose attaching hardware to torque values shown in fig. 822-5.

Inspectcables and Iinks (2 and 4, fig. 822-2) orcables (2),links (4) and shackles (19) forcondition. Replace if damaged. 5.

Inspect quick-release pins (3) for condition and unimpaired function. Replace if damaged

6.

Inspect eye terminals of cables for wear. Replace cables with worn eye terminals.

7. Only for cargo hook with forwatd and aft cable attachment: Inspect attaching hardware (18 thru 23, fig. 822-3) connecting the shackles (14) to cargo hook (21) for tightness. Tighten loose connections (refer to fig. 822-3 for torque value). In the case of the config. 1cargo hook, check for presence of cotter pins on attaching hardware (18, 19 and 20) connecting the shackles (14) to cargo hook (5). If a cotter pin is missing, tighten nut (18) and safety with cotter pin (17). For torque value, refer to fig. 822-3. 7A. Only for cargo hook with central cable attachment: Inspect attaching hardware (34 thru 36, fig. 822-3) connecting the shackles (14) to the cargo hook (32) for presence of cotter pin (33). If cotter pin is missing, tighten nut (34) and secure with cotter pin (33).

CHAPTER 822 Page 14

Revision 17

EUROCOPTER

MAINTENANCE MANUAL BO 105

8.

Inspect cargo hook for mechanical damage and corrosion. Remove damaged cargo hook and evaluate damage according manufacturer's instructions.

9.

Inspect electrical release cable (7, fig. 822-3) and Bowdenflex cable (2) of emergency release control for damage and secure attachment to the hook suspension cables. a.

Replace electrical release cable and Bowdenflex cable if damaged.

b.

Tighten loose cable clamps and replace as necessary.

c.

Screw connector (6) of electrical release cable tightly to the cargo hook receptacle and tighten receptacle attachment screws on left side of fuselage.

10.

Inspect buffer plate (2, fig. 822-5) for condition and security of installation. Replace if damaged.

11.

Inspect emergency release control in cockpit for condition and security of installation.

12.

a.

Tighten loose attaching hardware (bracket-to-cockpit floor, emergency release control-to-bracket).

b.

Replace damaged parts.

Move emergency load release actuating lever alternately to OPEN and CLOSED positions several times. While operating the lever, check fór free movement of the Bowdenflex cable. If binding occurs, determine and eliminate cause of binding. FUNCTIONAL TEST - CARGO HOOK SYSTEM

822 - 5

NOTE

Circuit breaker HOOK 1MD is labelled LOAD HOOK 1MD on helicopters with S/Ns up to and including 160.

Configuration 1: l.

Electrical release mechanism a.

Connect external power unit.

b.

Set switch LOAD HOOK 2MD on pilot's and copilot's collective pitch stick to CLOSED. Cargo hook must be closed. Otherwise close manually.

c.

Depress circuit breaker HOOK 1MD on instrument panel.

d.

Indicator light HOOK 3MD on instrument panel must not illuminate. Depress indicator light to test the lampo The bottom segment HOOK must illuminate. Release indicator light. Light must extinguish.

Revision 16

BO 105 CHAPTER 822 Page 15

* * * *

EUROCOPTER

2.

MAINTENANCE MANUAL 80 105

e.

Move switch LOAD HOOK 2MD on pilot's collective pitch stick to OPEN. The cargo hook opens (look to rnake sure) and the indicator light illurninates to indicate that the hook has opened.

f.

Operate switch LOAD HOOK 2MD on pilot's collective pitch stick to CLOSED. The indicator light must remain on and the cargo hook rernain open.

g.

Close cargo hook mechanically by operating the manual release. The indicator light must go out.

h.

Repeat steps 5. thru 7. with the copilot's collective - mounted switch LOAD HOOK 2MD.

i.

Pull circuit breaker HOOK 1MD and disconnect external power unit.

j.

Stow cargo hook by attaching to snap hook.

Mechanical release mechanism a.

Set switch LOAD HOOK 2MD on collective pitch sticks to CLOSED.

b.

Close cargo hook by operating the manual release.

c.

Slowly pull lever (3, fig. 822-3) of emergency release control, located between the pilot's pedals, aft to the OPEN position. The cargo hook shall open when the lever is at an angle of between 10° and 20° from its vertical position (see fig. 822-3, Detail A).

d.

If the cargo hook does not open within the above limits, readjust the release point as described in para 822-16.

e.

Move lever of emergency release control to its most forward position and attach cargo hook to snap hook.

Configuration II: 1.

Electrical release mechanism a.

Connect external power unit.

b.

Set pilot's/copilot's collective-mounted switch LOAD HOOK 2MD to CLOSED.

c.

Depress circuit breaker HOOK 1MD on instrument panel.

d.

Indicator light HOOK 3MD on instrument panel must illurninate when cargo hook is not loaded.

BO 105 CHAPTER 822 Page 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 e.

Apply a load exceeding SON to cargo hook. Indicator light HOOK 3MD must extinguish.

f.

Depress indicator light to test the lampo The bottom segment HOOK must illuminate. Release indicator light. Light must extinguish.

g.

Operate pilot's collective-mounted switch LOAD HOOK 2MD to OPEN.

h.

The cargo hook must open and release the attached load. At the same time, indicator light HOOK 3MD must illuminate and cargo hook must close again.

i.

Operate pilot's collective-mounted switch LOAD HOOK 2MD to CLOSE.

j .. Repeat steps 5. thru 9. with switch LOAD HOOK 2MD on copilot's collective pitch stick, if installed.

2.

k.

Pul! circuit breaker HOOK 1MD and disconnect external power unit.

l.

Stow cargo hook in hook retainer.

Mechanical release mechanism a.

Operate switch LOAD HOOK 2MD on collective pitch levers to CLOSED.

b.

Move lever (3, fig. 822-3) of emergency release control to CLOSED position.

c.

Load cargo hook in excess of 50 N.

d.

Slowly pull lever (3) of emergency release control aft to OPEN position. The cargo hook shall open when the lever is at an angle of between 10° and 20° from its vertical position (see fig. 822-3, Detail A) .

e.

If the cargo hook does not release the load between the above limits, readjust the release point as described in para 822-17.

f.

Move lever of emergency release control to its most forward position and stow cargo hook in retaining sling.

822 - 6 NOTE 1.

Removal - cable assembly The cable assembly removal procedure is identical for configurations 1 and 11.

Detach cargo hook from hook retainer (snap hook or sling) on left side of fuselage.

BO 105 CHAPTER 822 Page 17

MAINTENANCE MANUAL BO 10S

EUROCOPTER

2.

Remove electrical connector (11, fig. 822-2) from receptacle (12) on left side of fuselage. Install protective blank (14) on receptade.

3.

Disconnect Bowdenflex cable (8) on right side of fuselage, by unscrewing union nut (17) and disengaging cable endball (7). Install protective blanks (6) on open ends.

4.

Remove quick-release pins (3) and detach hook suspension cables.

5.

Stere cable assembly in specified manner.

822 - 7

Installation - cable assembly

CAUTION

• HELlCOPTERS S/N 1-100, S/N 201 AND SUBSO., AND THOSE WHICH HAVE HAD SB 80-21 EMBODIED, MUST BE EOUIPPED WITH ELECTRICAL RELEASE CABLE P/N 105-98326. THIS CABLE BEARS AN ID SLEEVE MARKED "22VB". • HELlCOPTERS S/N 101 - 200 MUST BE EOUIPPED WIT-H ELECTRICAL RELEASE CABLE P/N 105-98327 IF THEY HAVE NOT YET HAD SB 80-21 EMBODIED. THIS CABLE BEARS AN ID SLEEVE MARKED "22 VB, P/N 105-98327.

NOTE

r

Raising the helicopter is not required for installing the hook suspensjon cables if the attachment brackets have not previously been removed.

Depending on the cargo hook configuration, the four hook suspension cables (2, fig. 822-2) shall be connected to links (4) either directly by quick-release pins (3) or through shackles (19) and quick-release pins (3). The quick-release pins must be inserted from inboard to outboard. Attach the long cables to the forward cross tube and the short cables to the aft cross tube.

2. Connect electrical connector (11) to receptade (12). Install protective blank (14) on dummy receptacle. 3.

On the right side of the fuselage, connect Bowdenflex cable (8) via cable endball (7) to non-detachable part of the mechanical emergency release and screw unjon nuts (17) together. Wire-Iock bottom unjon nut to upper Bowdenflex cable (see fig. 822-2). Connect protective blanks (6) to each other.

4. Check cargo hook system fer proper electrical and mechanical functioning. Refer to para 822-5.

CHAPTER 822 Page 18

Revision 17

MAINTENANCE MANUAL 80 105

EUROCOPTER

DETAILZ

18

1~

DETAlL B

DETAlLA

11 --+---'-..t:a

5---\-\\

,-----3

4 - - - - -.......';;1

6 --16

z

,

10---

J

3------/ ~-8

'----4 a:I

2---~

CD

~I ~

1

Dimensions in mm

'-----2

'8

o "''------.------/ al

""~-----.-------~/

&, Bowdenflex cable assembled, union nuts wirelocked together 1 2 3 4 5 6 7 8 9 10

Cross tube fitting (RH, fwd) Hook suspension cable Quick-release pin Link Fitting half Protective blank Cable endball Bowdenflex cable Cross tube fitting (LH, fwd) Electrical release cable

Figure 822-2

Revision 17

11 12 13 14 15 16 17 18 19

Electrical connector Receptacle Dummy receptacie Protective blank Bearing ring Cross tube Union nut Lockwire Shackle

(1 of 2) Installation of cable assembly for cargo hook system 900 kg

CHAPTER 822 Page 19

EUROCOPTER

MAINTENANCE MANUAL BO 105

DETAILZ

~-18

DETAlLA

,/

a:

,.

o'

\

8, I

'.

~

./" ','

/--2

/

\

~

g

3

Dimensions in mm

&

Bowdenflex cable assembled, union nuts wirelocked together

Figure. 822-2 (2 of 2) Installation of cable assembly for cargo hook system 1200kg

CHAPTER 822 Page 20

Revision 17

EUROCOPTER

822 - 8

MAINTENANCE MANUAL SO 105

Removal - cargo hook

Configuration 1: (fig. 822-3, 1 of 2) 1. Remove attaching hardware (10,11,12, and 13) and cover (9). 2. Unscrew and remove nipple (8) with shims (27) and disengage Bowdenflex cable from the cable guide.

3. Disconnect electrical connector (6) of electrical release cable. 4.

Remove attaching hardware (17,18,19 and 20) and remove shackles (14) together with attached hook suspension cables from cargo hook.

Configuration 11: (fig. 822-3, 2 of 2) 1. Remove cover (26) and unscrew cable guide (29) sufficiently to permit disengagement of Bowdenflex

cable. 2. Remove locking, unscrew union nut (30) from nipple (25), and withdraw Bowdenflex cable. 3. Disconnect electrical connector (6) of electrical release cable from cargo hook. 4. Only for cargo hook with forward and aft cable attachment a. Remove attaching hardware (18, 19 and 20) and cover (23). If required, remove spacer (23) from cargo hook. b. Remove shackles (14) together with suspension cables from cargo hook. 5. Only for cargo hook with central cable attachment a. Unscrew wiring harness attaching clamp from cargo hook. b. Remove cotter pin (33) and remove attaching hardware (34, 35 and 36). c. 822 - 9

Detach shackles (14) and attached hook suspension cables from cargo hook. Installation - cargo hook

Configuration 1: (fig. 822-3, 1 of 2) 1. Attach hook suspension cablesto shackles (14). 2. Secure shackles to cargo hook with attaching hardware (18, 19 and 20). Torque according to fig. 822-3. Secure nuts (18) with cotter pins (17).

3. Connect Bowdenflex cable (2). 4. Connect electrical connector (6) of electrical release cable. 5.

Install cover (9) with attaching hardware (10, 11 and 12). Secure nuts (12) with cotter pins (13).

6. Perform functional test according to para 822-5

Revision 17

CHAPTER 822 Page 21

•

EUROCOPTER

MAINTENANCE MANUAL 80 10S

Configuration 11: (fig. 822-3, 2 of 2) •

1. Only for cargo hook with forward and aft cable attachment: a. Attach hook suspension cables to shackles (14). b.

Install shackles to cargo hook with spacers (22) and attaching hardware (18, 19 and 20). Torque according to fig. 822-3. Install protective caps (23).

2. Only for cargo hook with central cable attachment: a. Attach hook suspension cables to shackles (14). b. Attach shackles (14) to cargo hook with attaching hardware (34, 35 and 36) and secure connection with cotter pin (33). c. 3.

Install wiring harness attaching clamp to cargo hook.

Install nipple (25) on end of Bowdenflex cable and insert Bowdenflex cable in the cable guide. Screw cable guide in place. Screw union nut (30) on to nipple (25).

4. Connect electrical connector (6) of electrical release cable (7). 5. •

Perform functional test according to para 822-5.

6. Wire-Iock tab washer to union nut, refer to fig. 822-6 and 822-7.

CHAPTER 822 Page 22

Revision 17

MAINTENANCE MANUAL BO 105

EUROCOPTER

~-~-~·7 \2

I

27

28

8

DETAlLA

DETAlLe

3 6

-f---14

r/m--i----15

DETAlL B

1----16

19 18 17

I

\

I

~I

oI (;

28-36Nm 5

o,

:r

~,

'"o

g

&

Release range for cargo hook

1 Emergency release control 2 Bowdenflex cable 3 Lever 4 Switch 5 Cargo hook (Config.l) 6 Electrical connector 7 Electrical release cable 8 Nipple 9 Cover 10 Bolt

11 12 13 14 15 16 17 18 19 20 21

Figure 822-3

Revision 17

Washer Nut Cotter pin Shackle Trigger Sling Cotter pin Nut Washer Pin Cargo hook (Config.lI)

22 23 24 25 26 27 28 29 30 31

Spacer Protective cap Manual release control Nipple Cover Shim Sleeve Cable guide Union nut Placard

(1 of 2) Cargo hook system

CHAPTER 822 Page 23

MAINTENANCE MANUAL 80 105

EUROCOPTER

I •

,.1 DETAlL e

Direction of Flight

128-31 Nml 18,19,20,22,23

6-++1

""~------------,---------~/

I

& see also fig. 822-6 and fig. 822-7

21

Direction of Flight

+

DETAlLe

""~------------,.-----------'/

I

32 32 Cargo hook (Config.1I 1200kgload) 33 Cotter pin

34 Nut 35 Washer 36 Screw

Figure 822-3 (2 of 2) Cargo hook system

CHAPTER 822 Page 24

Revision 17

EUROCOPTER

822 - 10

MAINTENANCE MANUAL BO 105

Removal - cross tube fittings

1. Aemove cable assembly if installed. Aefer to para 822-6. NOTE

If the cross-tube fittings are to be reinstalled on the same landing gear, mark their installed positions to avoid having to realign them.

2.

Mark position of the fittings on the cross tubes.

3.

Aemove cable clamp from bracket (7, fig. 822-4). This release Bowdenflex cable (11) of emergency release control.

4.

Aemove attaching hardware (2, 3, 4, 5) from the fittings (1), and remove links (6) and fitting halves from the cross tubes.

822 - 11

NOTE

Installation - cross tube fittings

If the cross tube fittings are to be reinstalled in their original positions, step 1. can be omitted so long as the original positions were marked at removal.

1. Aaise helicopter with hoisting sling until the cable assembly does not touch the ground. Make sure helicopter rests on solid support. 2. Mate fittings to cross tubes. a.

Install fitting halves (1, fig. 822-4) and links (6) on the cross tubes so that Iinks abut the beveled sides of the fitting f1anges.

b.

Connect fitting halves and links together, using bolts (4 and 5), washers (3) and nuts (2), only hand-tighten nuts.

c.

Measure gap between opposing fitting halves at the point of connection by bolts (4). The gap must be wide enough to allow for a clearance of at least 1.5 mm when the nuts are tightened at final assembly.

d.

If the gap is too small, remove fitting halves and bond laminated shims on their inner surfaces, using cement (CM 672). Reinstall fitting halves on the cross tube and measure c1earance. If necessary, bond further laminated shims on fittings.

3. Align fittings on cross tube. For distance between set screw ring or half shell of cross tube and fitting of cable assembly, see fig. 822-2, (1 of 2) or fig. 822-2, (2 of 2).

Aevision 17

CHAPTEA 822 Page 25

I

EUROCOPTER

r

MAINTENANCE MANUAL 80 105

Depending on the cargo hook configuration, the four hook suspension cables (2, fig. 822-2) shall be connected to links (4) either directly by quick-release pins (3) or through shackles (19) and quick-release pins (3). The quick-release pins must be inserted from inboard to outboard. Attach the long cables to the forward cross tube and the short cables to the aft cross tube.

5. Align assembled fittings (5) and Iinks with hook suspension cables (2).

6. Check c1earance between fittings and bearing rings on the cross tubes and tighten nuts (2, fig. 822-4). Torque nuts according to fig. 822-4. 7. Inspect c1earance between fitting flanges. If a gap of at least 1.5 mm is not present, bond laminated shims on fitting halves until this clearance is obtained (refer to step 2.). 8. Remove cable assembly and lower helicopter to the ground with hoist sling.

CHAPTER 822 Page 26

Revision 17

MAINTENANCE MANUAL 80 105

EUROCOPTER

\\

r-,,\

\' i

\ \

~~. ~

A*-l' r===-~-=~~-[_~Y Direct~fFli9hl _

"

L . I

.

._-'---_~ ~

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!¡J I~

-- --.,Jt1rr -----:::'? ---_.-_ ---_. _.. - ~. -.---.. _. .~

DETAlL B DETAlLA

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--'11

111 -13 Nmr 2

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11----+if-

--r----

'1

a:

..,'

;;

0,

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o

!11-13Nml

6

al

Dimensions in mm 111 -13 Nml

&, Configuration for 1200kg load 1 Cross tube fitting 2 Nut 3 Washer 4 Bolt 5 Bolt 6 Link 7 Bracket Figure 822-4

Revision 17

8 9 10 11

Screw Washer Nut Bowdenflex cable (mechanical release mechanism)

Removal and Installation of cross tube fittings

CHAPTER 822 Page 27

--------..:.....-----MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 822 - 12

Remova1 - buffer p1ate

1. Remove screws (5 and 6, fig. 822-5). 2. Remove two-piece buffer plate (2), spacers (3) and washers (1 and 4) from fuselage shell. 822 - 13

Installation - buffer plate

1. Align bores of two-piece buffer plate (2, fig. 822-5) and insert the spacers in the aligned bores. 2. Install buffer plate and bonding jumper (7) to fuselage shell with screws (5 and 6) and washers (1 and 4) . 822 - 14

Removal - hook retainer (snap hook or sling)

1. Remove hardware (10, 12 and 13, fig. 822-5) attaching assembled support (14) and snap hook (9) or sling (18) to fitting (11) and remove assembled support and snap hook or sling. 2. If required, remove snap hook or sling by first removing the attaching hardware (15, 16 and 17) and both contoured washers (8). 822 - 15

Installation - hook retainer (snap hook or sling)

Installation is in reverse order of removal. For torque values, see fig. 822-5.

BO 105 CHAPTER 822 Page 28

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A

18

17

1

2 3

4 5

6 7

8 9

10 11 17

12 13

14 15 16

800285

17

18 Fig. 822-5

Washer Buffer plate Spacer Washer Screw Screw Bonding jumper Contoured washer Snap hook Screw Fitting Nut Washer Support Nut Washer Screw Sling

Buffer plate and hook retainer BO 105 CHAPTER 822 Page 29

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 822 - 16

Adjustment - Bowdenflex cable of cargo hook configuration 1

If during functional testing of the mechanical release mechanism, the cargo hook fails to open within the limits specified in para 822-5, the release point must be reset. l. Remove protective cover (9, fig. 822-3). 2. Unscrew nipple (8) from sleeve (28) and sleeve from support.

3. Disengage Bowdenflex cable (2) from cable guide. 4. Adjust Bowdenflex cable by adding or removing shims (27) between sleeve (28) and nipple (8) as follows:

NOTE

Do not interpose more than 3 shims between nipple and sleeve.

- Cable hook releases too late (lever of emergency release control at an angle greater than 20° from vertical) : interpose shim(s) between nipple and sleeve. - Cable hook releases too soon (lever of emergency release control at an angle less than 10° from vertical) : remove shim(s) from between nipple and sleeve. 5. Assemble sleeve, nipple and shim(s) and screw into support. 6. After adjusment of the Bowdenflex cable is completed, secure protective cover (9) with attaching hardware (10, 11 and 12). Safety nuts with cotter pins (13).

BO 105 CHAPTER 822 Page 30

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Adjustrnent - Bowdenflex cable of cargo hook configuration 11

822 - 17

If during functional testing of the rnechanical release rnechanisrn, the cargo hook fails to open within the lirnits specified in para 822-5, the release point rnust be reset. 1. Adjustrnent by shirnrning between nipple and nipple support (see fig. 822-6).

a.

Rernove cover (1, fig. 822-6).

b.

Unscrew cable guide (8) sufficiently to perrnit disengagernent of Bowdenflex cable (2).

c. d.

Rernove lockwire, unscrew union nut (6) frorn nipple (7), and withdraw Bowdenflex cable. Heat nipple with hot air to weaken locking compound, then unscrew and rernove nipple.

SECTION

2

A-A

8

6

7

8

A Fig. 822-6

Cover Bowdenflex cable Nipple support Shirn(s) Tab washer 6 Union nut 7 Nipple 8 Cable guide

1 2 3 4 5

Adjustrnent of Bowdenflex cable by shirnming

BO 105 CHAPTER 822 Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 e.

Adjust Bowdenflex cable as follows: NOTE

Do not interpose more than 3 shims (4) between nipple (7) and nipple support (3).

- Cargo hook releases too late (lever of emergency release control at an angle greater than 20 0 from vertical: interpose shim(s) between nipple and nipple support. - Cargo hook releases too soon (lever of emergency release control at an angle less than 100 from vertical) : remove shim(s) from between nipple and nipple support. f.

Fit tab washer (5) and shim (s) on threaded part of nipple. Brush-coat nipple threads with locking compound (CM 683) and screw nipple into nipple support. Bend legs of tab washer up against nipple.

g.

Insert end of Bowdenflex cable through nipple and engage it in the cable guide. Screw in cable guide all the wayand tighten.

h.

Screw union nut onto nipple and lockwire to tab washer.

i.

Install cover.

2. Adjustment by rotating the cable guide (see fig. 822-7). a.

Remove cover (1, fig. 822-7).

b.

Adjust Bowdenflex cable as follows: NOTE

Unscrew cable guide (7) only as far as the red marking. See fig. 822-7.

- Cargo hook releases too late (lever of emergency release control at an angle greater than 20 0 from vertical) : back off cable guide - Cargo hook releases too soon (lever of emergency release control at an angle less than 100 from vertical) : tighten cable guide. c.

After adjusting the Bowdenflex cable, rotate cable guide so that the cover can be installed (see section A-A, fig. 822-7).

d.

Install cover.

BO 105 CHAPTER 822 Page 32

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

SECTION

2

1 2 3 4 5 6 7

A-A

7

Cover Bowdenflex cable Nipple support Tab washer Union nut Nipple Cable guide

~

Red marking. Cable guide (7) must not protrude into the red area.

~

If nipple (6) removal and installation is required, refer to procedural step 1. Fig. 822-7

Adjustment of Bowdenflex cable by rotating the cable guide

BO 105 CHAPTER 822 Page 33/34

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 823

ANTISETTLING SHOES

Table of Contents Paragraph Title

Page

823 - 1

DESCRIPTION - ANTISETTLING SHOES

3

823 - 2

INSPECTION SCHEDULE - ANTISETTLING SHOES

4

823 - 3

INSPECTION FOR CONDITION - ANTISETTLING SHOES

5

823 - 4

REMOVAL - ANTISETTLING SHOES

5

823 - 5

INSTALLATION - ANTISETTLING SHOES

5

823 - 6

Replacement - abrasion protective plate

6

BO 105 CHAPTER 823 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 823 - 1

DESCRIPTION - ANTISETTLING SHOES

Antisett1ing shoes enable the helicopter to land on soft surfaces without sinking. They are installed on the aft end of each skid and are provided with abrasion protective plates for landings on hard surfaces.

I 0.5-, Nm I (§-~-2

..._---i- 3

-........¡.'-:::---

7

~----8

11-1.5 Nm

~

9 -----n

800291

1 2 3 4 5

Cover Screw Washer Bushing Washer

6 7 8 9 10

Bushing Antisettling shoe Protective plate Screw Bolt

Fig. 823-1

11

12 13

14 15

Washer Nut Washer Nut Cotter pin

Antisettling shoe BO 105 CHAPTER 823 Page 3

EUROCOPTER

• 823 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 823 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 823 - 3

INSPECTION FOR CONDITION - ANTISETTLING SHOES

Inspect antisettling shoes for mechanical damage, corrosion, deformation, and security. l. Mechanical damage and corrosion up to 0.2 mm depth are permissible without rework. Remove damage not exceeding 0.4 mm depth with a suitable tool and final polish with 400 grit abrasive cloth. 2. Touch up damaged surface protection with two-component zinc chromate primer (CM 456) and single-layer lacquer (CM 407) . 3. Tighten loose attaching hardware. Refer to fig. 823-1 for torque values. 4. Replace antisettling shoe if deformed (refer to paras 823-4 and 823-5).

823 - 4

REMOVAL - ANTISETTLING SHOES

l. Jack helicopter (e.g. using ground handling wheels) .

2. Remove screws (2, fig. 823-1) and washers (3) and remove cover (1). 3. Remove cotter pins (15), nuts (14) and washers (13). 4. Remove bolts (10) and pull antisettling shoes aft to remove them from the skids.

823 - 5

INSTALLATION - ANTISETTLING SHOES

l. Jack helicopter (e.g. using ground handling wheels). 2. Fit antisettling shoes on the underside of the aft ends of the skids and slide forward in position. Secure with bolts (10, fig. 823-1).

3. Install washers (13) and nuts (14) and torque nuts to values indicated in fig. 823-1. Install cotter pins (15). 4. Install cover (1) with screws (2) and washers (3).

BO 105 CHAPTER 823 Page 5

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

823 - 6

Replacement - abrasion protective plate

1. Remove antisettling shoes as outlined in para 823-4. 2. Remove nuts (12, fig. 823-1), washers (11) and screws (9) attaching protective plate to antisettling shoe; remove protective plate (8). 3. Fit new protective plate to antisettling shoe with screws (9), washers (11) and nuts (12). 4. Install antisettling shoe as described in para 823-5.

BO 105 CHAPTER

Page 6

823

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 824

SNOW SKIDS

Table of Contents Paragraph

Titel

824 - 1

DESCRIPTION - SNOW SKIDS

3

824 - 2

INSPECTION SCHEDULE - SNOW SKIDS

4

824 - 3

INSPECTION FOR CONDITION - SNOW SKIDS

5

824 - 4

REMOVAL - SNOW SKIDS

824 - 5

INSTALLATION - SNOW SKIDS

Page

."

5 6

BO 105 CHAPTER 824 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 824 - 1

DESCRIPTION - SNOW SKIDS

The snow skids can be fitted to the helicopter landing gear to enable the helicopter to land on soft snow without sinking. They consist of a forward and an aft section and are fitted to the left and right skid tubes by clamps. To prevent the snow skids from twisting, they are each supported by two struts which are attached to the aft crosstube.

BO 105 CHAPTER 824 Page 3

EUROCOPTER

• 824 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 824 Page4

Revision 18

EUROCOPTER

824 - 3

MAINTENANCE MANUAL BO 105

INSPECTION FOR CONDITION - SNOW SKIDS

1. Inspect snow skids (fig. 824-1) for damaged surface protection, cracks, deformation, other mechanical damage, corros ion and for security of installation. a.

Polish out mechanical damage and corros ion with abrasive cloth.

b.

If deformation is excessive, replace snow skids. Repair cracks using the gas-shielded welding method.

c.

Touch up damaged surface protection with wash primer (CM 423), then repaint with lacquer (CM 407) .

2. Inspect stringers and reinforcement plates for loose rivets. Replace loose rivets. 3. Visually inspect clamps (8), fittings (12) and fittings (17) for cracked welds. Replace parts having cracked welds. 4. Inspect forward end of snow skids for cracked welds. Repair cracks using gas-shielded welding method, or replace snow skids. 5. Inspect struts (15) for condition. a.

Replace deformed or cracked struts.

b.

Polish out mechanical damage to a depth of 0.2 mm with abrasive cloth.

c.

Touch up damaged surface protection with wash primer (CM 423), then repaint with lacquer (CM 407) .

d.

Replace rod ends including bearings ifaxial play exceeds 0.2 mm.

6. Inspect all locking devices for condition. Tighten loose attaching hardware to torque loads indicated in fig. 824-1. 824 - 4

REMOVAL - SNOW SKIDS

1. Jack helicopter using the ground handling wheels. 2. Remove attaching hardware (24, 26, 27 and 28, fig. 824-1) and remove struts (15) from fittings (12); two shirns are released when a strut is detached from a fitting. 3. Remove clamps (8) by removing nuts (6) and washers (7), and remove snow skids.

BO 105 CHAPTER 824 Page 5

EUROCOPTER

MAINTENANCE MANUAL 80 105

4. If required, disassemble snow skids into their forward and aft sections (1 and 5, respectively) by removing attaching hardware (4, 9 and 10), plate (3) and connecting profile (2). 5. If necessary, remove fittings (12) as follows: a.

Mark position and orientation of fittings on the rear crosstube.

b.

Remove attaching hardware (11, 13 and 14), and remove fittings.

824 - 5

NOTE

INSTALLATION - SNOW SKIDS

The installation procedure is the same for either the left or right snow skid.

l. Jack the helicopter using the ground handling wheels.

* * *

2. If the snow skid has been disassembled, connect the forward and aft sections (e.g. 1 and 5, fig. 824-1) via connectingprofiles (2) and plates (3) and secure together by means of bolts (4), washers (9) and nuts (10). 3. If previously removed, position fittings (12) on the rear crosstubes so that the cutouts in the fittings abut the respective bushing/sleeve (29) and hand-tighten with bolts (11), washers (13) and nuts (14). 4. Install snow skids on skid tubes using clamps (8), washers (7) and nuts (6); hand-tighten the nuts. 5. Install struts (15), with two shims (25) each, into fittings and secure with bolts (24), washers (26) and nuts (27). 6. Align snow skids parallel to the ground, adjusting the struts as necessary. 7. Tighten and lockwire jamnuts on struts. 8. Tighten all attaching hardware to torque loads indicated in fig. 824-1, and secure nuts (20 and 27) with cotter pins (21 and 28) . 9. Lower the helicopter using the ground handling wheels.

BO 105 CHAPTER 824 Page 6

Revision 14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 1 2 3 4 5 6 7 8 9

10 11 12 13

14 15 16 17 18 19 20

21 22 23 24 25 26

27 28 29

Snow skid, fwd left Connecting profile Plate Screw Snow skids, aft left Nut Washer Clamp Washer Nut Bolt Fitting Washer Nut Strut Washer Fitting Bolt Washer Nut Cotter pin Bolt Washer Bolt Shim Washer Nut Cotter pin Bushing, sleeve

DETAlL

2

DETAlL

3

A

B

B 6

29

5.5-6 Nm

15

I

DETAlL

e

8

I 2-4 Nm

15

I

8

DETAlL

e

800292

Fig. 824-1

Snow skid

BO 105 CHAPTER 824 Page 7/8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - : - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 825

EMERGENCY FLOTATION SYSTEM

Table oi Contents Paragraph

Title

Page

825 - 1

DESCRIPTION - EMERGENCY FLOTATION SYSTEM

825 - 2

TROUBLESHOOTING - EMERGENCY FLOTATION SYSTEM

4

825 - 3

INSPECTION SCHEDULE - EMERGENCY FLOTATION SYSTEM

6

825 - 4

INSPECTION FOR CONDITION - EMERGENCY FLOTATION SYSTEM

8

825 - 5

FUNCTIONAL TEST - EMERGENCY FLOTATION SYSTEM

9

825 - 6

REMOVAL - EMERGENCY FLOTATION SYSTEM

. .

10

825 - 7

INSTALLATION - EMERGENCY FLOTATION SYSTEM

11

825 - 8

Folding the Float . . . . . . . . .

11

..

. .

3

BO 105 CHAPTER 825 Page 1/2

EUROCOPTER

825 - 1

MAINTENANCE MANUAL BO 105

DESCRIPTION - EMERGENCY FLOTATION SYSTEM

l. General The Emergency Flotation Syste~ is provided with four inflatable floats which enable the helicopter to make a safe emergency landing on water. Four seconds after activating the system the helicopter is capable of floating at its full A.U.W. The time taken for complete inflation is approximately seven seconds, 2. Construction The Emergency Flotation System consists of the following components: 2 2 1 1 1 1 1 1

floats for each skid pressure cylinders magnetic valve 5GL pressure gauge circuit breaker 1GL test switch 8GL control light 3GL, green toggle switch 2GL with safety cover

The four floats, two on each side, are mounted on special skids which are longer than the standard type. Pressured air for the floats is delivered by the two pressure cylinders which are mounted on the right-hand side of the fuselage. Air pressure in the cylinders is shown by the pressure gauge. 3. Operation The system is supplied with 28V from main bus PP21 or, if installed, trom emergency bus PP20 through circuit breaker 1GL. Operation of toggle switch 2GL energizes magnetic valve 5GL which opens to allow pressurized air to inflate the floats. * The electrical circuit of the magnetic valve can be checked by operating * test switch 8GL, which is installed in the overhead panel. Serviceability is indicated by control light 3GL which incorporates a push switch for carrying out a lamp test.

Revision 12

BO 105 CHAPTER 825 Page 3

MAINTENANCE MANUAL BO 105

EUROCOPTER

825 - 2

TROUBLESHOOTING - EMERGENCY FLOTATION SYSTEM

General -

For troubleshooting purposes use wiring diagram 825-1 in the Wiring Diagram Manual (WDM)

-

Check that the electrical connection is secure

-

Check toggle switch 2GL on the instrument panel and test switch 8GL on the overhead panel for correct mechanical function

-

Connect an external power supply (EPU) (position the battery switch 16P on the instrument panel to BATT OFF/EPU ON)

-

Press circuit breaker 1GL

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Control light 3GL does not illuminate (push switch of the control light depressed)

Lamp defective

Check lampo Replace if necessary

Control light with push switch defective

Check if current at connection C1. If current at this point, change control light with push switch

Circuit breaker 1GL defective

Check circuit breaker for continuity and connections for correct contacto Replace defective parts

Electrical wiring defective

Check continuity of wiring in accordance with wiring diagram. Repair defective parts or replace

Table 825-1

BO 105 CHAPTER 825 Page 4

Troubleshooting (1 of 2)

MAINTENANCE MANUAL BO 105

EUROCOPTER

TROUBLESHOOTING (continued)

No.

2

TROUBLE SYMPTOM

Control light 3GL does not illuminate (test switch 8GL operated)

PROBABLE CAUSE

CORRECTlVE ACTION

Ground connection 135VV-B2 in the overhead panel loose or without contact

Check ground connection for continuity. If necessary repair or tighten screw connection

Test switch 8GL defective

with the test switch in the pressed position check connection 1 and 3 for continuity. Replace defective switch

Coil in magnetic valve 5GL defective

Check current between contact A and B of plug 5GLa. If current at this point replace magnetic valve

Ground connection at frame 7 (righthand) loose or without contact

Check ground connection for continuity. If necessary repair or tighten screw connection

Table 825-1

Troubleshooting (2 of 2)

BO 105 CHAPTER 825 Page 5

EUROCOPTER

• 825 - 3

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPlER 825 Page6

MAINTENANCE MANUAL BO 105

Revision 18

MAINTENANCE MANUAL 80 105

EUROCOPTER

BLANK PAGE

Revision 18

CHAPTER 825 Page7

EUROCOPTER

MAINTENANCE MANUAL BO 105

825 - 4

INSPECTION FOR CONDITION - EMERGENCY FLOTATION SYSTEM

NOTE

The floats must be inspected in accordance with the manufacturer's instructions.

CAUTION

AFTER EACH INFLATION, THE FLOATS MUST BE CAREFULLY INSPECTED BY AN APPROVED ORGANIZATION.

l. Inspect cylinder support (17, figure 825-2) for cracks, mechanical damage, corrosion, damag~d surface protection and security of attachment. a.

Discard clamps with cracks or mechanical damage.

b.

Remove minor mechanical damage and corros ion from the cylinder mounting using polishing cloth 400. Maximum depth of damage at any point on the cylinder support must not exceed 0.1 mm.

c.

Apply chemical conversion material (CM 316) to damaged surface protection, followed by two-component zinc chromate primer (CM 456) then single-layer lacquer (CM 407) .

d.

Tighten loose screw connections. Refer to figure 825-1 for correct torque values.

e.

Check wirelocking of protective cap. If necessary, retighten protective cap and secure with new locking wire.

2. Inspect pressure cylinder (18, fig. 825-2) for mechanical damage, security of attachment and correct filling. a.

Return the pressure cylinder to the manufacturer for further examination if mechanical damage is presente

b.

If locking wire of clamps is missing or damaged, check torque tightening of clamps and secure with new locking wire.

c.

If pressure gauge indicates below minimum, check pressure cylinders together with magnetic valve and pressure gauge in accordance with the manufacturer's documentation.

3. Inspect pressure lines and connections for damage and security. a.

Renew relevant parts of pressure lines damaged by abrasion, bends, dents or cracks.

b.

Tighten any loose securing items such as clamps and screws. Replace any such items that are missing.

c.

Tighten loose connections.

BO 105 CHAPTER 825 Page 8

EUROCOPTER

MAINTENANCE MANUAL 80 105

4. Inspect plug for correct connection and electrical wiring for damage. Replace damaged wiring. 5. Inspect float installation for damage and security. a.

Replace missing or damaged parts of the cover fastening.

b.

Tighten any loose securing items. Replace any such items that are missing.

6. with the floats installed, inspect condition of float skids (skid tubes, skid shoes, clamping bands, skid protection) . 7. Inspect the struts between skids and spoiler for damage and security. Replace damaged struts. 8. If floats are not installed on the skids, inspect parts of float skids in accordance with steps 3. and 6. 9. Inspect tube threaded connections for cracks and corrosion. Replace damaged parts. Spray with corrosion protection CARE. 825 - 5 NOTE

FUNCTIONAL TEST - EMERGENCY FLOTATION SYSTEM

The pressure cylinders and the floats must be inspected in accordance with the manufacturer's instructions.

General The functional test is normally carried out with stationary engines. If, as an exception, it is necessary to carry out the functional test with engines running they must be set to an idling speed of approximately 62% N 1 and approximately 100% N 2 for this purpose. -

Connect an external power supply (EPU) - 28 Vd.c./150A. (Set battery switch 16P on the instrument panel to BATT OFF/EPU ON) Press circuit breaker 1GL.

CAUTION

ENSURE THAT THE AREA AROUND THE FLOATS IS FREE FROM OBSTRUCTIONS. IT IS POSSIBLE DURING THE FUNCTIONAL TEST THAT THE FLOATS ARE INADVERTENTLY INFLATED.

1. Press control light 3GL on overhead panel to test the lamps. The two lamps of the control light EMERG. FLOAT TEST must illuminate brightly. 2. Release control light. The lamps of the control light must extinguish.

BO 105 CHAPTER 825 Page 9

EUROCOPTER

MAINTENANCE MANUAL 80 105

3. Operate and hold test switch 8GL EMERG. FLOAT TEST. The control lights must now illuminate less brightly than under point 1. - Magnetic valve 5GL on the pressure cylinders must not open. 4. Release test switch. Control light must extinguish. 5. Remove plug 5GLa from magnetic valve and connect a voltmeter to contacts A and 8 of the plug. 6. Raise cover and set toggle 'switch 2GL to ON. - Voltmeter must indicate approx. 28V. 7. Set toggle switch 2GL to OFF and lower cover over toggle switch. 8. Remove voltmeter from plug 5GLa. Connect plug to magnetic valve 5GL and secure with locking wire. 9. Pull circuit breaker 1GL.

* * 10. If the helicopter is fitted with a search and landing light on the RH * crosstube, press the Reset switch located next to the electrical * connection for the light on the RH side of the fuselage. * 825 - 6

REMOVAL - EMERGENCY FLOTATION SYSTEM

1. Disconnect battery and pull circuit breaker 1GL. 2. Jack-up helicopter approximately 40 cm. Refer to Chapter 05 for jacking procedure. 3. Loosen both connections (13, figure 825-2) on connecting pipeline (19). 4. Remove both protective caps from pressure bottle mountings and fit them to the free ends of the connecting pipeline. Secure protective caps with locking wíre. 5. Cover the other free ends of the pipelines with adhesive tape. 6. Loosen the electrical line (15) on the fuselage and cover the fuselage mounted connection with protective cap from blank connection (16). 7. Remove quick release pins (11) and allow the rubber cable (10) to hang free from the skid and spoiler. 8. Remove tube clamp (8). 9. Separate the pressure line from the T-piece (12) and cover the free ends with adhesive tape. 10. Remove screw connections (1, 2, and 3, 4) from the float skids.

80 105

CHAPTER 825 Page 10

Revision 15

EUROCOPTER

MAINTENANCE MANUAL 80 105

11.

Remove screws (4, figure 825-1) and washers (3). Remove pressure cylinders (21 and 22) with cylinder support (2) and magnetic valve with gauge (30). Refit screws (4) with washers (3).

12.

Fit standard equipment skids. Refer to Chapter 51.

825 - 7

INSTALLATION - EMERGENCY FLOTATION SYSTEM

1. Jack-up helicopter approximately 40 cm. Refer to Chapter 05 for jacking procedure. 2. Remove standard equipment skids from the landing gear. Refer to Chapter 51. 3. Install float skids (6 and 21, figure 825-2) with 22) .

floats (5, 9, 20 and

4. Install cylinder support (2, fig. 825-1) with pressure cylinders, connecting lines and magnetic valve with gauge on the fuselage using screws (4) and washers (3). 5. Remove blanking caps from connecting lines (19, fig. 825-2) then fit them to cylinder support (17) and secure with locking wire. 6. Remove adhesive tape from ends of the other lines then connect the pressure lines. 7. Fit tube clamps (8). 8. Remove protective cap from electrical connection and fit it to blank connection (16). Connect electrical line (15). 9. Secure rubber cable (10) to the skid tubes using screws, washers, nuts and bushes and to the spoiler using quick release pins (11). 825 - 8

Folding the Float

*

* * * NOTE If the helicopter is fitted with a search and landing light on the * RH crosstube, note the following: * If the emergency floats are inflated while the search and landing * light is operating, it will move in azimuth until it is pointing * in flight direction. In this position it can only be moved in * elevation. Unrestricted movement of the light is no longer possible * until the Reset switch, located next to the electrical connection * for the light on the RH side of the fuselage, is actuated. * * 2. Press Reset switch as necessary. * * * * 1. Fold the floats as instructied in the manufacturer's documentation.

Revision 15

BO 105 CHAPTER 825 Page 11

MAINTENANCE MANUAL 80 105

EUROCOPTER

2

3~4

I

.71

6.5 Nm

__- - 3 --4

32 16

800307

23

11

24

22 DETAll

B 13

Plate Cylinder support Washer Screw Nut Washer 7 Rubber shell 8 Washer 9 Screw 10 Pipe clamp 11 Pipeline 12 Pipeline nut 13 Thread reducer 14 O-ring 15 Screw 16 Washer 1 2 3 4 5 6

Figure 825-1 BO 105 CHAPTER 825 Page 12

17

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Pipe clamp Nut Bonding strap Clamp Pressure cylinder Pressure cylinder Screw Washer Pipe clamp Washer Nut O-ring Bonding strap Magnetic valve with gauge Electrical connection Hose assy

20

Pressure Cylinders and Cylinder Mountings

I

12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 Screw 2 Washer 3 Screw 4 Washer S Float (RH f orward) 6 Float skid (RH) 7 Pressure line 8 Tube clamp 9 Float (RH aft) 10 Rubber cable 11 Quick releas e pin 12 T-piece 13 Connection 14 Magnetic valve with gauge 15 Electrical line 16 Blank connection with protective cap 17 Cylinder support 18 Pressure cylinder 19 Pipeline 2 O Floa t (LH aft) 21 Float skid (LH) 22 Float (LH forward)

11

10 _ _

~ These screw connections are

not fitted to the LH and RH forward skid shoes

I 3-4 Nm I

/a

o

l0 Nm

I~

1.2

_-_ji'

1.2

f:::s/

'--

Ai----l.2 ,r-S-_-l0-N-m-'1

"):", -+.

[B i,

,

~---;-

800306

Figure 825-2

Rernoval and Installation - Ernergency Flotation Systern BO 105 CHAPTER 825 Page 13/14

SECTfON

A· A

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 826

FUEL JETTISON SYSTEM

Table of Contents Paragraph

Title

Page

826 - 1

DESCRIPTION - FUEL JETTISON SYSTEM

3

826 - 2

TROUBLESHOOTING - FUEL JETTISON SYSTEM

4

826 - 3

INSPECTION SCHEDULE - FUEL JETTISON SYSTEM

7

826 - 4

FUNCTIONAL TEST - FUEL JETTISON SYSTEM

8

826 - 5

Removal - Jettison Valve, Configuration 1

9

826 - 6

Installation - Jettison Valve, Configuration 1

10

826 - 7

Removal - Jettison Valve, Configuration 11

12

826 - 8

Installation - Jettison Valve, Configuration 11

12

BO 105 CHAPTER 826 Page 1/2

EUROCOPTER

826 - 1 1.

MAINTENANCE MANUAL BO 105

DESCRIPTION - FUEL JETTISON SYSTEM

General The fuel jettison system enables the pilot to reduce the mass of the helicopter quickly by irnmediate discharge of all the fuel contained in the forward and aft main tanks. Fuel in the supply tank is retained.

2.

Construction The fuel jettison system consists mainly of a jettison valve, attached to a bolt ring in the bottom of the forward main tank, and a drain pan and fuel discharge nozzle assembly installed directly below it. Configuration I: The jettison valve is opened and closed by a DC motor. Two limit switches control the opening and closing points. Configuration II: The jettison valve is an electrically operated solenoid-type valve.

3.

Operation Configuration I: After circuit breaker FUEL JETT 1QA is pressed, electrical power is applied to switch JET VALVE 3QA. After the switch is set to OPEN, the * valve will be supplied with electrical power. The valve is opened by a DC * motor and then switched off in its end position by the appropriate limit * switch. At the same time, the second limit switch makes an electrical connection to the close winding. The valve will be closed if switch 3QA is placed in the CLOSED position. Direct current can flow through the limit switch, close winding and armature to earth until the valve drive is switched off by the limit switch in the closed position of the valve. Configuration II: With switch 3QA set to OPEN, both solenoid coils of the jettison valve are supplied with electrical power through the relay contacts and the valve opens. With the valve open, the relay contacts interrupt the electrical circuit and electrical power is now supplied to both solenoids through series resistors. When switch 3QA is set to CLOSED, the valve is closed by spring pressure and the relay contacts close.

Revision 12

BO 105 CHAPTER 826 Page 3

EUROCOPTER

826 - 2

MAINTENANCE MANUAL 80 105

TROUBLESHOOTING - FUEL JETTISON SYSTEM

General -

The following wiring diagrarns in the Wiring Diagrarn Manual (WDM) are applicable for troubleshooting: Configuration I: 826-1 Configuration II: 826-2

-

Check for security of attachment of all those associated electrical connections that are accessible,

-

Check switch JET VALVE 3QA and circuit breaker FUEL JETT 1QA on instrurnent panel for correct rnechanical functioning.

-

Connect an external power supply (EPU). Set battery switch 16P on instrurnent panel to BATT OFF/EPU ON.

-

Press circuit breaker FUEL JETT 1QA.

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Jettison valve 2QA does not open when switch 3QA is in OPEN position

Circuit breaker 1QA defective

Check continuity of circuit breaker. Check connections for correct contacto Replace defective parts

Switch 3QA defective

Check continuity of switch. Replace if necessary

Electrical cable defective

Check cables for continuity in accordance with wiring diagrarn. Repair defective parts or replace

Table 826-1

BO 105 CHAPTER 826 Page 4

Troubleshooting (1 of 3)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Configuration I: DC motor or limit switch defective. Other electrical or mechanical defects within jettison valve

Check voltage between contacts A and E of plug 2QA. If electrical supply is satisfactory replace jettison valve

Configuration II: Electrical or mechanical defect in jettison valve

Check, one after the other, voltage between connections 1 and 2 as well as 3 and 2 of solenoid valve If electrical supply is satisfactory, replace jettison valve

2

Jettison valve does not close in CLOSED position of switch 3QA

Circuit breaker 1QA defective

Check continuity of circuit breaker. Check connections for correct contacto Replace defective parts

Switch 3QA defective

Check continuity of switch. Replace if necessary

Electrical cable defective

Check cables for continuity in accordance with wiring diagram. Repair defective parts or replace

Table 826-1

Troubleshooting (2 of 3)

BO 105 CHAPTER 826 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Configuration 1: DC motor or limit switch defective. ,Other electrical or mechanical defects within jettison valve

Check voltage at plug 2QA between contacts B and E If electrical supply is satisfactory, replace jettison valve

Configuration 11: Electrical or mechanical defect in jettison valve

Check, one after the other, voltage between connections 1 and 2 as well as 3 and 2 of solenoid valve If electrical supply is satisfactory, replace jettison valve

Table 826-1

BO 105 CHAPTER 826 Page 6

Troubleshooting (3 of 3)

EUROCOPTER

826 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 826 Page7

EUROCOPTER

826 - 4

MAINTENANCE MANUAL 80 105

FUNCTIONAL TEST - FUEL JETTISON SYSTEM

*-* NOTE Functional test can be carried out with full or empty main tank. *-1.

* * *

* * * 2.

*

* *

Configuration I: (jettison valve with DC motor and 1imit switch) a.

If there is fuel in the helicopter tanks, place container under fuel discharge nozzle.

b.

Switch on external or battery power.

c.

Press circuit breaker FUEL JETT 1QA.

d.

Raise cover and set switch JET VALVE 3QA to OPEN. The jettison valve shall open, and then automatically switch off in the end position (audible) . If the helicopter tanks contain fuel, fuel is released into the container.

e.

Set switch JET VALVE 3QA to CLOSED position. The jettison valve shall close, stopping the fue1 flow, and then automatically switch off in the end position (audible). .

f.

Remove container with discharged fuel, as applicable.

g.

Close cover of switch JET VALVE 3QA.

h.

Pull circuit breaker FUEL JETT 1QA and disconnect external or battery power, as applicable.

Configuration II: (jettison valve with solenoid valve) a.

If there is fuel in the helicopter tanks, place container under fuel discharge nozzle.

b.

Disconnect cable 269-22 (refer to WDM, circuit diagram 826-2) from switch JET VALVE 3QA.

c.

Switch on external or battery power.

d.

Press circuit breaker FUEL JETT 1QA.

e.

Raise cover and set switch JET VALVE 3QA to OPEN. Solenoid of jettison valve is energized and valve opens (audible). If the helicopter tanks contain fuel, fuel is released into the container.

f.

Set switch JET VALVE 3QA in CLOSED position. Solenoid of jettison valve is de-energized and the valve closes (audible). If the helicopter tanks contain fuel, the fuel flow shall cease.

BO 105 CHAPTER 826 Page 8

Revison 12

EUROCOPTER

MAINTENANCE MANUAL 80 105

g.

Pull circuit breaker FUEL JET IQA.

*

h.

Disconnect cable 268-22 (refer to WDM, circuit diagram 826-2) from switch JET VALVE 3QA.

* *

i.

Measure electrical resistance between connection 1 of switch JET VALVE 3QA and helicopter ground. The measured value must be smaller than 1 Ohm.

j.

Re-connect cable 269-22 to connection 1 of JET VALVE 3QA.

k.

Repeatwork steps d. to g.

l.

Remove container with discharged fuel, as applicable.

m.

Re-connect cable 268-22 to connection 1 of JET VALVE 3QA.

n.

Close cover of switch JET VALVE 3QA.

o.

Switch off external or battery power.

826 - 5 NOTE

Removal - Jettison Valve The helicopter must be defueled before the jettison valve is removed. Refer to chapter 06.

1.

Pull circuit breaker FUEL JETT 1QA on instrument panel and secure against inadvertent pressing.

2.

Remove screws (1, figure 826-1) with washers (2), then take out drain pan (3) •

3.

Remove O-ring (4).

4.

Remove nuts (12) from cover (14).

5.

Take out cover (14) with jettison valve (6).

6.

Remove screws (16) with washers (15) from cover and jettison valve.

7.

Remove O-ring (9).

8.

Disconnect electrical connector (11) from jettison valve.

9.

Remove screws (8) with washers (7) from jettison valve and intermediate flange (5).

10. Remove sealing compound from mating surfaces of jettison valve and intermediate flange. NOTE

Revision 13

If the jettison valve is not to be reused, install the jettison valve closing cover and cover plateo BO 105 CHAPTER 826 Page 9

*

EUROCOPTER

826 - 6

MAINTENANCE MANUAL 80 105

Installation - Jettison Valve, configuration I

l.

Make certain that pull circuit breaker FUEL JETT 1QA on operating panel has been pulled and secured against inadvertent pressing.

2.

Apply sealing compound (CM 644) to mating surfaces of jettison valve (6, fig. 826-1) and intermediate flange (5).

3.

Place jettison valve on interrnediate flange, and installed and tighten insert screws (8) with washers (7). Remove excess sealing compound.

4.

Insert new O-ring (9).

5.

Connect electrica1 connector (11) to jettison valve.

6.

Place cover (14) on jettison valve and secure with screws (16) and washers (15). Refer to figure 826-1 for torque tightening value.

7.

Secure screws (16) with lockwire.

8.

Place cover with jettison valve on main fuel tank bolt ring (17) and secure with new nuts (12) and washers (13). Refer to figure 826-1 for torque tightening value.

9.

Insert new O-ring (4) in drain pan (3).

10. Place drain pan into position and secure with screws (1) and washers (2) •

11. Perforrn functional test (refer to paragraph 826-4) .

BO 105 CHAPTER 826 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

A

DETAlL

. I 1

35

-¡

Nm

I

I

16

1 2 3 4 5

! I

~

15

6 7 8 9

•

14-(-... l..~6'" J ...

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13 12

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---!r'-'~:-.~--~"'"

10 11 12

----lilijll'

12.5-~ Nm I 10

13

14 15 16 17

--,..¡

9---

18 19

Screw Washer Drain pan O-ring Intermediate flange Jettison valve Washer Screw O-ring Electrical cable Electrical connector Nut Washer Cover Washer Screw Main fuel tank bolt ring Clamp Tube

----2

800313

3 4

~

Fig. 826-1

Installation required only if optional equipment such as snow skids, anti-sink pads or emergency floats are used.

Fuel jettison system, configuration 1 BO 105 CHAPTER 826 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB -·BO 105 826 - 7 NOTE

Removal - jettison valve, configuration 11 The helicopter must be defueled before the jettison valve is removed. refer to chapter 06.

1.

Pull circuit breaker FUEL JETT 1QA on instrument panel and secure against inadvertent pressing.

2.

Remove screws (13, figure 826-2) together with washers (14), and detach cover (12).

3.

Remove nuts (21, 24 and 25) together with washers (20, 23 and 26) and spring washers (19, 22 and 279. Do not remove the abutting the valve base plateo

4.

Remove screws (11 and 15) together with washers (10). Do not remove clamps (9) from wiring harness (28).

5.

Disconnect lug terminals of wiring harness (28) from the bolts of the electrical connections, and bend wiring harness and clamps (9) to one side.

6.

Loosen clamp (3).

l.

Pull bend (8) from pipe (2) and remove O-rings (6 and 7).

8.

Remove nuts (16) together with washers (17) from valve base plate (18) and withdraw jettison valve (5).

9.

Remove gasket (4). NOTE

826-8

If the jettison valve is not to be rensed, install the jettison valve closing cover and cover plate, Installation - jettison valve, configuration 11

l.

Hake sure that circuit breaker FUEL JETT 1QA on instrument panel is pulled out and secured against inadvertent depression.

2.

Position and align gasket (4, figure 826-2 on valve base plate (18).

j.

Insert jettison valve (5) together with gasket (4) through tank aperture and secure to bolt ring in tank bottom (1) with nuts (16) and washers (17) .

4.

Insert new O-rings (6 and 7).

5.

Push bend (8) into pipe (2) so that the flange of the bend is aligned with the valve base plateo

BO 105 CHAPTER 826 Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

6.

Secure bend and wiring harness clamp (9) to valve base plate with screws (11 and 15) and washers (10).

7.

Tighten clamp (3).

8.

Secure lug terminals ef wiring harness (28) te bolts ef electrical connections with nuts, washers and spring washers.

9.

Coat center (ground) connection with pretective lacquer (CM 501).

10. Perform functional check in accordance with para 826-4. 11. Secure cover (12) to tank bottom with screws (13) and washers (14).

105 826 Page 13/14

BO CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 Fuel tank bottom

2 3 4 5 6

7 8 9 10

11

12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27

6 6

28 29 30

Pipe Clamp Gasket Fuel jettison valve O-ring O-ring Blend Clamp Washer Screw Cover Screw Washer Screw Nut Valve base plate Flange Spring washer Washer Nut Spr ing Washer Washer Nut Nut Washer Spring washer Wire harness Clamp Tube

2VB 23VB

VIEWA

j

27 _ _ _ 26

1_1._0_-_1.4_N_m125

6

Installation required only if optional equipment such as snow skids, anti-sink pads or emergency floats are used.

800384

BO 105 CHAPTER 826

Page 15/16

;='

.

22 23

14

Fuel jettison system, configuration 11

I ~2110.5-o.7Nml .

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Figure 826-2

I =;! I:t-~~

13

24 1,.-1....,...3-.-,,-9-N-m 1

- - - - - - - - - - - - - M B B HELlCOPTERS - - - - - - - - - - - - MAlNTENANCE MANUAL MBB - BO 105

827

FUEL JETTlSON SYSTEM (76 mm OlA.)

Table of Contents

Paragraph

Title

Page

827 - 1

DESCRlPTlON - FUEL JETTlSON SYSTEM (76 mm OlA.)

. .

3

827 - 2

TROUBLESHOOTlNG - FUEL JETTlSON SYSTEM (76 mm OlA.)

3

827 - 3

lNSPECTlON SCHEDULE - FUEL JETTlSON SYSTEM (76 mm OlA.)

5

827 - 4

FUNCTlONAL TEST - FUEL JETTlSON SYSTEM (76 mm DlA.)

6

827 - 5

Rernoval - Jettison Valve

6

827 - 6

lnstallation - Jettison Valve

7

BO 105 CHAPTER 827 Page 1/2

EUROCOPTER

827 - 1 1.

MAINTENANCE MANUAL 80 105

DESCRIPTION - FUEL JETTISON SYSTEM (76 mm DIA.)

General The fuel jettison system enables the pilot to reduce the mass of the helicopter quickly by immediate discharge of all the fuel cóntained in the forward and aft main tanks. Fuel in the supply tank is retained.

2.

Construction The fuel jettison system consists mainly of a flanged tank discharge opening in the forward main tank to which is attached a valve and, underneath, a drain pan with fuel discharge nozzle. The jettison valve is opened and closed by a OC motor. Two limit switches control the opening and closing points.

3.

Operation After pressing circuit breaker FUEL JET VALVE 1QA electrical power is * applied to switch JET VALVE 3QA. After setting switch to OPEN, the valve * will be supplied with electrical power. The valve will be opened by a DC * motor and then switched off in its end position by the respective limit switch. At the same time, the second limit switch makes an electrical connection to the close winding. The valve will be closed if switch JET VALVE 3QA is placed in the CLOSED position. Direct current can flow through the limit switch, close winding and armature to earth until the valve drive is switched off by the limit switch in the closed position of the valve.

827 - 2

TROUBLESHOOTING - FUEL JETTISON SYSTEM (76 mm DIA.)

General Wiring diagram 827-1 in Wiring Diagram Manual (WDM) is applicable for troubleshooting Check for security of attachment of all those associated electrical connections that are accessible. Check switch JET VALVE 3QA and circuit breaker FUEL JET VALVE 1QA on instrument panel for correct mechanical functioning. Connect an external power supply (EPU). Set battery switch 16P on instrument panel to BATT OFF/EPU ON. Press circuit breaker FUEL JET VALVE 1QA.

Revision 12

BO 105 CHAPTER 827 Page 3

MAINTENANCE MANUAL BO 105

EUROCOPTER

TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Jettison valve 2QA does not open or close when switch 3QA is placed in OPEN or CLOSED position

Circuit breaker 1QA defective

Check continuity of circuit breaker. Check connections for correct contacto Replace defective parts

Switch 3QA defective

Check continuity of switch in accordance with wiring diagram. Replace defective switch

Faulty contacts in limit switch within jettison valve

Check voltage at jettison valve in accordance with wiring diagram. If electrical supply is satisfactory replace jettison valve

Open circuit within DC motor

Check voltage at DC motor in accordance with wiring diagram. If electrical supply is satisfactory, replace jettison valve

Electrical cable defective

Check cables for continuity in accordance with wiring diagram. . Repair defective parts or replace

Mechanical defect in jettison valve

Replace jettison valve

Limit switches set in correctly

Replace jettison valve

2

Jettison valve 2QA does not fully open or close in OPEN/ CLOSED position of switch 3QA

Table 827-1

BO 105 CHAPTER 827 Page 4

Troubleshooting

EUROCOPTER

827 - 3

Revision 18

MAINTENANCE MANUAL 80105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 827 PagaS

EUROCOPTER

827 - 4

MAINTENANCE MANUAL BO 105

FUNCTlONAL TEST - FUEL JETTlSON SYSTEM (76 mm OlA.)

General Functional test can be carried out with full main tank. Connect an external power supply (EPU). Set battery switch 16P on RH side of instrurnent panel to BATT OFF/EPU ON position. Press circuit breaker FUEL JET VALVE 1QA. 1.

Place container under fuel discharge nozzle.

*

* 2. Raise cover and set switch JET VALVE 3QA to OPEN. Jettison valve opens then switches automatically off at end position. At the same time fuel flows into container.

* 3.

Set switch JET VALVE 3QA in CLOSED position. Jettison valve closes and automatically switches off at end position.

* * 4. Close cover of switch JET VALVE 3QA.

*

5.

Pull circuit breaker FUEL JET VALVE 1QA and disconnect external power supply from helicopter.

827 - 5 NOTE

Removal - Jettison Valve Main tank must be emptied before removing jettison valve.

1.

Pull circuit breaker FUEL JET VALVE 1QA on operator panel and secure against inadvertent pressing.

2.

Remove screws (2, figure 827-1) with washers (3) then take out drain pan (1) •

3.

Remove screws (5) with washers (6) then remove flange (7) from jettison valve (11).

4.

Remove nuts (9) with washers (10) then remove jettison valve from fuel tank (12).

5.

Disconnect electrical connection. NOTE

BO 105 CHAPTER 827 Page 6

lf fuel jettison system will not be used again, appropriate covers must be installed and electrical wiring secured.

Revision 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 827 - 6

Installation - Jettison Valve

1.

Pull circuit breaker FUEL JET VALVE 1QA on operator panel and secure against inadvertent pressing.

2.

Fit new sealing ring (8, figure 827-1) to installation side of flange (7) •

3.

Apply sealing compound (CM 644) to mating surfaces between bottom plate of jettison valve (11) and flange (7).

4.

Secure flange with screws (5) and washers (6) to bottom plate of jettison valve then tighten. (Refer to figure 827-1 for torque tightening value). Secure screws with locking wire.

5.

Secure jettison valve to fuel tank connecting flange (12) with nuts (9) and washers (10). Refer to figure 827-1 for torque tightening value.

6.

Fit new sealing ring (4) to underside of flange (7).

7.

Connect electrical connection to jettison valve.

8.

Push drain pan (1) over flange (7) and secure to fuel tank with screws (2) and washers (3).

9.

Carry out a functional test (refer to paragraph 827-4) .

BO 105 CHAPTER 827 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlLA

11---+-

8----'7

-----f.¡'{/l

800314

~

Installation required only if optional equipment such as snow skids, anti-sink pads or emergency floats are used. Fig. 827-1

BO 105 CHAPTER 827 Page 8

~

1 Drain pan 2 Screw 3 Washer 4 Sealing ring 5 Screw 6 Washer 7 F1ange 8 Sealing ring 9 Nut 10 Washer 11 Jettison valve 12 Fuel tank connecting flange 13 Clamp 14 Tube

Fuel Jettison System (76 mm

Dia~)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

828

FUEL MICROFILTER SYSTEM

Table of Contents

Paragraph

Title

828 - 1

DESCRIPTION - FUEL MICROFILTER SYSTEM

3

828 - 2

TROUBLESHOOTING - FUEL MICROFILTER SYSTEM

4

828 - 3

INSPECTION SCHEDULE - FUEL MICROFILTER SYSTEM

5

828 - 4

INSPECTION FOR CONDITION - FUEL MICROFILTER SYSTEM

6

828 - 5

FUNCTIONAL CHECK - FUEL MICROFILTER SYSTEM

6

828 - 6

Removal - microfilter

7

828 - 7

Installation - microfilter

7

828 - 8

Replacement - filter element

8

Page

BO 105 CHAPTER 828 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 828 - 1 1.

DESCRIPTION - FUEL MICROFILTER SYSTEM

General The microfilter not only insures that foreign particles are filtered off, but also traps ice crystals, so that addition to the fuelof anti-ice additive is rendered unnecessary.

2.

Description The microfilters are located on the engine compartment floor between the fuel shut-off valve and the engine-mounted fuel filter, directly below the engine combustion chambers. The microfilter unit consists of a 10-micron element, a bypass valve incorporating an electrical clogging indicator, and a drain valve. A drip tray, located on the engine compartment floor under the drain valve, catches drained fluid from the filter and directs it overboard via the drainage system.

3.

Operation The warning segrnents FILT 1 and FILT 11 indicate clogging of the engine-mounted fuel filters and the microfilters. If clogging is indicated, the microfilter must be inspected first because it is located upstream of the engine-mounted fuel filter. When clogging causes a pressure difference across the microfilter of 0.27 bar (0.28 kp/cm2 ), a bypass valve in the filter unit will open. The differential pressure indicator installed upstream of the bypass valve will actuate sooner to indicate clogging at differential pressures of between 0.082 and 0.092 bar (0.084 to 0.094 kp/cm2 ). Prior to each flight, the drain valve must be checked for proper operation and the warning segrnents tested by pressing the warning button on the microfilter. Then the fuel pumps in the main fuel tanks must be switched on. The fuel pressure reading in the cockpit must be 0.49 bar (0.5 kp/cm2 ). After the pumps in the forward main tanks are switched on, switch on those in the supply tank. The pressure reading must then increase to approx. 0.98 bar (1.0 kp/cm2 ).

BO 105 CHAPTER 828 Page 3

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TROUBLESHOOTING - FUEL MICROFILTER SYSTEM

General Refer to wiring diagrarn 828-1 in the Wiring Diagrarn Manual (WDM). Inspect electrical connections for tightness. Connect external power source (EPU). Set battery switch 16P on instrurnent panel to BATT OFF / EPU ON.

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

Warning segrnent Faulty wiring FILT I or FILT II illurninates although rnicrofilter is not clogged Differential pressure switch in rnicrofilter defective

Table 828-1

BO 105 CHAPTER 828 Page 4

Troubleshooting

CORRECTIVE ACTION Check continuity of wiring using wiring diagrarn; repair or replace faulty parts. Replace rnicrofilter

EUROCOPTER

828 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 828

Page5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 828 - 4

INSPECTION FOR CONDITION - FUEL MICROFILTER SYSTEM

1.

Inspect mounting support (10, fig. 828-1) for tight installation. Drill out and replace loose rivets . .

2.

Inspect mounting support for corrosion. Polish out corroded areas with 400 grit abrasive cloth and resto re protective finish.

3.

Inspect screws (8 and 24) for tight installation. If necessary, tighten screws and replace lockwire.

4.

Inspect pipelines for leakage. Tighten appropriate union nuts as necessary.

5.

Inspect connection (1) for tightness.

828 - 5

FUNCTIONAL CHECK - FUEL MICROFILTER SYSTEM

l.

Fuse 9E must be in place in the fuse holder in the instrument panel (bottom right side) .

2.

Connect external power source.

3.

Warning segments FILT 1 and FILT 2 lEA must not come on.

4.

Remove connector 101QWa from pressure switch 101QW and connect pin A with pin B. Warning segment FILT 1 must come on.

5.

Remove connector 201QWa from pressure switch 201QW and connect pin A with pin B. Warning segment FILT 2 must come on.

6.

Reconnect connectors 101QWa and 201QWa and secure with lockwire.

BO 105 CHAPTER 828 Page 6

------------"""'"--MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 828 - 6 1.

Removal - microfilter

Disconnect following electrical connections. a.

Switch off external power supply.

b.

Set BATTERY MASTER switch to OFF.

c.·

Set MAIN TANK FUEL PUMPS 1 and 2 switches to OFF.

d.

Set SUPPLY TANK FUEL PUMPS ENG 1 and 2 switches to OFF.

e.

Disconnect connector 101QWa (mirofilter 1) or 201QWa (microfilter 2) from filter.

2.

Drain fuel from filter and associated lines by pressing in the drain valve (17, fig. 828-1) on the underside of the filter. Fuel drained from the valve is collected in the drip tray on the floor of the engine compartment and is directed overboard through drain lines.

3.

Disconnect lines by unscrewing un ion nut (20) between elbow (19) and flange (22).

4.

Remove screws (8) and washers (9) and remove microfilter from mounting support (10). This releases the spacer sleeves (7).

5.

If necessary, remove screws (24) and take off flange (22). Discard O-rings (23).

828 - 7 CAUTION

Installation - microfilter WHEN INSTALLING THE MICROFILTER, TAKE CARE THAT THE FLOW DIRECTION ARROW POINTS INBOARO.

l.

Insert new O-rings (23, fig. 828-1) and mount flange (22) to filter housing with screws (24). Wire-lock the screws.

2.

Position microfilter in the mounting support (10) with spacer sleeves (7) and secure with screws (8) and washers (9). Wire-lock the screw.

3.

Connect lines to flanges (22) by tightening union nuts (20).

4.

Install connector 101QWa or 201Qwa, as appropriate.

BO 105 CHAPTER 828 Page 7

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Replacement - filter element

1.

Remove lockwire from filter bowl and drain valve.

2.

Unscrew and remove filter bowl and element using a strap wrench.

3.

Discard filter element (14, fig. 828-1) and O-rings (12 and 13).

4.

Install new filter element and new O-rings in filter bowl.

S.

Screw filter bowl on filter element until the O-rings bottom, then apply slippage mark across junction of bowl and elemento

6.

Tighten filter bowl an additiona1 60° to 90°. NOTE

Tightening the filter bowl another 60° should seal the unit. If fuel continues to leak out, the bowl can be further tightened another 90° maximurn (90° is equal to approx. 17 Nm torque load) .

7.

Install lockwire on filter body and drain valve.

8.

Run engine to check microfilter for leakage.

BO lOS CHAPTER 828 Page 8

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2

3

.~. =n---7

24--:'1

800290

1 Connection 2 Screw 3 Cover 4 Screw 5 Switch 6 Wire 7 Spacer sleeves 8 Screw 9 Washer 10 Mounting support 11 Drainage collector assy 12 O-ring

13

14 15 16 17 18 19 20 21 22 23 24

O-ring Filter elernent O-ring O-ring Drain valve Hose assy Elbow Union nut Double tapered ring Flange O-ring Screw

Fig. 828-1 Microfilter BO 105 CHAPTER 828 Page 9/10

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

829

CROSSFEED LINES

Table of Contents

Paragraph

Title

829 - 1

DESCRIPTION - CROSSFEED LINES

3

829 - 2

TROUBLESHOOTING - CROSSFEED LINES

5

829 - 3

INSPECTION SCHEDULE - CROSSFEED LINES

6

829 - 4

FUNCTIONAL CHECK - CROSSFEED LINES

7

829 - 5

REMOVAL - CROSSFEED LINES

8

829 - 6

INSTALLATION - CROSSFEED LINES

8

Page

BO 105 CHAPTER 829 Page 1/2

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 829 - 1

DESCRIPTION - CROSSFEED LINES

1. General

The fuel system supply tank contains two fuel pumps, one for each engine. Two more pumps in the forward main fuel tank deliver a constant flow of fuel to replenish the supply tank. If a fuel pump in the supply tank should fail, the engine-mounted fuel pump will draw the fuel to the engine. The suction power of the engine-mounted fuel pump decreases with increasing altitude, thus limiting the maximum operating altitude. 2. Description

A crossfeed line interconnects each the supply tank fuel pump with one of the pumps in the main fuel tank. If one of the supply tank fuel pumps should fail, its corresponding main tank fuel pump will back up the engine-driven fuel pump by continuing fuel delivery, thus removing the ceiling limitation. 3. Operation NOTE

The following describes the operation of the crossfeed line for engine l.

The ENG I fuel pump in the supply tank (fig. 829-1) builds up a pressure of 1 bar in the ENG I feed lineo The interconnected main tank fuel· pump I builds up a pressure of 0.5 bar in feed lineo The fuel from the main tank flows into the supply tank through pressure relief valve. The non-return valve remains closed. If the ENG I fuel pump in the supply tank fails, the engine-mounted fuel pump will draw fuel from the supply tank, supported by the corresponding fuel pump I in the main tank. The pressure relief valve and non-return valve remain closed. Even if both interconnected tank fuel pumps should fail, the supply of fuel to the engine is maintained through the engine-mounted fuel pump. However, the maximum operating altitude is reduced.

BO 105 CHAPTER 829 Page 3

Q>

C> C>

'Unto

~ ....

OJ:I:O

I.Q:X::(1) 'U 1-' 0--30 .¡,.tt:lLn

::o

00

N \.O

t 1"%]

1-'I.Q 00

N \.O

SUPPLY TANK

FUEL PUMP J

~

H

FUEL PUMP JI

~~

+

tt:lto

~~

1-'

CH

n H o

:x::-n t-
Ul Ul

Hl

MAIN TANK

O1-' 1-'-

::l (1)

0--3 tt:l

Z

I

(1) (1)

Z

~~ to::o en I

to

EB

O

FUEL PUMP SUPPLY: PRESS. APPR. 1 bar

[]

NON-RETURN VALVE: OPENG. PRESS. 0.05 bar

9>

PRESS. RELlEF VALVE: OPENG. PRESS. 0.5 bar

l$J

PRESSURE TRANSMITTER FOR INDICATING INSTRUMENT IN COCKPIT

[C§3

OVERFLOW TUBE

.....

o

Ln

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 829 - 2

TROUBLESHOOTING - CROSSFEED LINES

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Fuel pressure too low

Defective fuel pump in main or supply fuel tank

Functionally check fuel pump according to para 829-4¡ replace defective fuel pump

2

Supply tank replenished too slowly or not at al!

Defective pressure relief valve (s)

Functionally check pressure relief valves¡ replace as necessary

Defective fuel pump(s) in main tank

Functionally check fuel pumps according to para 829-4¡ replace defective fuel pump

3

Fuel pump in Defective fuel pump main tank and in main tank engine-mounted fuel pump cannot produce the required delivery pressure of 0.7 bar after fuel pump in supply tank fails Defective engine-mounted fuel pump

Table 829-1

Functionally check fuel pump according to step 1., para 829-4¡ replace defective pump

Functionally check fuel pumP¡ replace as necessary

Troubleshooting

BO 105 CHAPTER 829 Page 5

EUROCOPTER

• 829 - 3

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 829 Page6

Revision 18

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NOTE

-

FUNCTIONAL CHECK - CROSSFEED LINES

The functional check may only be performed with the main tank full and the supply tank empty.

Supply tank ENG 1 and ENG 11 fuel pumps Main tank Fuel pumps 1 and 11

l. Switch on fuel pump 1 and measure the time it takes to transfer 20 kg of fuel from the main tank to the supply tank. The maximum time allowed is 5 minutes. - The fuel lines to ENG 1 are pressurized and the fuel pressure transmitter for system 1 must indicate approx. 0.5 bar. The fuel pump 1 is operating normally (fuel cock open) . - If the required pressure is not produced, check fuel pump l. 2. AIso switch on ENG 1 fuel pump.

- The pressure indication on the fuel pressure transmitter must increase to at least 0.7 bar. 3. Switch off both fuel pumps. - Fuel line pressure must remain constant at least 0.7 bar. If pressure drops, check both pumps 1 and ENG l. NOTE

If the ENG 1 fuel pump is switched on first, the pressure indication is at least 0.7 bar. This pressure will not be altered if fuel pump 1 is also switched on, because the fuel delivered by the latter flows through the pressure relief valve into the supply tank. The non-return valve (fig. 829-1) remains closed because the fuel pressure on the ENG 1 fuel pump side of the valve is greater than that on the fuel pump 1 side.

4. Functionally check fuel pumps 11 and ENG 11 in system 2 (refer to steps l. thru 3.).

BO 105 CHAPTER 829 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - ' - - - - - MAINTENANCE MANUAL MBB - BO 105 829 - 5

REMOVAL - CROSSFEED LINES

WARNING

OBSERVE FUEL HANDLING SAFETY PRECAUTIONS TO PREVENT SPARKS FROM FORMING ANO BECOMING A FIRE OR EXPLOSION HAZARD.

NOTE

The procedures for removing the crossfeed lines interconnecting fuel pumps 1 and ENG 1 and fuel pumps 11 and ENG 11 are identical.

1. Defuel the helicopter (refer to Chapter 06).

2. Remove assembled tank cover and fuel quantity transmitter from forward main tank (refer to para 62-5). 3. Remove assembled tank cover and fuel quantity transmitter from supply tank (refer to para 62-13). 4. Unscrew coupling nuts (6 and 10, fig. 829-2) and remove fuel line assembly (8) from supply tank. 5. Unscrew coupling nuts (11 and 16) an remove fuel line assembly (15). 6. Remove screws (3) and washers (4) and remove fitting halves (5). Unscrew coupling nut (1) and withdraw fuel line (2) from main tank.

INSTALLATION - CROSSFEED LINES

829 - 6

NOTE

The procedures for installing the crossfeed lines interconnecting fuel pumps 1 and ENG 1 and fuel pumps 11 and ENG 11 are identical.

l. Insert fuel lines (2 and 18, fig. 829-2) through the tank cover aperture

in the main tank and loca te in position. 2. Connect fuel line to fuel tank with coupling nut (1). 3. Locate fuel line assembly (15), consisting of fuel line (14), tee (13) and non-return valve (12), in position inside supply tank and connect to fuel pump and outlet fitting with coupling nuts (11) and (16), respectively. 4. Locate fuel line assembly (8), consisting of non-return valve (9) and pressure relief valve (17), in supply tank and connect to tee (13) with coupling nut (10). Connect to fuel line (2) by screwingcoupling nut (6) on elbow (7).

BO 105 CHAPTER 829 Page 8

_ _ _ _ _ _ _ _ _ _ _ _ _ MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

s

~~-

6 7

DETAlLA

V

I

J

2

I

3

I 1.5-1.~

Nm

I DETAlL

/'

B

8 DETAlLe

9

16

18

6

'----10 14----~

1 Coup1ing nut 2 Fue1 1ine 3 Screw 4 Washer 5 Fitting ha1ves 6 Coupling nut 7 Elbow 8 Fue1 1ine assemb1y 9 Non-return va1ve 10 Coup1ing nut

11

DETAlL

D

800289

Fig. 829-2

Crossfeed lines

80 105 CHAPTER 829 Page 9/10

11

12 13 14 15 16 17 18

Coupling nut Non-return valve Tee Fuel line Fue1 line assembly Coupling nut Pressure re1ief va1ve Fue1 1ine

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

830

SELF-SEALING FUEL TANKS

Table of Contents

Page

Paragraph

Title

830 - 1

DESCRIPTION - SELF-SEALING FUEL TANKS

3

830 - 2

TROUBLESHOOTING - SELF-SEALING FUEL TANKS

3

830 - 3

INSPECTION SCHEDULE - SELF-SEALING FUEL TANKS

830 - 4

INSPECTION FOR CONDITION - SELF-SEALING FUEL TANKS

5

830 - 5

REMOVAL - SELF-SEALING FUEL TANKS

6

830 - 6

INSTALLATION - SELF-SEALING FUEL TANKS

7

·4

BO 105 CHAPTER 830 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 830 - 1

DESCRIPTION - SELF-SEALING FUEL TANKS

1. General

Self-sealing fuel tanks are used on helicopters that may be exposed to gunfire. They retain their self-sealing capability up to hits with 7.62 mm shells (NATO standards). 2. Construction

The self-sealing fuel tanks consist of three individual compartments arranged in the same way as the series tanks, with which they can be exchanged without constructional changes. 3. Function

The self-sealing fuel tanks are so constructed that, following penetration of a tank wall by a projectile, the intermediate layer of the wall develops its vulcanizing characteristics after fuel contact and seals the existing hole by expansiono The capacity of these tanks is less than that of series tanks. 830 - 2

TROUBLESHOOTING - SELF-SEALING FUEL TANKS

Troubleshooting of the self-sealing tanks must be carried out in accordance with the troubleshooting procedures for the fuel system described in Chapter 62.

BO 105 CHAPTER 830 Page 3

EUROCOPTER

• 830 - 3

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 830 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 830 - 4

INSPECTION FOR CONDITION - SELF-SEALING FUEL TANKS

l. Inspect cable connections and cable plugs for security and cables for chafing. Tighten loose cable connections and cable plugs. Replace damaged cables. 2. Inspect fuel and vent lines for tight connection, leakage and damage.

a.

Tighten loose connections, replace damaged lines.

b.

Re-tighten union nuts of leaking connections by 1/6 of a turno If leakage continues¡ replace sealing element or connection.

c.

If leakage is present in area of flanges, re-tighten flange screws (torque value 2.5 - 3 Nm) .

3. Inspect drain holes in bottom shell for fuel leakage. If fuel leakage is present, perform leak test in accordance with chapter 62. If leakage cannot be repaired, remove fuel tank, refer to paragraphs 62-4 to 62-15. 4. Inspect drain valves for leaking fuel. If leakage is evident, inspect attaching hardware for specified torque. Inspect drain valves and replace if leaky, refer to para 62-16.

5. Inspect area around fuel pump access covers for leaking fuel. If leakage is evident, remove access covers and inspect fuel pump attaching hardware for specified torque. If leakage continues, replace sealing ring, refer to para 62-19.

BO 105 CHAPTER 830 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 830 - 5

REMOVAL - SELF-SEALING FUEL TANK

Special tools: Screwdriver with chafe guard, cornmercial item WARNING

TAKE ALL NECESSARY PRECAUTIONS TO PREVENT FlRE ANO EXPLOSION HAZARDS.

1.

Defuel helicopter according to Chapter 06.

2.

Disconnect battery and external power supply (refer to Chapter 92).

NOTE

o The removal procedure for the self-sealing tanks is basically the same as that for series fuel tanks. For this reason, refer to Chapter 62. o The self-sealing fuel tanks have a thicker tank wall and therefore cannot be installed through the apertures in the floor panel. The floor panel itself must be removed.

3.

Remove closing cover of supply tank together with fuel quantity transmitter and fuel low level warning transmitter. Refer to para 62-12.

4.

Remove fuel lines secured with clamps to the closing cover of forward main tank, then remove the closing cover together with fuel quantity transmitter. Refer to para 62-5.

5.

Remove closing cover of rear main tank. Refer to para 62-8.

6.

Remove fuel pumps from supply tank and forward main tank. Refer to para 62-19.

7.

Remove jettison system closing cover from lower section of forward main tank. Refer to para 62-5.

8.

Remove the drain valve of the supply tank and the forward and rear main tanks. Refer to para 62-17.

9.

Unscrew side floor panels and disconnect fuel line from connections on the left and right sides of the supply tank. Refer to para 62-12.

10.

Remove the two pipe clamps by which the filler neck of the forward main tank and the protective sleeve are secured to the fuselage mounted filler neck. Refer to para 62-5.

11.

Remove the fuel lines from the supply tank and the main tank. Refer to paras 62-5 and 62-12.

BO 105 CHAPTER 830 Page 6

- - - - - - - - - - - - - , - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 12.

Remove the vent flange of supply tank, the vent flanges of the forward main tank and the vent flange of the rear main tank from the underside of the floor panel.

13.

Remove floor panel together with the small baggage compartment cover.

14.

Remove clamp protectors and pipe clamps from the overflow flanges of the forward main tank. Refer to para 62-5.

15.

Remove clamp protectors and pipe clamps from inlet flange of forward main tank and from supply flange of rear main tank. Refer to paras 62-5 and 62-8.

16.

Remove the overflow flanges of the supply tank from the overflow pipes and lift supply tank out of tank compartment.

17.

Remove flanges (22 and 35, fig. 62-5) on side of supply tank.

18.

Remove the overflow flanges of the forward main tank from the overflow pipes, and the inlet flange from the main tank connecting tube.

19.

Pull forward main tank filler neck off fuselage-mounted filler neck, then remove forward main tank from the tankcompartment.

20.

Pull the supply flange of the rear main tank off the main tank connecting tube, then remove the rear main tank from the tank compartment.

830 - 6

INSTALLATION - SELF-SEALING FUEL TANKS

Special tools: Screwdriver with chafe guard, cornmercial item

NOTE

The installation procedure for the self-sealing tanks is basically the same as that for the series tanks. For this reason, refer to Chapter 62.

1. Ensure that all sharp edges, corners, anchor nuts, rivet heads and stud fasteners are covered with adhesive tape (CM 614). 2. Check the foam padding in the tank compartment for security and completeness.

3.

Clean inside of fuselage at installation area, and tank compartments and remove foreign objects from these areas.

4.

Check vent lines in floor panel for free passage.

BO 105 CHAPTER 830 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5.

Check adhesion of filler neck protective sleeve and, if necessary, rebond with rubber ~ernent (CM 653) .

6.

Install flanges (22 and 35, fig. 62-5) on the left and right sides of the supply tank.

7.

Rub talcurn powder (CM 108) on the outer surfaces of the fuel tanks, then install the tanks into their respective tank cornpartrnents.

8.

Fit overflow flanges of the supply tank and overflow flanges of the forward main tank on overflow tubes of the tank dividing wall.

9.

Position the inlet flange of the forward main tank and the outlet flange of the rear main tank on the main tank connecting tube located at the bottom in frame 9.

10.

Fit a pipe clamp on each of the six flanges and tighten them. Fit a clamp protector over each of the six pipe clamps.

11.

Push forward main tank filler neck on the tube of the fuselage-mounted filler neck (minimum 20 mm over rim of tube). Secure tank filler neck and protective sleeve with two pipe clamps then tighten the pipe clamps. Refer to para 62-7.

12.

Insta11 fuel lines in forward main tank. Install pipe lines to the overflow tubes in the supply tank.

13.

Inspect seal between floor panel and tank compartment and, if necessary, renew by spraying the upper edges of the tank compartment with parting and sliding agent (CM 709) and applying sealing compound (CM 644) to the appropriate contact surfaces of the floor panel.

14.

Install floor panel. NOTE

When securing the forward vent flange of the forward main tank, the longer of the two pipelines also rnust be secured.

15.

Secure the vent flange of the supply tank, vent flanges of the forward main tank and the vent flange of the rear main tank to the floor panel.

16.

Install fuel pumps in the supply tank and the main tank. Refer to para 62-21.

17.

Install fuel pipelines in the supply tank. Refer to para 62-15.

18.

Connect fuel pipelines in the forward main tank. Refer to para 62-7.

19.

Install drain valves in the supply tank and in the forward and rear main tanks. Refer to para 62-18.

BO 105 CHAPTER 830 Page 8

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 20.

Examine fuel tanks internally for foreign objects.

21.

Install closing cover of supply tank together with fuel quantity transmitter and low level warning transmitter. Refer to para 62-15.

22.

Install closing cover of the forward main tank together with fuel quantity transmitter and secure fuel pipeline of the rear main tank pump to the closing cover. Refer to para 62-11.

23.

Fit closing cover to the bottom section of the forward main tank. Refer to para 62-7.

24.

Fit closing cover of rear main tank. Refer to para 62-11.

25.

Connect fuel pipelines to flanges (22 and 35, fig. 62-5) on the supply tank. Bond the protective sleeves to the side walls with adhesive (CM 653), then tighten the pipe clamps.

26.

Check fuel system for leakage and function. Refer to paras 62-43 and 62-44.

BO 105 CHAPTER 830 Page 9/10

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

831

LONG RANGE FUEL TANK

TabIe of Contents

Paragraph

Title

Page

831 - 1

DESCRIPTION - LONG RANGE FUEL TANK

3

831 - 2

TROUBLESHOOTING - LONG RANGE FUEL TANK

4

831 - 3

INSPECTION SCHEDULE - LONG RANGE FUEL TANK

7

831 - 4

INSPECTION FOR CONDITION - LONG RANGE FUEL TANK

8

831 - 5

FUNCTIONAL CHECK - LONG RANGE FUEL TANK

9

831 - 6

REMOVAL - LONG RANGE FUEL TANK

11

831 - 7

INSTALLATION - LONG RANGE FUEL TANK

12

831 - 8

Removal - control unit

13

831 - 9

Installation - control unit

13

831 - 10

Removal - discharge valve .

13

831 - 11

InstalIation - discharge vaIve

13

831 - 12

Removal - fIoat switch

14

831 - 13

InstalIation - fIoat switch

14

831 - 14

Removal - bag tank

15

831 - 15

InstalIation - bag tank

15

831 - 16

PRESSURE TEST - LONG RANGE FUEL TANK

17

831 - 17

FUELING - LONG RANGE FUEL TANK

19

831 - 18

DEFUELING - LONG RANGE FUEL TANK

19

BO 105 CHAPTER 831 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 831 - 1

DESCRIPTION - LONG RANGE FUEL TANK

1. General The fuel system has provlslons for the installation of two long range fuel tanks in the cargo compartment, each with a capacity of 200 l. Either one or both tanks may be installed as required, with the one-tank installation possible on either side (right or left) . 2. Description Each long range fuel tank is installed by sliding it along two rails (9, fig. 831-4) screwed to the cargo compartment floor, and then locking it in position against the stops at the end of the rails by quick release pins (8). If only one tank is to be installed it is to be partioned off from the empty side of the cabin by a protective wall. The long range fuel tank is connected to the main tank via the discharge valve (6) and the fuel delivery line (20) which is fitted with a quick disconnect coupling (22). The fuel delivery line is provided special protection through the protective hose (19) which incorporates a bayonet lock (21). The vent lines (5) and drain lines (11 and 12) are connected to the corresponding fuel system lines and overboard drain via quick disconnect couplings. Installed in each long range fuel tank is a float switch (4) which energizes a FULL caption on the control unit when approx. 180 1 of fuel are in the tank. A float switch (18) in the main fuel tank releases the respective discharge valve (6) only when the fuel level in the main tank has dropped to approx. 200 l. The control unit (see fig. 831-1) for the long range fuel tank is mounted on the center console (configuration 1) or on the instrument panel (configuration 11) . 3. Operation The system is supplied with power from the main bus PP21 through the 5 ampo circuit breakers located on the left and right sides of the control unit. When the fuel level in the main tank drops to approx. 200 1, the float switch 11QA closes, energizing relay lSQA which, in turn, releases the discharge va1ves. Simultaneously, discharge valve release is indicated by the illumination of the TANSFER caption. If toggle switch 14QA is set to L OPEN or R OPEN, the corresponding discharge valve will be opened by an actuator which automatically shuts off when reaching its travel limito At the same time, the corresponding L CLOSED or R CLOSED caption will extinguish and the fuel transfer will begin.

80 105 CHAPTER 831 Page 3

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS When the fue1 level in the long range fuel tank, frorn which fuel is being transferred, has dropped to approx. 180 1, the float switch 12QA breaks the circuit to the FULL caption which then extinguishes. The rising fuel level in the rnain tank eventually reopens float switch 11QA, causing the TRANSFER caption to extinguish and the relay lSQA to be deenergized. When the long range fuel tank is ernpty, the discharge valve can be closed again via toggle switch 14QA and the associated R CLOSED or L CLOSED caption will Illurninate. If the TRANSFER caption should light up again during flight, the contents of the second long range fuel tank can be transferred by the sarne procedure. If either the float switch 11QA or the relay lSQA should fail, the discharge valves can be opened directly by selecting toggle switch 7QA to EMERGENCY. Prior to each flight, the pushbutton/indicators can be functionally checked by pressing their captions. 831 - 2

TROUBLESHOOTING - LONG RANGE FUEL TANK

General Troubleshoot using wiring diagrarn 831-1 in the Wiring Diagrarn Manual (WDM) •

Check all electrical connections for tightness and all switches and circuit breakers for unirnpaired rnechanical functioning. Press circuit breakers (S and 7, fig. 831-1) and then functionally check the associated pushbutton/indicators (1, 2 and 4) by pressing their captions. Troubleshoot using either external (EPU) or battery power, and press circuit breakers (5 and 7) .

80 105 CHAPTER 831 Page 4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Discharge valve does not open with toggle switch 14QA in L OPEN or R OPEN; TRANSFER caption il1urninates

Faulty wiring

Check wiring for continuity and repair as necessary

Defective discharge valve

Pull out connectors 13QAa and test for voltage. Replace discharge valve if necessary

Defective switch 14QA or relay lSQA

Replace control unit

Faulty wiring

Check wiring for continuity and repair as necessary

Defective discharge valve

Pull out connector 13QAa and test for voltage. Replace discharge valve if necessary

Defective switch 7QA

Replace control unit

2

3

Discharge valve does not open with switch 7QA in EMERGENCY

Discharge valve does Faulty wiring not close with switch 14QA in CLOSED

Check wiring for continuity and repair as necessary

Defective discharge valve

Pull out connector 13QAa and test for voltage. Replace discharge valve if required

Defective switch 14QA

Replace control unit

Table 831-1

Troubleshooting (1 of 2)

BO 105 CHAPTER 831 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued)

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

4

TRANSFER caption 10QA does not illuminate despite less than 200 1 being in the main tank

Faulty wiring

Check wiring for continuity and repaire as necessary

Defective float switch llQA

Replace float switch

5

TRANSFER caption 10QA does not extinguish despite more than 200 1 of fuel being in the main tank

Defective float switch llQA

Replace float switch

6

FULL captions 8QA and 9QA do not illuminate despite long range fuel tanks being full

Defective float switch 12QA in corresponding long range fuel tank

Replace float switch

7

L CLOSED caption 8QA Defective limit switch and R CLOSED caption of corresponding 9QA do not illuminate discharge valve despite associated discharge valve being heard to close

Replace discharge valve

8

Fuel fumes in cabin

Leaking quick disconnect coupling

Replace seal or replace coupling

9

Persistent leakage of fuel from drain port

Jammed drain valve

Operate drain valve several times. Replace drain valve if necessary

Table 831-1

BO 105 CHAPTER 831 Page 6

Troubleshooting (2 of 2)

EUROCOPTER

831 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (reter to Chapter 101)

CHAPTER 831

Page7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 831 - 4

INSPECTION FOR CONDITION - LONG RANGE FUEL TANK

1.

Check cables for security and chafing. Secure loose cables. Discard cables with chafe marks.

2.

Check hose lines for looseness, chafing and signs of leakage. a.

Secure loose lines, discard hose lines with chafe marks.

b.

If leakage from connections is evident, tighten the affected union nut by 1/6 turn; if leakage persists, replace sealing elemento

c.

If leakage is evident in the flange area, tighten bolts of the affected flange (torque value 3 Nm) .

3.

Check bonding straps for damage and looseness. Discard damaged bonding straps, tighten loose bolt connections (torque value 3 Nm) .

4.

Inspect bonding jumpers connected to all parts of the long range fuel tank without ground connection for continuity. The contact resistances measured across the fuel tank-to-fuselage ground point to the individual bonding jumpers on the tank must not exceed 25 milliohm.

5. Check long range fuel tank for secure installation, mechanical damage and corrosion.

a.

Tighten loose attaching hardware (guide rails on the floor: 8 Nm, guide rails on the support frame: 6.5 Nm).

b.

Polish out mechanical damage and corros ion with 400 grit polishing cloth: 1)

A maximum of two rework areas of 20 cm2 each is permissible in each section between two reinforcement frames or between one reinforcement frame and the edge of the tank. Permissible rework depth: 0.15 mm as a maximum.

2)

For each reinforcement frame a maximum of two rework areas of 5 cm2 each is permissible. Permissible rework depth: 0.1 mm as a maximum.

c.

Treat damaged surface protection with chemical conversion material (CM 316), two-component zinc chromate primer (CM 456) and two-component PUR topcoat (CM 426) .

d.

If cracks are evident, send long range fuel tank to the manufacturer or authorized repair facility.

BO 105 CHAPTER 831 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 FUNCTIONAL CHECK - LONG RANGE FUEL TANK

831 - 5 1.

2.

3.

General a.

To perform the electrical system function check, the main and long range fuel tanks must be fueled and defueled. Observe all safety precautions pertaining to fuel system servicing.

b.

The long range fuel tank can only be defueled through the main tank.

c.

A fuel transfer operation must not be interrupted during the functional check.

d.

The functional check procedure is the same for both (right and left) long range fuel tanks.

e.

Visually and aurally check functioning of long range fuel tank discharge valves.

Preparatory work a.

Ensure that associated system circuit breakers are pressed.

b.

Before proceeding with the functional check, ensure that the main fuel tank contains 220 l of fuel, the long range fuel tank is full, and toggle switch (3, fig. 831-1) is set to NORMAL.

Perform functional check as follows: a.

Connect and switch on the external power supply (EPU).

b.

Test caption lamps. The FULL/L CLOSED (green), FULL/R CLOSED (green) and TRANSFER (yellow) captions must illuminate.

c.

Functionally check the left long range fuel tank. Press LEFT circuit breaker (7) on instrument panel: - FULL/L CLOSED captions (1) illuminate - all other associated captions remain off discharge valve of left long range fuel tank is closed.

d.

Functionally check the right long range fuel tank. Press RIGHT circuit breaker (5) on instrument panel: - FULL/R CLOSED captions (2) illuminate - all other associated captions remain off - discharge valve of right long range fuel off tank is closed.

BO 105 CHAPTER 831 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 e.

Defuel main tank until 170 1 remain; observe tank contents indicator. The TRANSFER caption (4) comes on when the fuel content in the tank is less than 200 l.

f.

Set toggle switch 14QA (6) to L OPEN. - leftlong range fuel tank discharge valve apens (visual and aural check) - L CLOSED caption (1) extinguishes - TRANSFER caption (4) comes on - fuel 1evel in main tank rises (observe contents indicator) - as soon as the fuel content of the main tank is less than 180 1, the FULL caption (1) extinguishes - when approx. 200 1 af fuel are in the main tank, the TRANSFER caption (4) extinguishes.

g.

Set toggle switch (6) to CLOSED: - discharge va1ve of left long range fuel tank closes (visual and aural check) . - L CLOSED caption (1) comes on when the discharge valve is closed.

h.

Return toggle switch (6) to L OPEN: - discharge valve of left long range fuel tank must not open (visual and aural check) - L CLOSED caption (1) continues to illuminate.

l.

Set toggle switch (3) to EMERGENCY: - discharge valve of long range fuel tank opens (visual and aural check) - L CLOSED caption (1) extinguishes.

j.

Set toggle switch (3) to NORMAL: discharge valve of left long range fuel tank remains open - L CLOSED caption (1) does not illuminate.

k.

Set toggle switch (6) to CLOSED - discharge valve of left long range fuel tank closed (visual and aural check) - L CLOSED caption (1) comes on when the discharge valve closes.

l.

Repeat steps d. thru k. for the right long range fuel tank.

m.

Connect bonding jumpers to all parts of the long range fuel tank that have no bonding connection. The contact resistances measured across the fuel tank-to-fuselage ground point to the individual bonding jumpers on the tank must not exceed 25 milliohms.

n.

Pull circuit breaker and switch off external power.

BO 105 CHAPTER 831 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 REMOVAL - LONG RANGE FUEL TANK

831 - 6

NOTE

The removal procedure for the right and left long range fuel tanks is identical.

1.

Pull out LEFT and RIGHT circuit breakers in the control unit and secure to prevent them from being unintentionally pressed.

2.

Open rear clamshell doors.

3.

Defuel long range fuel tank according to para 831-18. WARNING

NEITHER FUEL NOR FUEL FUMES MUST BE ALLOWED TO REMAIN IN THE TANK.

4.

Purge the long range fuel tank with air until all fuel fumes have been removed.

5.

Disconnect electrical connector (2, fig. 831-4) and connect to dummy receptacle on tank.

6.

Unscrew quick disconnect couplings of drain lines (11 and 12) and vent lines (5 and 7) and cap open hose ends and connections.

7.

Disconnect bayonet lock (21) of protective hose (19) and quick disconnect coupling (22) of fuel delivery line (20) from the main tank. Cap open line and connection.

8.

Remove quick release pins (8) and withdraw the long range fuel tank from the rails.

9.

Install dummy cover in the cargo compartment floor.

10. Store the removed tanks in an appropriate manner. 11. If required, remove the rails. If the rails are removed, secure the cargo

compartment floor by installing shorter screws on the outer right and left sides.

BO 105 CHAPTER 831 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 831 - 7 NOTE

INSTALLATION - LONG RANGE FUEL TANK The installation procedure for the right and left tanks is identical.

1.

Check long range fuel tank for condition, refer to para 831-4.

2.

Remove dummy cover from cargo compartment floor.

3.

If previously removed, install tank rails. NOTE

o The long range fuel tank shall be installed so that the filler neck is located aft at the side of the cabin i.e., left tank filler neck on left side, right tank filler neck on right side (looking forward from the rear). o If only one tank is installed, protect the inboard side of the tank with a protective wall.

4.

Slide in tank on the rails (9, fig. 831-4) until it rests against the stops at the rail ends, then lock in place with quick release pins (8).

5.

Remove protective caps and connect quick disconnect coupling (22) on the end of fuel delivery line (20) together with protective hose (19) with bayonet lock (21) to the main tank.

6.

Remove protective caps and connect the quick disconnect couplings on the ends of the drain lines (11 and 12) and vent lines (5 and 7) to the fuselage-mounted lines.

7.

Remove protective caps and connect electrical connector (2). When installing, take care not to plug it into the dummy receptacle (if not potted) .

8.

Perform functional and pressure test, refer to paras 831-5 and 831-16.

BO 105 CHAPTER 831 Page 12

- - - - - - - - - - - - - ' - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 831 - 8

Removal - control unit

1.

Remove control unit from the instrument panel or the center control according to configuration.

2.

Unplug electrical connector from control unit and cap openings.

831 - 9

Installation - control unit

Installation is in reverse order of removal. 831 - 10

Removal - discharge valve

l.

Remove long range fuel tank as described in para 831-6.

2.

Remove electrical connector (3, fig. 831-2) from discharge valve (8) and plug into dummy receptacle on tank.

3.

Remove nuts (9) and washers (10), loosen clamps (5) and pull protective hoses (1) off coupling nuts (4).

4.

Unscrew and remove coupling nuts from discharge valve; cap open ends of fuel delivery lineo

5.

Remove nuts (7) and washers (6) and detach discharge valve.

831 - 11

Installation - discharge valve

1.

Visually inspect discharge valve (8, fig. 831-2) prior to installation.

2.

Position discharge valve and secure in place with washers (6) and nuts (7) .

3.

Remove protective caps from the ends of the fuel delivery line (2) and connect latter to the discharge valves using coupling nuts (4).

4.

Push protective hoses (1) over the coupling nuts and tighten clamps (5) with screws (10) and nuts (9).

5.

Remove cap from electrical connector (3) and connect latter to the discharge valve.

BO 105 CHAPTER 831 Page 13

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 831 - 12

Removal - float switch

1.

Remove long range fuel tank as described in fig. 831-6.

2.

Undo cable tie on protective sleeve (4, fig. 831-3) and push back sleeve to expose splice connectors (5).

3.

Separate electrical leads (6) at splice connectors.

4.

Remove screws (2) and washers (1); withdraw flange (3) together with gasket (7) and float switch (9) from tank cover (10).

5.

Bend open the tab washer (8) and unscrew and remove float switch from flange. Pull electrical leads out through the flange and remove gasket.

6.

Close aperture in the tank cover with a protective cap until the float switch is reinstalled.

831 - 13 1.

Installation - float switch

Visually inspect float switch prior to installation. NOTE

Install a new tab washer.

2.

Thread tab washer (8, fig. 831-3) over electrical leads (6) and slide up against float switch (9). Install gasket (7) on flange (3).

3.

Insert electrical leads through the bottom of the flange.

4.

Screw float switch into the flange and secure with the tab washer.

5.

Remove cap from tank cover aperture and visually inspect interior of tank for foreign objects.

6.

Insert assembled float switch through the tank cover aperture. Align flange with mating holes in tank cover and install washers (1) and screws (2) .

7.

Connect electrical leads using splice connectors (5) in accordance with associated wiring diagram in the Wiring Diagram Manual (WDM).

8.

Push protective sleeve (4) back over the splice connectors and install cable tie.

9.

Test long range fuel tank for leakage as described in para 831-16.

BO 105 CHAPTER 831 Page 14

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831 - 14

Removal - bag tank

1.

Defuel long range fuel tank (refer to para 831-18) .

2.

Remove long range fuel tank (refer to para 831-6).

3.

Remove vent line flanges and gaskets by removing the screws and washers from the bag tank container lid.

4.

Push back protective sleeve (4, fig. 831-3) and separate the exposed spliced connections (5).

5.

Remove tank cover (10) together with float switch and gasket by removing the attaching screws and washers.

6.

Remove drain line from overflow trough (14, fig. 831-4) on filler neck (13) and remove filler neck and adjacent dummy cover and gaskets by removing the attaching nuts and washers from the rear wall of the bag tank container.

7.

Remove protective hose (1, fig. 831-2) from fuel delivery line (2), together with gasket and metal ring, by removing the nuts and washers from the bag tank container and by loosening clamp (5) on discharge valve (8); remove fuel delivery line by unscrewing the coupling nuts on the discharge valve and bag tank. NOT~

Drain residual fuel in a suitable container.

8.

Aftcr rcmoving the drai.n line, r.cmovc drain val.ve by r.emoving the attachjng nuts and washers.

9.

l~emovc

scrcws, nuts and washers securing thc bag tank container lid and rcmovc containcr lid.

lO. Unlace nyl.on cords and remo ve bag tank from conl.Jiner.

11. SLorc removed bag \.¿¡nk 1~

a~;

prcscribed in chapLcr 6).

fnstal lali.on - bag Lank

RTI

-

\.

Vi~;uiJlly in~;pecL

;J.

Cov(~r rive\. nu\.s in conl.aincr wiLh el suililblc maLeridl lo prCVl)n\' dr:vr'jopm()n\. 01 prC~;~;lIrc ilnd Chdr(~ mJrk~;.

bag \.ank lor condiLi.on prior lo

in~;IJIIJ\.ion.

1\0 \ O~) CIII\I''I'I':1\ 1\31 I';HW \~)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

NOTE

3.

If necessary, clean the container lid and the rim of the container. Before positioning the lid, apply sealing compound (CM 686) around the rim of the container.

Powder the outer surfaces of the bag tank with talcum and insert bag tank into the container. NOTE

Torque-tighten all flanges to between 2.5 and 3.0 Nm.

4.

Push the protective hose (1, fig. 831-2) onto the fuel delivery line (2). Position gasket and metal ring and screw the fuel delivery line to the bag tank and to the discharge valve.

5.

Install the protective hose on the studs of the container, with the gasket interposed between the metal ring and the protective hose, using nuts and washers. Secure protective hose at the discharge valve end with clamp (5).

6.

Install drain valve with gasket, washers and nuts and install the drain lineo

7.

Secure the bag tank in place in the container with nylon cords.

8.

Install bonding jurnper between filler neck and gasket.

9.

Position filler neck and adjacent dummy cover, together with the gaskets, on the rear wall of the container and secure with nuts and washers.

10. Fit container lid and secure with screws, washers and nuts. Connect two bonding jumpers to container lid, including free end of jumper on filler neck. 11. Position vent line flanges and gaskets and tighten with nuts and washers. 12. Install free end of bonding jumper between tank cover and gasket, and install bracket for attaching the vent line routeing clamp. 13. Install tank cover with assernbled float switch and gasket in tank aperture and secure with nuts and washers. Make spliced connection (5, fig. 831-3) and push back the protective sleeve (4) to cover it. 14. Test long range fuel tank for leakage in accordance with para 831-16.

BO 105 CHAPTER 831 Page 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 831 - 16

PRESSURE TEST - LONG RANGE FUEL TANK TO AVOID FIRE ANO EXPLOSION HAZARDS OBSERVE ALL SAFETY PRECAUTIONS.

WARNING

A pressure test is performed whenever a bag tank is replaced (refer to paras 831-14 and 831-15) or bag tank - mounted components, such as vent line flanges, tank cover and float switch assembly, filler neck, fuel delivery lines and drain valve, are reinstalled. l.

Equipment required -

2.

pressure supply (gaseous nitrogen or dry air) U-tube manometer (0.01 - 0.5 bar) pressure regulating valve hoses and clamps to fit manometer and regulating valve plug for drain line on filler neck quick disconnect coupling 390 210-8 28VDC power supply for discharge valve

Pressure test the bag tank container as follows: CAUTION

NOTE

THE TEST PRESSURE MUST NOT EXCEED 1000 mm WATER COLUMN (0.1 BAR). To prevent damaging the bag tank, it must have the same pressure applied to it as the container in which it is enc.losed.

a.

Oi.sconnect vent line at the tee between the forward and aft vent flange.

b.

Connect pressure supply (gaseous nitrogen or air) to the tee.

c.

Conncct U-tubc manometer to free end of vent lineo

d.

Disconnect and plug the drain line on filler neck.

C.

Conncct vent line lo drain line, using quick disconnect couplings (390 210-8) and a connecting piece.

t.

Open shutoff valve of pressure supply (gaseous nitrogen or air) and pressurize both the baq tank and container to 0.03 bar.

q.

Mter 30 minutes (lo allow temperature inside tank to match outside LcmpcrJlure), check and record the pressure.

h.

Allow JnoLhc¡" 30 minutes lo elJpse and record the pressure again. Compare this prcssure with the previously recorded pressure. If there has becn 105s of pressure, test all connections and container lid for !l',lks, using ,1 scLuti~~1l cC soap and water.

BO 10~ CBAPTER 831 Page 17

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3.

Pressure test the bag tank as follows: a.

When removing the plug from the drain line, air (or nitrogen) must be heard to escape; reconnect drain line to filler neck.

b.

Disconnect vent line-to-drain line connection.

c.

Pressurize bag tank to 0.08 bar.

d.

Check and record pressure after 30 minutes (to allow temperature inside tank to match outside temperature) .

e.

Allow another 30 minutes to elapse and record pressure again. Compare this pressure with the previously recorded pressure. Any loss of pressure could be the result of: - leaking flange connections: and/or - leaking bag tank: air escaping from drain line on filler neck. If the pressure drops, check all accessible areas of the long range fuel tank for leaks using leak detection spray (CM 711) or leak detection agent (CM 758) .

f.

Remove all pressure from bag tank by connecting the vent and drain line disconnect points to each other using the connecting piece.

g.

Remove test equipment; connect vent line to tee.

BO 105 CHAPTER

Page 18

831

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 831 - 17 WARNING

FUELING - LONG RANGE FUEL TANK o GROUND THE HELICOPTER PRIOR TO FUELING. DO NOT REMOVE GROUND CONNECTION UNTIL COMPLETION OF FUELING. o DO NOT OPERATE ANY ELECTRICAL SWITCHES OR UNITS DURING FUELING. o OBSERVE ALL FUEL HANDLING REGULATIONS.

1.

Ground the helicopter. Ensure that discharge valve is closed.

2.

R CLOSED and L CLOSED captions must illuminate.

3.

Make ground connection between fuel hose nozzle and long range fuel tank; open filler neck.

4.

Fill long range fuel tank with fuel.

5.

Close filler neck.

6.

Remove ground.

831 - 18 WARNING

DEFUELING - LONG RANGE FUEL TANK o GROUND THE HELICOPTER PRIOR TO DEFUELING. DO NOT REMOVE GROUND UNTIL COMPLETION OF FUELING. o DO NOT OPERATE ANY ELECTRICAL SWITCHES OR UNITS DURING DEFUELING. o OBSERVE ALL FUEL HANDLING REGULATIONS.

1.

Ground the helicopter, switch on external power (EPU) or helicopter battery, and press circuit breaker.

2.

Remove fuel from main tank until the TANK FREE caption comes on.

3.

Open the discharge valve as follows: - Set toggle switch 14QA to L OPEN / R OPEN - L CLOSED / R CLOSED caption extinguishes

4.

Close discharge valve after completion of fuel transfer by setting toggle switch to CLOSED (visual and aural check) .

5.

Remove ground connections, pull circuit breaker, and disconnect EPU or battery from helicopter electrical system.

BO 105 CHAPTER 831 Page 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Center console - mounted fuel control panel (configuration I) 3

7

5

4

lONG AANGE TANK

ITRANsl FEA FUll R.ClSO OPEN

EMEAGENCY

2

6

Instrument panel - mounted fuel control panel (configuration Ir) 2

o ©

3

¡LG. RANGE TANKI

FUlL

FULL

1----11 «1 U)

L.CLSO. TAANS I t - - - - - - ; - - 4 -FEA

7-+-~

©

lt--t-- 5

F----:::=---i- 6

© 800158

1 2 3 4 5 6 7 Fig. 831-1 105 CHAPTER 831 Page 20

BO

Pushbutton/indicator 8QA Pushbutton/indicator 9QA Norrnal-emerg·, toggle switch 7QA Pushbutton/indicator 10QA Right tank circuit breaker SQA Toggle switch 14QA Left tank circuit breaker 6QA

Long range fuel tank - control panel 20VE

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - _ MAINTENANCE MANUAL MBB - BO 105

5 4

3 4

5

2

.. '

..,.....8

10

7

9 VIEW

800293

Fig. 831-2

6 9 2 10

Protective hose Fuel delivery line 3 Electrical connector 4 Coupling nut 5 Clamp 1

2

A

6 7 8 9

la

Washer Nut Discharge valve Nut Screw

Removal and installation - discharge valve BO 105 CHAPTER 831 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

.-----.

3 ~~-----5

#--------6

J-------7

DETAlLA

~J--------8

1 Washer Screw Flange 4 Protective sleeve 5 Splice connector 6 Electrical lead 7 Gasket 8 Tab washer 9 Float switch 10 Tank cover 2 3

800295

Fig. 831-3 BO 105 CHAPTER 831 Page 22

Removal and installation - float switch

MBB HELICOPTERS MAINTENANCE MANUAL MEB ---':B=-=01-:0-=-5- - - - - - - - 3 2

15

16

DETAILB

9

18

17

8

10 9

1 Control unit 20VE 2 Electr ical connector ~ ~~~~tran?e fuel tanks (right and left) tank F~~~t~~di~~~~~~es long range fuel

8

19

5 Vent line

20

6 Discharge valve 7 Outboard vent line 8 Qu~ck releas e pin 9 Gu~de rail 10 Drain valve 11 Drain line 12 Outboard drain line 13 Filler neck 14 Filler neck overflow trough 15 Flange . 16 Gasket 17 Contents indicator 18 Float switch (in main tank) 19 Protective hose 20 Fuel delivery line 21 Bayonet lock 22 Quick disconnect coupling

Fig. 831-4

DETAlLe

21 .00294

Long range fuel tank BO 105 CHAPTER 831 Page 23/24

22

21

4

5

4 5

- - - - ' - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

832

FUEL SYSTEM WITH DIVIDED SUPPLY TANK

Table of Contents

Paragraph

Title

832 - 1

DESCRIPTION - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

3

832 - 2

TROUBLESHOOTING - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

5

832 - 3

INSPECTION SCHEDULE - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

7

832 - 4

INSPECTION FOR CONDITION - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

9

Page

832 - 5

FUNCTIONAL CHECK - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

10

832 - 6

REMOVAL - DIVIDED SUPPLY TANK .

11

832 - 7

INSTALLATION - DIVIDED SUPPLY TANK

13

BO 105 CHAPTER 832 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 832 - 1 l.

DESCRIPTION - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

General This optional supply tank differs from the basic supply tank by being divided into two separate compartments (left and right) of equal capacity. The right and left engines are supplied with fuel from the right and left compartments respectively.

2.

Description In this fuel system, the two basic feed lines connecting the main tank transfer pumps with the divided supply tank each include a check valve and are connected through a crossfeed line (see fig. 832-1).

3.

Operation The reason for the dual-compartment design of the supply tank is to ensure continued supply of fuel to an engine in the event of loss of fuel through leakage from one of the compartments. This is achieved as follows: Both compartments are continually replenished through two transfer pumps in the main tank. These pumps are connected through a crossfeed line and check valves so that the operative pump will continue to feed both compartments if the other pump should fail (see fig. 832-1). Both supply tank compartments are vented through a cornmon vent port in compartment l. For this purpose a vent slot is provided in the tank dividing wall, at the top near the tank cover, to combine the air in both compartments. The slot is located above the fuel level which is controlled by overflow pipes; this prevents fuel from flowing though the slot from one compartment to the other. Water in the tank compartments is drained through a drain valve situated in the fuselage undersurface below each compartment. Each tank compartment contains a fuel qüantity transmitter and a low-Ievel warning switch for providing fuel contents indication. Compartment I (left engine) contains fuel quantity transmitter 2EB and fuel low-Ievel warning switch 3EB, and compartment 2 (right engine) contains fuel quantity transmitter 12EB and fuel low-level warning switch 13EB. On helicopters S/N 1 thru 60, an additional fuel quantity indicator 11EB, which indicates the fuel contents of the main tank (M), is installed on the instrument panel to the left of the dual fuel quantity indicator SEB. The dual fuel quantity indicator SEB indicates the fuel contents in the supply tank compartments 1 (S I) and 2 (S II).

BO 105 CHAPTER 832 Page 3

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Rlght Englne

Left Engine

o t

OC]

Pressure Valve

fE]

Pressure Transmitter

ffi

Pump IMech.driven)

O

Fuel o.uantity Transmitter

Pressure Switch

~--v

Pump (Electrically driven)

L...!....J

Drain

Filter

r

Fuel Shut-Off Valve

I I : Pressure Une

ro mm

800312

Fig. 832-1 BO 105 CHAPTER 832 Page 4

'-.../

Fuel system with divided supply tank - schematic diagram

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 On helicopters S/N 61 and subsq., a triple fuel quantity indicator indicates the fuel contents of the main tank (M) and both supply tank compartments 1 (S 1) and 2 (S Ir). The low-level warning switches 3EB and 13EB, in compartments 1 (S 1) and 2 (S 11) respectively, are connected in parallel and to warning light 7EB REST. Warning light 7EB REST comes on when energized by one of the fuel low-level warning switches, or when test switch TEST WARNING LIGHT 6EB is pressed. 832 - 2

TROUBLESHOOTING - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

Use wlrlng diagram 832 in the Wiring Diagram Manual (WDM) for troubleshooting the system. No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Fuel pressure indication too low

Pressure transmitter defective

Replace pressure transmitter (refer to Chapter 62)

Pressure indicator defective

Replace pressure indicator (refer to Chapter 91)

Electrical wiring between transmitter and indicator defective

Check continuity of wiring according to wiring diagram; replace any defective wiring (refer to Chapter 91 or 92)

Fuel pump in supply tank defective

Remove fuel pump (refer to paragraph 62-19)

Pressure transmitter defective

Replace pressure transmitter (refer to Chapter 62)

Pressure indicator defective

Replace pressure indicator (refer to Chapter 91)

Fuel filter clogged

Remove fuel filter element (refer to Allison Operation and Maintenance Manual)

2

3

Fuel pressure indication too high

Warning light FILT I or FILT II illuminates

Table 832-1

Troubleshooting

(1 of 2) BO 105 CHAPTER 832 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

4

Warning light REST fails to illuminate although fuel quantity indicator for supply tank shows fuel contents to be less than 60 kg

REST warning light defective

Replace warning light (refer to Chapter 91 or 92)

Low level warning switch defective

Replace low-level warning switch (refer to paragraph 62-22)

Electrical wlrlng between transmitter and instrument defective

Check continuity of wiring according to wiring diagram¡ replace any defective wiring (refer to Chapter 91 or 92)

Fuel quantity transmitter defective

Replace fuel quantity transmitter (refer to para 62-25)

Indicator wrongly adjusted or defective

Check indicator and replace if necessary (refer to Chapter 91)

5

Fuel quantity indicator failed or showing false values

6

Fuel dripping from drain holes in bottom shell

Leaking fuel tank

Replace leaking fuel tank (refer to paras 62-4 to 62-15)

7

Fuel dripping from drain ports of fuel and vent lines in the side shell

Leaking fuel or vent lines

If possible, tighten fuel line connections, otherwise replace fuel lineo Replace vent lines.

8

Fuel dripping from drain valves

Drain valve or gasket defective

Check valve for specified torque. If necessary, replace drain valve and/or gasket (refer to para 62 -16)

9

Fuel dripping from fuel pump access cover

Damaged fuel pump flange or gasket

Remove access cover. Check flange hardware for specified torque. If necessary, replace fuel pump and/or gasket (refer to para 62-19)

Table 832-1 BO 105 CHAPTER 832 Page 6

Troubleshooting

(2 of 2)

EUROCOPTER

832 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (reter to Chapter 101)

CHAPTER 832

Pagel

EUROCOPTER

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 832 Page8

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 832 - 4

INSPECTION FOR CONDITION - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

1.

Check accessible cable connections and electrical connectors for tight and secure fit, and cables for chafe marks. Tighten loose cable connections and connectors, and replace damaged cables.

2.

Check accessible fuel and vent line connections for tight and secure fit, leaks, and damage. a.

Tighten loose lines and replace damaged ones.

b.

Tighten union nuts on leaking lines by 1/6 of a turno If leak persists, replace gasket or line connection as necessary.

c.

If leakage in flange area is evident, tighten relevant flange attaching hardware (2.5 - 3 Nm torque).

3.

Inspect drain holes in bottom shell for leaking fuel. If leakage is evident, perform leakage test according to para 62-43. If the leakage cannot be rectified, remove supply tank (refer to paras 62-4 to 62-15).

4.

Inspect fuel and vent line drain ports in the side shell for leaking fuel. If leakage is evident, tighten appropriate connections or replace affected lines as necessary.

5.

Inspect fuel pump access covers for leaking fuel. Fuel leaking from a cover indicates a leaking fuel pump connection. Unscrew and remove access cover and check pump attaching hardware for specified torque load (see fig. 62-6). If specified torque load is confirmed, replace faulty gasket (see para 62-19).

6.

Inspect drain valve for leaking fuel. If leakage is evident, inspect line connections for specified torque load (see fig. 62-5). If connections are correctly torqued, replace drain valve (refer to para 62-16).

7.

Switch on fuel pumps and inspect fuel filters for security, leakage, and damage (cracks, deformation, chafe marks etc.). (Refer to Al1ison Operation and Maintenance Manual) .

8.

a.

If leakage from filter housing is evident, tighten housing by hand, and replace O-ring if necessary. (Refer to Allison Operation and Maintenance Manual) .

b.

Replace damaged fuel filter. (If an evaluation is required, refer to Allison Operation and Maintenance Manual) .

Visually inspect differential pressure switch, pressure transmitter, and drain valve for leakage. If leakage is evident, check for specified torque; if necessary, replace associated sealing element (O-ring or gasket) .

BO 105 CHAPTER 832 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 832 - 5

FUNCTIONAL CHECK - FUEL SYSTEM WITH DIVIDED SUPPLY TANK

WARNING

o TO PREVENT FIRE ANO EXPLOSION HAZARDS, OBSERVE THE APPLICABLE SAFETY REGULATIONS. o THE HELICOPTER MUST BE GROUNDED DURING THE FUNCTIONAL CHECK.

1.

Remove fuel from fuel tanks (refer to chapter 06).

2.

Remove interior side panels.

3.

Inspect both vent line ports for blockage and, if necessary, clear them.

4.

Refuel the helicopter (refer to Chapter 06) by operating the main tank fuel pumps alternately. Observe that the dual fuel quantity indicator needles on the MAIN and SUPPLY scales indicate that the respective tanks are being filled. In addition, the REST warning light for the supply tank must extinguish as soon as more than 60 kg (75 1) of fuel are in the tank.

5.

After refueling is completed, compare the summation of the individual readings on the MAIN and SUPPLY scales of the dual fuel quantity indicator with the amount of fuel transferred from the refueling vehicle. If the fuel tanks were empty prior to refueling, approx. 8kg (10 1) must be added to the summation of the individual readings because the fuel quantity indicatorshows only the amount of usable fuel in the tanks. Both values should be approximately equal if both fuel tanks are full.

6.

Switch on fuel pumps in the tanks and check that they are running by listening for operating noises.

7.

Functionally check the fuel cocks by moving switches FUEL COCK 1 and 2 from SHUT to OPEN. The fuel cocks must be heard to open. Switch on SUPPLY TANK 1 and 2 fuel pumps. The pressure indication on the instrument panel must be 0.7 bar for both pumps.

8.

Switch off all fuel pumps and close both fuel cocks.

9.

Unscrew the fuel lines in the left and right engine compartments from their respective engine connections. Position a container to catch the fuel spillage and check the fuel lines and both fuel filters for free passage by switching on the supply tank fuel pumps and momentarily opening the fuel cocks. At the sametime, check pressure transmitters and differential pressure switches for leakage. Switch off the fuel pumps and connect the fuel lines to the left and right engines.

BO 105 CHAPTER 832 Page 10

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO lOS 10. Functionally check the three drain valves in the bottorn shell and both drain valves on the fuel filters. Fuel rnust flow out when the valves are pressed upward. The fuel drained frorn the fuel filters rnust flow frorn the respective leakage line in the bottorn shell. 11. Inspect all fuel purnps for correct rnounting, and all connections, flanges, covers and hose connections {or correct assembly, leakage and security. 832 - 6

WARNING

REMOVAL - DIVIDED SUPPLY TANK o TO PREVENT FIRE AND EXPLOSION HAZARDS, OBSERVE THE APPLICABLE SAFETY REGULATIONS. o PURGE THE FUEL TANKS BEFORE REMOVING THEM (REFER TO STEP 3.).

The following tools and rnaterials are required: Screwdriver with chafe protection (for loosening and tightening the tube clarnps within the tanks) Rubber cernent (CM 653) Sealing cornpound (CM 644) Talcurn powder (CM 108) Terrnoflex adhesive tape, SO mm wide 1.

Defuel helicopter according to chapter 06.

2.

Disconnect battery and external power supply (refer to chapter 92).

3.

Purge fuel tanks with air or nitrogen as follows:

4.

a.

Open all drain valves by pushing the valve stern up and then turning it.

b.

Open lid of fuel filler neck and insert hose for delivering the purging agent. Seal filler neck opening with adhesive tape (CM 614).

c.

Purge tank for approx. 2 hours using either filtered, compressed air at 2 - 4 bar or nitrogen at a flow rate of 0.5 kg/min.

d.

Remove delivery hose and wait approx. 1 hour before commencing with the maintenance work.

Rernove cabin interior furnishings e.g., bench seat, pilot/copilot seats, and floor/wall panels.

BO 105 CHAPTER 832 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - = - - - - - - - MAINTENANCE MANUAL MBB - BO 105

5.

Remove tank access cover (2, fig. 832-3) together with attached fuel quantity transmitter (1) and low-level warning switch (9). a.

Unscrew and remove screws attaching fuel quantity transmitter and low-level warning switch to access cover (2).

b.

Disconnect electrical leads from fuel quantity transmitter (1) and low-level warning switch (9).

c.

Remove nuts and washers and detach tank access cover (2) and ring from tank bolt ringo

6.

Remove dump port cover from the lower part of the forward main fuel tank.

7.

Loosen the clamp fastening the fuel line to the access cover (2, fig. 832-2) of the fwd main tank. Then remove the tank cover with attached fuel quantity transmitter (1).

8.

Remove tank cover of aft main tank (refer to chapter 62).

9.

Remove the two fuel pumps installed in both the supply tank and in the fwd main tank.

10. Remove the two drain valves (5, fig. 832-3) in the divided supply tank and the drain valve in the fwd and aft main tanks. 11. Remove access door to control linkage compartment and remove cover and gasket (7) from the front of the supply tank. ') . 1L

Remove side floor panel. attachment screws and remove floor panels. Disconnect fuel lines from left and right outer walls of the supply tank after first removing the bonded rubber sleeves. Remove fuel line from tank bolt ringo

13. Loasen the two hose clamps securing the rubber filler neck of the fwd main tank and the protective sleeve on the fuselage mounted fuel filler neck (refer to chapter 62). 14. Remove the fuel lines in the supply tank and fwd main tank. 15.

Remove the bolts securing the supply tank vent pad ring, both fwd main tank vent pad rings, and the aft main tank vent pad ring to the underside of the floor panel.

16. Unbutton fue1 tanks from underneath the floor panel. Remove floor panel

and access door to small baggage compartment. 17. Remove moulded rubber hose clip covers and hose clips from both overflow pipes connecting the fwd main tank and supply tank with the supply tank. 18. Remove rubber hose clip cover and hose clip from both ends of the pipe

connecting the fwd main tank to aft main tank. 19. Pull supply tank moulded connectors off the overflow pipes and remove

supply tank from tank bay. BO 105

CHAPTER 832 Page 12

- - - - - - - - - - - - - M E B HELlCOPTERS - - - - - - - - - - - - MAlNTENANCE MANUAL MEB - BO 105 20. Remove the fuel line fittings from the bolt rings in the left and right walls of the supply tanks. 21. Pull fwd main tank moulded connectors off the overflow pipes to the supply tank and off the pipe to the aft main tank. Then pull fwd main tank filler neck off fuselage-mounted filler neck and remove fwd main tank from the tank bay. 22. Pull aft main tank moulded connector off the pipe to the fwd main tank and remove aft main tank from the tank bay. 832 - 7

lNSTALLATlON - DlVlDED SUPPLY TANK

1.

Check that all sharp edges, corners, retainers and spreader buttons are covered with strips of protective tape.

2.

lnspect foaming in tank bays for complete coverage and proper adherence to the surfaces.

3.

Clean tank bays and fuselage compartment located above and remove loo se objects.

4.

Check fuel vent lines in floor panels for clear passage and possible leaks.

5.

Check rubber sleeve of fuel filler neck for proper attachment. lf required, rebond it using rubber cement (CM 653) .

6.

Install a fuel line fitting on each of the bolt rings in the left and right walls of the supply tank.

7.

Treat bag tank outer walls with talcum powder (CM 108) and place bag tanks in their respective tank bays in the following manner: - supply tank between frames No. 4 and No. 5 in the bay located forward of the tank dividing wall, - fwd main tank at frame No. 7 in the bay aft of the tank dividing wall, - aft main tank at frame No. 10 in the bay aft of frame No. 9. CAUTlON

8.

AVOlD DAMAGlNG THE FUEL BAG TANKS DURlNG lNSTALLATlON.

Push both supply tank moulded connectors and both fwd main tank forward moulded connectors onto the respective ends of the two overflow pipes located in the wall between these tanks. Then push the fwd main tank aft moulded connector and the aft main tank moulded connector onto the respective ends of inter-tank connecting pipe down in frame 9.

BO 105 CHAPTER 832 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 9.

Install hose clips on each of the six flanges. Tighten hose clips and install hose clip covers on all hose clips.

10. Push fwd main tank filler neck onto pipe of the fuselage-mounted fuel filler neck (overlapping the rim by at least 20 mm). Clamp fwd main tank filler neck and rubber protective sleeve with two hose clips and secure hose clips. 11. Install floor panels and access door to small baggage compartment. Re-button bag tanks to the retainers in the walls of the tank bays and the underside of the floor panel. 12. Bolt fuel tank pad rings to underside of floor panels. 13. Insert the fuel 1ines into the fwd main tank and push the appropriate ends of the fuel lines through the two overflow pipes and into"the supply tank. Secure the fuel lines to the ends of the overflow pipes in the supply tank with clamps. 14. Install two fuel pumps each in the fwd main tank and in the supply tank. 15. Install the two fuel lines in the supply tank between the pumps and the moulded connectors in the tank side walls. Connect the fuel lines in the fwd main tank to the fuel pumps. 16. From within the control linkage compartment, install cover and gasket (7, fig. 832-3) on the front of supply tank. 17. Install the drain valves, two in the supply tank, one each in fwd and aft main tanks. 18. Examine the interior of the bag tanks for foreign matter. 19. Install the fuel tank cover and attached fuel quantity transmitter and low-level warning switch in the supply tank. NOTE

When installing the fuel tank cover be sure dividing wall of fuel supply tank is in its proper place between supporting frames (8) of fuel tank cover.

20. Install fuel tank cover and attached fuel quantity transmitter in the fwd main tank and attach fuel line of rear main tank pump to fuel tank cover. Install dump port cover to lower side of fwd main tank. 21. Install the fuel tank cover to the aft main tank. 22. Connect fuel lines, together with new aluminium gaskets, to outer fittings on the left and right walls of the supply tank and secure with lockwire. Cement rubber sleeves in place on left and right tank walls, using rubber cement (CM 653) and tighten hose clips. 23. Perform functional and lea k testing of the fuel system in accordance with para 832-5 and para 62-43 respectively. BO 105 CHAPTER 832 Page 14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUALMBB - BO 105

DETAlLA

I

800311

I 6

1 2 3 4 5 6

I 7

~

Overflow pipe on S/N 160 and prior

~

Overflow pipe on S/N 161 and subsq.

11

Fuel quantity transmitter Tank access cover Fuel pump Crossfeed line Check valve Hose clip cover Fig. 832-2

7 8 9 10 11 12

Hose clip Overflow pipe Fuel pump Check valve Grornmet Moulded tank connector

Forward main fuel tank BO 105 CHAPTER 832 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS -----~""-------­ MAINTENANCE MANUAL MBB - BO 105

10

11

12

6. 10,11

--

DETAlL

A

&

S/N 16·0 and prior

~

S/N 161 and subsq.

800310

1

2 3

4 5 6

Fuel quantity transmitter Tank access cover Dividing wall Fuel pump Drain valve Fuel line fitting Fig. 832-3

80 105

832 Page 16

CHAPTER

Cover and gasket Support frames 9 Low-level warning switch 10 Hose clip cover 11 Hose clip 12 Grommet 7

8

Divided supply tank

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

833

EXTERNAL LOUDSPEAKER SYSTEM

Table of Contents

Paragraph

Title

833 - 1

DESCRIPTION - EXTERNAL LOUDSPEAKER SYSTEM

3

833 - 2

TROUBLESHOOTING - EXTERNAL LOUDSPEAKER SYSTEM

4

833 - 3

INSPECTION SCHEDULE - EXTERNALLOUDSPEAKER SYSTEM

7

833 - 4

INSPECTION FOR CONDITION - EXTERNAL LOUDSPEAKER SYSTEM

8

833 - 5

FUNCTIONAL CHECK - EXTERNAL LOUDSPEAKER SYSTEM

8

833 - 6

Removal - Loudspeaker .

9

833 - 7

Installation - Loudspeaker

Page

10

BO 105 CHAPTER 833 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 DESCRIPTION - EXTERNAL LOUDSPEAKER SYSTEM

833 - 1 1. General

The external loudspeaker system, which is operated with a hand-held microphone or a headset-microphone, serves to broadcast messages at a sufficient loudness level. It is mounted by a bracket either between the forward and aft crosstubes or directly to the aft crosstube, according to the configuration. 2.

Description The external loudspeaker system consists mainly of the following components: -

3.

2 1 1 1 1 1

speakers 6TD, 7TD (450W) microphone 5TD control unit 3TD (for volume control) with preamplifier VV450 amplifier 4TD relay 2TD circuit breaker 1TD

Operation The external loudspeaker system is supplied with dc voltage from auxiliary bus PP22 and is protected by circuit breaker 1TD. The circuit for relay 2TD is protected by fuse Sil (or fuse 9TD in configuration 11) in control mit 3TD. The external loudspeaker system can be operated through: - headset-microphone - hand-held microphone The hand-held microphone has priority over the headset microphone when the press-to-talk switch is actuated. If ground-based transmissions between a cornrnand center and several mobile stations are obstructed, the helicopter can be used to relay messages between them without affecting intercornrnunication between pilot and copiloto

BO 105 CHAPTER 833 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 833 - 2

TROUBLESHOOTING - EXTERNAL LOUDSPEAKER SYSTEM

General Refer to the following wiring diagrams in the wiring Diagram Manual (WDM) :

Configuration 1: 833-1 Configuration 11: 833-2 Where possible, check that all associated electrical connections are tight and secure. Functionally check circuit breaker SPEAKER 1TD and other system switches. Connect external power (EPU) and set battery switch 16P on instrument panel to BATT OFF/EPU ON: Depress circuit breaker SPEAKER. No.

TROUBLE SYMPTOM

PROBABLE CAUSE

1

The loudspeaker system does not operate via hand-held or headset microphone

Defective circuit breaker Check circuit breaker 1TD for continuity and connections for proper contacto Replace defective parts Defective fuse 9TD (configuration 11 only)

Check fuse for continuity. Replace if defective

Defective fuse Sil in control unit 3TD

Check fuse for continuity. Replace if defecti ve

Defective toggle switch SI in control unit 3TD

Inspect toggle switch for continuity and connections for proper contacto Replace defective parts

Defective relay 2TO

Check relay for voltage between pins Al and X2.· RepIace relay if no voltage is present

TabIe 833-1

BO 105 CHAPTER 833 Page 4

CORRECTIVE ACTION

Troubleshooting (1 of 3)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued)

No.

2

3

4

TROUBLE SYMPTOM

No sound is broadcast through loudspeaker system via headset microphone

No sound is broadcast through loudspeaker via hand-held microphone Sound broadcast through one speaker only

PROBABLE CAUSE

CORRECTlVE ACTION

One or more defective fuses (Si101, Si102, Sil03) in final amplifier 4TD

Check fuses for continuity. Replace defective fuses

Defective preamplifier 3TD

Replace preamplifier

Defective final amplifier 4TD

Replace final amplifier

Defective wiring

Check wiring for continuity using relevant wiring diagram repair or replace defective parts

Defective press-to-talk switch on corresponding cyclic pitch stick

Check press-to-talk switch and replace as necessary

Defective headset microphone

Replace headset

Defective station box

Replace affected station box

Refer to item no. 1

Refer to item no. 1

Defective press-to-talk switch in hand-held microphone or hand-held microphone defective

Check press-to-talk switch and, if necessary, replace hand-held microphone

Refer to item no. 1

Refer to item no. 1

Defective loudspeaker, final stage fuse, or final stage

Reverse connectors 4TDc and TDd in speaker outputs of final amplifier 4TD

Table 833-1

Troubleshooting (2 of 3) 80 105 CHAPTER 833 Page 5

- - - - - - - - - - - - - MBB HELICOPTERS -------=-------MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION - After connector reversal, sound is only broadcast through the other speaker: Check fuses Si10l and Si103 in final amplifier 4TD and replace as necessary Replace final amplifier if fuses are intact - After connector reversal, sound is only broadcast through the same speaker: Replace inoperative speaker

5

6

Scratched or distorted transrnission

Scratch noises occur when the audio level control is operated

Defective speaker membrane

Replace speaker

Magnetic slot of one of the speakers defective

Clean magnetic slot

Defective slide-actuated Replace potentiometer potentiometer in preamplifier 3TD

Table 833-1

BO 105 CHAPTER 833 Page 6

Troubleshooting (3 of 3)

EUROCOPTER

833 - 3

Revision 18

MAINTENANCE MANUAL 60 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 833

Page7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSPECTION FOR CONDITION - EXTERNAL LOUDSPEAKER SYSTEM

833 - 4 1.

Inspect speaker (5, fig. 833-2) or (7, fig. 833-1) and bracket for cracks, deformation, other mechanical damage, corros ion, damaged surface protection and security of installation. a.

Replace bracket if cracked or deformed.

b.

Polish out other mechanical damage, corros ion and damaged surface protection with 400 grit abrasive cloth. After applying wash primer (CM 423), touch up surface with single-layer lacquer (CM 403).

c.

Tighten loose attaching hardware.

2.

Repair or replace damaged electrical cables.

3.

Inspect electrical connectors for condition and tightness. Replace damaged parts and tighten loosen connectors.

4.

Replace missing or damaged lockwires.

833 - 5

FUNCTIONAL CHECK - EXTERNAL LOUDSPEAKER SYSTEM

1.

Connect external power supply and select battery switch 16P on right side of instrument panel to BATT OFF/EPU ON.

2.

Depress circuit breakers SPEAKER, NAV 1 and NAV 2.

3.

Depress circuit breaker for pilot/copilot station box.

4.

Set audio level control to O and toggle switch Sl on control unit 3TD to ON. NOTE

During speech testing, operate the audio level control slowly to avoid feedback at high audio volume.

5.

Broadcast through the loudspeaker system by speaking into the hand-held microphone whilst slowly operating the audio level control on control unit 3TD to monitor the sound.

6.

Set transmission mode selector switch of pilot's station box to L/S (loudspeaker).

7.

Press pilot's cyclic-mounted press-to-talk switCh and broadcast through the loudspeaker system from the pilot's headset microphone. While doing this, monitor the sound by slowly operating the audio level switch from side to side.

8.

If the copilot's station box is installed, repeat steps 6. and 7 using copilot's controls.

9.

Set toggle switch Sl on control unit 3TD to OFF. Pull circuit breaker SPEAKER and pilot/copilot station box circuit breaker.

BO 105 CHAPTER 833 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Removal - Loudspeaker

833 - 6 1.

2.

Configuration I - loudspeaker installation on aft crosstube (see fig. 833-1) a.

Remove electrical connector (9) from airframe-mounted receptacle; blank off receptacle with protective cap (8).

b.

Mark installed position of clamps (2).

c.

Have someone support the speaker during removal procedure.

d.

Remove hardware (4 thru 6) attaching speaker mounting support to clamps.

e.

Remove loudspeaker (7) and attached mounting support (1).

f.

Remove attaching hardware (4 thru 6) from lower end of clamps (2) and remove clamps (2).

g.

If required, remove screws to detach mounting support (1) from speaker.

Configuration Ir - loudspeaker installation between crosstubes (see fig. 833-2) . a.

Disconnect electrical connectors (4 and 10) from receptacles on speaker and airframe.

b.

Loosen screws (7) in plier-shaped clamping jaws (8).

c.

Slide speaker along lateral strut (9) until the pin of pin plate (11) disengages from the hole in the semi-circular tilt adjustment plate (9) on end of strut.

d.

Remove screws (7i and pry open the clamping jaws to remove the speaker. Unscrew and remove pin plateo

e.

Remqve speaker mounting tube as follows: 1)

Remove inner hardware attaching mounting tube (6) to the clamps (14) on both crosstubes.

2)

Remove c1amps (14) from the crosstubes by removing the outer attaching hardware (15); remove and discard adhesive tape.

BO 105 CHAPTER 833 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - = - - - - - - MAINTENANCE MANUAL MBB - BO 105 Installation - Loudspeaker

833 - 7 1.

Configuration 1 - loudspeaker installation on aft crosstube (see fig. 833-1) . a.

If previously removed, install mounting support (1) on speaker (7) with two screws (4), washers (5) and nuts (6).

b.

Take care to fit the clamps (2) at the crosstube positions marked upon removal, using laminated shim (3) as necessary. For the time being, attach the clamps to the crosstube by installing screws (4), washers (5) and nuts (6) in the holes in the lower end of the clamps

c.

Have someone hold the speaker mounting support (1) in position between the upper holes of the clamps (2), then install the upper screws (4), washers (5) and nuts (6) and handtighten them.

d.

Orient speaker to direct sound in the desired direction. Alternately torquetighten top and bottom screws (4).

e.

Remove protective cap (8) from receptacle and reconnect electrical.

f.

Perform functional check in accordance with para 833-5.

(2) .

2.

Configuration 11 - loudspeaker installation between crosstubes (see fig. 833-2) . a.

If previously removed, install speaker mounting tube as follows: 1)

Apply adhesive tape to clamp (14) attachment areas on the forward and aft crosstubes.

2)

Fit both halves of each clamp in place on the forward and aft crosstubes and install the outer clamp attaching hardware (15) without tightening at this time.

3)

Fit the loudspeaker mounting tube (6) between the clamp halves on the forward and aft crosstubes and install and tighten the inner clamp attaching hardware (13) on each crosstube. Tighten the outer clamp attaching hardware.

b.

Install pin plate (11), with pin facing semi-circular plate, on clamping jaws (8) with screws.

c.

From below, fit speaker (5) by its open clamping jaws to the lateral strut (9) of the mounting tube and attach loosely with screws (7).

d.

Tilt speaker to the desired angle of elevation (28°, 38°, or 48°) and insert pin of pin plate in the corresponding hole in the semicircular tilt adjustment plate (9).

e.

Tighten clamping jaw attachment screws (7).

f.

Remove caps from receptacles and install electrical connectors (4 and 10) and lockwire.

BO 105 CHAPTER 833 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

9

800299

DETAlL

A

Fig. 833-1

1 Mounting support 2 Clamp 3 Laminated shim 4 Screw 5 Washer 6 Nut 7 Loudspeaker 8 Protective cap 9 Electrical connector

External loudspeaker system (configuration 1) BO 105 CHAPTER 833 Page 11/12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A

_---2

,11,

'-10

3

6

--=--::

..... ,--

DETAlL

B

14

1 2 3 4 5 6 7 8 15

110-14 Nm

I

800301,

Fig. 833-2

External loudspeaker systern (configuration

Ir)

BO 105 CHAPTER 833

Page 13/14

Amplifier Control unit Circuit breaker Electrical connector Loudspeaker Mouting tube Screw Clamping jaws

9 Lateral strut with tilt adjustment plate Electrical connector Pin plate 12 Screw 13 Attaching hardware 14 Clamp 15 Attaching hardware 10 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 834

EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

Table of Contents Paragraph

Title

834 - 1

DESCRIPTION - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

3

834 - 2

TROUBLESHOOTING - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

5

834 - 3

INSPECTION SCHEDULE - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

8

834 - 4

INSPECTION FOR CONDITION - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

9

834 - 5

FUNCTIONAL CHECK - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

9

834 - 6

Removal - loudspeaker

10

834 - 7

Installation - loudspeaker

11

834 - 8

Removal - amplifier

11

834 - 9

Insta11ation - amplifier

12

Page

BO 105 CHAPTER 834 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 834 - 1

DESCRIPTION - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

1. General The integrated loudspeaker system is installed in the helicopter fuselage between frames 4V and 3B. It is used by the helicopter crew to broadcast messages at a sufficient loudness level. 2. Description The system consists of the following components: -

2 1 1 1 1 1 1

loudspeakers 6TD, 7TD (450 W) microphone STD control unit 3TD (controls volume) with preamplifier VV4S0 amplifier 4TD relay 2TD circuit breaker 1TD fuse 9TD

3. Operation The external loudspeaker system is supplied with dc voltage from auxiliary bus PP22 and is protected by circuit breaker 1TD and fuse 9TD in control unit 2VE. Heatset-microphone and hand-held microphone are connected to the pilot/copilot junction box or to the control unit. Switch Sl is selected to ON and energizes relay 2TD, activating amplifier 4TD. Then four-position selector switch on control unit is set to L/S. If the toggle switch on the junction box is selected to L/S-FMI, all on-board mirophones may be operated, with circuit switching giving the hand-held microphone priority over the headset-microphone. Setting the toggle switch to ON enables the loudspeaker system to be operated from a ground station using the helicopter as a relay station.

BO 105 CHAPTER 834 Page 3

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

r=T~:::;!'-

2

~~~~1Jr-1

4

4

800160

Amplifier Control unit Circuit breaker 4 Loudspeaker

1 2 3

Fig. 834-1

BO 105 CHAPTER 834 Page 4

External loudspeaker system BO 105 S

- - - - - - - - - - - - - M B B HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 834 - 2

TROUBLESHOOTING - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

General Troubleshoot in conjunction with wiring diagram 834-1 in the Wiring Diagram Manual (WDM). -

Where possible, check that all associated electrical connections are tight and secure. Functionally check circuit breaker SPEAKER 1TD and other system switches. Connect external power supply (EPU) and select battery switch 16P on instrument panel to BATT OFF/EPU ON. Depress circuit breaker SPEAKER.

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECT1VE ACT10N

1

The loudspeaker system does not operate via hand-held or headset-microphones

Defective circuit breaker 1TD

Check circuit breaker for continuity and connections for proper contacto Replace defective parts

Defective fuse 9TD (configuration I1 only)

Check fuse for continuity. Replace if defective

Defective fuse Sil in control unit 3TD

Check fuse for continuity. Replace if defective

Defective toggle switch Sl in control unit 3TD

1nspect toggle switch for continuity and connections for proper contacto Replace defective parts

Defective relay 2TD

Check relay for voltage between pins Al and X2. Replace relay if no voltage is present

Table 834-1

Troubleshooting (1 of 3)

BO 105 CHAPTER 834 Page 5

- - - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - ' - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) NO.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

One or more defective fuses (Si 101, Si 102, Si 103) in final amplifier 4TD

Check fuses for continuity. Replace defective fuses

Defective preamplifier 3TD

Replace preamplifier

Defective final amplifier Replace final amplifier 4TD

2

3

4

No broadcasting through loudspeaker system from headset microphone

No broadcasting through loudspeaker system from hand-held microphone

Broadcasting from one speaker only

Defective wiring

Check wiring for continuity using relevant wiring diagram. Repair or replace defective parts

Defective press-to-talk on corresponding cyclic pitch stick

Check press-to talk switch and replace as necessary

Defective headset microphone

Replace headset

Defective station box

Replace affected station box

Refer to item no. 1

Refer to item no. 1

Defective press-to-talk switch in hand-held microphone or hand-held microphone defective

Check press-to-talk switch and, if necessary, replace hand-held.microphone

Refer to item no. 1

Refer to item no. 1

Defective loudspeaker, final stage fuse or final stage

Reverse connector 4TDc and TDd in speaker outputs on final amplifier 4TD

Table 834-1

BO 105 CHAPTER 834 Page 6

Troubleshooting (2 of 3)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued)

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION -

After connector reversal, broadcasting frorn other speaker only: Check fuses Si 101 and Si 103 in final amplifier 4TD and replace as necessary. Replace final amplifier if fuses are intact Broadcast frorn same speaker after connector reversal: Replace inoperative speaker

5

6

Scratched or distorted transrnission

Scratch noises occur when the audio level control is operated

Defective speaker membrane

Replace speaker

Magnetic slot of one of the speakers defective

Clean magnetic slot

Defective slide-actuated Replace potentiometer potentiometer in preamplifier 3TD

Table 834-1

Troubleshooting (3 of 3)

BO 105 CHAPTER 834 Page 7

EUROCOPTER

• 834 - 3

MAINTENANCE MANUAL 80105

INSPECTION SCHEDULE (reter to Chapter 101)

CHAPTER 834 Page 8

Revision 18

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 834 - 4

INSPECTION FOR CONDITION - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

l. Pull circuit breaker lTD and unscrew and remove fuse 9TD froro instrument panel. 2. Remove turnlock fasteners and cover (4, fig. 834-2). Unscrew right and left fairings (6) and remove thero downward froro the airfrarne. 3. Inspect loudspeaker (7) and mounting bracket for cracks, de format ion, other mechanical darnage, corrosion,darnaged surface protection, ahd security of installation. a.

Replace mounting bracket if cracked or deformed.

b.

Polish out roechanical darnage, corrosion, and darnage to surface protection using 400 grit abrasive cloth. After applying wash primer (CM 423), touch up with single-layer lacquer (CM 407).

c.

Tighten loose attaching hardware.

4. Repair or replace darnaged electrical cable. 5. Inspect electrical connections for condition and security; replace damaged parts and tighten loose connector. 6. Replace rnissing or darnaged lockwires. 7. Inspect amplifier (2) for security of installation; tighten loose attaching hardware as necessary. 8. Inspect prearnplifier for security of installation, tighten loose attaching hardware as necessary. 834 - 5

FUNCTIONAL CHECK - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

l. Connect external power supply (EPU) and select battery switch l6P on instrument panel to BATT OFF / EPU ON. 2. Press circuit breaker SPEAKER on instrument panel; press circuit breaker on pilot/copilot station box. 3. Select toggle switch Sl on control unit 3TD to ON; reset volume control to O. 4. Move selector switch on control unit to L/S.

BO 105 CHAPTER 834 Page 9

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

5.

Connect headset-microphone and hand-held microphone.

6.

Broadcast through the loudspeaker system by speaking into the hand-held microphone. At the same time, turn up the volume at the volume control.

7.

Move toggle switch in junction box to L/S-FMI.

8.

Press press-to-talk button on cyclic stick and make a test broadcast via the headset-microphone.

9.

Verify priority of the hand-held microphone by simultaneously pressing the press-to-talk buttons of the hand-held microphone and the headset-microphone.

10.

Switch off control unit 3TD and pull circuit breaker SPEAKER and circuit breaker on pilot/copilot station box.

834 - 6

Removal - loudspeaker

l.

Pull circuit breaker lTD and unscrew and remove fuse 9TD on instrument panel.

2.

Remove turn lock fasteners and cover (4, fig. 834-2). Unscrew right and left fairings (6) and remove them downward from the airframe.

3.

Disconnect angle connectors (8 and 6, fig. 834-3) of right and left loudspeaker from amplifier (1).

4.

Unscrew bonding jumpers (4 and 5) from mounting bracket; disconnect electrical lead from anti-collision light (5, fig. 834-2).

5.

Remove clamps (10, fig. 834-3) from mounting bracket. Remove four screws (1, fig. 834-2) from each loudspeaker and remove loudspeaker.

BO 105 CHAPTER 834 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 834 - 7

Installation - loudspeaker

Install loudspeaker in reverse order of removal .

.,....,.,....+-+--2

I 6

5

4

800161

Screw 2 Amplifier 4TD 3 Cover 4 Cover 5 Anti-collision light 6 Fairing 7 Loudspeaker 1

Fig. 834-2 834 - 8

Removal and installation - loudspeaker

Removal - amplifier

1. Pull circuit breaker 1TD and unscrew and remove fuse 9TD. 2. Remove turnlock fasteners and cover (4, fig. 834-2). 3. Disconnect electrical lead from anti-collision light (5) and disconnect angle connectors (6, 7 and 8, fig. 834-3) from amplifier (1); unscrew and remove bonding jumper (9). 4. Remove four screws from cover (2) and two screws (11) from mounting bracket. Remove cover by pulling downward and carefully pull amplifier out of mounting bracket. BO 105 CHAPTER 834 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 834 - 9

Installation - amplifier

Install amplifier in reverse order to rernoval.

4

I

,

5

~~::~jt~'--'-:~¡=:J'==-==='==~'-'-'-T /

/ -./'

800162

3

"8 '0 9

6 7

/

" 2

'0

3

Amplifier 2 Cover 3 Loudspeaker 4 Bonding jumper RH 5 Bonding jumper LH 6 Angle connector LH 7 Angle connector (amplifier) 8 Angle connector RH 9 Bonding jumper (amplifier) 10 Clamps 11 Screws (rnounting bracket)

1

Fig. 834-3

BO 105 CHAPTER 834 Page 12

Rernoval and installation - amplifier

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

835

SAFETY HARNESS (WINCH OPERATOR)

Table of Contents

Page

Paragraph

Title

835 - 1

DESCRIPTION - SAFETY HARNESS

3

835 - 2

INSPECTION SCHEDULE - SAFETY HARNESS

4

835 - 3

INSPECTION FOR CONDITION - SAFETY HARNESS

5

835 - 4

REMOVAL - SAFETY HARNESS FLOOR FITTING

5

835 - 5

INSTALLATION - SAFETY HARNESS FLOOR FITTING

5

BO 105 CHAPTER 835 Page 1/2

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

835 - 1 l.

DESCRIPTION - SAFETY HARNESS

General The safety harness is attached by means of a snap hook to a fitting on the cabin floor behind the pilot's seat, and is used to secure someone working in the cabin (e.g. winch operator) when the door is open during hover flight.

2.

Construction The safety harness is of a type used by mountaineers and consists of a number of strong webbed straps which can be adjusted tofit the wearer. It includes a connecting strap, adjustable in length and made from the same material with a snap hook on each end for attaching to a ring fitting on the back, to the harness and to a lug fitting in the cabin floor.

BO 105 CHAPTER 835 Page 3

EUROCOPTER

• 835 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 835 Page4

Revision 18

EUROCOPTER

835 - 3

MAINTENANCE MANUAL BO 105

INSPECTION FOR CONDITION - SAFETV HARNESS

1. Inspect safety harness for worn condition, loose stitching and deterioration, especially at stitches and areas where webbing contacts attachment rings, lug fittings and buckles. 2.

Inspect rings, lug fittings and buckles for deformation and other damage.

3.

Repair harness assembly according to manufacturer's (Fa. Auto-Flug GmbH, 25462 Rellingen, IndustriestraBe 10)

835 - 4

REMOVAL - SAFETV HARNESS FLOOR FITTING

1. Bend open tab washer (2, fig. 835-1). 2. Remove hex screw (1) attaching tab washer, lug fitting (3) and spring pin (4) to cabin floor. 3.

Discard tab washer.

NOTE

835 - 5

If harness lug fitting is not required after removal, replace with a tiEH:lown ringo

INSTALLATION - SAFETV HARNESS FLOOR FITTING

1. Insert spring pin (4, fig. 835-1) into its mating bore in the cabin floor. 2. Fit lug fitting (3) then tab washer (2) into installed position ans screw in hex screw (1). For specified torque value refer to fig. 835-1. 3. Secure by bending up tab washer (2).

Revision 18

CHAPTER 835 Page5

I

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlLA

135-40 Nm I

2----~

3----'~

4---r-J.~n

DETAILB 800296

1 Hex screw 2 Tab washer 3 Lug fitting 4 Spring pin 5 Cabin floor Fig. 835-1 BO 105 CHAPTER 835 Page 6

Removal and installation - safety harness floor fitting

eeurocopter

MAINTENANCE MANUAL SO 105

_anEAOO~

836 RESCUE WINCH Table of Contents

Paragraph Title

.' .........

Page

836-1

DESCRIPTION - RESCUE HOIST ASSEMBLY

3

836-2

TROUBLESHOOTING - RESCUE HOIST ASSEMBLY

7

836-3

INSPECTION FOR CONDITION - RESCUE HOIST ASSEMBLY

13

836-3A

INSPECTION - WINCH UNIT

14A

836-3K

INSPECTION FOR CONDITION RELAY BOX - RELAY BOX 23VE . . . . . . . . . . . . . . . .

14A •

836-4

FUNCTIONAL TEST - RESCUE HOIST ASSEMBLY

15

836-5

CABLE INSPECTION - RESCUE HOIST ASSEMBLY

19

836-6

Winch boom assembly

23

836-7

Cleaning - winch boom assembly

24

836-8

Removal - winch boom assembly

24

836-9

Storage and transport - winch boom assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

836 -10

Disassembly - winch boom assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

836 - 11

Inspection and repair - winch boom assembly

33

836 -12

Assembly - winch boom assembly

37

836 -13

Installation - winch boom assembly

836 -14

Hook/bumper assembly

39

836 -15

Flushing - hook/bumper assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

836 -16

Removal - hook/bumper assembly

41

836 - 17

Disassembly - hook/bumper assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

836 -18

Inspection and repair - hook/bumper assembly

44

836 -19

Assembly - hook/bumper assembly

46

836 - 20

Installation - hook/bumper assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

Revision 25

"

38

CHAPTER 836 Page 1

Aeurocopter ~ lIf'l

MAINTENANCE MANUAL BO 10S

EAOS Compomy

Paragraph Title

•

-

Page

836- 21

Winch unit

836 - 22

Lubrication - winch unit

.

48

836 - 23

Removal - winch unit

.

49

836- 24

Inspection and repair - winch unit

.

51

836 - 25

Installation - winch unit

.

51

836 - 25A

REPLACEMENT - Printed ciruit card 20MF

.

51

836-26

Winch motor

.

52

836 - 27

Removal - winch motor

.

52

836 - 28

Inspection and repair - winch motor

.

52

836 - 29

Installation - winch motor

.

53

836- 30

Cartridge

.

54

836 - 31

Removal - cartridge

.

54

836 - 32

Installation - cartridge

.

54

836-33

Servo motor

.

55

836 - 34

Removal - servo motor

.

55

836 - 35

Inspection and repair - servo motor

.

55

836 - 36

Installation - servo motor

.

57

836- 37

Mounting fittings

.

58

836 - 38

Removal - mounting tittings

.

58

836 - 39

Inspection and repair - mounting tittings

.

58

836 - 40

Installation - mounting tittings

.

59

836 - 41

Cable Exchange

.

61

836-42

INSPECTION SCHEDULE - RESCUE HOIST ASSEMBLY

.

73

48

-

,-.

CHAPTER 836 Page 2

Revision 25

_eurocopter 836 -1

MAINTENANCE MANUAL BO 105

DESCRIPTION - RESCUE HOIST ASSEMBLY

1. Rescue hoist. The rescue hoist consists of winch boom assy (14, figure 83~ 1), control elements, mounting • fittings and safety harness (refer to chapter 835). 2. Winch boom assy. The winch boom assy consists of boom (9), winch unit (8), hooklbumper assy (7), relay box (11), protective resistor (10), for!< lever (12), servo motor (13) and bearing support (17). a. Winch unit (8). The winch unit is the hoisting gear of the rescue hoist. The winch unit consists of winch motor including holding brake, gearbox including friction clutch, cable guide rollers, cable tension rollers and cable cutter. 1) Winch motor including holding brake. The OC reversible motor drives the cable drum via the gearbox. The motor is provided with on electro-magnetic disk brake. The winding of the holding brake is connected in parallel to the field winding of the motor. The brake is released as soon as there is a voltage on the motor. The brake is engaged by spring force as soon as the power supply to the motor is switched off. The high-speed motor takes a few revolutions to slow down to standstill as a result of its kinetic energy. This results in cable overtravel. 2) Gearbox including friction clutch. The gearbox consists of one spur gear and two planetary gear stages. The friction clutch is located between the spur gear and the first planetary gear stage. The friction clutch Iimits the pull to approximately 3600 to 4500 N. • 3) Cable guide rollers. The cable drum accommodates a cable of 30 m length in 5 layers. The cable guidance mechanism ensures that the cable is wound up properly in even layers. Two cable guide rollers control the reciprocating cable movements parallel to the drum axis via level wind pino The cable drum drives the cable guide rollers. 4) Cable tension rollers. The cable tension rollers tauten the cable on the cable drum. The cable tension mechanism consists of two tension rollers coated with plasticsand a rachet clutch. a) Reel-out of cable. The cable drum drives the two cable tension ro11ers via a single-acting clutch. The cable tension rollers are driven at a higher speed than the cable drum in order to tauten the cable.

Revision 22

CHAPTER 836 Page3

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 b)

3.

Reel-in of cable. During reel-in operation the clutch disengages the cable tension rollers from the drive. The rollers are dragged by the cable against the brake resistance of the clutch in order to tauten the cable.

5)

Cable cutter. In an emergency the cable can be cut with an electrically primed charge.

6)

Limit switch DOWN. Lirnit switch DOWN is redundant. After the automatic switch-off is initiated by lirnit switch STAGE 1, approximately 6 cable turns remain on the cable drum. If lirnit switch STAGE 1 fails, limit switch STAGE 2 is actuated 3 cable turns latero The remaining three cable turns on the drum ensure sufficient frictional engagement of cable relative to drum.

b.

Hook/bumper assy (7). The hook is supportedby a ball bearing in the bumper assy. Thus the load can be rotated without twisting of the cable. The stop plate of the bumper assy actuates limit switch UP. Following the switch-off, the cable runs on briefly (cable overtravel). The cable lifts spring plate (25, figure 836-13) resulting in a compression of the bumper springs. The spring tension keeps the cable taut on the cable drum when the winch unit is out of operation and prevents pendulum motions of the hook/bumper assy.

c.

Fork lever (12, figure 836-1) and bearing support (17). The winch boom is pivoted in bearing support and fork lever. The boom is extended and retracted by servo motor (13). Tolerances in height of the fuselage can be compensated by adjusting screw (14, figure 836-8) located inside the bearing support.

d.

Servo motor (13, figure 836-1). The servo motor is a double field motor with one retract coil and one extend coil. Two limit switches on the motor limit the travel range to approximately 65°. The time required for one full travel is approximately 15 seconds.

Control and monitoring system. a.

On helicopters up to S/N 160 no rescue hoist operation is possible if one of the two generators fails. The cable cutter remains operational.

b.

Indicator light WINCH on the instrument panel (1) indicates that the system is operational. Circuit breaker WINCH must be pushed and switch WINCH on overhead panel (4) must be in position ON. The 4 kW heating (optinal equipment) is automatically switched off.

BO 105 CHAPTER 836 Page 4

EUROCOPTER

4.

MAINTENANCE MANUAL 80 105

c.

Indicator light CABLE CUTTER indicates the operational status of the cable cutter. Circuit breaker CABLE CUTTER must be pushed, switch CABLE CUTTER TEST must be pushed, cartrige must be installed and winch control grip must be connected to overhead panel.

d.

The rescue hoist is controlled by switch WINCH on winch control grip (5) or by switch WINCH on collective stick (2). Switch WINCH on collective stick overrides switch WINCH on winch control grip.

e.

The cable cutter is actuated by switch CABLE CUTTER on collective stick or by switch CABLE CUTTER on winch control grip.

Power supply and fuse protection. a.

The winch motor is supplied with electrical power from starter bus PPl via fuse 3MF in main relay box (6).

b.

The servo motor on helicopters S/N 1 to 160 is supplied with electrical power from auxiliary bus PP22 via circuit breaker WINCH on the instrument panel.

c.

The servo motor on helicopters S/N 161 and subsequent is supplied with electrical power from main bus PP21 via circuit breaker WINCH on the instrument panel.

d.

The cable cut ter is supplied with electrical power from emergency/ main bus PP20/21 via circuit breaker CABLE CUTTER on the instrument panel.

e.

The winch control unit is supplied with electrical power from circuit breaker WINCH via fuse 24MF.

f.

Lamp test circuit WINCH is supplied with electrical power from circuit breaker WINCH on the instrument panel via fu se 2SMF.

g.

Circuit board 20MF in relay box 23VE (11) is supplied with electrical power from fu se 3MF in main relay box.

BO 105 CHAPTER 836 Page 5

MAINTENANCE MANUAL BO 105

EUROCOPTER

2

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Figure 836-1 BO 105 CHAPTER 836 Page 6

.. .... ./

& &

Rescue hoist assy, fixed installation p/N D134-358 (Exterior feature: rocker switch on collective stick) Rescue hoist assy, fixed installation p/N 105-B1106 (Exterior feature: fourway switch on collective stick)

Rescue hoist

Revision 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 836 - 2

TROUBLESHOOTING - RESCUE HOIST ASSEMBLY

General Perform troubleshooting in conjunction with w1r1ng diagrams 836-1 thru 836-4 in the Wiring Diagram Manual (WDM). Two block diagrams included at the end of this paragraph provide a general surrey of the electrical system. Check all associated switches and circuit breakers for unimpaired mechanical functioning. If heater is installed, set HEATER switch to OFF. Power for troubleshooting may only be provided by either an external power source (EPU) or by running the engines and operating the generators. Refer to Chapter 92 for EPU engag~ment procedure. Depress 1MF and 2MF circuit breakers.

PROBABLE CAUSE

NO.

TROUBLE SYMPTOM

1

Lamp defective Indicator light WINCH (18MF) does not go on after setting Fuse WINCH (24MF) switch WINCH (4MF) defective to ON

2

Indicator light CABLE CUTTER TEST (7MF) does not go on after pushing test switch CABLE CUTTER TEST (SMF)

CORRECTIVE ACTION Push-to-test lampo Replace defective lampo Replace defective fuse.

Switch WINCH (4MF) defective

Check switch WINCH. Replace defective switch.

Electrical line defective

Check electrical lineo Replace defective lineo

Lamp defective

Push-to-test lampo Replace defectiye lampo

Winch control grip not installed

Connect winch control grip to connector on overhead panel.

Switch WINCH (4MF) defective

Check switch WINCH. Replace defective switch.

Table 836-1

Troubleshooting (1 of 4)

BO 105 CHAPTER 836 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 TROUBLESHOOTING - RESCUE HOIST ASSEMBLY NO.

3

TROUBLE SYMPTOM

Winch boom cannot be extended or retracted

(Continuation)

PROBABLE CAUSE

CORRECTIVE ACTION

Cartridge not installed

Install cartridge (refer to paragraph 836-32).

Switch CABLE CUTTER TEST (SMF) defective

Check switch CABLE CUTTER TEST. Replace defective switch.

Electrical line defective

Check electrical lineo Replace defective lineo

Switch WINCH (14MF) on winch control grip or switch WINCH (12MF or 11MF) on collective stick defective

Check switches: Replace defective switch.

Control plate (33MF) Check control plate: or relay panel (36VE) Disconnect electrical connector (33MFA). Operdefective ate switch WINCH on collective stick. There must be 28 V at Al (EXTEND) and at A3 (RETRACT). Replace defective control plateo Subsequently test rescue hoist for function (refer to paragraph 836-4). Check relay panel: Operate switch WINCH on collective stick. There must be 28 V at point 1 (EXTEND) and at point 3 (RETRACT) of terminal junction (18SVV). Replace defective relay panel. Subsequently test rescue hoist for function (refer to paragraph 836-4) .

Table 836-1

BO 105 CHAPTER 836 Page 8

Troub1eshooting (2 oí 4)

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING - RESCUE HOIST ASSEMBLY NO.

TROUBLE SYMPTOM

(Continuation)

PROBABLE CAUSE

CORRECTIVE ACTION

Servo motor defective Check servo motor: Disconnect electrical connector (16MFa) from servo motor. Operate switch WINCH on collective stick. There must be 28 V at point J of the connector (RETRACT) and at point K (EXTEND). Replace defective servo ,motor (refer to paragraph 836-33) . Electrical line defective

Check electrical line for continuity. Replace defective line.

4

Servo motor of winch boom does not switch off in end position

Limit switch of servo motor defective

Send servo motor to manufacturer for repair.

5

Cable cannot be reeled in or reeled out

Switch WINCH (14MF) or switch WINCH (12MF or llMF) defective

Check switches. Replace defective switch.

Winch motor defective Measure voltage on winch motor (connector 17MFa, point A+ and G-) . Check thermo switch (receptacle 17MFA, point E and D) . Check limit switch UP (receptacle l7MFB, point A and F). Check limit switch DOWN (receptacle l7MFB, point C and D). Replace defective winch motor (see paragraph 836-26) .

Table 836-1

Troubleshooting (3 of 4) BO 105 CHAPTER 836 Page 9

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING - RESCUE HOIST ASSEMBLY NO.

TROUBLE SYMPTOM

(Continuation)

PROBABLE CAUSE

CORRECTIVE ACTION

Relay box (23VE) defective

Check fuse or circuit breaker (22MF). Replace defective fuse or push circuit breaker. Check relay for function. Replace defective relay. Subsequently test rescue hoist for function (refer to paragraph 836-4) .

6

7

The red cable marking protrudes more than 1.1 m out of winch unit following automatic switch-off DOWN

Circuit board (20MF) in relay box (23VE) defective

Replace printed circuit board. Subsequently test rescue hoist for function (refer to paragraph 836-4) .

Limit switch DOWN STAGE 1 defective or not properly set

Check limit switch. Limit switch must be repaired by MEB exclusively.

Magnetic brake of winch motor defective

Magnetic brake must be repaired by MEB exclusively.

Circuit board (20MF) defective resulting in delayed actuation of holding brake

Replace circuit board. Subsequently test rescue hoist for function (refer to paragraph 836-4).

Less than 6 cable Refer to No. 6 turns remain on cable drum following automatic switchoff DüWN

--_._._... _ - - - - _ .. 'l'able 836-1

BO 105 CHAPTER 836 Page 10

Troubleshooting (4 of 4)

MAINTENANCE MANUAL SO 105 ~;R~~~~~----l I

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EFFECTIVITY: after retrofit in accordance with ASB B0105-80-141 Figure 836-2 Block diagram - rescue hoist Configuration: Rescue hoist assy, fixed installation P/N 105-81106 (Exterior feature: four-way switch on collective stick)

Revision 24

CHAPTER 836 Page 11

MAINTENANCE MANUAL 80 105

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Figure 836-3 Block diagram - rescue hoist Configuration: Rescue hoist assy, fixed installation P/N D134-358 (Exterior feature: rocker switch on collective stick) CHAPTER 836 Page 12

Revision 24

MAINTENANCE MANUAL BO 105

EUROCOPTER

836 - 3

INSPECTION FOR CONDITION - RESCUE HOIST ASSEMBLY

1.

Clean winch boom assy (refer to paragraph 836-7).

2.

Check winch boom assy for secure installation.

3.

Check winch boom supports for play. The play on the winch boom end must not exceed 50 mm in vertical direction and 70 mm in horizontal direction. Replace worn parts (refer to paragraph 836-6). CAUTION

WHEN REELING IN THE CABLE WITHOUT ANY LOAD ON THE HOOK, THE PENDULUM MOTION OF HOOK/BUMPER ASSY (7, FIGURE (836-1) MAY BE AMPLIFIED TO SUCH AN EXTENT THAT HOOK/BUMPER ASSY TURNS UPSIDE DOWN OR IS PULLED SLANTINGLY AGAINST THE WINCH UNIT RESULTING IN DAMAGE TO THE CABLE. MECHANICAL DAMAGE TO WINCH UNIT OR BUMPER 1S REGARDED AS EVIDENCE FOR CABLE DAMAGE, WHICH IS DIFFICULT TO DETECT.

4.

Visually inspect winch unit and bumper for mechanical damage and corrosion. If a mechanical damage to winch unit housing, bumper housing (13, figure 836-13), guard ring (22) cable guide roller or stop plate (1) is evident, inspect cable in the vicinity of bumper for condition (refer to paragraph 836-5) as cable damage must be suspected. Touch up paint damage with lacquer (CM 407).

5.

Check that hook can be easily rotated and check catch for function. If hook is hard moving, grease bearing (with CM 101) .

6.

Visually inspect winch boom assy (figure 836-7) for mechanical damage and corrosion. Eliminate damage (refer to paragraph 836-11) .

7.

Visually inspect welding seams on winch boom assy for cracks. Esspecially the welding seams around the console. (refer to fig. 836-18). If cracks are evident replace parts.

8.

Check riveting on winch boom assy for looseness. Replace loose rivets.

80 105 CHAPTER 836 Page 13

MAINTENANCE MANUAL 80 105

EUROCOPTER

NOTE

If cable overtravel is excessive following the automatic switchoff in operation mode UP the springs of the bumper are compressed by the cable. The cable may be excessively stressed. Two indicator pins (4, figure 836-4) are provided to indicate that springs were fully compressed.

9. Inspect indicator pins within spring assembly for length and damage. a.

Reel out hook/bumper assy to convenient height (approximately 1 m) . Push circuit breaker WINCH on instrument panel and set switch WINCH to position ON. Actuate winch unit using switch WINCH on collective stick or switch WINCH on winch control grip.

b.

Inspect indicator pin(4, figure 836-4) by loosening boot (5). In the event that the indicator pin is damaged and/or has incorrect length, shorter by more than 2 mm (measurement X, figure 836-4) replace indicator pin (refer to paragraph 836-18)'and inspect cable for condition, refer to paragraph 836-5.

c.

Fasten boot.

d.

Reel in hook/bumper assy and switch off the system. Set switch WINCH on overhead console to position OFF .. Pull circuit breaker WINCH.

10. Check electrical connections and accessible electrical lines for damage. Replace damaged electrical connectors or lines.

* 11. Inspect switch guards on CABLE CUTTER emergency switches for sufficient

* spring tension. Repair or replace defective switch guards. * * 12. Inspect skid guard (18, fig. 836-1) for condition, tight installation and * proper attachment of cable to crosstube .

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1 2 3 4 5

Stop plate Stop plate support Spring Indicator pin Boot

800216

Figure 836-4 Inspection - indicator pins for displacement BO 105 CHAPTER 836 Page 14

Revision 12

Gteurocopter

MAINTENANCE MANUAL MBB - BO 105

836 - 3A 1NSPECT10N - W1NCH UN1T Special tools: Fixing device Pinion adapter Torque wrench

NOTE

105-81112 W1 105-81112 W2

1f the permissible damage lirnits are exceeded and/or other damage requiring repair is evident, have winch unit repaired by ECO.

l.

Remove cartridge (refer to para. 836-30) and reinstall protective cover (2, fig. 836-4B).

2.

Check cable wind-up overtravel. a.

Push circuit breaker W1NCH on instrument panel. Set switch W1NCH on overhead panel to position ON. 1ndicator light W1NCH on instrument panel must go on.

b.

This step only applies if optional equipment 4KW/3KW + 1KW ELECTR1CAL HEAT1NG AND VENT1LAT1NG SYSTEM is installed. 1)

Push circuit breaker HEAT1NG on instrument panel. Set switch HEAT1NG on overhead panel to position HEAT1NG. The four indicator lightsHEAT1NG must not go on and heating must be off.

2)

Switch off the system. Set switch HEAT1NG to position OFF and pull circuit breaker HEAT1NG.

CAUT10NIF THE BOOM IS OPERATED WITH A SERVO MOTOR OC 2050 M4D, THE DIRECTIONAL MOVEMENT MUST NOT BE CHANGED BEFORE THE MOTOR HAS COME TO A FULL STOP (RUN-OUT TIME IS APPROXIMATELY 5 SEC.) A OIRECTIONAL SWITCH-OVER CAN BE PERFORMED IMMEDIATELY IF THE BOOM 1S OPERATED BY A SERVO MOTOR 13.1-0100 or 13.1-0110. c.

Extend winch boom and reel out hook/bumper assy by approx. 1 m. Reel in cable and guide hook or cable by hand until automatic switch-off occurs. After the automatic switch-off, measure dimension Y (cable wind-up overtravel) inside the bumper with a depth gauge through bore (2, fig. 836-5) and record this value.

Revision 7

BO 105 CHAPTER 836 Page 14A

MAINTENANCE MANUAL MBB

~

BO 105

The cable wind-up overtravel can be adjusted by exchanging spring (6, fig. 836-14). For this purpose, three springs with a length of 166, 195 and 215 mm respectively, are available. A longer spring will reduce cable overtravel (refer to para. 836-17 for spring replacement procedure). If the required dimension Y is not obtained by exchanging the spring, it must be supposed that the motor brake is defective. In this case, remove winch motor (refer to para. 836-27)and have it repaired. 3.

Remove hook/bumper assy (refer to para. 836-16).

4.

Inspect stop plate and cable guide. a.

Inspect stop plate (20, fig. 836-4B) for cracks, mechanical damage and separation from the rubber bumper. Replace stop plate if cracks or separation from the rubber bumper are evident. Polish out mechanical damage with polishing cloth 400 and touch up reworked area with single-layer lacquer (CM 407) .

b.

visually inspect cable guide (25) for scores and corrosion. Remove scores and corrosion to 0.5 mm in depth on cable contact areas and to 0.2 mm in depth on not more than 20% of the areas contacting switch plate (21), using polishing cloth 400.

c.

Inspect indicator pins (23) for damage and correct protruding length (dimension "X") (refer to fig. 836-4B). If pins are damaged or dimension "X" is less than 2 mm, replace pins as follows: 1)

Remove existing pins.

2)

Using Loctite (CM 651), bond new pins in place so that dimension "X" equals 2 mm.

5.

Remove winch unit (refer to para. 836-23).

6.

Remove winch motor. a.

Remove nuts (8, fig. 836-4B) and screws (7).

b.

Remove winch motor (9) from gearbox assembly (12).

c.

Install winch unit to maintenance device (8, fig. 836-20), using the existing screws (red marking). Use the bores with the red marking on the upper part of the winch unit.

d.

Install winch unit together with maintenance device in support.

BO 105 CHAPTER 836 Page 14B

Revision 7

fteurocopter

MAINTENANCE MANUAL MBB - BO 105

7.

Remove covers (1, 4 and S, fig. 836-4B).

8.

Remove cover (3). For configuration I, al so remove sealing (6).

9.

Remove protective cover (2) for cable cutter.

10. Remove cable (refer to 836-41, item 2.) . 11. Remove screws (11, fig. 836-4B), and remove gearbox assembly (12) from winch unit (10). 12. Inspect cable. a.

Visually inspect cable for kinks, crushing, loose wires and strands.

b.

Replace cable in case of single strand breakage, kinks, crushed or loose wires or outer strand cleavages of 0.5 mm in straight cable. For replacement of cable, refer to para. 836-41, item 2. For examples of cable damage, refer to fig. 836-6.

c.

Clean contaminated cable with clear water.

13. Inspect level wind nut and guide plateo a.

Inspect level wind roller retainer (13, fig. 836-4B) for ease of movement and absence of bearing play. For this purpose, turn level wind roller retainer by hand. Ball bearing damage must not be evident, otherwise have winch unit paired.

b.

Inspect level wind rollers (15) for play, rough running and corrosion. If any of the these conditions are evident, have winch unit repaired.

c.

Check guiding slots in guide plate (14) for sharp edges. Round off sharp edges using polishing cloth 400, as necessary.

14. Degrease accessible gears and pinions, using a dry, lint-free cloth. 15. Inspect gears and pinion. a.

Inspect gears and pinion for cracks, worn tooth flanks and bearing play.

b.

If any of these conditions are evident, have winch unit repaired.

Revision 7

BO 105 CHAPTER 836 Page 14C

_eurocopter

MAINTENANCE MANUAL MBB - BO 105

16. Inspect winch and gearbox housing. a.

Inspect winch and gearbox housing for mechanical and corrosion damage. Polish out minor mechanical and corrosion damage to housing, using polishing cloth 400. Treat reworked area with chemical conversion material (CM 316) and touch up with single-layer lacquer (CM 407) .

b.

Polish out corrosion on mating surfaces, using polishing cloth 400. 80 % of the original mating surfaces must remain intacto

17. Inspect cable drum. a.

Wherever accessible in installed position, visually inspect side plates and drum grooves of the cable drum (18, fig. 836-4B) for mechanical and corrosion damage, and groove ridges for chipping.

b.

Polish out mechanical and corrosion damage with polishing cloth 400, and round off chipped areas on the ridges of the eable drum grooves.

c.

After polishing out damage, treat areas with chemical conversion material (CM 316) .

18. Inspect tension rollers. NOTE

Evenly removed material on the tension rollers surface shall not be considered as damage but as natural wear.

a.

Inspect rubber coating on tension rollers (16) for condition.

b.

If rubber coating shows signs of debonding, run-in grooves or pits, have winch unit repaired.

19. Inspect level wind screws. a.

Inspect level wind screws (17) for corros ion and wear, and edges of screw grooves for nicks and seores.

b.

Nicks and scores on edges of screw grooves are not permissible as they are an indication of damage to the level wind pino In this case, have winch unit repaired.

c.

Remove minor corrosion damage with polishing cloth 400.

20. Remove grease from spider assembly gears (19) and inspect flanks of gear teeth for wear. If wear is evident, have wineh unit repaired. 21. Inspect electrical connections for condition.

BO 105 CHAPTER 836 Page 14D

Revision 7

fteurocopter

MAINTENANCE MANUAL MSS - BO 105

22. Inspect friction clutch and gearbox assembly as follows: a.

Inspect gears of gearbox and pinion of friction clutch for cracks, worn tooth flanks and play. If any of these conditions are evident, have winch unit repaired.

b.

Check breakaway force of friction clutch as follows: 1)

Slide fixture (1, fig. 836-4A) over friction clutch housing (2).

2)

Set torque wrench (6) to 6 Nm and install to pinion (4), using pinion adapter (5).

3)

Applying torque wrench evenly, tighten screw (3) to such an extent that the friction clutch housing does not turn in the fixture.

4)

Determine breakaway force of friction clutch repeatedly and record the value each time. The applied torque shall be within 5 Nm and 8 Nm.

5)

If this value cannot be obtained, consu1t EUROCOPTER DEUTSCHLAND GmbH, Customer Service.

Revision 7

BO 105 CHAPTER 836 Page 14E

_eurooopter

MAINTENANCE MANUAL SO 105

4

~

4 Pinion 5 Pinion adapter 105-81112 W2 6 Torque wrench

1 Fixture 105-81112 W1 2 Friction clutch housing 3 Screw

Figure 836-4A

--5

Checking the breakaway force of the friction clutch

23. Install gearbox assembly as follows: •

a. Grease pinion (4, fig. 836-4A) of friction clutch with grease (CM 115). b. Apply a coat of corrosion preventive paste (CM 503) to outer edges of housing of gearbox assembly (12, fig. 836-48) and install gearbox assembly to winch unít (10) with screws (11). c. Torque-tighten screws (11) and secure with lockwire. 24. Install cable (refer to para. 836-41).

CHAPTER 836 Paga 14F

Revision 22

_eurocopter

MAINTENANCE MANUAL BO 105

25. Ughtly grease all accessible gears and bearings, using grease (CM 112). 26. Install covers. a. Install covers (1, 4 and 5, fig. 836-48). b. Install cover (3). For configuration 1, sealing (6) must be additionally inserted in cover (3). c. Fix cover with screws and secure with lockwire. 27. Install winch motor.

•

a. Grease driving pinion of winch motor (9, fig. 836-48) with grease (CM 112). b. Apply corrosion preventive paste (CM 503) to outer edges of gearbox housing. c. Attach winch motorto gearbox assembly- the electrical connector must point downward-using nuts (8) and screws (7). For specified torque refer to fig. 836-16. 28. Install winch unit (refer to para. 836-25). 29. Install hooklbumper assy (refer to para. 836-20). 30. Check cable wind-up overtravel (refer to para. 836-3A, item 2). 31. Install cartridge per para. 836-30. 32. Perform functional test in accordance with para. 836-4.

Revision 22

CHAPTER 836 Page 14G

_eurocopter

MAINTENANCE MANUAL MSS - 80 105

Cover (gearbox) Protective cover (cable cutter) Cover (switch box) Cover (cable access) Cover (cable drum housing) &6 Sealing 7 Screw 8 Nut 9 Winch motor 10 Winch unit 11 Screw 12 Gearbox assembly 13 Level wind roller retainer 14 Guide plate 15 Level wind roller 16 Tension roller 17 Level wind screw 18 Cable drum 19 Gear assembly (spider assembly) 20 Stop plate 21 Switch plate 22 Spring 23 Indicator pin 24 Boot 25 Cable guide 1

2 3 4 5

& Configuration 1 only

(fig. 836-20, Detail A)

Figure 836-48 Partial disassembly of winch unit (1 of 2) BO 105 CHAPTER 836 Page 14H

Revision 7

MAINTENANCE MANUAL Maa - BO 105

8

1-

r

3--+

6 --\+-----I-iI

i3-

14-

Figure 836-4B Partial disassembly of winch unit (2 of 2) BO 105

Revision 7

CHAPTER 836 Page 14I/J

MAINTENANCE MANUAL MBB - 80105

8 9

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A

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. (2 of 2) d'~sassembly of winch unü Figure 836-4B Part~al .

Revision 7

BO 105 CHAPTER 836 Page l4I/J

B

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fteuroco.pter

MAINTENANCE MANUAL BO 105

anEAffi~

836 - 3B INSPECTION FOR CONDITION - RELAY BOX 23VE NOTE

If damage limits are exceeded or damage is determined which can not repaired as follows, the relay box 23VE has to send to ECO for repair or if necessary, the complete winch boom assembly.

1.

Make sure that the helicopter is deenergized and the EPU is disconnected.

2.

Pull circuit breakers 1MF and 2MF on the center console.

3.

Remove lockwire from screw (2, Bild 836-4C) and discard.

4.

Remove screws (2) with washers (3), detach clamp band (4) and remove cover (5) from housing (1).

5.

Examine the seal (8) in the housing (1) for damage. Replace damaged seal (8) as follows: a.

Remove seal (8) from the housing (1) and remove residues of adhesive with Alcohol (CM 238).

b.

Installa newseal (8)onthehousing (1) withAdhesive (CM 694) orSilicone Rubber (CM 619) accordingto the Manufacturer Instructions.

6.

Examine the housing (1), the electrical components and connections for damage and corros ion. If damage or corrosion is determined which can not repaired, the relay box 23VE has to send to ECO for repair or if necessary, the complete winch boom assembly.

7.

If corros ion is determined on the printed circuit card (7), remove the printed circuit card (see section 836-25A).

8.

If the corros ion does not exceed the damage limits, remove the corrosion as follows:

9.

a.

Remove the corrosion from mechanical and electrical connections with a brush made of brass as necessary.

b.

Remove corrosion from components with a suitable tool (e.g. abrasive paper grad 400 or600). Make sure that you only use tools which do not cause new corrosion (e.g. a steel wire brush on aluminium components).

c.

Examine the repair area with a5 times magnitying glass. Make sure that you have removed all corrosion.

d.

Make sure that the repair does not exceed the repair limits. If the repair exceeds the repair limit, replace the respective component or the relay box 23VE completely.

e.

Remove all foreign material (e.g. chipping, dust) with a vacuum cleaner.

f.

Apply corrosion preventive compound (CM 506) according to the Manufacturer Instructions to the repair area.

Install cover (5) with the clamp band (4) on the housing (1) using screws (2) and washers (3). Safety screws (2) with lockwire (CM 775).

10. Do a functional test of the rescue hoist assembly (see section 836-4).

Revision 25

CHAPTER 836 Page 14K

Seurocopter 811 EAOO

MAINTENANCE MANUAL 80 105

ClJm!MmY

1

5

L2?'<----

1 Housing 2 Screw 3 Washer 4 Clamp band

Figure 836-4C CHAPTER 836 Page 14L

8

5 6 7 8

Cover Electrical components Printed circuit card Seal

-

Inspection for condition - relay box 23VE Revision 25

_~Jool~opter 836 - 4

MAINTENANCE MANUAL 80105

FUNCTIONAL TEST - RESCUE HOIST ASSEMBLY

NOTE

• If a cable inspection is to be performed at the same time as the functional test, it is advisable to include the cable inspection in the functional test.

CAUTION

THE GUAROEO COVERS FOR THE CABLE CUTTER SWITCHES ON COLLECTIVE STICK ANO WINCH CONTROL GRIP MUST BE CLOSEO TO PRECLUOE INAOVERTENT CUTTING OF THE CABLE. • Placement and function of the winch switch depends on the S/N of the Helicopter. Up to S/N 160 a rocker type switch is used, and placed on the pitch control stick. From S/N 161 a 4 way switch is used (refer to figures 836-2 thru 836-3). For operation refer to the OPM 104.

EFFECTIVITY

Helicopter after retrofit in accordance with ASB B0105-80-141

1. Check switching off of power supply. a.

Make sure that electrical connectors 118Wa and 132Wa have been disconnected from the hoist boom.

b.

Switch external power supply onto helicopter electrical system.

c.

Make sure that winch main switch 4MF is at OFF.

d.

Press circuit breakers 1MF and 2MF on the control panel.

e.

Using voltmeter (select OC range), measure votlage on receptacle 118Wbetween pin A (+) and pin H (-). The nominal voltage is OV OC

f.

Connect electrical connectors 118Wa and 132Wa to hoist boom.

EFFECTIVITY 2.

± 1V OC.

AII

Check that the system is operative. a.

Push circuit breaker WINCH on instrument panel. Set switch WINCH on overhead panel to position ON. Indicator Iight WINCH on instrument panel must go on.

b.

If optional equipment 4KW/3KW + 1KW ELECTRICAL HEATING ANO VENTILATING SYSTEM is installed: 1) Push circuit breaker HEATING on instrument panel. Set switch HEATING on overhead panel to position HEATING. The four indicator lights HEATING must not go on and heating must be out of operation. 2) Switch off the system. Set switch HEATING to position OFF and pull circuit breaker HEATING.

c.

Push circuit breaker CABLE CUTTER on instrument panel. Briefly operate test switch CABLE CUTTER TEST on overhead panel. Indicator light CABLE CUTTER TEST must go on. The winch control grip must be connected.

Revision 24

CHAPTER 836 Page 15

MAINTENANCE MANUAL 80 105

3.

CAUTION

THE DIRECTIONAL MOVEMENT OF A BOOM, OPERATED WITH A SERVO MOTOR DC 2040 M 4 C, MUST NOT BE CHANGED BEFORE THE MOTOR HAS COME TO A FULL STOP (RUN OUT TIME IS APPROXIMATELY 5 SEC.) A DIRECTIONAL SWITCH-OVER CAN BE PERFORMED IMMEDIATELY IF THE BOOM 18 OPERATED BY A SERVO MOTOR 13.1-0100.

WARNING

THE RESCUE HOIST MUST ALWAYS BE OPERATED BY ONE PERSON ONLY. 81MULTANEOUS CONTROL COMMANDS ON COLLECTIVE STICK AND WINCH CONTROL LEVER ARE NOT PERMISSIBLE.

Perform functional test of the rescue hoist control. a.

Extend winch boom and reel out hook/bumper assy by 1 m. Briefly operate switch WINCH on winch control grip and switch WINCH on collective stick one afterthe other. Winch boom and winch unit mustfollow the control commands.

b.

Inspect cable in the vicinity of bumper for condition (referto paragraph 836-5) if cable inspection is to be performed.

CAUTION

• DO NOT SLANT HOOK/BUMPER ASSY WHEN REELlNG IN THE CABLE TO PREVENT DAMAGE TO THE CABLE CAUSED BY KINKING. • PLACE CABLE ON A CLEAN SURFACE ONLY (E. G. PAPER) TO PRECLUDE PREMATURE WEAR OF CABLE AND CABLE TENSION ROLLERS CAUSED BY DIRT.

4.

Perform functional test of limit switch DOWN. a.

Reel out cable until automatic switch-off occurs. Guide cable in such a waythat itforms loops (shaped Iike a figure eight) with a big radius and place on a clean surface. Afterthe automatic switch-off, check the number of cable turns on the cable drum. There must be at least 6 cable turns. Ifthis requirement cannot be met, repair winch unit (refer to paragraph 836-17).

CHAPTER 836 Page 16

MAINTENANCE MANUAL BO 105 b.

Inspect cable in the area of cable drum forcondition (referto paragraph 836-5) ifthe cable inspection isto be performed.

CAUTION

• THE CABLE MUST NOT BE REELED IN WHEN TWISTED OR KINKED. IF THE CABLE FORMS A LOOP, THE REEL-IN PROCESS MUST BE IMMEDIATELY INTERRUPTED TO CORRECT THE CABLE. • THE CABLE MUST BE TAUTLY REELED ON THE DRUM. A LOOSELY REELED CABLE WILL SQUEEZE ITSELF INTO THE UNDERLYING CABLE TURNS WHEN UNDER TENSION. THIS WILL CAUSE DAMAGE TO THE CABLE. WHEN REELlNG IN THE CABLE, TAUTEN THE CABLE VERTICALLY BY HAND AS LONG AS IT IS NOT LOADED BY THE BUMPER. • DO NOT SLANT HOOK/BUMPER ASSY WHEN TAUTENING THE CABLE TO PRECLUDE DAMAGE TO THE CABLE CAUSED BY KINKING.

WARNING

5.

6.

• WHEN TAUTENING THE CABLE, WEAR GLOVES TO PROTECT YOUR HANDS AGAINST INJURIES.

Perform functional test of limit switch UP. a.

Inspect cable for condition (refer to paragraph 836-5) if cable inspection is to be performed.

b.

Reel in cable until automatic switch-off occurs. Tauten cable by hand as long as it is not loaded by the bumper. Afterthe automatic switch-off, measure dimension Y (cable overtravel) insidethe bumperwith a depth gauge through bore (2) (referto figure 836-5). The cable overtravel can be adjusted byexchanging spring (16, figure 836-9) (referto paragraph 836-7). Three differenttypes of springs with a length of 166, 195 and 215 mm respectively are available. A long spring reduces cableovertravel. Ifthe required dimension Y is not obtained by an exchange of springs, it must be supposed that the motor brake is defective. In this case repair winch motor (refer to paragraph 836-21).

Switch off the system. Set switch WINCH on overhead panel to OFF. Pul! circuit breaker WINCH and CABLE cunER on instrument panel.

Revision 24

CHAPTER 836 Page 17

MAINTENANCE MANUAL SO 10S

>-D

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Cable overtravel Y must be within 10 to 45 mm

Figure 836-5

CHAPTER 836 Page 18

1 Spring plate 2 Bore 3 Hook/bumper assy

Inspection - cable overtravel Y

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 836 - 5

CABLE INSPECT10N - RESCUE H01ST ASSEMBLY

Special tool: 2 wing bolts

D1N 316-M8x60-g-4.6

NOTE

If the functional test is to be performed at same time as the cable inspection, the cable inspection can be included in the functional test. For cable inspection it is recommended fo use the EPU.

CAUT10N

1.

o

DO NOT SLANT HOOK/BUMPER ASSY WHEN CABLE 1S UNDER TENS10N TO PREVENT DAMAGE TO THE CABLE CAUSED BY K1NK1NG.

o

FOR CLEAN1NG OF THE CABLE USE CLEAR WATER SO THAT THE 1MPREGNAT10N OF THE CABLE 1S NOT WASHED OUT.

o

DO NOT LUBR1CATE CABLE W1TH GREASE AS TH1S W1LL 1MPA1R THE FUNCT10N OF THE CABLE TENS10N ROLLERS.

1nspect cable in the vicinity of bumper for condition. a.

Reel out cable. Stop reel-out before bumper touches the ground.

b.

Disconnet boot of bumper assy on one side. Evenly screw down both wing bolts in threaded holes of bumper housing (13, figure 836-13) until they stop in order to lift spring plateo Thus the cable attachment area becomes accessible.

c.

Inspect the first metre of cable (measured from load hook cover) in the non-loaded condition without load hook cover for cable breakage, deformation, cable crush, and loose wire strands. 1f evidence of broken wire strands, cable crush, deformation and/or loose wire strands with deaves of 0.5 mm in a non-deformed condition is detected, replace cable. For cable replacement refer to paragraph 836-41. Refer to figure 836-6 for illustration of possible cable damage.

d.

Clean dirty cable with clear water.

BO .105 CHAPTER 836 Page 19

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

PLACE CABLE ON A CLEAN SURFACE ONLY (E. G. PAPER) TO PRECLUDE PREMATURE WEAR OF CABLE ANO CABLE TENSION ROLLERS CAUSED BY DIRT.

CAUTION

2.

Inspect cable in the area of cable drum for condition. a.

Reel out cable until automatic switch-off occurs. Guide cable during reel-out so that it forms a loop (shaped like a figure eight) with a big radius on a clean surface. -

b.

After the automatic switch-off, visually inspect visible cable portion on the drum through sight glass of winch unit for condition. Replace cable if damaged.

CAUTION

WARNING

3.

o

THE CABLE MUST NOT BE REELED IN WHEN TWISTED OR KINKED. IF THE CABLE rORMS A LOOP, THE REEL-IN PROCESS MUST BE IMMEDIATELY INTERRUPTED TO CORRECT THE CABLE.

O

THE CABLE MUST BE TAUTLY REELED ON THE DRUM. A LOOSELY REELED CABLE WILL SQUEEZE ITSELF INTO THE UNDERLYING CABLE TURNS WHEN UNDER TENSION. THIS WILL CAUSE DAMAGE TO THE CABLE. WHEN REELING IN THE CABLE, TAUTEN THE CABLE VERTICALLY BY HAND AS LONG AS IT IS NOT LOADED BY THE BUMPER.

O

DO NOT SLANT HOOK/BUMPER ASSY WHEN TAUTENING THE CABLE TO PRECLUDE DAMAGE TO THE CABLE CAUSED BY KINKING. WHEN TAUTENING THE CABLE, WEAR GLOVES TO PROTECT YOUR HANDS AGAINST INJURIES.

Inspect cable for condition. a.

Reel in cable. Tauten cable by hand (approximately 50 N) as long as it is not loaded by the bumper. Guide cable in a soft cloth and check for broken wires. Fibres on cable indicate broken wires.

b.

Visually inspect cable during reel-in for kinks, squeezing, and loose wires and strands.

c.

In case of single strand breakage, nicks, crushed, loose wires or out side cleaves which are ~n the non-deformed condition ~ 0.5 mm, replace cable. For cable replacemend refer to paragraph 836-41. Refer to figure 836-6 for illustration of possible cable damage.

BO 105 CHAPTER 836 Page 20

RELICO~ll$RS

5----------__-------------MBB ---MAIN'tENANCE MAJlllllL 1GB - !lO lO

Clea\les ~o.s mm not acceptabl 8

Loase stra

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cable ctUs'n 8001 108

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ExaroP les cable daroag

BO 105 caAP TER 836 ~age 21/ 22

O~ter 836 - 6

MAINTENANCE MANUAL 80 105

Winch boom assembly

1 Winch unit

2 Hook/bumper assy 3 Winch boom 4 Protective resistor

.

a: QlI

~ :I:

1

~

",1

5 6 7 8 9

Wiring harness Fork lever Servo motor 8earing support Relay box

o

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9

8

Figure 836-7 Winch boom assy

CHAPTER 836 Paga 23

Oeurocopter an EACS Compeny

836 - 7

MAINTENANCE MANUAL BO 105

Cleaning - winch boom assembly

1. For cleaning install winch boom assy in helicopter or position in its normal attitude so that no cleaning agent enters electrical components. 2. Wash away salt with water. Use standard items such as water plus detergent to remove dirt.

836 - 8

Removal - winch boom assembly

1. Extend winch boom. Push circuit breaker WINCH on instrument panel and set switch WINCH on overhead panel to position ON. Control winch boom servo motor with switch WINCH on collective stick. 2. Switch off the system. Set switch WINCH to position OFF and pull circuit breaker WINCH. 3.

Oisconnect electrical connector (4, figure 836-8) from fuselage. Protect connector with a cap (8).

4.

Remove cartridge (refer to paragraph 836-31) and install protective cover WAS-282 (4, figure 836-16). CAUTION

• USE A THREE-PERSON CREW TO L1FT WINCH BOOM OUT OF MOUNTING FITTINGS AS THERE IS A RISK OF OAMAGING MOUNTING FITTINGS ANO WINCH BOOM BEARING SUPPORT. • OBSERVE TRANSPORT ANO STORAGE INSTRUCTIONS (REFER TO PARAGRAPH 836-9) AS THERE IS A RISK OF OAMAGING THE SERVO MOTOR ROO ANO THE CABLE.

5. Screw in adjusting screw (6, figure 836-8) using a pino Thus the stress is eliminated from the self-Iocking pins on the mounting fittings. EFFECTIVITV 6.

1

Step 6. is valid for configuration I only.

Remove self-Iocking pins (1) from mounting fittings (7 and 9). Carefully withdraw winch boom from slide rings (2) and lift out of mounting fittings (7 and 9).

EFFECTIVITV

Step 7. is valid for configuration 11 only.

Remove self-Iocking pins (1 and 22) from mounting fittings (7, 9 and 21). Carefully lift winch boom out of mounting fittings (7, 9 and 21). 8.

Remove winch control grip (5, figure 836-1). Oisconnect electrical connector from overhead panel and blank off.

9.

Remove skid guard assembly (18, fig. 836-1) from skid tube.

CHAPTER 836 Page 24

Revision 23

MAINTENANCE MANUAL SO 105 836 - 9

Storage and transport - winch boom assembly

CAUTION

• DO NOT LOAD FORK LEVER DURING TRANSPORT TO PRECLUDE DAMAGE TO SERVO MOTOR ROO. • DO NOT LOAD HOOK/BUMPER ASSY PERPENDICULARLY TO THE CABLE DIRECTION DURING TRANSPORT ANO STORAGE TO PRECLUDE DAMAGE TO THE CABLE IN THE VICINITY OF BUMPER. • DO NOT TOUCH BUMPER OR PUSH AGAINST IT DURING TRANSPORT. • STORE WINCH BOOM IN TRANSPORT BOX. ENSURE CORRECT POSITION OF HOOK/BUMPER ASSY. THE WEIGHT OF THE HOOK/BUMPER ASSY MUST BE NEUTRALlZED BY APPROPRIATE CUSHIONING.

836 -10

Disassembly - winch boom assembly

1. Remove hook/bumper assy (refer to paragraph 836-16). 2.

Remove wineh unit (refer to paragraph 836-23).

3.

Remove servo motor (refer to paragraph 836-34).

4.

Remove fork lever (16, figure 836-9). Remove serews (11 and 14).

5. Disassemble fork lever (refer to figure 836-10). EFFECTIVITV a.

Remove seals (7, figure 836-1 O). Remove self-aligning bearing (9) only if neeessaryfor repair. Remove snap rings (8) and press out self-aligning bearing.

b.

Remove seals (2). Remove spherieal bearing (4) only if neeessary for repair. Remove snap rings (3) and press out spherical bearing.

EFFECTIVITY

6.

Valid for eonfiguration I only.

Valid for eonfiguration 11 only.

e.

Remove hinged lever (16, figure 836-10A) as follows: Remove attaehing hardware (17,18, 19and 20), remove hinged lever (16) and, if installed, washer (21).

d.

Remove seew (15) and quiek release pin (14).

e.

Remove seals (2, 7) and bushing (6). Remove snap rings (3, 8) and press out bearings (4, 9).

1.

Remove bushing (5) from bearing (4).

Disassemble wineh boom bearing support (refer to figure 836-11). a.

Remove serews (3).

b.

Pull off bearing support (15) from bearing joumal (1).

e.

Remove retaining ring (8) and extraet self-aligning bearing (7) from bearing jouma!.

Revision 23

CHAPTER 836 Page 25

I

Oeurocopter llIl

7.

MAINTENANCE MANUAL SO 105

EACS Compeny

d.

Pull off cover ring (6), retaining ring (5) and seal (2) from bearing journal.

e.

Remove cap (17). Remove screws (16) and locking plate (10). Unscrew adjusting screw (9) by turning upward.

For inspection of components as described in paragraph 836-11 it is not necessary to remove the components of the electrical system. Loosen attaching hardware only to facilitate visual inspection of the tube.

8. Disconnect wiring harness (5, figure 836-7) from protective resistor (4) if this is necessary for repair. 9. Disassemble relay box 23VE as required for repair.

CHAPTER 836 Page 26

_eurocopter

MAINTENANCE MANUAL 80105

an EAOO Campany

BLANK PAGE

CHAPTER 836 Page 27

_eurocopter

MAINTENANCE MANUAL SO 105

en EAOS Compeny

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Figure 836-8 CHAPTER 836 Page 28

13

~~16 ~17

Removal and installation - winch boom assy (1 of 2) Revision 23

MAINTENANCE MANUAL BO 105

22---l.

/-----3

Configuration 11

a:

Sperical bearing

21

(of servo motor)

22

1

Self-Iocking pin

2

Slide ring

3

Servo motor red

4

Connector

13

Self-aligning bearing Adjusting screw

11 12

Winch boom

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5

Bearirig support

14

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6

Adjusting screw

15

Locking plate

7

Console

16

Screw

8

Blind cover

17

Cap

9

Bearing support

18

Screw

Lever half

19

Adjusting plate

20

Nut

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al

10

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Mounting fitting Quick-release pin

Figure 836-8 Removal and installation - winch boom assy (2 of 2) Bauausf?hrung I

Revision 23

CHAPTER 836 Page 28A

_eurocopter 8n

MAINTENANCE MANUAL BO 105

EADS Company

BLANK PAGE

CHAPTER 836 Page 288

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

3

~

4

3

Winch fixing assy Winch boom Claülp 4 Protective resistor 5 Boom mounting assy 6 Sealing plug 7 Bearing support 8 Adjusting screw 9 Relay box 10 Self-locking pin 11 Screw 12 Washer 13 Lever half 14 Screw 15 Washer 16 Fork lever 17 Nylstop nut 18 Washer 19 Split pin 20 Spacer 21 Boom axle 22 Lever half 23 Washer 24 Screw 25 Nylstop nut 26 Washer 27 Split pin 28 Washer 29 Nylstop nut 30 Split pin 31 Axle 32 Washer 1 2 3

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Removal and installation - fork lever BO 105 CHAPTER 836 Page 29/30

28 30 29

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Figure 836-9

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MAINTENANCE MANUAL BO 105

Cornpeny

A

B DETAll

A 2

3

11:

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1 2 3 4 5 6 7 8 9 10 11

Fork lever Seal Snap ring Spherical bearing Bushing Bushing Seal Snap ring Self-aligning bearing Bushing Bearing bushing

,&.

Position of notch (point of rupture) on spherical bearing outer ring

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Revision 23

2

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Disassembly and assembly - fork lever (Configuration 1)

•

CHAPTER 836 Page 31

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MAINTENANCE MANUAL BO 105

Compeny

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SECTIONA - A

1 2 3 4 5 6 7 8 9 10 11

Fork lever Seal Snap ring Bearing Bushing Bushing Seal Snap ring Bearing Bushing Bushing

SECTIONB -

12

13 14 15 16 17 18 19

20

21

8

Bushing Bushing Quick release pin Screw Hinged lever Screw Washer Nut Washer Washer

Figure 836-1 OA Disassembly and assembly - fork lever (Configuration 11)

CHAPTER 836 Page 31A

Revision 23

O~~pter

MAINTENANCE MANUAL SO 105

BLANK PAGE

CHAPTER 836 Page 31B

_eurocopter 8Il

MAINTENANCE MANUAL BO 105

EAOO Campeny

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Bearing journal Gasket Screw Washer Retaining ring Cover ring Self-aligning bearing Retaining ring

Figure 836-11

CHAPTER 836 Page 32

9 1.0 11 12 13 14 15 16 17

Adjustment screw Locking plate Washer Screw Adjusting screw Safety spring Bearing support Screw Cap

Disassembly and assembly - winch born bearing support

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 836 - 11

Inspection and repair - winch boom assembly

1.

The winch boom assy 1s tested for function as outlined in paragraph 836-4.

2.

Inspect and repair hook/bumper assy (refer to paragraph 836-18).

3.

visually inspect winch unit and servo motor of winch boom for condition or overhaul if prescribed in the inspection instructions (paragraph 836-42). Repair if damage is evident (refer to paragraphs 836-24 and 836-35) .

4.

Inspect winch boom tube (2, figure 836-9) including winch fixing assy (1) and boom mounting assy (5). The components of the electrical system need not be removed for this inspection. Loosen attaching hardware to facilitate visual inspection of the tube. a.

Check clearance X (figure 836-12). Minimum clearance: 1 mm. If the clearance falls below this minimum, the deforrnation of the boom in the bending radius is unacceptable: Replace winch boom tube.

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1

2 3

Boom mounting assy Retaining plate Winch boom tube

Inspection - clearance between boom mounting assy and retaining plate (dimension X)

BO 105 CHAPTER 836 Page 33

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

visually inspect welding seams and area of riveting for cracks using a (5 power) magnifying glass. Replace winch boom tube if a crack is evident.

c.

Check for loose rivets. Replace loose rivets.

d.

Visually check sealing of joint between boom mounting assy and winch boom tube for condition. Renew damaged sealing with sealing compound (CM 635) .

e.

Visually inspect bearing journal (1, figure 836-11) for cracks using a (5 power) magnifying glass and for mechanical damage and corrosion. 1)

Replace winch boom if a crack is evident.

2)

Eliminate damage (refer to Chapter 02). Damage limits: 29.9 mm and 34.8 mm in diameter and 0.3 mm in depth on 10 % of the circumference.

5.

Visually inspect wiring harness including protective resistor (4, figure 836-9) for damage to the insulation and all connectors for corrosion damage. Replace damaged components. To do so, disconnect wiring harness from protective resisitor. Shrink on a new shrinkable sleeve on the disconnect using hot airo

6.

Inspect lever halves (13 and 22) . Visually inspect lever halves for cracks using a (5 power) magnifying glass and for mechanical damage and corrosion. Pay particular attention to the vicinity of bores.

7.

a.

Replace lever half if a crack is evident.

b.

Eliminate damage (refer to Chapter 02). Damage limits for bores: 7.9 mm, 11.9 mm and 19.9 mm in diameter and 0.3 mm in depth on 10 % of the circumference. Rework limit for the remaining zones: 0.3 mm in depth on 20 % of the surface, but not reducing wall thickness by more than 10 %.

Inspect winch boom axle (21). a.

Visually inspect winch boom axle for cracks using a (5 power) magnifying glass and for mechanical damage and corrosion. 1)

BO 105 CHAPTER 836 Page 34

Replace winch boom axle if a crack is evident.

MAINTENANCE MANUAL 80 105 2) Eliminate damage (refer to Chapter 02). Damage and wear limits: 24.9 mm and 19.9 mm in diameter and 0.3 mm in depth on 10 % of the circumference. b.

8.

Visually inspectthreaded inserts for mechanical damage and corrosion. Replace threaded inserts if damaged.

Inspect axle (31). Inspect axle for cracks, mechanical damage and corrosion. a.

Replace axle if a crack is evident.

b.

Eliminate damage (refer to Chapter 02). Damage limit: 9.4 mm in diameter and 0.3 mm in depth on 10 % of the circumference.

9.

Visually inspect the quick-release pins for condition. Replace damaged quick-release pins.

10. Inspect bearing support (figure 836-11). a.

Visually inspect bearing support (15) for cracks using a (5 power) magnifying glass and for mechanical damage and corrosion. 1) Replace bearing support if a crack is evident. 2) Eliminate damage (refer to Chapter 02). Rework limit in bearing seat: 61.95 mm in diameter and 0.3 mm in depth on 10% of the circumference. Rework limit in bore for self-Iocking pin: 15.8 mm in diameter and 0.5 mm in depth on a maximum of 10 % of the circumference. Rework Iimits of the remaining surfaces: 0.1 mm in depth on the entire surface and 0.5 mm in depth on 10% of the surface.

b.

Inspect adjusting screw (9) for condition. Replace adjusting screw if thread is damaged or if méchanical damage is evident. Local damage is acceptable.

c.

Inspect cover ring (6) for conditíon. Replace cover ring if deformed.

d.

Inspect gasket (2) for condition. Replace gasket if hard, brittle, cracked, worn or if sealing surface is deformed.

e.

Inspect cap (17) for condition. Rework damaged sealing surface.

1.

Inspect self-aligning bearing (7) for condition. Replace bearing if corrosion or rough running is evident. Pack bearing with grease (CM 101).

Revision 23

CHAPTER 836 Page 35

1"

-eurocopter •

•

MAINTENANCE MANUAL BO 105

lIIIEAOO Compeny

11. Inspect fork lever (figure 836-10 or figure 836-1 OA). a. Visually inspect welding seams and their vicinity for cracks using a (5 power) magni1ying glass. Replace fork lever if a crack is evident. b. Inspect fork lever for deformation. Replace fork lever if deformation is evident.

•

EFFECTIVITY

Valid for configuration I only.

c. Dimensionally inspect slot for wear. Wear limit: 12.5 mm. d. Inspect area around slot for cracks using a (5 power) magni1ying glass. Replace fork lever if a crack is evident. e. Inspect bearing seat of spherical bearing (4) and seat of self-aligning bearing (9) for signs of corrosion. If signs of corrosion are evident, remove bearing and eliminate damage (referto Chapter 02). Rework limit: 51.93 mm, 34.94 mm in diameter and 0.3 mm in depth on 10 % of the circumference.

I

f.

Inspect bearings (4, 9, figure 836-10) for condition. Replace bearings when corroded, damaged, rough running or play. Grease bearings with grease (VM 101).

g. Inspect seals (2 and 7) for condition. If brittle, cracked, worn or if sealing surface is deformed, replace seal. h; Visually inspect bushing (10) for wear of teflon sliding surface. Replace bushing if worn. EFFECTIVITY

Valid for configuration 11 only.

i.

Inspect fork lever for mechanical damage and corrosion. Repair surface defects in accordance with Chapter 02. Rework limit: 0.2 mm

j.

Visually inspect hinged levers (16, figure 836-1 OA) for mechanical damage, corrosion and, using a (5 power) magni1ying glass, for cracks. Inspect boreholes forwear. Polish out surfacedefects in accordance with chapter 02. Damage Iimits: 0.1 mm in depth; max. allowable diameter is 10.03 mm. Replace if cracks are evident or the damage limits are exceeded.

k. Visually inspect screw (17) for corrosion. Replace screw if corroded.

1.

Inspect bearings (4, 9) for condition. Replace bearings when they are corroded, damaged, have rough running or play. Grease bearings with grease (VM 101).

m. Inspect bushings (12, 13) for mechanical damage and corrosion. Replace bushings ifthe damage limits are exceeded. Damage limits: Bushing (12): max. allowable diameter is 42.02 mm; bushing (13): max. allowable diameter is 35.02 mm. n. Inspect seals (2, 7) for damage. Replace if damaged. o. Inspect bushings (5, 6) for damage and wear. Polish out minor damage, using 400 grit abrasive cloth in accordance with Chapter 02. Replace the bushings if the damage limits are exceeded. Damage Iimits: Bushing (5): max. allowable diameter is 15.05 mm; Bushing (6): max. allowable diameter is25.15mm. p. Visually inspect bushing (10) for wear of teflon sliding surface. Replace bushing if worn. 12. Visually inspect bearing pivot (4, figure 836-17) for mechanical damage and corrosion. Polish out mechanical damage and corrosion (refer to Chapter 02). Damage and wear limits: 8.9 mm, 9.9 mm in diameter and 0.3 mm in depth on 10 % of the circumference. CHAPTER 836 Page 36

Revision 23

MAINTENANCE MANUAL SO 105 836 - 12

Assembly - winch boom assembly

1. Assemble fork lever. EFFECTIVITY

Valid for configuration I only.

a.

Install spherical bearing (4, figure 836-1 O), snap rings (3) and seals (2). Observe position of notch (point of rupture) on spherical bearing relative to position of bushing (5, Detail A). .

b.

Install self-aligning bearing (9), snap rings (8) and seals (7). Observe installation position of seals (see Detail B).

EFFECTIVITY

Valid for configuration 11 only.

c.

Install bearings (4, 9, figure 836-10) and secure with snap rings (3, 8).

d.

Insert bushing (5) in bearing (4) so that the flange of the bushing is on the underside of the fork lever.

e.

Install seals (2, 7) and bushing (6), taking care that the chamfer ofeach seal is opposite the respective snap ringo

1.

Secure quick-release pin (14) to fork lever with screw (15).

g.

Install hinged lever (16). Clearance between contact surfaces must be 9, 1 +0,2 mm, install washer (21) as necessary. Torque load nut (19) (torque value see figure 836-1 OA) and safetywith split pino If necessary, torque nut to the next split-pin hole.

2. Assemble winch boom support (see figure 836-11). a.

Packthread and sliding surface of adjusting screw (9) with grease (CM 102). Screw in adjusting screw (9) and adjusting screw (13) together with safety spring (14) into bearing support (15).

b.

Slide retaining ring (5), gasket (2) and cover ring (6) onto bearing journal (1).

c.

Slide self-aligning bearing (7) onto bearing journal (1) and install retaining ring (8).

d. Attach bearing support (15) to self-aligning bearing and fasten with screws (3) and washers (4). Secure screws with lockwire. e.

Installlocking plate (10) and screws (16) and secure with lockwire. Install cap (17).

3.

Install fork lever (16, figure 836-9).

4.

Install servo motor (refer to paragraph 836-36).

5.

Install winch unit (refer to paragraph 836-25).

6.

Install hook/bumper assy (refer to paragraph 836-20).

Revision 23

CHAPTER 836 Page 37

tDeurocopter l1li

MAINTENANCE MANUAL 80 105

EADS Campany

836 - 13

Installation - winch boom assembly

CAUTION

• OBSERVE INSTRUCTIONS FOR STORAGE ANO TRANSPORT (REFER TO PARAGRAPH 836-9) AS THERE IS A RISK OF OAMAGING THE SERVO MOTOR ROO ANO THE CABLE.

• Lift winch boom into mounting fittings with a three-person crew as there is a risk of damaging mounting fittings and winch boom bearing support.

•

EFFECTIVITY

Valid for configuration I only.

1. Insert winch boom assy in mounting fittings (9 and 7, figure 836-8) and slide rings (2). Install self-Iocking pin (1). EFFECTIVITY

I

a.

Valid for configuration 11 only.

Insert winch boom assy in mounting fittings (9, 7 and 21 ,figure 836-8) and slide rings (2). Install self-Iocking pin (1,22).

2. Adjust winch boom bearing support if winch boom is installed for the first time or if winch boom bearing support has been disassembled. Tolerances in height of fuselage mounted fittings relative to the attachments of the winch boom are compensated for in this way. a.

Remove cap (17), screw (16) and locking plate (15).

b. Move winch boom in desired position by turning adjusting screw (14). Push winch boom tube upward to relieve the bearing. The bearing support is properly adjusted if spherical bearing of servo motor red (11) is centered between lever halves (10). c.

Install screws (16) and locking plate (15). Secure screws with lockwire. Install cap (17).

3.

Unscrew adjusting screw (6) using a pin until bearing support seats on console (7) free of play. Check on first installation that there is satisfactory contact surface between bearing support (5) and adjusting plate (19). Ensure contact surface by relocating (inner and outer) adjusting plates.

4.

Install cartridge (refer to paragraph 836-32).

4A.lnstall skid guard assembly (18, fig. 836-1) on skid tube. 5. Connect electrical connector (4) and secure with lockwire. Take travel of winch boom into consideration when routing the cable to the connector. 6. Connect winch controllever (5, figure 836-1) to overhead panel. 7. Check that the system is operational (refer to paragraph 836-4). 8.

Inspect cable in the vicinity of bumper assy for condition (refer to paragraph 836-5).

9. Check Iimit switch UP for function (refer to paragraph 836-4).

CHAPTER 836 Page 38

Revision 23

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836 - 14

Ho o k / b u mp e r

a s s e mb 1 Y

&

Shown offset by 45 o

~

Flanged area of threaded insert (21) and sleeve (9) Figure 836-13

Hook/bumper assy

(1 of 2) BO 105 CHAPTER 836

Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

1 2 3 4 5 6 7 8

Stop plate Stop plate support Cable guide Indicator pins Boot Screw Cover Slide ring 9 Sleeve 10 Spring 11 Spring 12 Screw 13 Bumper housing 14 Washer 15 Hook Figure 836-13

836 - 15

16 17 18 19 20 21 22 23 24 25 26 27 28 29

Spring Locking plate Screw Locking bushing Cable attachment screw Threaded insert Guard ring Stop plate Shim Spring plate Shim Dowel pin Bushing Axial bearing

Hook/bumper assy

(2 of 2)

Flushing - hook/bumper assembly

Special tool: 2 wing bolts CAUTION

DIN316-M8x60-g-4.6 HOLD HOOK/BUMPER ASSY IN SUCH A WAY THAT CABLE IS NOT KINKED.

l.

Reel out hook/bumper assy. Push circuit breaker WINCH on instrument panel and set switch WINCH on overhead panel to ON. Actuate winch unit with switch WINCH on co1lective stick.

2.

Pull off boot (5, figure 836-13) from cover (7).

3.

Evenly screw in the two wing bolts in threaded bores of bumper housing (13) to lift spring plateo Thus the water can be drained from the housing when flushing the spring plateo

4.

Immerse hook/bumper assy in water.

5.

Install boot on cover and reel in hook/bumper assy.

6.

Switch off the system. Set switch WINCH on overhead panel to OFF. Pull circuit breaker WINCH on instrument panel.

BO 105 CHAPTER 836 Page 40

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Removal - hook/bumper assembly

Special tools: 2 wing nuts Mounting wrench 1.

Reel out cable to convenient height (approximately 1 m) . CAUTION

2.

DIN 316-M8x60-g-4.6 105-81210 W1

DO NOT SLANT HOOK/BUMPER ASSY TO PREVENT DAMAGE TO CABLE BY KINKING.

Evenly screw in the two wing bolts in threaded bores of bumper housing (13, figure 836-13) until they abut in order to lift spring plate (25). CAUTION

DO NOT KINK CABLE WHEN PULLING OFF STOP PLATE (1) FROM STOP PLATE SUPPORT (2).

3.

Pull off stop plate (1) from stop plate support (2) and remove cable guide (3).

4.

Pull off boot (5) from cover (7). CAUTION

HOOK/BUMPER ASSY IS SEPARATED FROM CABLE BY UNSCREWING CABLE ATTACHMENT SCREW. HOLD HOOK/ BUMPER ASSY.

NOTE

If during removal of the cable attachment screw the cable should jaro and become twisted, hold the cable attachment screw with mounting wrench, P/N 105-81210 W1 and rotate the bumper housing (13).

5.

Remove locking plate (17) and unscrew cable attachment screw (20) using mounting wrench 105-81210 W1. Insert through bore of stop plate support (2).

6.

Detach cable through slot of stop plate support (2).

7.

Pull off stop plate from cable.

8.

Remove both wing bolts if hook/bumper assy is to be disassembled.

BO 105 CHAPTER 836 Page 41

MAINTENANCE MANUAL BO 10S

I

836 -17

Disassembly - hooklbumper assembly

Special tools:

Mounting tool Mounting tool

10~1210 W3 or 0136-842 10~1210 W2 or 0136-841

1. Clamp hook/bumper assy on hook (see figure 836-13). 2. Remove guard ring (22). Remove screw (12) and pul! off guard ringo CAUTION

• COVER (7) IS UNDER SPRING TENSION. WHEN REMOVING THE LAST TWO SCREWS (6) HOlD COVER AGAINST SPRING lOAD. • THE TWO WING NUTS (SPECIAl TOOl FOR REMOVAl OF HOOKlBUMPER ASSY) MUST NOT BE SCREWED IN SO THAT THERE IS NO ADDITIONAl SPRING lOAD.

3. Remove cover (7). 4. Remove spring (16) from threaded insert (21).

• • 5.

a. Rotate threaded insert (S, figure 836-14) using mounting tool1 05-8121 OW3 or 0136-842 (1) until end of spring is visible through bore of sleeve (4). Block spring end with mandrel (2). b.

Unscrewthreadedinsertfromblockedspringusingmountingtool10~1210W30rD136-842.Simulta­

neously push threaded insert with mandrel (3) So that spring end contacts mandrel (2) during the unscrewing process. Loasen tight threaded insert with a hammer blow onto mandrel (3). Pul! off boot (8) from caver (7) and stop plate support (9).

6. Oetach spring (6) from stop plate support (9).

I

a. Place stop plate support on mounting tooI 10~121 OW3 or 0136-842. b. Unscrew spring from stop plate support with mounting tool1 0~121 OW2 or 0136-841.

CHAPTER 836 Page42

Revision 22

e

eurocopter

MAINTENANCE MANUAL BO 10S

3---------H:

~.------9

....- - - - ' - - - 8

7

I I

II II I I

II .................... ..... :~:

tfH--Hf----iI---1--- 6

I 1

II

I I I I I

I

I

-----tIIlIIRil .::

& &

Clamphere Block spring end with mandrel

Figure 836-14 Revision 22

:::

1 Mounting too1105-81210 W3 or D136-842 2 Mandrel 3 Mandrel 4 Sleeve 5 Threaded insert 6 Spring 7 Cover 8 Boot 9 Stop plate support

I

Removal - Spring from threaded insert CHAPTER 836 Page43

- - - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 836 - 18

Inspection and repair - hook/bumper assembly

1.

Inspect buffer plate (1, figure 836-13) for cracks mechanical damage, and separation of the rubber from the buffer plateo If evidence of cracks and/or separation of the rubber from the buffer plate are detected, replace buffer plateo Mechanical damage can be polished out with fine emery cloth.

2.

Visually inspect stop plate support (2) for corrosion damage. Eliminate damage (refer to Chapter 02). Damage limit: 0.2 mm in depth on a maximum of 20 % of contact surface with cable guide (3). 0.3 mm in depth on the remaining surfaces.

3.

Inspect boot (5) for

4.

Inspect cable guide (3).

5.

6.

~ondition.

Replace boot if cracked or brittle.

a.

Visually inspect cable guide for scores and corrosion damage. Eliminate scores and corrosion damage (refer to Chapter 02). Damage limit: 0.5 mm in depth on contact surface with cable. 0.2 mm in depth on a maximum of 20 % of the contact surface with stop plate support (2).

b.

Inspect indicator pin (4) for mechanical damage and correct length (refer to figure 836-4, length "X"). In case of mechanical damage and/or incorrect length ("X" smaller as 2 mm), replace indicator pin as follows. 1)

Remove damaged pins.

2)

Insert new pins using loctite (CM 651). The dimention "X" must be 2 mm.

Inspect threaded plug (21, figure 836-13). a.

Visually inspect threaded plug for mechanical damage and corrosion. Damage to the flanged area (see figure 836-13) is not permissible as this area is highly loaded. Polish out mechanical damage and corros ion on the remaining area (refer to Chapter 02). Damage limit: 0.2 mm in depth and 0.2 mm in depth on 20 % of the round thread.

b.

Perform penetrant inspection per MIL-I-6866 in the flanged area (see figure 836-13). Replace threaded plug if a crack is evident.

Inspect spring plate (25) including sleeve (9). a.

Inspect the portion of the sleeve which slides through cover (7) for mechanical damage. Eliminate damage (refer to Chapter 02). Damage limit: 45.8 mm in diameter and 0.3 mm in depth on 10 % of the circumference.

BO 105 CHAPTER 836 Page 44

- - - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 b.

Visually inspect transition zone of spring plate/sleeve for cracks using a (5 power) magnifying glass. Replace spring plate/sleeve if a crack is evidente

NOTE

Apart from the magnetic brake, springs (10, 11 and 16) are decisive for the cable overtravel (dimension Y, figure 836-5) of the winch unit. In order to adjust cable overtravel following winch motor replacement, spring (16, figure 836-13) is available in three different lengths (166, 195 and 215 mm). Cable overtravel is reduced by the installation of a long spring. If spring (16) is replaced because of a spring damage, a spring of identical length mustbe installed.

7.

Visually inspect springs (10, 11 and 16) for irregular deformation (bent spring axis) and corrosion. Replace spring if deformed or if corrosion is evidente

8.

Inspect cover (7) including slide ring (8).

9.

a.

Visually inspect contact surface of springs for mechanical damage and corrosion. Eliminate damage (refer to chapter 02).

b.

Visually inspect flange, in particular in the areas of changing wall thickness, for cracks using a (5 power) magnifying glass.

c.

Visually inspect slide ring for wear. Replace slide ring if worn.

Inspect bumper housing (13) including hook (15). a.

Visually inspect bumper housing and hook for cracks, mechanical damage and corrosion. Replace part if a crack is evidente Eliminate damage (refer to chapter 02). Damage limits: 0.5 mm in depth on 10 % of the surfaces.

b.

Visually inspect threaded inserts for damage, secure installation and for signs of corrosion below threaded inserts. If there are signs of corrosion, remove threaded inserts and inspect for corrosion. Corrosion is acceptable at two threaded inserts as a maximum.

c.

Check that hook can be easily rotated. Remove axial bearing if hard to rotate or if rough running: Press out and press in dowel pin (27) of bearing through threaded bore for screw (12) using a mandrel.

d.

Visually inspect bushing (28) for corros ion damage. Replace bushing if corrosion damage is evidente

10. Visually inspect shims (24 and 26, if installed) for mechanical damage and corrosion. Eliminate damage (refer to chapter 02).

BO 105 CHAPTER 836 Page 45

_eurocopter 836 - 19

MAINTENANCE MANUAL BO 10S

Assembly - hooklbumper assembly

1. Pack contact surfaces of threaded insert (21, figure 836-13), sleeve (9) and spring plate (25), bumper housing (13) as well as all threads and spring ends with grease (CM 102). 2. Spray the remaining surfaces ¡nside bumper housing (13) with corrosion preventive compound (CM 508). 3. Screw spring (16) an stop plate support (2). 3A. Assemble springs (10,11), shims (24,26), spring plate (25), sleeve (4, figure 836-14), threaded insert (5), cover (7) and boot (8) as shown in figure 836-14.

4. Insert spring (16, figure 836-13) in sleeve (9). Screw in threaded insert in spring with mounting tool

•

105-81210 W3 or 0136-842 (1, figure 836-14). Check through lateral bore in sleeve that spring is fully screwed down. The axes of stop plate support (9) and threaded plug (5) must be in alignment so that cable is not kinked after the installation.

5. Insert spring plate (25, figure 836-13) together with existing shims (24 and 26) and springs (10 and 11) in bumper housing (13) and install cover (7). Secure screws (6) with lockwire. Following replacement of spring(s) one shim each must be installed (see figure 836-13). 6.

Install hook/bumper assy (refer to paragraph 836-20).

836 - 20

Installatlon - hooklbumper assy

Special tools:

2 wing bolts Mounting wrench

0IN316-M8x6D-g-4. 105-81210 W1

1. Evenly screw in both wing bolts in threaded bores of bumper housing (13, figure 836-13) until they abut in order to Iift spring plate (25). 2. Slightly pack cable attachment screw (20) an contact surface with cable and the threads with grease (CM 102). 3. Install stop plate (1) an cable. 4. Insert cable through slot in cable attachment screw (20).

CAUTION

00 NOT SLANT HOOKlBUMPER ASSY WHEN THE CABLE IS UNOER TENSION TO PRECLUOE OAMAGE TO THE CABLE BY KINKING.

5. Screw down cable attachment screw in threaded insert until it abuts using mounting wrench 105-81210 W1 and unscrew again untillocking plate (17) can be inserted. Install screw (18) with locking bushing (19).

CHAPTER 836 Page 46

Revision 22

- - - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 6.

Install boot (5) on cover.

7.

Secure two-part cable guide (3) with screws to stop plate support (2). Secure screws with lockwire. CAUTION

DO NOT KINK CABLE WHEN ATTACHING STOP PLATE (1) TO STOP PLATE SUPPORT (2).

8.

Attach stop plate (1) to stop plate support (2).

9.

Evenly unscrew both wing nuts. If wing nuts are not unscrewed evenly spring plate (25) may jam inside bumper housing (13). CAUTION

o PLACE CABLE ON A CLEAN SURFACE (E. G. PAPER) TO PRECLUDE PREMATURE WEAR OF CABLE AND TENSION ROLLERS CAUSED BY DIRT.

o THE CABLE MUST NOT BE REELED IN WHEN TWISTED OR KINKED. IF THE CABLE FORMS A LOOP, THE REEL-IN PROCESS MUST BE IMMEDIATELY INTERRUPTED TO CORRECT THE CABLE. o THE CABLE MUST BE TAUTLY REELED ON THE DRUM. A LOOSELY REELED CABLE WILL SQUEEZE ITSELF INTO THE UNDERLYING CABLE TURNS WHEN UNDER TENSION. THIS WILL CAUSE DAMAGE TO THE CABLE. WHEN REELING IN THE CABLE, TAUTEN THE CABLE VERTICALLY BY HAND AS LONG AS IT IS NOT LOADED BY THE BUMPER.

vmRNING

WHEN TAUTENING THE CABLE, WEAR GLOVES TO PROTECT YOUR HANDS AGAINST INJURIES.

10. Tauten the cable. a.

Extend winch boom and reel out cable until automatic switch-off occurs. Guide cable in such a way that it forms loops (shaped like a figure eight) with a big radius and place on a c1ean surface.

b.

Reel in cable. Guide cable by hand during reel-in operation. Tauten cable by hand (approximately 50 N) as long as it is not loaded by the hook/bumper assy.

11. Check limit switch UP for function (refer to paragraph 836-4).

BO 105 CHAPTER 836 Page 47

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 836 - 21

W~ n c h

u n i t

836 - 22

Lubrication - winch unit

l.

Remove winch unit (refer to paragraph 836-23).

2.

Remove cover froro gearbox case (2, figure 836-15) and switch box (1).

3.

Reroove old grease with a rag prior to packing with new grease.

4.

Pack gears in gearbox case (2) with grease (CM 112). NOTE

Do not pack the two big gears (switch gears) in switch box.

5.

Pack gears in switch box (1) with grease (CM 112).

6.

Install cover on gearbox case and install cover including seal on switch box. Secure screws with lockwire. CAUTION

.,, .

ANY GREASE ON THE PLASTICS COATED CABLE TENSION ROLLERS MUST BE WIPED OFF IMMEDIATELY.

Slightly pack all accessible gears with grease (CM 101) through openings A and B (see figure 836-15). Gears need not be rotated.

8.

Slightly pack cable guide rollers (metal rollers with crosswise grooves) with grease (CM 101) through opening B (see figure 836-15).

9.

Install winch unit (refer to paragraph 836-25) .

---'1'---2

1 2 A B Figure 836-15 BO 105 CHAPTER 836 Page 48

Lubrication - winch unit

Switch box Gearbox case Opening A Obening B

eeurocopter 836 - 23

MAINTENANCE MANUAL BO 105

Removal - winch unit

Special tools:

Protective cover

WA5-282

1. Remove hooklbumper assy (refer to paragraph 836-16). CAUTION

THE AUTOMATIC SWITCH-oFF "UP" IS NOT OPERATIVE WHEN THE HOOKlBUMPER ASSY IS REMOVED. OPERATE SWITCH IN JOGGING MODE ONLY.

2. Reel in cable to a residuallength of approximately 15 cm. This reduces the risk of a cable damage. 3. Switch off the system. Set switch WINCH on overhead panel to position OFF. Pull circuit breaker WINCH and circuit breaker CABLE CUTTER.

·1

4. Disconnect electrical connectors (13, 14 and 17, figure 836-16). WARNING

IF THE WINCH UNIT IS TO BE REMOVED FOR SHIPPING, REMOVE CARTRIDGE ANO SENO IT SEPARATELY, PACKED IN THE ORIGINAL CONTAINER.

5. Remove cartridge (refer to paragraph 836-31) and install protective cover WA5-282 (4). CAUTION

• WHEN REMOVING WINCH UNIT FROM WINCH SUPPORT ENSURE FREEDOM OF MOVEMENT BETWEEN CABLE ANO WINCH SUPPORTTO AVOID DAMAGE TO THE CABLE. • PUT DOWN WINCH UNIT IN SUCH A WAY THAT CABLE IS NOT KINKED ANO PROTECTIVE COVER WAS-282 IS NOT LOADED. • THE MASS OF THE WINCH UNIT IS APPROXIMATELY 25 KG. IT IS RECOMMENDED REMOVING THE WINCH BOOM TO FACILlTATE REMOVAL OF WINCH UNIT.

6. Remove screws (2, 5 and 6) and Iift winch unít out o, winch boom.

Revision 22

CHAPTER 836 Page49

- - - - - - - - - - - - - - : . . MEB HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

1 2 3 4 13

5 6 7 8

14

9

10

15

11

12

16

13

17

14

18

800230

~ Figure 836-16

BO 105 CHAPTER 836 Page 50

15 16 17 18

Winch unit Screw Locking plate Protective cover WAS-282 Screw Screw Locking plate winch support Winch motor Self-locking nut Socket screw Gearbox base plate Connector, winch motor Connector, limit switch Sleeve/Cartridge Threaded bushing Connector, cartridge Hook/bumper assy

Removal and installation - winch unit, winch motor and cartridge

Oeurocopter lIl1

836 - 24

MAINTENANCE MANUAL BO 105

EA06 Compeny

Inspection and repair - winch unit

1. When installed, the winch unit is inspected for condition as outlined in paragraph 836-3 and tested for function as outlined in paragraph 836-4. 2.

Repairs and overhaul of the winch unit must be performed by MBB exclusively.

836 - 25

Installation - winch unit

CAUTION

• WHEN L1FTING WINCH UNIT IN WINCH SUPPORT, ENSURE FREEDOM OF MOVEMENT BETWEEN CABLE AND WINCH SUPPORT TO AVOID DAMAGE TO THE CABLE. • SCREWS (2,5 AND 6, FIGURE 836-16) HAVE DIFFERENT LENGTH. THEY MUST BE INSERTED IN PAIRSIN SUCH A WAY THAT THE NUMBER ON THE SCREW HEAD CORRESPONDS TO THE NUMBER ON WINCH (8).

1. Tighten screws (2, 5 and 6) to specified torque (refer to figure 836-16) and secure with lockwire. 2.

Remove protective cover WAS-282 (4) and install cartridge (refer to paragraph 836-32).

3. Connect electrical connectors (13, 14 and 17) to winch unit and secure with lockwire. 4.

Install hook/bumper assy (refer to paragraph 836-20).

5. Visually inspect winch unit for secure installation. 6. Test rescue hoist for function (refer to paragraph 836-4). Inspection steps affecting the winch boom servo motor may be omitted.

CHAPTER 836 Page 51

Aeurocopter ~

MAINTENANCE MANUAL BO 105

"" EAOS Complsny

--

836 - 25A Replacement - printed circuit card 20MF 1. Make sure that the helicopter is deenergized and the EPU is disconnected. 2.

Pull circuit breakers 1MF and 2MF on the center console.

3. Remove lockwire from screw (3, Bild 836-16A) and discard. 4.

Remove screws (3) with washers (4), detach clamp band (6) and remove cover (7) from housing (5).

5.

Remove nuts (1 and 13), washers (2 and 11) with spring washer (12) and remove threaded pin (10) with spacer (8).

6. Carefully pull out the printed circuit card (9) from the multipole connector (15) in horizontal direction. CAUTION

OBEY IPC FOR MODIFICATION OR REPLACEMENT OF THE PRINTED CIRCUIT CARD BEFORE INSTALLlNG. BECAUSE ONLY A SPECIFIED PRINTED CIRCUIT CARD CAN INSTALLED TO THE DIFFERENT WINCH UNITS TO PREVENT MALFUNCTION.

-

7. Install printed circuit card (9) in reverse order of removal. 8. Apply sealing compound (CM 635) to the nut (1) and the washer (2). 9. Examine the seal (14) in the housing (5) for correct installation and damage. Replace damaged seal (14) (see section 836-3B, 5.). 10. Install cover (7) with the clamp band (6) on the housing (5) using screws (3) and washers (4). Safety screws (3) with lockwire (CM 775). 11. Do the functional test of the rescue hoist assembly (see section 836-4).

~-

CHAPTER 836 Page 51A

Revision 25

eeurocopter •

lIt1

MAINTENANCE MANUAL BO 105

EADS Company

"'~

15

1 Nut 2 Washer 3 Screw 4 Washer 5 Housing 6 Clamp band 7 Cover 8 Spacer

Figure 836-16A

Revision 25

9 Printed circuit card 10Threaded pin 11 Washer 12 Springwasher 13 Nut 14Seal 15 Multipole connector

Replacement - printed circuit card 2üMF

CHAPTER 836 Page 518

O~~pter

MAINTENANCE MANUAL BO 105

-.

836 - 26 Winch motor

836 - 27

Removal - winch motor

CAUTION

• WHEN HOOKlBUMPER ASSY IS REELED IN, THE ORIVE PINION OF THE WINCH MOTOR IS UNDER A TORSIONAL LOAD. TO AVOID DAMAGE TO THE ORIVE PINION WHEN REMOVING THE WINCH MOTOR, THE HOOKlBUMPER ASSY MUST BE REELED OUT. • WITHOUT WINCH MOTOR THE CABLE DRUM IS NOT BRAKED. PLACE HOOKlBUMPER ASSY ON A SUPPORT TO UNLOAD THE CABLE. • PUT DOWN HOOKlBUMPER ASSY IN SUCH WAY THAT CABLE IS NOT KINKED.

1. Reel out hooklbumper assy. Push circuit breaker WINCH on instrument panel and set switch WINCH on overhead panel to position ON. Actuate winch unit via switch WINCH on collective stick or winch control grip. Place hooklbumper assy on a support. 2.

-

Switch off the system. Set switch WINCH on overhead panel to position OFF. Pull circuit breaker WINCH on instrument panel.

3. Disconnect electrical connector (13, figure 836-16) from winch motor. 4.

Remove nuts (10) and screws (11) and detach winch motor from winch unit.

836 - 28

Inspection and repair - winch motor

The winch motor must be repaired by the manufacturer exclusively.

-

CHAPTER 836 Page 52

Oeurocopter

MAINTENANCE MANUAL SO 105

en EAOS Compeny

836 - 29

Installation - winch motor

CAUTION

BEFORE INSTALLlNG WINCH MOTOR, OBEY IPC FOR THE CORRECT WINCH MOTOR AND PRINTED CIRCUIT CARD 20MF, WHICH IS INSTALLED INTO THE RELAY BOX 23VE. BECAUSE ONLY A SPECIFIED WINCH MOTOR WITH A SPECIFIED PRINTED CIRCUIT CARD SHOULD INSTALLED INTO THE WINCH UNIT TO PREVENT MALFUNCTION.

1. Pack drive pinion of winch motor (9, figure 836-16) with grease (CM 112). 2. Attach winch motor to gearbox base plate (12). Connector (13) must point downward. 3. Connect electrical connector (13) and secure with lockwire. 4. Tighten cable on cable drum. CAUTION

a.

PLACE CABLE ONLY ON A CLEAN SURFACE (E. G. PAPER) TO PRECLUDE PREMATURE WEAR OF CABLE TENSION ROLLERS CAUSED BY DIRT.

Reel out cable until automatic switch-off occurs. Guide cable during reel-out in such a way that it forms loops (shaped like a figure eight) with a big radius on a c1ean surface.

CAUTION

• THE CABLE MUST NOT BE REELED IN WHEN TWISTED OR KINKED. IF THE CABLE FORMS A LOOP, THE REEL-IN PROCESS MUST BE IMMEDIATELY INTERRUPTED TO CORRECT THE CABLE. • THE CABLE MUST BE TAUTLY REELED ON THE DRUM. A LOOSELY REELED CABLE WILL SQUEEZE ITSELF INTO THE UNDERLYING CABLE TURNS WHEN UNDER TENSION. THIS WILL CAUSE DAMAGE TO THE CABLE. WHEN REELlNG IN THE CABLE, TIGHTEN THE CABLE VERTICALLY BY HAND AS LONG AS IT IS NOT LOADED BY THE BUMPER. • DO NOT SLANT HOOKlBUMPER ASSY WHEN TIGHTENING THE CABLE TO PRECLUDE DAMAGE TO THE CABLE CAUSED BY KINKING.

WARNING

b.

WHEN TIGHTENING THE CABLE, WEAR GLOVES TO PROTECT YOUR HANDS AGAINST INJURIES.

Reel in cable. Tighten cable with your hand (approximately 50 N) as long as it is not loaded by hook/ bumper assy.

5. Test rescue hoist for function (refer to paragraph 836-4). Steps affecting the winch boom servo motor may be omitted.

Revision 25

CHAPTER 836 Page 53

I

-eurocopter •

Illl

MAINTENANCE MANUAL BO 105

EAOO Compeny

836 - 30 Cartridge

I

836 - 31

I

REMOVAL AND INSTALLATION OF CARTRIDGES HAS TO BE CARRIED OUT BY BRIEFED PERSONNEL, AS CARTRIDGES CONTAIN EXPLOSIVE MATERIAL.

WARNING

Removal - cartridge

• FOR STORAGE OF THE REMOVED CARTRIDGE USE THE ORIGINAL CONTAINER, WHICH THEN HAS TO BE PLACED IN A CLOSED AND LOCKED STEEL SHELF. DO NOT STORE MORE THAN 5 KG IN ONE SHELF.

WARNING

• OBSERVE THE EXPLOSIVES.

APPLlCABLE

REGULATIONS

FOR

AMMUNITION

AND

1. Remove connector (17, figure 836-16) of cable cutter. 2. Carefully unscrew threaded bushing (16) out of cable cutter bore. 3. Carefully pull cartridge (15) out of cable cutter bore.

836 - 32

•

Installation - cartridge

WARNING

KEEP ORIGINAL CONTAINER FOR STORAGE AND SHIPPING.

1. Carefully screw cartridge (15, figure 836-16) into cable cutter bore. 2. Carefully screw threaded bushing (16) onto cable cutter and tighten by hand. 3. Connect electrical connector (17). Secure sleeve (15), threaded bushing (16), electrical connector (17) with lockwire. 4. Check that cable cutter is operative. Push circuit breaker WINCH and circuit breaker CABLE CUTIER on instrument panel. Set switch WINCH on overhead panel to position ON. Briefly actuate test switch CABLE CUTIER TEST on overhead panel. Indicator light CABLE CUTIER TEST must go on.

CHAPTER 836 Page 54

Revision 22

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- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 836 - 33

S e r v o

836 - 34

Removal - servo motor

1.

mo t o r

Disconnect electrical connector from servo motor. CAUTION

o

WHEN PULLING OFF LEVER HALVES (14, FIGURE 836-17) HOLD SPHERICAL BEARING (12) OF SERVO MOTOR ROD TO AVOID BENDING OF SERVO MOTOR ROD.

O

IFAXLE (13) IS REMOVED, THE SWING ANGLE OF THE WINCH BOOM IS NO LONGER LIMITED.TO AVOID ANY DAMAGE SECURE WINCH BOOM.

2.

Remove nylstop nuts (9 and 17) and screw (16). Carefully pull lower lever half downward.

3.

Remove locking plate (2).

4.

Remove screws (7) and pull bearing pivots (4) out of servo motor mounting. Detach servo motor.

836 - 35

Inspection and repair - servo motor

The servo motor must be repaired by the manufacturer exclusively.

BO 105 CHAPTER 836 Page 55

- - - - - - - - - - - - - M B B HELICOPTERS ------~------­ MAINTENANCE MANUAL MBB - BO 105

DETAlL

2

3

A

&

4

I

&I

70 Nm

+-----.,.-6

VIEW

B \J'1----+-?

~~3----8 rM'-....-~--T-----

4

~

B

800233

& &

Align with pin hole Groove must point at screw (7)

Figure 836-17 BO 105 CHAPTER 836 Page 56

Removal and installation - servo motor

(1 of 2)

_~!!;.copter

MAINTENANCE MANUAL BO 105

1

Screw

11

Split pin

2

Locking plate

12

Spherical bearing -

3 4

Screw

Axle

Washer

13 14

Servo motor

15

Cover ring

7

Screw

16

Screw

8

Fork lever

Nylstop nut

9

Nylstop nut

17 18 19

I: 10

Bearing pivot

Washer

Figure 836-17

836 - 36

servo motor red Lever half

Washer Split·pin

Removal and installation - servo motor)(2 of 2)

Installation - servo motor

1. Pack both bearing pivots (4, figure 836-17) and thread ends of both screws (7) with grease (CM 101). 2. Insert servo motor (6) together with washers (5) in fork lever and insert both bearing pivots (4). The groove in bearing pivot must point at screw (7) (see figure 836-17). 3. Screw down both screws (7). It must not be possible to rotate bearing pivots. Secure screws with lockwire. 4. Screw down screws (3) and secure with thread sealant (CM 620). 5.

Install locking plate (2). Secure screws (1) with lockwire.

6. Install lever half (14). Torquevalues perfigure 836-17. Secure nylstop nuts (9 and 17) withsplit pins. Secure . screws (16) with lockwire. 7. Test servo motor for function. a. Push circuit breaker WINCH on instrument panel. Set switch WINCH on overhead panel to position ON. b.

Briefly operate switch WINCH on winch control grip or switch WI NCH an collective stick. The winch boom must follow the control command.

c.

Switch off the system.

Revision 23

CHAPTER 836 Page 57

Oeurocopter 11ft EACS

MAINTENANCE MANUAL BO 105

Comp8ny

836 - 37 Mounting fittings

836 - 38

Removal - mounting fittings

1.

Remove console (4, figure 836-18). Loosen nylstop nuts (14) by a fewrotations. Removescrews (8). Carefully detach console from sliding rings. Blank off threaded bores on fuselage with caps.

2.

Remove support (1). Blank off threaded bores on fuselage with caps.

3.

Disassemble mounting assy (23) or mounting assembly (23, configuration 11 only) if slide ring (18) or bolt (16) is to be replaced.

836 - 39

Inspection and repair - mounting fittings

1.

Clean fitting (27, figure 836-18), support (1) and fuselage mounted fittings with a lint- free cloth made damp with dry cleaning solvent (CM 202).

2.

Inspect console (4) and fork (6). a.

Visually inspect console (4) for cracks, mechanical damage and corrosion. 1) Visually inspect the marked area 3 Ooint between console (4) and fitting (27), and contact area of fitting (27) to fuselage mounted fitting), for cracks, using a (5 power) magnitying glass. Replace damaged item before next flight with external hoist if a crack is evident. 2) Visually inspect the marked area 5 (contact area of fitting (27) to fuselage fitting and contact area on fuselage mounted fitting) for corrosion and mechanical damage. Eliminate damage (refer to chapter 02). If the damage limits are exceeded, replace damaged item before next flight with external hoist. Damage limit: 24.8 mm in diameter and 0.3 mm in depth on 10% of the circumference. Inside bore for self-Iocking pin: 15.8 mm in diameter and 0.5 mm in depth on 20 % of the bore surface.

b.

Check fork (6) for deformation and dimensionally check fork gap. Damage limit 12.5 mm. Replace fork if deformed.

3. Visually inspect support (1) for cracks, corrosion and mechanical damage. a.

Visually inspect the marked area 3 (contact area of support to fuselage mounted fittings) for cracks, using a (5 power) magnitying glass. Replace support before the next flight with external hoist if a crack is evident.

b. Visually inspectthe marked area 5 (contact area of supportto fuselage mounted fittings) for corrosion and mechanical damage. Eliminate damage (referto Chapter02). Ifthe damage limits are exceeded, replace support (1) before next flight with external hoist. Damage limits: 0.5 mm in depth on 30 % of the surface. On the peg: 24.8 mm in diameter and 0.3 mm in depth on 10% ofthe circumference. Inside bore for self-Iocking pin: 15.8 mm in diameter and 0.5 mm in depth on 20 % of the bore surface.

CHAPTER 836 Page-58

Revision 23

o 4.

eurocopter l1li

MAINTENANCE MANUAL BO 105

EADS Comp8ny

Inspect fuselage mounted fittings and fuselage structure in the area of mounting fittings.

á. Visually inspect mounting fittings and fuselage structure for cracks, other mechanical damage and corrosion and for loose rivets. Repair damage to fuselage structure. Eliminate damage an mounting fittings (referto chapter 02). Damage limit: 0.1 mm in depth on the entire surface and 0.5 mm in depth on 10% ofthe surface, but not reducing wall thickness by more than 10%. b.

Inspect slide rings (18, figure 836-18) for condition. Replace damaged slide rings.

836 - 40 1.

Installation - mounting fittings

Install support (1, figure 836-18). a.

Spray sepetating agent (CM 720) to support (1) and fuselage mounted fitting.

b.

Apply 2-component adhesive (CM 6041) (26) thinly to the contact area of the support (1).

c.

Align support (1) as shown in figure 836-18. Tighten screws (3) by hand. Allowthe adhesiveto cure (refer to manufacturer's instructions).

d. Tighten screws (3) to torque value specified in the figure 836-18 and safety with locking wire. Remove surplus adhesive paste. e.

2.

Apply a bead-seal of sealing compound (CM 662) (25) circumferential to the support (1) (refer to figure 836-18, section A-A).

Install console (4). a.

Spray sepetating agent (CM 720) to fittin (27) and fuselage mounted fitting.

b. Apply 2-component adhesive (CM 6041) (26) thinly to the contact area of the fitting (27). c.

Loasen nylstop nuts (14) offork (6). Insertfork inslide rings (18). Tighten nylstopnuts (14)totorquevalue specified in figure 836-18 and secure with split pino Tighten the screws (8) by hand.

.d.

Check positioning ofthe console. Make shure that the cell mounted bracket (24) does not touch the console (6) on its face side. Allow the adhesive to cure (refer to manufacturer's instructions).

e.

Tighten the screws to torque value specified in figure 836-18. Remove surplus adhesive paste.

f.

Apply a bead-seal of sealing compound (CM 662) (25) circumferential to the fitting (27) (refer to figure 836-18, section 8-8).

Revision 23

CHAPTER 836 Page 59

o

eurocopter

MAINTENANCE MANUAL SO 105

an EACS CompIIny

9

'.

10

~

27

Figure 836-18 CHAPTER 836 Page 60

I

Removaf, disassembly and assembly - mounting fittings Revision 23

Oeurocopter 8ft

MAINTENANCE MANUAL BO 10S

EAOS ClImpony

25

1 27

26--+-€rA 26----H!t-.'

o

-------o

SECTIONB - B

SECTIONA - A

I

&

Align center line parallel to rotor mast (3? tilt)

&

Align with pin hole

& & &

Visually inspect this area for cracks Apply Pos 26 to the underside Inspect the contact areas for corrosion

1 2 3 4 5 6 7 8 9 10 11 12 13

Support Washer Screw Console Solt Fork Washer Screw Nut Adjusting plate Adjusting plate Screw Washer

I

14 15 16 17 18 19 20 21 22 23 24 25 26 27

Nylstop nut Split pin Solt Washer Slide ring Washer Nylstop nut Split piri Mounting assy Mounting assy Cell mounting bracket Sealing compound CM 662 2-component adhesive paste CM 6041 Fitting

Figure 836-17A (2 ot 2) Revision 23

CHAPTER 836 Page 60A

_

eurocopter

MAINTENANCE MANUAL SO 105

en EAOS Company

BLANK PAGE

CHAPTER 836 Page 60S

e

eurocopter

836 - 41

MAINTENANCE MANUAL 80 10S

Cable Exchange Maintenance device locally fabricated (see fig. 83&-19) Drilling machine with drive shaft and driver nut 7/16 inch Measuring instrument with audio signal, commercial type

Special tools:

Limit switch and Iimit switch actuator are in two different configurations with regard to type and placement. The difference between the two configurations are: In configuration 1, the actuator cam is rivetecl to the Iimit switch gear assembly, with the cam operating the switch upon rotatíon of the gear and cam assembly. In configuration 11 the actuator is in form of a pin installed onto the adjustable switch plate, operating the Iimit switch upon ratation of the switch plate assembly (refer to figure 83&-20). Due to the these variations, a different approach has to be taken to perform the adjustments of the Iimit switch and Iimit switch actuator. The following text iIIustrates both of these configurations.

NOTE

1. Preparatory Work a. Reel out cable approx. 1.5 m and remove hooklbumper assy from the cable (refer to para 83&-16) b. Remove winch unit from the winch boom assembly (refer to paragraph 83&-23). c. Remove winch motor from the winch unit (refer to paragraph 83&-27). d. Install winch unittothe maintenance device (8, fig. 83&-20) using the red bores (9) on topofthewinch unit. e. Remove switch box cover (5). In configuration 1, also remove sealing.

1.

Remove cable access cover (6).

g. Remove transparent cable drum access cover (2). h. Remove gearbox cover (1). i.

Remove cable cutter protector (3).

Revision 22

CHAPTER 836 Page 61

•

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 2.

Cable Exchange a.

b.

Removal of the cable 1)

Pull cable out of the winch unit by hand until only one turn remains on the drum. Thereby guide cable into a box.

2)

Slowly continue pulling until the cable attachment clamp becomes visible in the cable access holeo

3)

Loosen attachment clamp by removing the two socket head screws with locking cups.

4)

Pull end of the cable with the attachment clamp out of the cable access hole, and remove clamp.

5)

Pull cable completely out of the winch unit via the cable guide roller assembly.

Preparations for cable installation 1)

Disassemble ratchet (10, fig. 836-20): Remove cotter pin (13), sleeve (12), spring (11) and ratchet (10) .

Step 2) and 3) only for configuration 1 2)

Loosen the two screws of the limit switches down, but do not remove.

3)

Disassemble limit switch gear (17): Remove cotter pin (16), sleeve (15), limit switch gear (17), washer (14). Keep washer (14) for reinstallation.

Step 4) only for configuration 11 4)

Remove switch plate assembly by removal of the 4 outer hex screws.

5)

Visually inspect all parts of the winch unit for damage. If required remove dirt with a dry cloth only.

6)

Check timing of cable guidance mechanism (fig. 836-21): Turn cable drum clockwise, until cable guide roller assembly (1) reaches the left end of its travel range and circle marker on the cable drum is in the center of the cable access holeo The markers on the front side of the two level wind screws (3) must align.

7)

Unpack cable and lay cable over a cable drum or equivalent.

BO 105 CHAPTER 836 Page 62

_eurocopter c.

3.

MAINTENANCE MANUAL MSS - 80 105

Installation of the cable 1)

Rotate cable drum in counter clock wise direction until the mounting hole for the cable clamp is visible in the cable access hole (7, fig. 836-20)

2)

Insert red end of the cable into the cable guide reller assembly, push cable until it is visible through the cable access holeo

3)

Guide cable through the slot in the cable drum until it extends through the cable access hole, so that cable clamp can be meunted.

4)

Press cable clamp onto the cable approximately 7 mm from the red end of the cable.

5)

Push cable end back inte the winch unit housing. Install cable clamp to the cable drum side with twe socket head screws. Terque screws with 3 Nm.

6)

Reinstall ratchet assembly: Place the ratchet (10), the spring (11), and the sleeve (12) on axis of the driving roller assembly and secure with a cotter pin (13).

Adjustment of the lirnit switches down:

CAUTION

e THE CABLE MUST BE REELED IN WHEN TWISTED OR KINKED. IF THE CABLE FORMS A LOOP, THE REEL-IN PROCESS MUST BE IMMEDIATELY INTERRUPTED TO ADJUST THE CABLE. e THE CABLE MUST BE TAUTLY REELED ON THE DRUM. A LOOSELY REELED CABLE WILL SQUEEZE ITSELF INTO THE UNDERLYING CABLE TURNS WHEN UNDER TENSION. THIS WILL CAUSE DAMAGE TO THE CABLE. WHEN REELING IN THE CABLE, TAUTEN THE CABLE VERTICALLY BY HAND AS LONG AS IT IS NOT LOADED BY THE BUMPER.

a.

Reel up cable using a handdrill which is cennected to the uprnost gearstage via a 7/16 inch nut (fig. 836-22). For configuration 11 rernove cotter pin (3). Slightly tauten cable by hand during reeling in.

b.

With ene cable turn on the drum interrupt reel up and press cable towards the drurn side te ensure that the cable is fully seated and taut in the drurn grooves.

Revision 7

BO 105 CHAPTER 836 Page 63

* * * * * * * *

* * *

_eurocopter

NOTE

c.

MAINTENANCE MANUAL MBB - BO 105

The correct number of cable layers requested are fully wound if the cable layers and cable mounting passage in the side wall of the drurn are visible through the cable drurn access hole (refer to figure 836-20). Continue reeling up until 4 cable turns are on the cable drurn.

Step d. through f. only for configuration I d.

Place washer (14, fig. 836-20) and limit switch gear (17) on cable drurn axis, and tighten the two screws of the limit switches (19).

e.

Connect measuring device to limit switch, pins C and H on connector (fig. 836-23).

f.

Calibrate setting of the limit switch gear until the switch opens (acoustic signal switched off) .

Step g. through i. only for configuration II g.

Place limit switch plate (20) in position and install the 4 hex screws (21). Do not torque screws at this time.

h.

Connect measuring instrurnent to the pins C and H of the limit switch plug (fig. 836-23).

l.

Rotate limit switch gear assembly in clockwise direction until limit switch is open (acoustic signal switched off). Then torque the 4 hex screws.

j.

Reel up cable until the switch closes (acoustic signal switched on).

k.

Slowly reel out the cable by hand until the switch opens again (acoustic signal switched off) .

l.

Mark cable with scotch tape or equivalent at point of exit at the cable guidance plateo Unwind 120 mm of cable, and mark cable again.

m.

Unwind cable except for 3 remaining full layers (for full length of cable, refer to NOTE in step c.). Measure unwound length of cable up to second marking. Cable length should not be less than 190 mm. Procedure if cable length is less than 190 mm 1)

Wind cable until 4 full layers are wound on the drurn, and add the missing difference from actual length to requested length of 190 mm.

2)

Depending on the type of configuration, adjust limit switch plate or limit switch gear assembly until limit switch is open (acoustic signal switched off) .

BO 105 CHAPTER 836 Page 64

Revision 7

fteurocopter 3)

MAINTENANCE MANUAL MBB - BO 105

Repeat step j. to m. until requested mínimum length of 190 mm is measured.

n.

Connect measuring instrument to pins C and D of the limit switch plug (fig. 836-23). .

o.

Reel up cable until the switch closes (acoustic signal switched on) .

p.

Slowly reel out the cable by hand until the switch opens again. At least six full cable turns must remain on the drum.

Step q. only for configuration 1 q. 4.

Install washer (14, fig. 836-20) and sleeve (15) and secure with cotter pin (16).

Reassembling of the winch unit CAUTION

a.

IT HAS TO BE ASSURED, THAT DURING THE REEL UP PROCESS THE CABLE IS WOUND FREE OF TWISTS AND DEFORMATIONS. IT 15 RECOMMENDED TO GUIDE THE CABLE OVER A ROPE REEL OR EQUIVALENT.

Reel up cable to a residual length of approximately 150 mm.

Step b. for configuration b.

1

only

Secure screws of the limit switch (19, figure 836-20) with safety laquer (CM 680) .

Step c. for configuration 11 only

5.

c.

Install split pin (3, figure 836-22) and secure nut.

d.

Remove used grease from gears using cloth and apply new one (CM 112) •

e.

Reinstallation of covers (figure 836-20). Install cover (5) and seal (4) (latter for configuration 1 only) , cover (6) of cable access hole cover (2) of cable drum housing, transmission housing cover (1), and cable cutter protection cover (3). Secure all screws with safety wire.

Reinstallation of the winch unit a.

Remove winch unit from the maintenance device.

b.

Reinstall winch motor (refer to paragraph 836-29) .

c.

Reinstall winch unit (refer to paragraph 836-25).

Revision 7

BO 105 CHAPTER 836 Page 65

* * * * *

*

_eurocopter

MAINTENANCE MANUAL M88 - 80 105

.1

110 82

•!

:2

I /' ~

I

I

~

lf1

l' +-" 8.5

10

~

8S : I

lO N N

I

, : ;

1

800249

Dimensions in mm Material: Aluminium Figure 836-19 80 105 CHAPTER

Page 66

836

Maintenance Tool (locally fabricated)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A Configuration 11

Configuration 1

17

, •

3

6

2

only for configuration 1

----_/

'V

6

8

s

7 800250

8

Figure 836-20

6

Partly disassembled for cable replacement BO 105 CHAPTER 836

Page 67/68

1 Cover (Transmission Housing) 2 Cover (Cable Drum Housing) 3 Protective Cover (Cable Cutting Device) 64 Seal 5 Cover (Switch Housing) 6 Cover (Cable Entrance) 7 Cable access hole (Cutout) in Housing) 8 Maintenance Device 9 Winch Agregate

10 11 12 13

r

6 i~ 6

17 18 19 20 21

Ratchet Spring Sleeve Cotter Pin Washer Sleeve Cotter pin Limit Switch Gear Cable Clamp Limit Switch Limit Switch Plate Allen Screw

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

I

\

\ \

o I

¡ 4

Assembly marker mus! be in vertical position 800250

Figure 836-21

1

Cable guide roller assembly 2 Marking 3 Cable guide drum 4 Maintenance tool

Adjustment of the cable guide BO 105 CHAPTER 836

Page 69

- - - - - - - - - - - - . : . . . M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 Connection part 2 Nut 7/16 inch 3 Split pin ~

Figure 836-22

BO 105 CHAPTER

Page 70

836

only for configuration 11

Cable wind-up with special tool (Drill and extention)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

h--

~_.

-------, I

800253

IL...-

Figure 836-23

.J

Lirnit switch connector BO 105 CHAPTER 836 Page 71/72

EUROCOPTER

MAINTENANCE MANUAL BO 105

836 - 42 INSPECTION SCHEDULE (reter to Chapter 101)

Revision 18

CHAPTER 836 Page 73

EUROCOPTER

MAINTENANCE MANUAL 80 105

BLANK PAGE

CHAPTER 836 Page 74

Revision 18

MAINTENANCE MANUAL 80105

EUROCOPTER

12) Press annunciator

Lamptest

13) Winch control grip (winch operator)

Extend winch boom, reel out cable by approximately 1 m

14) Winch boom

Condition, secure installation to fuselage

15) Check of indicator pins and cable inspection a)

Boot on hook/bumper assy

Detach at the bottom, fold inside out

b)

Indicator pins

Check for damage. If damaged and length is more than 2 mm shorter, replace indicator pin and inspect cable.

c)

Cable in vicinity of bumper

Condition

d)

Boot

Refold and attach

16) Winch control grip (winch operator)

Reel in cable until automatic switch-off occurs, retract winch boom

17) Collective pitch (pilot)

Extend winch boom, reel out cable by approximately 1 m, reel in cable until automatic switch-off occurs, fully retract winch boom

18) Main switch WINCH

Set to OFF

19) Skid guard assembly

Installed

* *

* c.

Inspection prior to every rescue hoist operation 1)

Electrical connections (2)

Secure fit, secured

2)

Retaining belt and safety belt

Condition, secure installation, fas ten belt

3)

Winch control grip (winch operator)

Connected

Revision 12

BO 105 CHAPTER 836 Page 75

MAINTENANCE MANUAL BO 105

EUROCOPTER

4)

Circuit breaker WINCH, Circuit breaker CABLE CUTTER

Pushed

5)

Main switch WINCH

Set to ON, indicator light WINCH must illuminate

6)

Winch control grip

Extend winch boom, reel out cable by approx. 1 m

7)

Winch boom

Condition, secure installation to fuselage, winch unit and hook/bumper assy for signs of impact

8)

Check of indicator pins inside hook/bumper assy and cable inspection a)

boot and hook/ bumper assy

Detach at the bottom, fold inside out

b)

indicator pins

Check for damage. If damaged and length is more than 2 mm shorter, replace indicator pin and inspect cable.

c)

cable in vicinity of bumper

Condition

boot

Refold and attach

d)

Winch control grip (winch operator)

Reel in cable until automatic switch-off occurs, fully retract winch boom

10)

Switch CABLE CUTTER TEST

Push, indicator light CABLE CUTTER TEST must il1uminate

11)

Main switch WINCH

Set to OFF

9)

2.

Periodical Inspection NOTE

o For life limitations parts refer to chapter 101-9. o One cable operation cycle comprise: Reel out ofcable (full or partial) in flight and subsequent reel-in until automatic switch-off occurs.

BO 105 CHAPTER 836 Page 76

PERIODICAL INSPECTIONS - RESCUE HOIST

S'c:::

..... .....

,

ASSE~BLY

t/)

o

Maintenance and Inspection Work

::J

Remarks

Time Limit

e

g

....¡

1.

Inspect rescue hoist for condition (refer to paragraph 836-3)

20 cable operating

2.

Perform functional test of rescue hoist (refer to paragraph 836-4)

20 cable operating cycles

3.

Inspect cable (refer to paragraph 836-5)

20 cable operating cycles

4.

Lubricate winch unit (refer to paragraph 836-22)

Each time cable is replaced or Ix annually.

5.

Disassemble and inspect winch boom assy. (refer to paragraphs 836-10 and 836-11)

The inspection interval occurring first is relevant

4 years (installation ~nd storage time)

Disassemble and insFect hook/bumper assy. (refer to paragraphs 836-17 and 836-18)

The inspection interval occurring first is relevant

200 cable operating cycles or every 4 years (installation and storage time)

*

*

O

1200 h or 4 years (installation and storage time)

*

> z

6.

7.

()

::z::

:t>'

"O

"O~ OJ~tx:l

10:;00

ro

ce ......

....¡wo ....¡ 0"1 ln

8.

Remove and inspect mounting fittings (refer to paragraphs 836-38 and 836-39) Inspection of winch unlt (refer to para. 836-3A)

~ycles

The inspection interval occurring first is relevant

o ~., * * * *

* * *

* * First accomplishment * after 4 years, then * every 2 years * following installation * of a new winch unit * or after last inspection per TBO.

*

*

3:

> Z

-i

m

~ z

m 3:

e > r

s:

m

m I

....~o C1I

MAINTENANCE MANUAL Mee - BO 105

3.

Time between overhauls - rescue hoist assembly

COMPONENT

P/N

TBO

Winch unit

105-81215

300 cable operating cycles or 8 years, whichever occurs first

* * *

Winch unit

WE-3821-3

300 cable operating cycles or 8 years, whichever occurs first

* * *

Servo motor

DL 2050 M4D

8 years

Servo motor

13.1-0100

8 years

Servo motor

13.1-0110

8 years

BO 105 CHAPTER 836 Page 78

* * *

Revision 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 837

EXTERNAL REARVIEW MIRROR

Table of Contents Page

Paragraph

Title

837 - 1

DESCRIPTION - EXTERNAL REARVIEW MIRROR

3

837 - 2

INSPECTION SCHEDULE - EXTERNAL REARVIEW MIRROR

4

837 - 3

INSPECTION FOR CONDITION - EXTERNAL REARVIEW MIRROR

5

837

REMOVAL - EXTERNAL REARVIEW MIRROR

6

837 - 5

INSTALLATION - EXTERNAL REARVIEW MIRROR

6

837 - 6

ADJUSTMENT - EXTERNAL REARVIEW MIRROR

7

4

BO 105 CHAPTER 837 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

837 - 1

DESCRIPTION - EXTERNAL REARVIEW MIRROR

The external rearview mirror is available in two configurations and used by the pilot to supervise the lifting, transport, and lowering of cargo hook loads. Configuration 1 (fig. 837-1): The external rearview mirror is centrally mounted by two brackets to the horizontal spars below the left hand windshield on the copilot's side. Configuration 11 (fig. 837-2): The external rearview mirror is installed by a clamp to the forward tip of the right skid tube.

WARNING

THE EXTERNAL REARVIEW MIRROR MUST BE COVERED DURING NIGHT FLYING TO AVOID DAZZLING THE PILOT.

BO 105 CHAPTER 837 Page 3

EUROCOPTER

• 837 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 837 Page4

Revision 18

- - - - - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 837 - 3

INSPECTION FOR CONDITION - EXTERNAL REARVIEW MIRROR

l. Inspect external rearview mirror for contamination, blind spots and cracks.

a.

Clean dirty mirror using suitable cloth.

b.

Replace mirror if broken or has blind spots.

2. Inspect mirror mounting components for corrosion and damaged surface protection. gri~

a.

Remove corros ion with 400

abrasive cloth.

b.

If necessary, touch up surface protection with single-layer lacquer (CM 407) .

3. Inspect mirror mounting components for security, deformation and cracks. Configuration 1 (fig. 837-1): a.

Inspect quick release pins (1) for condition and operation; replace damaged pins.

b.

Inspect brackets (2 and 3) for security, deformation and cracks. Check holes for wear. Replace brackets if deformed or cracked, or if holes are worn.

c.

Inspect spherical bearings (7 and 8) for play, restrained movement and corrosion; replace as necessary.

d.

Inspect strut (4) for deformation. Align or replace strut as follows: 1)

Remove strut (4) and Y-strut (5) with attached mirror (9) from brackets (2 and 3) .

2)

Remove staked lip of bushing (14) on Y-strut (5) with milling cutter and press out bushing to release strut.

3)

Realign strut and Y-strut or replace strut.

4)

If necessary, install spherical bearings (7 and 8) in strut (refer to Chapter 02).

5)

Cool bushing (15) to approx. -50 OC and install in spherical bearing (7).

6)

Insert strut end without bushing between attachment lugs of Y-strut (5) and align strut holes. Cool bushing (14) to approx. -50 OC and insert centrally in aligned holes. Stake protruding ends evenly.

BO 105 CHAPTER 837 Page 5

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 e.

If previosly removed, attach mirror to Y-strut handtight with clamp (12); fit strut (4) and Y-strut (5) in brackets and secure with three quick release pins. For mirror adjusting procedure, refer to para 837-6.

Configuration 11 (fig. 837-2): If necessary, tighten screws (4 and 6) or replace deformed or cracked mounting strut (3). Refer to para 837-6 for mirror adjusting procedure. 837 - 4

REMOVAL - EXTERNAL REARVIEW MIRROR

Configuraton 1 (fig. 837-1): 1. Remove the two quick release pins (1) from bracket (3). 2. Remove quick release pin (1) frorn bracket (2). Detach mirror mounting strut (4, 5).

Configuration 11 (fig. 837-2): 1. Remove screw (6) frorn clamp (5) and loosen screw (4). 2. Slide rnirror off skid tube (8). 837 - 5

INSTALLATION - EXTERNAL REARVIEW MIRROR

Configuration 1 (fig. 837-1): 1. Fit end of strut (4) with installed spherical bearing (7) in bracket (2) and secure with quick release pin (1). 2. Fit free ends of Y-strut (5) in bracket (3) and secure with two quick release pins (1).

Configuration 11 (fig. 837-2): 1. Loosen screw (4) on clamp (5) and slide mirror with attached mounting strut and clamp onto front end of right skid tube until abuts the protective skid shoe (7).

2. Turn the clamp on the skid tube until their respective holes align, then install screw (6). 3. Tighten screw (4).

BO 105 CHAPTER 837 Page 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - 130 105

837 - 6

ADJUSTMENT - EXTERNAL REARVIEW MIRROR

1. If previously removed, install cargo hook (refer to Chapter 822). 2. Jack helicopter so that cargo hook is suspended above the ground. 3. Align mirror so that the pilot has a comfortable, unobstructed view of the car:go 'hook:

In both configurations, the mirror can be rotated up and down and from side to side at the clamp and screw respectively, on the back of the mirror. Torque-tighten screw according to figs. 837-1 and 837-2. 4. Verify correct alignment of mirror before lowering the helicopter.

BO 105 837 Page 7

CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A· A

DETAlL

B· B

~n'5::-- 8

2

3

-~~--9

~.---~--10,

11

[UNrn] 5

VIEwA 800282

12

1 Quick release pin 2 Bracket 3 Bracket 4 Strut 5 Y-strut 6 Hole 7 Spherical bearing 8 Spherical bearing Fig. 837-1 BO 105 CHAPTER 837 Page 8

9

10 11

12 13 14 15

Mirror Screw Nut Clamp Protective cover Bushing Bushing

External rearview mirror (configuration 1)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

,

VIEwA

A :-----1,2

~

7 6 5

800283

1 2 3 4 5

Screw Nut Mounting strut Screw Clamp

Fig. 837-2

6 7 8 9

10

Screw Skid shoe Skid tube Mirror Clamp

External rearview mirror (configuration 11) BO 105 CHAPTER 837 Page 9/10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

838

HIGH LANDING GEAR

Tabie of Contents

Paragraph

Title

838 - 1

DESCRIPTION - HIGH LANDING GEAR.

3

838 - 2

INSPECTION SCHEDULE - HIGH LANDING GEAR.

4

838 - 3

INSPECTION FOR CONDITION - HIGH LANDING GEAR

5

838 - 4

REMOVAL - HIGH LANDING GEAR

8

838 - 5

INSTALLATION - HIGH LANDING GEAR

8

Page

BO 105 CHAPTER 838 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 838 - 1

DESCRIPTION - HIGH LANDING GEAR

l. General The high landing gear is a tubular skid gear like the standard version. The increased height of its eross tubes enables equipment to be installed on the underside of the fuselage. The eros s tubes will bend and regain their original shape at arate of deseent of approx. 1m/seco Landings at higher rates of descent will produce permanent crosstube spread. 2. Description The high landing gear essentially consists of two aluminum erosstubes which run late rally through the underside of the fuselage at frames 4 and 9, and two skid tubes, one on each side of the fuselage and attached to the ends of the erosstubes by skid shoes and clamps. The crosstubes are fixed in mounts on the fuselage by means of pivoted bearing rings and canical elastomer bushings with integrated clamps. Skid protection plates are installed on the underside of the skid tubes to absorb wear. The forward ends of the skid tubes are filled with polyurethane foam and sealed with GRP, and the aft ends fitted with caps. Dual-tread steps are mounted on each side of the front crosstubes of eonfiguration 1 (see fig. 838-6) and configuration 11 and also on each side of the rear crosstube of configuration 11. Provisions are made on the aft end of the skid tubes for installing ground handling wheels.

BO 105 CHAPTER 838 Page 3

EUROCOPTER

• 838 - 2

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 838

Page4

MAINTENANCE MANUAL BO 105

Revision 18

_eurocopter

MAINTENANCE MANUAL MBB - BO 105

INSPECTION FOR CONDITION - HIGH LANDING GEAR

838 - 3

l. Check landing gear instal1ation for dimensional accuracy in the Y and Z axes (refer to fig. 838-1).

t-· ~-r - '-¡r'

f

11

11

t

7~,.

(/

y-

ti

t

CL.

~-I-t

~

U _

IJ

11

t.

B00167

Fig. 838-1

Instal1ed position

If the helicopter is lopsided on either or both axes, take action described in steps 3 thru 8. 2. Inspect crosstubes for deformation and other signs of damage. Check for crosstube deformation by measuring between the underside of the fuselage or fuselage mounted equipment and the underside of the skid tubes with no weight on the skids (see fig. 838-2) Ground clearance with no weight on the skids: Normal: 720 mm Minimum without equipment: 650 mm Minimum with equipment: 300 mm

Fig. 838-2

Ground clearance

EO 105 CHAPTER 838 Page 5

MAINTENANCE MANUAL M88 - 80 105

If the ground clearance is less than 650 mm or 300 mm, according to configuration, replace affected crosstubes (refer to paras 838-4 and 838-5) . Remove damage, such as scratches and nicks, with abrasive cloth (180 grit or finer) only if they have sharp edges, then blend out to a transition radius of approx. 20 mm. See fig. 838-3 for damage limits.

Zone A: max. 0.3 mm in depth on 30% of surface area.

Zone B: max. 0.5 mm in depth on 30% of surface area. Fig. 838-3

Crosstube - damage limits

Touch up damaged surface protection as follows: Polish out affected areas down to bare metal using 360 grit abrasive c10th, and clean with degreasing agent (CM 209) . Apply two-component zinc chromate primer (CM 417) or two-component wash primer (CM 423) and allow to dry. Apply single-layer lacquer (CM 407) or PUR topcoat (CM 416) and allow to dry. 3. Visually inspect skids for cracks, deformation and mechanical damage.

*

* * * * * * * *

Mechanical damage (scratches and nicks) is acceptable to a depth of up to 0.5 mm on 30% of the total surface area of the top side of the skid tube and to a depth of up to 1.0 mm on 30% of the total surface area of the bottom side of the skid tube. Dents which do not exceed 5 mm in depth and 30 mm in diameter are acceptable. Blend out sharp-edged scratches and nicks to a transition radius of approx. 20 mm, using 400 grit abrasive cloth. For damaged surface protection touch-up procedure, refer to step 2. If skids exhibit cracks, deformation or mechanical damage in excess of the above limits, replace them. Remove screws (10, fig. 838-6) from rivet nuts (24) and detach skid protection plates (4). Remove screws (11) and tab washer (12). Pry open clamp (9) and remove skid tubes (1).

1 -

J'----I 1-_--'-_

.L..-_~:

--'----"-- _ _

800166.1

1700 ± 2

Fig. 838-4 BO 105 CHAPTER 838 Page 6

175 ± 2

Skid installation

Revision 6

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 Reinstall skid tubes in reverse order of removal. Adjust skid tubes according to fig. 838-4. 4. Visually inspect skid protection plates (4, 5, fig. 838-6) for evidence of excessive wear. Damage is permissible provided skid tube protection is not impaired. The skid protection plates are removed by unscrewing screws (10). 5. Inspect clamps (9) for tight installation and damaged surface protection. Surface damage such as scratches and nicks, are permissible to a depth of 0.2 mm. Surface blending using abrasive cloth is only required in the event of high metal or sharp edges. Repair cracks in welded areas by rewelding. ' If clamps are loose, reset skid t'ubes to dimensions shown in fig. 838-4. For screw torque loads, see fig. 838-6. Touch up damaged surface protection as follows: Remove loose paint from affected areas with 360 grit abrasive cloth and clean with degreasing agent (CM 209). Apply two-component zinc chromate primer (CM 423) and allow to dry. Apply single-layer lacquer (CM 407) and allow to dry. 6. Inspect skid shoes for damaged surface protection and tight installation according to inspection criteria in step 5. Permissible depth of damage is 0.3 mm. For skid shoe removal and installation procedures, refer to paras 838-4 and 838-5. 7. Inspect set screw rings for tight installation and evidence of damage. Replace set screw ring if rubber is cracked or has separated from the metal. Realign loose set screw rings and torque load screws to values shown in fig. 838-7. For removal and installation procedures, refer to paras 838-4 and 838-5. NOTE

Bearing rings and set screw rings are only removed when necessitated by damage repairs to bearing rings, or when inspection of close-tolerance screw seat in the set screw rings reveals unacceptab1e play (castellated nut rotates with close-tolerance screw) .

8. Inspect bearing rings for cracks, damaged surface protection, and dimensional accuracy. If visual inspection with a magnifying glass gives reason to suspect presence of cracks, perform a penetrant inspection per MIL-STD-6866. Replace cracked bearing rings as follows: Unscrew and remove attaching hardware (11, 12, 13, 14, 15, fig. 838-7) and remove bearing ring (10). To install the bearing ring, position bearing ring in landing gear mounting on frame, and insert close-tolerance screw (11) from inside the bearing ringo Install stepped washer (13) and nut (12) on close-tolerance screw and torque nut to value shown in fig. 838-7, then secure with cotter pin (15) .

BO 105 CHAPTER 838 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Blend repair surface damage, such as scratches and nicks, not deeper 0.3 mm, using 180 grit or finer abrasive cloth. Check bore for dimensional accuracy. If bore diameter exceeds 15.1 mm, replace bearing ringo Touch up damaged surface protection, but not the lacquer coating, according to step 2. Apply lacquer coating to match color of fuselage. 9.

Inspect close-tolerance screws for wear, and replace if diameter is less than 14.9 mm.

10.

Inspect bushings for wear, and replace if diameter is less than 15.1 mm.

838 - 4

REMOVAL

~

HIGH LANDING GEAR

l. Raise helicopter approx. 1.20 meters using hoist. 2. Unscrew and remove attaching hardware (17, 18, 19, 20, 21, 22, 23, fig. 838-6) and detach skid tubes (1) and assembled parts. 3. Remove cockpit steps (7 and 8, paired) on crosstube as follows: From either step (7 or 8), remove plug (16) and nut (15) from the 10-mm-long threaded end of the common support rod (13) and remove the step. Remove the other step by pulling the support rod out through the crosstube. 4. Unscrew and remove necked-down bolts (16, fig. 838-7) from set screw rings (9) and remove tab washers (17). Detach bonding jumpers (22) and tabwasher (20) by removing attaching hardware (18, 19, 21). Pull set screw rings off crosstube using sliding agent (CM 710) to aid removal. 5. Guide crosstubes (2) out through frame 4 or 9, as applicable, and through frame-mounted bearing rings (10), and remove from helicoper.

838 - 5

INSTALLATION - HIGH LANDING GEAR

l. Guide crosstubes (2, fig. 838-7) in through frame 4 or 9, as applicable, and through the frame-mounted bearing rings (10).

2. Install set screw rings (9) on crosstubes using sliding agent (CM 710), and slide them along the crosstubes and into the bearing rings (10). 3. Install bonding jumpers (22) and tab washers (20) and secure with attaching hardware (18, 19, 20 and 21). Install necked-down bolts (16) and tabwashers (17) and secure fingertight.

BO 105 CHAPTER 838 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

4. Centralize crosstubes (see fig. 838-5) on the fuselage by shifting them back and forth in the frame-mounted bearing rings until an equal length of crosstube, measured along the top surface of the crosstube from the inboard end of the bearing ring to the end of the cross tube, extends from either side of the fuselage.

/,"._.+-._., (

I. \

.

I

\

\. J

Crosstube 800164

Fig. 838-5 Centralizing the crosstube

NOTE

Bonding jumper attachment surfaces must be free from non-conducting protective finish.

5. Tighten and secure necked-down bolts (16) and apply corrosion protective lacquer (CM 501) to bonding terminals. 6. Mount assembled skids (1) and skid shoes (3) on the ends of the crosstubes and install and tighten attaching hardware (17, 18, 19, 20, 22 and 23, fig. 838-6). Secure nuts (20) and screws (22) with cotter pins (21) and tab washers (23) respectively. 7. Install cockpit steps (7 and 8) as follows: with one step already in place on one end of the support rod (13), insert the other free end through the bore in the crosstube and install the other step on it. Tighten steps against the crosstube with washer (14) and nut (15) and install plug (16). BO 105 CHAPTER 838 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

Configuration 1

Configuration 11

Steps mounted on front crosstube only

Steps mounted on front and rear crosstube

6 3

3

5

DETAlL

5

A

1 2 3 4 5 6

14 15 1 25 Nm

I

12 11 112 Nm

~

-,

10

Fig. 838-6 BO 105 CHAPTER 838 Page 10

I

Skid tube Crosstube Skid shoe Skid protection plate Skid protection plate Step 7 Step 8 Step 9 Clamp 10 Screw 11 Screw 12 Tab washer 13 Support rod 14 Washer 15 Nut 16 Plug 17 BoH 18 Washer 19 Washer 20 Nut 21 Cotter pin 22 Screw 23 Tab washer 24 Rivet nut

High landing gear

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Configuration

Configuration 11

1

Steps mounted on front crosstube only

Steps mounted on front and rear crosstube

3

5

DETAlL

5

A I

~~ 17 . 18 "--19 20 21

800166

Fig. 838-7

1 Skid tube 2 Crosstube 3 Skid shoe 4 Skid protection plate 5 Skid protection plate 6 Step 7 Step 8 Step 9 Set screw ring 10 Bearing ring 11 Close tolerance screw 12 Nut 13 Stepped washer 14 Bushing 15 Cotter pin 16 Necked-down bolt 17 Tab washer 18 Screw 19 Washer 20 Tab washer 21 Nut 22 Bonding jumper 23 Screw

High landing gear BO 105 CHAPTER 838 Page 11/12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 839

SERVICE HOUR METER

Table of Contents Paragraph

Title

839 - 1

DESCRIPTION - SERVICE HOUR METER

839 - 2

TROUBLESHOOTING - SERVICE HOUR METER

3

839 - 3

FUNCTIONAL TEST - SERVICE HOUR METER

4

839 - 4

REMOVAL - SERVICE HOUR METER

4

839 - 5

INSTALLATION - SERVICE HOUR METER

5

Page . .

3

BO 105 CHAPTER 839 Page 1/2

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 839 - 1

DESCRIPTION - SERVICE HOUR METER

l. General When in operation the service hour meter will add up all running times of the main transmission. Thus the indicator records the total life of the airframe. 2. Constructional Desgin The cylindrical, unilluminated service hour meter shows in the center of its circular face a four-digit ho~r counter. The unit is mounted in the very right side of the overhead panel and connected, via an electric line, to the oil pressure switch of the main transmission. Power consumption is approx. 60 mW. 3. Operation Imediately after start of main transmission, low oil pressure warning light will extinguish and service hour meter will be supplied, via the oil pressure switch, with 28V DC. A small black disk with two white dots located in 12 o'clock position of the counter's face will rota te six times per minute when counter is in operation. 839 - 2

TROUBLESHOOTING - SERVICE HOUR METER

Use wlrlng diagram 839 in the Wiring Diagram Manual (WDM) for troubleshooting the system. No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Counter standstill with transmission running

Wiring to oil pressure switch defective

Check soldering joints meter and wiring for continuity; resolder if necessary or replace wiring

Meter defective

Check meter for function; refer to paragraph 839-3. Replace if necessary

Table 839-1

Troubleshooting

BO 105 CHAPTER 839 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 839 - 3

FUNCTIONAL TEST - SERVICE HOUR METER

General Conduct functional test after installation of unit - engines may not be running. Dismantle RH transmission cowling. 1. Unplug connector 22 EWa, connect A and B with jumper wire. 2. Hook up external power unit; ensure fuse 26 EW is installed and intacto 3. Watch white dots rotate in upper position of meter's face. Movement of dots proves service hour meter to be operative and wiring to be intacto 4. Oil pressure switch 22 EW may be tested by connecting an ohrnrneter to switch contacts A and B; scale reading must now be ltinfinite".

5. Disconnect external power unit from helicopter; remove jumper wire and replace connector 22 EWa at oil pressure switch. Reinstall transmission cowling. 839 - 4

REMOVAL - SERVICE HOUR METER

l. Remove all six screws from overhead panel cover plate and lower carefully; unplug connector 133 VVa and suspend cover plate by bonding jumper.

2. Mark ET1-G20 wire with lt+" and ET2-E20N with ends.

lt_lt

before unsoldering wire

3. Hold on to body of service hour meter while unscrewing both frontal screws; separate meter from cover plateo

BO 105 CHAPTER 839 Page 4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

839 - 5

INSTALLATION - SERVICE HOUR METER

1. Fit body of service hour meter to overhead panel cover plate for installation and hold in that position until both frontal screws have been securely twisted into flange of unit from below. 2. Resolder marked wires to unit's hook terrninals. 3. Plug-in connector 133 VVa. 4. Conduct functional test; refer to paragraph 839-3. 5. Using six screws, replace overhead panel cover plateo

BO 105 CHAPTER 839 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 840

LIGHTNING PROTECTOR

Table oi Contents

Page

Paragraph

Title

840 - 1

DESCRIPTION - LIGHTNING PROTECTOR . . . .

3

840 - 2

INSPECTION SCHEDULE - LIGHTNING PROTECTOR

4

840 - 3

INSPECTION FOR CONDITION - LIGHTNING PROTECTOR

5

80 105 CHAPTER 840 Page 1/2

_eurocapter 840 - 1

MAINTENANCE MANUAL M88 - 80 105

DESCRIPTION - LIGHTNING PROTECTOR

The lightning protector is a wire conductor connecting the eros ion resistant titanum strip with the blade fitting. It can be installed on the main rotor blade .as either one of two differing configurations: Configuration 1 (early type), copper wire integrated in a GRP shell which is bonded to the blade and covered with protective (scotch) tape. -

Configuration 11 (current type), separate copper wire bonded to the blade and covered with protective (scotch) tape.

The current of the lightning discharge is carried from the titanium strip to the blade fitting via the lightning protector and a spark gap (approx. 5 mm), and from the blade fitting to the fuselage via the main rotor head.

Revision 6

BO 105 CHAPTER 840 Page 3

* *

EUROCOPTER

• 840 - 2

MAINTENANCE MANUAL 80105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 840 Page4

Revision 18

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

840 - 3

INSPECTION FOR CONDITION - LIGHTNING PROTECTOR

1. Inspect protective (scotch) tape for loose bonding surfaces, blisters, and general condition. Repair protective tape if damaged. 2. Inspect GRP shell for delamination. Repair GRP shell if delaminated.

BO 105 CHAPTER 840 Page 5/6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 841

ENGINE AIR CLEANER

TabIe of Contents

Page

Paragraph

TitIe

841 - 1

DESCRIPTION - ENGINE AIR CLEANER

3

841 - 2

TROUBLESHOOTING - ENGINE AIR CLEANER

4

841 - 3

INSPECTION SCHEDULE - ENGINE AIR CLEANER

6

841 - 4

INSPECTION FOR CONDITION - ENGINE AIR CLEANER

7

841

FUNCTIONAL CHECK - ENGINE AIR CLEANER

7

5

841 - 6

REMOVAL - ENGINE AIR CLEANER

..

8

841 - 7

INSTALLATION - ENGINE AIR CLEANER

9

BO 105 CHAPTER 841 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 841 - 1 1.

DESCRIPTION - ENGINE AIR CLEANER

General The engine air cleaner separates solid particles, such as sand and dust, from the engine intake air, thus protecting engine parts, especially the compressor, from erosiono The separated contaminants are sucked out of the air cleaner housing and discharged overboard.

2.

Description The air cleaner system essential¡y consists of: - housing with bypass door and scavenge outlets - 750 separator tubes - engine bleed air tapping lines

3.

Operation Contaminated air drawn in during flight operation is directed through the 750 separator tubes to the engines. As the air flows through the separator tube panels, it is made to swirl by the fixed vortex generators in the tubes, causing the solid particles to be thrown by centrifugal force radially outward against the tube inner walls. These particles then collect in a low pressure area at the bottom of the wedgé-shaped cleaner housing, from where they are ejected overboard through the two scavenge outlets by the low pressure-inducing engine bleed air. If the engine air cleaner is not required, the bypass door on the front of the cleaner housing can be opened to allow direct flow of air to the engines. Configuration 1: Bypass door opened by Bowden cable. Configuration 11: Bypass door opened by actuator. Shutting off the air cleaner system by opening the bypass door does not simultaneously cut off the flow of engine bleed airo For configuration 11 circuit function, refer to wiring diagram 841-1 in the wiring diagram manual (WDM).

BO 105 CHAPTER 841 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 841 - 2

TROUBLESHOOTING - ENGINE AIR CLEANER

General The following preliminary operations apply to configuration 11 only: refer to wiring diagram 841-1 in the Wiring Diagram Manual (WDM) Check for tight electrical connection to actuator. Check mechanical functioning of switches and circuit breakers. Connect externaI power unit (EPU). Battery switch on instrument panel in position BATT OFF/EPU ON. Press circuit breaker 1KC. No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

High engine exhaust gas temperature (T4)

Dirty separator tubes

Inspect separator tubes and cIean as necessary

2

Power difference between engines (power check)

Leaking or defective check valves in bleed air system

Inspect check valves and replace as necessary

Leaking O-rings in bIeed air line connections to engine

Inspect bleed air connections on engine for leakage and replace O-rings as necessary

Defective circuit breaker 1KC

Check continuity of circuit breaker and repIace as necessary

Defective toggle switch 2KC

Check toggle switch and replace as necessary

Faulty wiring between main busbar PP21 and bypass door actuator

Check continuity of wiring using wiring diagram; repair or replace wiring as necessary

Configuration 11 supplement: 3

Bypass door opens or does not close

TabIe 841-1 BO 105 CHAPTER 841 Page 4

Troubleshooting (1 of 2)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING

(continued)

No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Poor connector contact at plug connections

Check connector; remove corrosion; replace connector as necessary

Either one of the actuator limit switches defective

Inspect limit switches, and replace actuator as necessary

Defective actuator winding

Check continuity of actuator winding; replace actuator if defective

Table 841-1

Troubleshooting (2 of 2)

BO 105 CHAPTER 841 Page 5

EUROCOPTER

• 841 - 3

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 841

Page6

MAINTENANCE MANUAL BO 10S

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 841 - 4 1.

INSPECTION FOR CONDITION - ENGINE AIR CLEANER

Inspect air cleaner housing and bypass door for mechanical damage, corros ion and tight installation. a.

Replace cracked parts.

b.

Polish out corroded areas with 400 grit abrasive cloth and restore surface protection.

c.

Tighten loose screws.

d.

Apply grease (CM 101) to bypass door mounting.

2.

Inspect separator tubes for clogging and contamination. If either clogging or contamination is present, remove the cleaner panel and rinse the separator tubes.

3.

If more than approx. 5% of the tubes in a cleaner panel are damaged, replace cleaner panel.

4.

Inspect bleed air tubes and hoses, check valves, and tube and hose connections for condition. Repair leaks and replace damaged parts.

5.

Configuration 1 only: Inspect Bowden cable and bypass door for unrestricted movement.

6.

Configuration 11 only: Inspect electrical wiring for tight installation and chafe marks. Secure loose wires, and replace chafed wires.

841 - 5

FUNCTIONAL CHECK - ENGINE AIR CLEANER

l.

Connect external power supply. Set switch l6p to BAT OFF/EPU ON.

2.

Push in circuit breaker SANO FILT lKC.

3.

Push switch SANO FILTER 2KC on overhead console forward; the bypass door will open and the actuator will automatically switch off in the end position. Perform visual check.

4.

Push switch SANO FILTER 2KC on overhead console backward; the bypass door will close and the actuator will automatically switch off in the end position. Pcrform visual check.

5.

Pull out circuit breaker and disconnect external power supply from the helicopter.

BO 105 CHAPTER 841 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS ------------~ MAINTENANCE MANUAL MBB - BO 105 841 - 6

REMOVAL - ENGINE AIR CLEANER

1.

Remove engine cowling.

2.

Disconnect tubes (5, 6, fig. 841-3) at tee fitting (4) in the transmission compartment; unscrew tee fitting. NOTE

3.

Perform step 3. only if removal of bleed line is not required.

Screw plug (5, fig. 814-1) in hose (7) and secure to angle (4) with washer (3) and caste1lated nut (1); safety with cotter pin (2).

5

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2

I 3 ~-4

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800302

0-\-----7

1 2 3

4 5

6 7

Caste1lated nut Cotter pin Washer Angle Plug Screw Hose Fig. 841-1

BO 105 CHAPTER 841 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4.

Unscrew and remove air cleaner panels (4, fig. 841-4).

5.

Configuration 1: Disconnect Bowden cable from bypass door mechanism. Configuration 11: Disconnect electrical lead from actuator.

6.

Remove screws (10) and take off air cleaner housing (2).

7.

If required, remove bleed air system as follows: a.

At firewall passage,· disconnect check valves (4, fig. 841-6) from line fittings (9) and firewall fitting (1).

b.

Unscrew fittings (7) and remove tubes (6). Plug open engine ports.

c.

Remove hose clamps and remove hose (2).

d.

Remove firewall fitting (1).

841 - 7

INSTALLATION - ENGINE AIR CLEANER

1.

Remove engine cowling.

2.

Install bleed air system as follows: a.

Install hose (2, fig. 841-6) with clamps.

b.

Install firewall fitting (1) and insert line manifold; seal gap between them with sealing compound (CM 633).

c.

Connect tubes (6) to engines using fittings (7).

d.

Connect check valves (4) to line fittings (9); arrows must point in direction of flow.

3.

Fasten air cleaner housing (2, fig. 841-4) to mounting support (1) on roof with screws (10).

4.

Configuration 1: Connect Bowden cable to bypass door mechanism. Configuration 11: Connect electrical lead to actuator.

5.

Insert air cleaner panels (4) in air cleaner housing and screw up tightly.

6.

Connect tubes (5, 6, fig. 841-3) to tee fitting (4) in transmission compartment.

7.

Install engine cowling. BO 105 CHAPTER 841 Page 9

- - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

\

=

800381

1 Separator tube Bypass door Operating lever

2 3

Fig. 841-2 BO 105 CHAPTER 841 Page 10

Air cleaner system (configuration 1)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

7 12 ---+--r--""l\-'ít'1'O~"'-

I

10 --+-+.---1

I

I

L_~_ SP7

2

6

8

3

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800171

7

1 Bleed air tapping ports 2 Firewall fitting 3 Bleed air hose in transmission compartment 4 Tee fitting Fig. 841-3

S

4

11

LH tube RH tube Air cleaner housing with cleaner panels 8 Ejector

5 6 7

9 Mounting support (roof

stiffener) Wiring harness l42VB la Control rod passage seal 11 12 Bypass door and actuator

Engine air cleaner system - Configuration

11

BO 105 CHAPTER 841 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 9

8

6

5 7

4

\~------3

... .......

10

,"'\0,------------- 4 4-----------z!'.':!1 11-~~~~--------3

~'\....._..__-

=

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---- 7

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1 Mounting support (roof stiffener) 2 Air cleaner housing 3 Bypass door 4 Cleaner panel 5 Seal Fig. 841-4 BO 105 CHAPTER 841 Page 12

'\"

",

6 Scavenge outlet Ejector 8 Air inlet scoop (oil cooler) 9 Air outlet (oil cooler) 10Screws 7

Engine air cleaner - Configuration 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Dirty air in

4

Clean air out

Dirt laden scavenge air DETAlL

A

2

3

Clean air the engines

800179

Dirt laden scavenge air discharged overboard via air cleaner housing and ejector

1 Vortex generator Body Outlet tube 4 Air c1eaner panel 5 Engine bleed air discharge nozzle 6 Ejector

2 3

Fig. 841-5

Air cleaner panel and separator tubes - Configuration

1

and

11

BO 105 CHAPTER 841 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 1

2

3 4 5 6 7

8 9

800180

BO 105 CHAPTER 841 Page 14

Fig. 841-6

Firewall fitting Hose Hose - ENG 2 Check valve Hose - ENG 1 Tube Engine fitting Tee fitting Threaded connection

Bleed air lines - Configurations 1 and 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 842

ENGINE AIR CLEANER (WITH BLEED AIR SHUTOFF)

Table of Contents Paragraph

Title

842 - 1

DESCRIPTION - ENGINE AIR CLEANER

842 - 2

TROUBLESHOOTING - ENGINE AIR CLEANER

4

842 - 3

INSPECTION SCHEDULE - ENGINE AIR CLEANER

6

842 - 4

INSPECTION FOR CONDITION - ENGINE AIR CLEANER

7

842 - 5

FUNCTIONAL CHECK - ENGINE AIR CLEANER

7

842 - 6

REMOVAL - ENGINE AIR CLEANER

.

8

842 - 7

INSTALLATION - ENGINE AIR CLEANER

9

Page

.

3

BO 105 CHAPTER 842 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 842 - 1

DESCRIPTION - ENGINE AIR CLEANER

l. General The engine air cleaner separates solid particles, such as sand and dust, from the engine intake air, thus protecting engine parts, especially the compressor, from erosiono The separated contaminants are sucked out of the air cleaner housing and discharged overboard. 2. Description The air cleaner system essentially consists of: - housing with bypass door and scavenge outlets - separator tubes - engine bleed air tapping lines 3. Operation

Contaminated air drawn in during flight operation is directed through the separator tubes to the engines. As the air flows through the separator tube panels, it is made to swirl by the fixed vortex generators in the tubes, causing the solid particles to be thrown by centrifugal force radially outward against the tube inner walls. These particles then collect in a low pressure area at the bottom of the wedge-shaped cleaner housing, from where they are ejected overboard through two scavenge outlets by the low pressure-inducing engine bleed airo The bypass door for shutting off the air cleaner is opened by means of an actuator. As the door opens, a delayed action valve in the bleed air feed, line automatically closes after allowing time for the remaining contaminants to be discharged froro the air cleaner system. Therefore, when the air cleaner is shut off, there is no loss of engine power from continous bleed air tapping.

BO 105 CHAPTER 842 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 842 - 2

TROUBLESHOOTING - ENGINE AIR CLEANER

General refer to w~r~ng diagram 841-1 in the Wiring Diagram Manual (WDM) inspect electrical connections to actuator and check valve -fer tight installation check mechanical functioning of switches and circuit breakers connect externa! power supply (EPU). Set battery switch on instrument panel to BATT OFF/EPU ON. push in circuit breaker 1KC. No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

High engine exhaust temperature (T4)

Dirty separator tubes

Inspect air cleaner panels and clean as necessary

2

Power difference between engines (power check)

Leaking or defective check valves in bleed air system

Inspect check valves and replace as necessary

Leaking O-rings in bleed air connections to engine

Inspect bleed air connections en engine for leaks, and replace O-rings as necessary

Defective circuit 1KC

Check continuity of circuit breaker and replace as necessary

Defective toggle switch 4KC

Check toggle switch and replace as necessary

Faulty wiring between main busbar PP21 and bypass door actuator

Check continuity of wiring using wiring diagram; repair or replace wiring as necessary

3

Bypass door opens or does not close

Table 842-1

BO 105 CHAPTER 842 Page 4

Troubleshooting (1 of 2)

- - - - - - - - - - - ' - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

4

TROUBLE SYMPTOM

Check valve does not close when bypass door opens, or vice versa

PROBABLE CAUSE

CORRECTIVE ACTION

Poor electrical connector contact

Check connector; remove corrosion; replace connector as necessary

Either one of the actuator limit switches defective

Inspect limit switches, and replace actuator as necessary

Defective actuator winding

Check continuity of actuator; replace actuator if defective

Defective toggle switch 4KC

Inspect toggle switch and replace as necessary

No bonding jumper contact

Inspect bonding jumper; remove corros ion from bonding connections. Replace bonding jumper as necessary

Poor electrical connector Inspect connector; remove corrosion; contact replace connector as necessary Faulty wiring between toggle switch 4KC and valve

Check continuity of wiring using wiring diagram; repair or replace wiring as necessary

Defective valve

Replace defective valve

Table 842-1

Troubleshooting (2 of 2)

BO 105 CHAPTER 842 Page 5

EUROCOPTER

• 842 - 3

MAINTENANCE MANUAL BO 10S

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 842 Page6

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 842 - 4

INSPECTION FOR CONDITION - ENGINE AIR CLEANER

l. Inspect air cleaner housing and bypass door for mechanical damage, corrosion, and tight installation. a.

Replace cracked parts.

b.

Polish out corroded areas with 400 grit abrasive cloth, and restore surface protection.

c.

Tighten loose screws.

d.

Apply grease (CM 101) to bypass door mounting.

2. Inspect cleaner panel separator tubes for clogging or dirt. lf either condition exists, remove cleaner panel and flush separator tubes with water.

3. Replace air cleaner panel if more than approx. 5% of the separator tubes are damaged. 4. Inspect bleed air tubes and hoses, check valves, and tube and hose connections for condition. Remove leaks and replace damaged parts. 5. Inspect electrical wiring on actuator and check valve for loose contact and evidence of damage; tighten or replace as necessary. 6. Inspect check valve for tight installation; tighten loose check valve. 7. Inspect bonding jumpers for corroded bond connections; remove corrosion. 842 - 5

FUNCTIONAL CHECK - ENGINE AIR CLEANER

l. Connect external power supply (EPU). Set switch 16P to BATT OFF/EPU ON.

2. Push in circuit breaker SAND-FILT 1KC. 3. Lamp test a.

Press and hold indicator light TEST WARNLIGHTS. Segments BLEED AIR/SF and EPU ON must come on (two light bulbs per segment).

b.

When the indicator light is released, both segments must go out.

4. Press switch SANDFILTER 4KC on overhead console forward. a.

The bypass door closes; perform visual check.

b.

The check valve in the bleed air tapping line must be completely open within 25 seconds. BLEED AIRlsF must light up after 3 seconds.

BO 105 CHAPTER 842 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5. Press switch SANDFILTER 4KC on overhead console aft. The bypass door opens; perform visual check. The check valve closes completely. Segment BLEED AIR/SF must not go out before the valve has closed. 6. Pull out circuit breaker, and disconnect external power supply from the helicopter. REMOVAL - ENGINE AIR CLEANER

842 - 6

1. Remove engine cowling. 2. Unscrew tubes from the tee fitting in transmission compartment, and unscrew tee fitting from hose (12, fig. 842-2). NOTE

Perform step 3. only if bleed air line removal is not required.

3. Screw hose (12) to plug. 4. Unscrew and remove air cleaner panels (4, fig. 842-1). 5. Disconnect electrical lead from actuator. 6. Remove screws (10) and take off air cleaner housing (2). 7. If required, remove bleed air lines as follows: a.

Remove check valves (21, fig. 842-2) by unscrewing line fittings (19).

b.

Remove adapters (17) and detach tubes (18, 20); install plugs in open engine ports.

c.

Disconnect electrical wiring and bonding jumper (6) from shutoff valve (5) •

d.

Remove shutoff valve (5) by removing clamps (14); unscrewadapters (13) from hoses (12 and 16); discard gaskets (15).

e.

Pull hose (16) out of firewall fitting after removing hose clamps.

f.

Remove firewall fitting.

g.

Seal passage in firewall if the air cleaner is removed for a long periodo

8. Install engine cowling.

BO 105 CHAPTER 842 Page 8

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

842 - 7

INSTALLATION - ENGINE AIR CLEANER

l. Remove engine cowling. 2. If previously removed, install bleed air lines as follows: a.

Install hoses (12 and 16, fig. 842-2) to shutoff valve (5) using adapters (13), gaskets (15) and clamps (14).

b.

Align hose (12) with plug (10) in angle (9); secure hose (16) to cabin rear wall and floor of transmission compartment with hose clamps.

c.

Install firewall fitting (22); insert manifold (23) of hose (16) through firewall fitting.

d.

Install tube and hose lines on engines with adapters (17).

e.

Install check valves (21) with fittings (19); arrows must point in the direction of flow.

f.

Seal firewall fitting with sealing compound (CM 633) .

g.

Connect electrical wiring and bonding jumper (6) to shutoff valve (5).

3. Secure air cleaner housing (2, fig. 842-1) to mounting support (1) on cabin roof with screws (10). 4. Connect electrical wiring to actuator.

5. Position air cleaner panels (4) in air cleaner housing and secure with screws. 6. Screw tee fitting on hose (12, fig. 842-2). 7. Connect tubes to tee fitting in transmission compartment. 8. Install engine cowling.

BO 105 CHAPTER 842 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 9

8

6

5

7

4

\~-------3

-;-------2

•••••••••••••

tI • • • •

•

10

~~-----------4

4 -----------~~

r---------- 3 ~~~~-----7

C> C>

o r----~--...:._

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1 Mounting support (roof stiffener) 2 Air cleaner housing 3 Bypass door

4 Air cleaner panel 5 Seal 6 Scavenge outlet 7 Ejector Fig. 842-1

BO 105 CHAPTER

Page 10

842

8 Air inlet (oil cooler) 9 Air outlet (oil cooler) 10 Screw

Engine air cleaner

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS VIEW

D

VIEW

B

DETAlL

VIEWC

A

~1_4 I

I

2

~E&-~~

.

r~------I I

..

----.------~

~ Connect hose (12) fitting to tee fitting of engine air cleaner.

~ Screw hose to plug (10) when engine air cleaner is removed. The plug is only present when the helicopter is equipped with a cabin rear wall of sandwich construction.

(.

Bleed air connection to engines

12

1

\

2 3

\

4 5 6

7 8

\

9

10 11 12

\

13

6-~

14

15 16 17

18 19 20 21 22

5

''''------_.

800301

Fig. 842-2

-

.

--

Engine air cleaner (with bleed air shutoff) BO lOS CHAPTER 842 Page 11/12

/

23

Bleed air lines Illuminating segments Circuit breaker Switch Shutoff valve Bonding jumper Nut, washer Cotter pin Angle Plug Washer Hose Adapter Clamp Gasket Hose Adapter Tube Fitting Hose Check valve Firewall fitting Manifold

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

843

ENGINE INLET SCREEN

Table of Contents

Paragraph

Title

843 - 1

DESCRIPTION - ENGINE INLET SCREEN . . . .

3

843 - 2

INSPECTION SCHEDULE - ENGINE INLET SCREEN

4

843 - 3

INSPECTION FOR CONDITION - ENGINE INLET SCREEN

5

843 - 4

REMOVAL - ENGINE INLET SCREEN . .

5

843 - 5

INSTALLATION - ENGINE INLET SCREEN

5

Page

BO 105 CHAPTER 843 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

843 - 1

DESCRIPTION - ENGINE INLET SCREEN

The engine inlet screen preventsforeign objects in the transmission compartment from being ingested into the compressor of each engine. The screen is a metal-braided type housed in a frame having four welded lugs for mounting to brackets on the forward engine firewall by studs.

BO 105 CHAPTER 843

Page 3

EUROCOPTER

• 843 - 2

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 843 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 843 - 3

INSPECTION FOR CONDITION - ENGINE INLET SCREEN

l.

Inspect engine inlet screen for clogging; clean as necessary.

2.

Inspect engine inlet screen for tight installation; tighten any loase screws and replace damaged studs.

3.

Inspect engine inlet screen for deformation and cracks; repair damage or replace screen.

4.

Inspect welds for cracks; reweld if possible, or replace screen.

843 - 4

REMOVAL - ENGINE INLET SCREEN

1.

Remove engine cowlings.

2.

Detach LH screen by removing four studs (8, fig. 843-1).

3.

Unscrew piston housing of rotor brake from flange on main transmission. Remove four studs on RH inlet screen. Raise piston housing to remove screen.

4.

The stud brackets (5) can be removed from the cover plate (1) of firewall (3) by rernoving two screws (6), nuts (2) and washers (7).

843 - 5

INSTALLATION - ENGINE INLET SCREEN

Installation is in reverse order of removal.

BO 105 CHAPTER 843 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

q,~---10

:~~-9

5

"'

4

8

3

Cover plate Nut Firewall 4 Stud fastener 5 Bracket 1 2 3

Fig. 843-1 BO 105 CHAPTER 843 Page 6

6 7 8 9

10

Screw Lockwasher Stud Lug Engine inlet screen

Engine inlet screen

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

844

PENDULUM ABSORBERS

Table of Contents

Paragraph

Title

844 - 1

DESCRIPTION - PENDULUM ABSORBERS

3

844 - 2

TROUBLESHOOTING - PENDULUM ABSORBERS

3

844 - 3

INSPECTION SCHEDULE - PENDULUM ABSORBERS

4

844 - 4

INSPECTION FOR CONDITION - PENDULUM ABSORBERS

5

844 - 5

REMOVAL - PENDULUM ABSORBERS

6

844 - 6

REPAIR - PENDULUM ABSORBERS

10

844 - 7

INSTALLATION - PENDULUM ABSORBERS

12

Page

BO 105 CHAPTER 844 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 844 - 1

DESCRIPTION - PENDULUM ABSORBERS

Pendulurn absorbers are tuned to cancel out vibrations occurring during forward flight at a low speed and fIare-out. Sleeves are larninated on the inboard end of each rotor blade to provide installation pads for the pendulurn absorber. Pendulurn absorbers have a housing as part of the assembly. It houses the pivot shaft and pivot shaft bearings. Pendulurns are installed on the pivot shaft ends. The pivot shaft is supported by oil-Iubricated ball bearings. Oil-Iubricated pendulurn absorbers are existing in two configurations that differ in type of pendulurn and installation on pivot shaft. 844 - 2

TROUBLESHOOTING - PENDULUM ABSORBERS

Only loss of oil frorn oil chambers with consequent wear of ball bearings can cause possible failure of absorbers. Bearing wear reduces absorbing efficiency and therefore necessitates replacernent of all sealing parts as well as bearings. No part is governed by rnandatory retirernent requirernents. Deteriorating conditions call for exchange of parts affected. Bearings are sealed into an oil-bath.

BO 105 CHAPTER 844 Page 3

EUROCOPTER

• 844 - 3

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 844 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 844 - 4

INSPECTION FOR CONDITION - PENDULUM ABSORBERS

1.

Inspect shaft seals for leakage. If leakage is evident, replace seals.

2.

Inspect ball bearings for play, binding and roughness, by moving the pendulum. If play or damage is evident, replace ball bearings.

3.

Inspect shaft for axial play. If play exceeds max. permissible 0.06 mm, shim as required.

4.

Inspect pendulum brackets for surface damage. a.

Surface damage not exceeding 0.2 mm in depth does not require rework.

b.

Polish out surface damage between 0.2 mm and max. 0.7 mm in depth using polishing cloth No. 400 and restore protective finish.

5.

Inspect protective finish of one-piece pendulum weight for damage. If damaged, restore protective finish.

6.

Inspect safety devices of attaching hardware for integrity. If not intact, check hardware torque and install new safety devices.

7.

Check oil level. Make certain oil level is level with vent screw in side of upper bracket.

8.

Inspect split line of upper and lower pendulum brackets for cracks and corrosion (not for P/N 105-81022.01/.02). a.

If corroded, remove, repair and reinstall pendulum absorber in accordance with paras 844-5 thru 844-7 respectively.

b.

Replace cracked parts.

BO 105 CHAPTER 844 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 REMOVAL - PENDULUM ABSORBERS

844 - 5 1.

Before removing the pendulum absorber, identify it with its corresponding rotor blade, using colored tape.

2.

Remove attaching hardware from pendulum absorber brackets and remove pendulum absorber.

3.

If required, disassemble pendulum absorbers as follows: Pendulum absorber (Configuration 1) a.

Remove upper bracket (1, fig. 844-2) with pendulum and bearing assembly from rotor blade.

b.

Remove lockwire (25), remove hex screws (23) and drain the oil.

c.

After removing split pin (19), bolt (17) and washer (18) from one end, remove pendulum and any existing shims.

d.

Remove shaft (10), and detach spacer (7) with O-ring (8).

e.

Remove sealing ring (4) with O-ring (3) and shaft seal (5), ball bearing (6) and shaft seal (9) as shown in figure 844-1.

f.

Detach shaft seal (5, fig. 844-2) and O-ring (3) from sealing ring (4).

1 Disc (36 mm dia., 10 mm thick) 2 Drift (18 mm dia., 200 mm long)

Figure 844-1 BO 105 CHAPTER 844 Page 6

Removal of bearing assembly

------------->.--- MEB

HELICOPTERS ----------~-­ MAINTENANCE MANUAL MEB - BO 105

8

10

1 Upper bracket Lower bracket 3 O-ring 4 Sea ling r ing 5 Shaft seal 6 BaH bearing 7 Spacer 8 O-ring 9 Shaft seal 10 Shaft 11 Weight 12 Eyebolt 13 Washer 14 Washer 15 Castellated nut 16 Split pin 17 Bolt 18 Washer 19 Split pin 20 Screw 21 Washer 22 Castellated nut 23 Hex screw 24 Sealing ring 25 Lockwire 26 Sleeve 27 Shirn 2

11 18

_fIIIlIt.o-15- 7Nm

~13

U-

ll

~14 8:-15 -18-10 Nml

800132.3

'-16

Figure 844-2

l

Pendulurn absorber (Configuration 1) BO 105 CHAPTER 844 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Pendulum absorber (Configuration 11) a.

Remove upper bracket (1, fig. 844-3) with weights (11) and bearing assemblies from rotor blade.

b.

Remove lockwire (23) and hex screws (21). Drain the oil.

c.

Remove tapered pin (12) and pendulum weight (11) and any existing shims from one shaft end.

d.

Remove shaft (10) with spacer (7) and O-ring (8).

e.

Remove sealing ring (4) with O-ring (3) and shaft seal (5), ball bearing (6) and shaft seal (9) as shown in figure 844-1.

BO 105 CHAPTER 844 Page 8

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

--1

7

--2

12

/'

10

800131.6

1

2 3

4 5

6 7 8 9

10 11

Upper bracket Lower bracket O-ring Sealing ring Shaft seal BaH bearing Spacer O-ring Shaft seal Shaft Pendulum weight Figure 844-3

12 13 14 15 16 17

18 19

Tapered pin Nut Washer Screw Nut Washer Split pin Not itemized

20 2122 23 24 25

Not itemized Hex screw Sealing rif,lg Lockwire Sleeve Shim

Pendulum absorber (Configuration 11) BO 105 CHAPTER 844 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 844 - 6

REPAIR - PENDULUM ABSORBERS

Pendulum absorbers (Configurations 1 and 11) 1.

Inspect pendulum absorbers for mechanical damage and corrosion. If damage is detected, and does not exceed the tolerances as quoted in figure 844-4, use polishing cloth No. 400 and polish damaged surfaces as required to remove mechanical and/or corrosive damage.

2.

Dye-penetrant inspect surface of zone 1 (figure 844-4) for cracks, according to MIL-STD-6866. If cracks are detected on top and/or bottom mounting bracket replace damaged bracket.

3.

Repair or replace defective surface protection by using two-component zinc chromate primer (CM 456) and two-component PUR-lacquer (CM 426).

BO 105 CHAPTER 844 Page 10

----------->----MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

800254

TYPE OF DAMAGE

DAMAGE AND REPAIR LIMITS ZONE 1

ZONE 2

O Mechanical and corros ion

NOTE

~

& ~

0.2 mm of depth on max. 100 mm 2 after repair

0.3 mm of depth on max. 200 mm 2 after repair

Damage and repair limits apply to both upper and lower pendulum brackets. The largest permissible bore diameter is 8.3 mm. It is permissible to exceed the bore diameter by 0.02 mm on one quarter of the bore circumference. is permissible to polish out the bore contact surfaces to a depth of 0.01 mm on one quarter of the bore circumference.

It

Damage and repair limits for outer surfaces are same as those tor the inner surfaces. Figure 844-4

Pendulum absorber, damage and repair limits BO 105 CHAPTER 844 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSTALLATION - PENDULUM ABSORBERS

844 - 7

l.

If previously disassembled, reassemble pendulum absorber as follows: Pendulum absorbers (Configuration I) a.

Install inner shaft seal (2, fig. 844-5) in sealing ring (3) using a drift (1).

800152.1

Drift Shaft seal 3 Sealing ring 1 2

Figure 844-5

Installation of shaft seal

b.

Install O-ring (4, fig. 844-2) in sealing ring (3) and press sealing ring into upper bracket (1) until one of the slots of the sealing ring is brought into alignrnent with the oil filler inlet (upper bore hole) .

c.

Clean ball bearing (6) prior to installation with dry cleaning solvent (CM 202). Then lubricate with oil (CM 103). Install ball bearing in upper bracket (1) and push into place by hand. For ease of installation press on outer ring of ball bearing.

d.

Lubricate outer shaft seals (9) with silicone grease (CM 104) and install in upper bracket.

e.

Slide eyebolt (12) on shaft (10).

f.

Coat bolt (17) with corrosion preventive paste (CM 510), insert bolt to install eyebolt (12) on shaft (10). Install washer (18) and split pin (19).

g.

Slide spacer (7) with O-ring (8) over shaft (10) until making contact with eyebolt. Check for correct installation of spacer.

BO 105 CHAPTER 844 Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 h.

Insert shaft into upper bracket end and slide spacer (7) and O-ring (8) over free end of shaft. Check for correct installation of spacer.

i.

Slide eyebolt (12) on free end of shaft, apply corros ion preventive paste (CM 510) to bolt (17) and install.

j.

Set dial indicator against end of shaft, secure housing in place, and move shaft in axial direction. Install shims (27) as necessary on one end of shaft to eliminate play in excess of 0.06 mm.

k.

Secure bolt (17) with washer (18) and split pin (19). Secure both bolts with lockwire.

l.

Service pendulum absorber with oil (CM 103) through upper oil filler inlet until oil flows out of the side vent holeo Swing pendulum during servicing to allow oil to circulate.

m.

Install hex screws (23) with sealing rings (24) into upper bracket and secure screws together with lockwire.

Pendulum absorbers (Configuration 11) a.

Perform steps a. through d. in accordance with assembly instructions for configuration I.

b.

Install pendulum weight (11, fig. 844-3) at one end of shaft (10).

c.

Coat tapered pin (12) with corros ion preventive paste (CM 510), insert in the aligned bores of the pendulum weight and shaft. Install washer (14) and nut (13) on tapered pino

d.

Slide spacer (7) with O-ring (8) over shaft until making contact with pendulum weight. Be sure spacer installation is correcto

e.

Install shaft in upper bracket and slide the second spacer (7) with O-ring (8) on the end of the shaft. Be sure spacer installed position is correct.

f.

Slide eyebolt over free end of shaft (11), apply corrosion preventive paste (CM 510) on tapered pin and install.

g.

Set dial indicator against end of shaft, secure housing in place, and move shaft in axial direction. Install shims (25) as necessary on one end of shaft to eliminate play in excess of 0.06 mm.

h.

Secure tapered pin (12) on threaded end with washer (14) and nut (13) .

i.

Service pendulum absorber with oil (CM 103) through upper oil filler inlet until oil flows out of the side vent hole. Swing pendulum during servicing to allow oil to circulate.

j.

Install hex screws (21) with sealing rings (22) into upper bracket and secure screws together with lockwire. BO 105 CHAPTER 844 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 2.

Install pendulum absorbers as follows:

NOTE

o The following steps apply for initial installation of pendulum absorbers. o When a pendulum absorber is replaced with a new part, the installation pad must be reworked to mate with the pendulum absorber in accordance with the following steps (except substep a.). Use a file to remove resin coat debris from contact surfaces on installation pacto o When a pendulum absorber is removed and reinstalled in its original location use the existing installation pad and attach upper and lower bracket on blade sleeve with screws. a.

Remove tear-up cloth from sleeve on blade where pendulum absorber will seat (required at initial installation of pendulum absorber only) .

b.

When mating the pendulum absorber with the blade sleeve, rework installation pad where pendulum absorber will seat with a file as may be necessary, until a circumferential free play of 0.1 to O.S mm is obtained between sleeve and upper and lower brackets. Sufficient play is provided if the preassembled pendulum absorber can be easily displaced spanwise for approx. 1 cm away from the sleeve.

c.

Locate lower bracket on underside of blade and trace contour of oval opening on sleeve with a color pencil.

d.

Apply a coat of adhesive film (CM G03) over the circumference of the blade inboard end and the sleeve pad ends adjacent to area where pendulum absorber will seat and in the area adjacent to the line traced along oval opening on underside of blade sleeve. Apply adhesive tape (CM G09) to blade at either side of sleeve adjacent to adhesive film coat area.

e.

Apply a length of 4 mm-thick wax pad (CM 73G) over the entire blade circumference on top of adhesive film-coated area to mask pendulum absorber upper and lower bracket edges facing the rotor blade attachment end and along the oval opening.edges on underside of blade. This will prevent excess resin from spreading after application of resin combination at final installation of pendulum absorber.

f.

Separate upper and lower bracket from blade and spray-coat flange faces of bracket assembly with parting agent (CM 709) .

BO lOS CHAPTER 844 Page14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 g.

Degrease contact area on sleeve with acetone (CM 203) and apply a coat of resin combination (resin, CM 640 and hardener, CM 641) mixture ratio 5: 1.

h.

Apply a length of adhesive film (CM 603) to flange faces, one per upper and lower bracket. This, when the film is removed, provides an approx. 0.2 mm gap between flange faces to permit positive gripping action for the brackets when they are installed on the blade sleeve.

i.

Locate pendulum absorber on sleeve until resting upon the sleeve and aligned with the sleeve pad ends, complete installation and tighten bolts (tightening torque 5 Nm) and secure against axial displacement (e.g. install a suitable piece of wood between pendulum absorber and blade attachment fitting).

j.

Cure rotor blade in horizontal position (with oval opening in lower pendulum absorber bracket facing downward) at approx. 25 OC for approx. 12 hours.

k.

When resin combination has cured remove pendulum absorber and wax pad, adhesive film, crepe paper tape and excess res in from sleeve and pendulum absorber. Use a file to remove excessive resin from sleeve in the area where inner upper pendulum absorber bracket does not make physical contact with the sleeve (excess resin tolerance limit 1 mm) .

l.

Clean oval opening area on sleeve with acetone (CM 203) and mask installation area around oval opening area with crepe masking tape (CM 609) .

m.

Apply UP putty (CM 303 and CM 304) to oval opening area and allow to dry. Polish oval opening area with wet polishing paper (grade 320) and apply finish coat (CM 412, CM 413 and CM 420). Refer to manufacturer's instructions for information regarding mixture ratio and woring life. Allow to dry and remove crepe paper tape.

,.

n.

....

Install pendulum absorber on sleeve and tighten nuts evenly. Apply torque gradually on diagonally opposite bolt and nut assemblies for the specified tightening torque and secure with cotter pins.

BO 105 CHAPTER 844 Page 15/16

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845

CHIP WARNING INDICATION

Table of Contents

Paragraph

Title

845 - 1

DESCRIPTION - CHIP WARNING INDICATION

3

845 - 2

TROUBLESHOOTING - CHIP WARNING INDICATION

3

845 - 3

INSPECTION SCHEDULE - CHIP WARNING INDICATION

5

845 - 4

Removal - chip detector

6

845 - 5

Inspection and cleaning - chip detector

6

845 - 6

Installation - chip detector

6

Page

BO 105 CHAPTER 845 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 845 - 1

DESCRIPTION - CHIP WARNING INDICATION

1. General The chip warning indication warns the pilot of excessive chip contarnination in the transmission sump by switching on a warning light. 2. Configuration. The system mainly consists of an electrically operated chip detector 5EV connected by an electric cable to a warning light 4EV located on the instrument panel 2VE. 3. Operation.

The chip warning indication is provided dc voltage by the main bus PP21 through protective fuse 8E. Metal chips and particles in splinter and granular form circulating with the oil are attracted by the chip detector along with the normal wear debris. This material builds up until it bridges the contact gap on the detector magneto When the gap is bridged warning light 4EV is connected to ground and lights up. 845 - 2

TROUBLESHOOTING - CHIP WARNING INDICATION

General Troubleshoot the circuit using applicable wiring diagram in Wiring Diagram Manual (WDM). Connect external power supply (EPU). Inspect fuse 8E for proper function. Test the lamp of warning light

4EV via test switch GEB.

No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Warning light T PLUG 4EV illuminates, although no metal particles have accumulated on chip detector 5EV

Wires EV5E20 or 679-20 shorted to ground

Check continuity oí wiring using applicable wiring diagram. Repair or replace faulty wiring

Table 845-1

Troubleshooting (1 oí 2)'

BO 105 CHAPTER 845 Page 3

- - - - - - - - ' - - - - - - M B B HELICOPTERS - - - - - - ' - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

2

Warning light T PLUG 4EV does not illuminate, although transmission oil is severely contaminated

Electric chip detector 5EV defective

Disconnect plug 5EVa and connect pin A to ground. Warning light T PLUG 4EV must illuminate. Replace chip detector

Faulty wiring or faulty plugs 5EVa or 2VEd

Check continuity of wiring using applicable wiring diagram. Repair or replace faulty parts

Table 845-1

Troubleshooting (2 of 2)

MAIN BUS

PP2128V-

I

10ED

4EV

800150

CAUTION L1GHT ",., ' .... O~

e:J \ /

I

O ,

e,,"'1 -= ~

OIL COOL

'----J

T PLUG

.;

-----,I

I '-------------+' [;] I

I

I

L----91 1 CHIP DETECTOR

5EV

Fig. 845-1 BO 1095 CHAPTER 845 Page 4

Chip warning indication schematic diagram

EUROCOPTER

845 - 3

Revision 18

MAINTENANCE MANUAL 80105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 845

Page5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 845 - 4

Removal - chip detector

1. Before proceeding with removal, remove fuse 8E, remove battery power and, if engaged, disconnect external power supply. 2. Open rear clamshell doors and remove access cover from cargo compartment panelling beneath main transmission. 3. Disconnect plug 5EVa from chip detector and install protective cap on plug. 4. Press in chip detector by hand, turn counterclockwise, and remove from self-closing valve (5, fig. 845-2). 845 - 5

Inspection and cleaning - chip detector

1. Remove chip detector in accordance with para 845-4. 2. Inspect chip detector for indication of metal particles. Analyse metal particles in accordance with fig. 11-14, and perform corrective action required by table 11-2. 3. Clean chip detector with dry cleaning solvent (CM 202) . 4. Inspect chip detector for damage and test magnetismo Replace defective chip detector. 5. Connect plug 5EVa to chip detector. Insert fuse 8E and apply battery power. 6. Bridge contact gap on chip detector. Warning light T PLUG must illuminate. 7. Disconnect plug 5EVa. Remove battery power and fuse 8E. 8. Install chip detector in accordance with para 845-6. 9. Test lamp of warning light 4EV with test switch GEB. 845 - 6

Installation - chip detector

1. Use new O-rings when installing the chip detector. 2. Insert chip detector in self-closing valve and turn clockwise until it locks into place. 3. Reconnect plug 5EVa and install lockwire. 4. Install access cover on cargo compartment panelling. 5. Install fuse 8E. 6. Connect battery power. 7. Test lamp of warning light 4EV with test switch GEB. BO 105 CHAPTER 845 Page G

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

6---I~:llI1

5 - - ! - .",,-=-.,;j

1 Diode p1ate 2WW 2 Warning light T PLUG 4EV 3 Chip detector 5EV 4 Transrnission sump 5 Self-closing valve 6 Detector contact gap

Fig. 845-2

Chip warning indication BO 105 CHAPTER 845 Page 7/8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

846

STABILITY AUGMENTATION SYSTEM (SAS)

Table of Contents

Paragraph

Title

846 - 1

DESCRIPTION - STABILITY AUGMENTATION SYSTEM . .

3

846 - 2

TROUBLESHOOTING - STABILITY AUGMENTATION SYSTEM

4

846 - 3

INSPECTION SCHEDULE - STABILITY AUGMENTATION SYSTEM

8

846 - 4

INSPECTION FOR CONDITION - STABILITY AUGMENTATION SYSTEM

9

846 - 5

FUNCTIONAL CHECK - STABILITY AUGMENTATION SYSTEM

9

846 - 6

Removal - Actuator control rods . . . . . . .

10

846 - 7

. Inspection and repair - Actuator control rods

10

Page

846 - 8

Installation - Actuator control rods

10

846 - 9

Adjustment - Electrical zero of actuators

11

846 - 10

Inflight check of stability augmentation system

19

BO 105 CHAPTER 846 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 846 - 1

DESCRIPTION - STABILITY AUGMENTATION SYSTEM

1. General The SAS system provides helicopter attitude control in the pitch and roll axes. It reduces pilot workload in cruising flight, e.g., IFR flights without copilot. 2. Description 1 control unit 28VE with - circuit breaker 1CA STDBY/OFF toggle switch 2CA PITCH STDBY/ON pushbutton/indicator 4CA ROLL STDBY/ON pushbutton/indicator sCA 1 base plate 29VE containing - gyro amplifier 8CA (ROLL axis) - gyro amplifier 9CA (PITCH axis) - static inverter 6CA - distributor 130VV 1 control rod and actuator llCA (pitch axis) 1 control rod and actuator lOCA (roll axis) 1 switch 7CA on each cyclic stick 3. Operation The stability augmentation system is supplied with 28VDC from main bus PP21 or emergency bus PP20 and is protected by circuit breaker lCA. When toggle switch STDBY/OFF is moved to STDBY, the SAS system is energized and the rate gyro cornmences run-up. At the same time, the orange PITCH STDBY and ROLL STDBY captions come on. The SAS system will be operational approximately ten seconds after the ROLL STDBY/ON and PITCH STDBY/ON pushbutton/indicators are pressed and will then hold the existing roll and pitch attitudes of the helicopter. Simultaneously, the orange ROLL STDBY and PITCH STDBY captions will go out and the green ROLL ON and PITCH ON captions will come on. When the pilot's or copilot's cyclic-mounted cut-off switch 7CA is pressed, the SAS system will become disengaged; the rate gyro will continue to operate.

BO 105 CHAPTER 846 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The SAS system uses rate gyros as axis rate sensors and transistorized minicomputers for processing incoming signals. The roll and pitch channels each use their own rate gyro and computer which are housed together in the gyro amplifier unit. The pitch and roll rate gyros sense helicopter motion and transmit corresponding output signals which are applied to the respective actuator driving amplifiers as direct signals and partially integrated signals. These signals,together with the corresponding actuator position and rate inputs, are surnrned and the resulting amplifier output signals produce proportional linear movement of the connected actuators. The extension and retraction of the actuator rams produce pitch and control motions which correct the attitude deviations sensed by the rate gyros. 846 - 2

TROUBLESHOOTING - STABILITY AUGMENTATION SYSTEM

General Troubleshoot in conjunction with the applicable wiring diagram in the Wiring Diagram Manual (WDM). Inspect all associated electrical connections for security and tight fit. Inspect all associated switches and circuit breakers for proper mechanical functioning. Engage external power supply (EPU). Press circuit breaker 1CA.

BO 105 CHAPTER 846 Page 4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

ROLL STDBY caption does not illuminate when toggle switch 2CA is in STDBY.

Defective roll rate gyro amplifier 8CA.

Replace roll rate gyro amplifier 8CA.

Defective control unit 28VE.

Check continuity of wiring using wiring diagram.

Dummy plug replacing second cyclic stick not connected.

Insert dummy plug.

Defective base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

Defective interconnecting Check continuity of wiring using wiring cable between control diagram. unit 28VE and base plate with gyro amplifier 29VE. 2

ROLL ON caption does not illuminate when pushbutton/indicator ROLL ON is pressed with toggle switch 2CA in STDBY

Defective roll rate gyro amplifier 8CA.

Replace roll rate gyro amplifier 8CA.

Defective control unit 28VE.

Check continuity of wiring using wiring diagram.

Dummy plug replacing second cyclic stick not connected.

Insert dummy plug.

Defective base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

Table 806-1

Troubleshooting (1 of 3) BO 105 CHAPTER 846 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

3

4

TROUBLE SYMPTOM

No inflight roll attitude control by roll actuator

PITCH STDBY caption does not illuminate with toggle switch 2CA in STDBY

PROBABLE CAUSE

CORRECTIVE ACTION

Defective interconnecting cable between control unit 28VE and base plate with amplifier 29VE.

Check continuity of wiring using wiring diagram.

Defective roll rate gyro amplifier 8CA.

Replace gyro amplifier 8CA.

Defective base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

Defective interconnecting cable between control unit 28VE and base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

Defective actuator (position or rate of change of position transmitters)

Replace actuator and control rod assembly.

Defective pitch rate gyro amplifier 9CA.

Replace gyro amplifier 9CA.

Defective control unit 28VE.

Check continuity of wiring using wiring diagram.

Dummy plug replacing second cyclic stick not connected.

Insert dummy plug.

Defective base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

Table 846-1 BO 105 CHAPTER 846 Page 6

Troubleshooting (2 of 3)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

5

PITCH ON caption does not illuminate when pushbutton/ indicator PITCH ON is pressed with toggle switch 2CA in STDBY

Defective pitch rate gyro amplifier 9CA.

Replace gyro amplifier 9CA.

Defective control unit 28VE.

Check continuity of wiring using wiring diagram.

Dummy plug replacing second cyclic stick not connected.

Insert dummy plug.

Defective base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

Defective interconnec~ ting cable between control unit 28VE and base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

Defective pitch rate gyro amplifier 9CA.

Replace gyro amplifier 9CA.

Defective actuator (position or rate of changeof position transmitters) .

Replace actuator and control rod assembly.

Defective base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

Defective interconnecting cable between control unit 28VE and base plate with gyro amplifier 29VE.

Check continuity of wiring using wiring diagram.

6

No inflight pitch attitude control by pitch actuator

Table 846-1

Troubleshooting (3 of 3)

BO 105 CHAPTER 846 Page 7

EUROCOPTER

• 846 - 3

MAINTENANCE MANUAL BO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 846 Page8

Revisiol1 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 846 - 4

INSPECTION FOR CONDITION - STABILITY AUGMENTATION SYSTEM

1. Inspect actuator control rods: a.

Inspect tubular surface of control rods for condition. Discard bent control rods. Polish out scratches, nicks, chafe marksand corrosion. Refer to Chapter 41 for damage and repair limits.

b.

Touch up damaged surface protection according to Chapter 02, using two-component zinc chromate primer (CM 456) and two-component PUR topcoat (CM 426) .

c.

Inspect rod end spherical bearings for corrosion, roughness and play (movement of the control rods about the longitudinal axis must still be possible by hand). If there is radial play in excess of 0.1 mm, roughness or corrosion, replace rod ends with spherical bearings.

d.

Check rod ends for condition of seal. If seal is damaged or missing, disassemble, inspect, reassemble and apply new seal, using silicone rubber (CM 612), according to Chapter 41.

e.

Inspect sealing boot on upper control tube-to-rod end connection for damage and porosity; replace damaged parto

2. Inspect top and bottom attaching hardware for tightness. Where cotter pins are missing, check for specified tightening torque (see fig. 846-3) and tighten as necessary. Secure with cotter pins. 3. Inspect base plate with gyro amplifiers for security of installation; tighten loose screws.

4. Inspect connectors and leads for condition and security. 846 - 5

CAUTION

FUNCTIONAL CHECK - STABILITY AUGMENTATION SYSTEM THE SAS MUST

RE~~IN

SWITCHED OFF AT OATs BELOW -35 OC.

1. Press SAS circuit breaker. 2. Select toggle switch STDBY/OFF to STDBY. ROLL STDBY and PITCH STDBY

captions must be illuminate. 3. Allow rate gyro to run up for at least 10 seconds, then press the ROLL ON and/or PITCH ON pushbutton indicator(s). The corresponding STDBY and ON captions must go off and come on 1 respectively. 4. Press pilot's and copilot's cyclic-mounted SAS cut-off switches in turno The pitch and roll channels shall simultaneously disengage from the ON mode to the STDBY mode, causing the ON captions to go off and the STDBY captions to come on. 5. Turn off the SAS system by selecting toggle switch STDBY/OFF to OFF (all captions go off) and pull SAS circuit breaker. BO 105 CHAPTER 846 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Removal - Actuator control rods

846 - 6 NOTE

The removal procedure for both actuator and control rod assemblies is identical.

1. Remove left engine cowling and left cargo compartment fairings to the extent required. 2. Disconnect electrical connectors from base plate (3, fig. 846-3). 3. Remove control rod attaching hardware and remove actuator and control rod assembly. Inspection and repair - Acutator control rods

846 - 7

1. Disassemble control rod assembly as described in Chapter 41. 2. Inspect control rods for condition. Refer to Chapter 41 for damage and repa ir limit s .

846 - 8

NOTE

Installation - Actuator control rods

The installation procedure is identical for both actuator and control rod assemblies. Lateral control is color-coded BLUE Longitudinal control is color-coded RED.

1. When installing the control rod, check electrical zero position as follows: a.

Connect electrical connector of control rod to receptacle in base plate (3, fig. 846-3).

b.

Press circuit breaker 1CA. Select toggle switch STDBY/OFF (9, fig. 846-1) to STDBY.

c.

The actuator must be at its electrical zero position after 5 minutes have elapsed.

d.

Measure dimension L4 with an internal micrometer. If this dimension does not correspond with the value specified in the table (fig. 846-4), the zero position is wrong and must be adjusted according to para 846-9.

2. Disconnect electrical connector from base plateo

BO 105 CHAPTER 846 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3.

Assemble control rod so that dimension L2 is identical to the dimension L2 recorded at disassembly: a.

Remove lockwire from nut (2, fig. 846-4) of control rod, back off nut and disengage serrated washers (3) from groove in actuator ramo

b.

Rotate rod end (1) until dimension L2 is obtained. Align rod ends 90° aparto

c.

Fit serrated washers (3) in groove and tighten nut (2). Install lockwire.

4.

Locate control rod in position with the actuator at the bottom.

5.

Connect upper rod end to upper bellcrank with attaching hardware (4, 5 and 6, fig. 846-3). Safe nut with cotter pin (7).

6.

Connect bottom rod end to lower bellcrank with attaching hardware (8, 10 and 11). Safe nut with cotter pin (9).

7.

Connect electrical connector to base plateo

8.

Take care that cable does not foul any moving parts.

9.

Check rigging of main rotor controls (refer to Chapter 102) .

10.

Install engine cowling and cargo compartment fairings.

11.

Perform inflight check of SAS system in accordance with para 846-10.

846 - 9 1.

Adjustment - Electrical zero of actuators

Zero adjustment in STBDY mode a.

Measure and record dimension L4 (fig. 846-4).

b.

Switch off SAS system and remove applicable gyro amplifier. Open the box housing the gyro amplifier by removing the seven screws securing the cover.

c.

Calculate difference between the actual L4 dimension and the specified L4 dimension of 27.48 mm. This difference divided by 0.18 is the number of times the adjusting screw on the potentiometer RSO must be turned to obtain electrical zero. 1)

Pitch axis actuator - To reduce dimension L4: Turn potentiometer adjusting screw clockwise. - To increase dimension L4: Turn potentiometer adjusting screw counterclockwise.

BO 105 CHAPTER 846 Page 11

EUROCOPTER

MAINTENANCE MANUAL 80 105

2) RolI axis actuator -

To reduce dimension L4: Turn potentiometer adjusting screw counterclockwise.

-

To increase dimension L4: Turn potentiometer adjusting screw clockwise.

d. After adjusting the potentiometer, reinstall cover on gyra amplifier box with two screws and connect the 32-pin connector.· e.

2.

I

After allowing 5 minutes to elapse in the STDBY mode, measure and record dimension L4 again. If it is between 27.15 mm and 27.85 mm, no further adjustment of the potentiometer R50 is required and, provided that no adjustment of the ON-mode potentiometer is necessary, the cover can be replaced and the gyra amplifier reinstalled in the helicopter.

Zero adjustment in ON-mode. a.

Engage the SAS system and, after allowing 5 minutes to elapse, measure and record dimension L4 (see fig.846-4).

b.

Switch off the SAS system and remove the cover from the applicable gyra amplifier by removing seven screws.

c.

Obtain electrical zera dimension L4 as follows: 1) Pitch axis actuator The difference between the actual L4 dimension and the specified L4 dimension of 27.48 mm divided by 0.66, is the number of times the adjusting screw of potentiometer R51 must be turned to obtain electrical zero. -

To reduce dimension L4: Turn potentiometer adjusting screw clockwise.

-

To increase dimension L4: Turn potentiometer adjusting screw counterclockwise.

2) RolI axis actuator The difference between the actual L4 dimension and the specified L4 dimension of 27.48 mm divided by 0.17, is the number of times the adjusti ng screw of potentiometer R51 must be turned to obtain electrical zero -

To reduce dimension L4: Turn potentiometer adjusting screw counterclockwise.

-

To increase dimension L4: Turn potentiometer adjusting screw clockwise.

CHAPTER 846 Page 12

Revision 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 d.

After adjusting the potentiometer, reinstall cover on gyro amplifier box with two screws and connect 32-pin connector.

e.

After allowing 5 minutes to elapse in the STDBY mode, measure and record L4 dimension again. If it is between 27.25 and 27.85, no further adjustment of potentiometer R51 is required and the cover can be replaced and the gyro amplifier reinstalled in the helicopter.

---.f-!--1 "'--~L.--2

'--~'----3

6

7

1 Pitch actuator 2 Rol! actuator 3 Base plate with gyro amplifier 29VE 4 Control unit 28VE 5 SAS cut-off switch 7CA Fig. 846-1

8

9

6 ROLL pushbutton/indi.cator SCA STDBY (orange) ON (green) 7 PITCH pushbutton/indicator 4CA ,STDBY (orange) ON (green) 8 SAS Circuit breaker 1CA 9 SAS OFF/STDBY toggle switch 2CA Stability augrnentation system BO 105 CHAPTER 846 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

n:.,..-----,

I ~~~f-----------'I I

o

I

o

-?,¡-:----¡--¡--¡-¡--- 2

-"'-----:-.;---3

o

1 Roll gyro amplifier 8CA 2 Distributor 130VV 3 3tatic inverter 6CA Fig. 846-2 BO 105 CHAPTER 846 Page 14

o

4 Connector 29VEA Connectors 29VEB and 29VEC 6 Connectors 29VED and 29VEE 7 Pitch gyro amplifier 9CA

5

Base plate

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DETAlL

A

tl1:t-r---- 1 ll-tI~~+----

2

'-------3

DETAlL

B

8

J 1 Pitch actuator 2 Roll actuator 3 Base plate

4 bolt 5 Washer

11

Fig. 846-3

10

9

6 Nut 7 Cotter pin 8 Bolt 9 Cotter pin 10 Nut II Washer

Removal and installation - actuator and control rod assembly BO 105 CHAPTER 846 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS ------------~ MAINTENANCE MANUAL MBB - BO 105

L1

L2

678 mm.!, 1

742 mm:. 0.5

678mm + 1

L4

L3

742 mm ,!.O.5

32 mm,!:.O,S

32 mm:t 0.5

MOTOR TYP'

FUNCTION

27.48 mm:!O.35 in zero signar position

Long. Control

FAS 20 MB

27.48 mm:!O.35 In zero signal posltion

Lat. Control

FAS 20 MB

11CP

PART NO.

CONNECTOR COLOR CODE

D 133-1358

red

D 133-1359

blue

11CR

I··'r I 2

5

3

L1

L2 800300

Rod end Nut 3 Serrated washers

1

2

Fig. 846-4

BO 105

CHAPTER 846 Page 16

4 Actuator Control rod

5

Actuator and control rod assembly

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

o I

I

I I

o

---

---

.......

¡~

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

O

.........

......

800144

Fig. 846-5

Gyro amplifier box with potentiometers RSO, R51

BO 105 CHAPTER 846 Page 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 846 - 10 NOTE

Inflight check of stability augmentation system o In order that the performance of the SAS system be tested under the most favourable test conditions in flight, do not allow the following forward CG limits to be exceeded. o Forward CG limit: Each 100 kg decrease in the gross mass increases the arm by 1 cm, as shown opposite. m = distance from datum

2300 2200 2100 2000 1900

kg kg kg kg kg

/ / / / /

3.15 3.16 3.17 3.18 3.19

m m m m m

l.

Oetermine take-off mass and center of gravity in accordance with the Flight Manual.

2.

Perform inflight check between sea level and 5000 feet in forward flight at 110 kt. (If 110 kt cannot be attained, perform inflight check on 75% torque. )

3.

Check SAS system in ON mode.

4.

a.

Rapidly pull cyclic stick approx. 1 cm aft and hold there for 1 second, then return cyclic stick to initial position.

b.

Fly "hands-off" for as long as possible up to maximum 30 seconds.

c.

Rapidly push cyclic stick forward (in flight direction) and hold there for 1 second, then return cyclic stick to initial position.

Check SAS system in STOBY mode. a.

5.

Move cyclic stick in accordance with step 3.a. thru

C.

The SAS system is functioning properly if the time flown "hands-off" is significantly longer in the ON mode than in the STOBY mode after control inputs are roade.

BO 105 CHAPTER 846 Page 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

847

FOLLOW-UP TRIM

Table of Contents

Paragraph

Title

Page

847 - 1

DESCRIPTION - FOLLOW-UP TRIM

3

847 - 2

TROUBLESHOOTING - FOLLOW-UP TRIM

5

847 - 3

INSPECTION SCHEDULE - FOLLOW-UP TRIM

8

847 - 4

INSPECTION FOR CONDITION - FOLLOW-UP TRIM

9

847 - 5

FUNCTIONAL CHECK - FOLLOW-UP TRIM

9

847 - 6

Rernoval - control unit

10

847 - 7

Installation - control unit

10

847 - 8

Rernoval - control unit printed circuit boards

11

847 - 9

Installation - control unit printed circuit boards

11

847 - 10

Rernoval - control unit subassemblies

11

847 - 11

Installation - control unit subassemblies

12

847 - 12

Rernoval - inductive pickup

12

847 - 13

Installation - inductive pickup

12

847 - 14

Adjustrnent - inductive pickup

12

BO 105 CHAPTER 847 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 847 - 1

DESCRIPTION - FOLLOW-UP TRIM

1. General

The follow-up trim system augments the series electrical trim system. It reduces the pilot's workload during maneuvering flights (e.g., hover, external load transporting, winch operation) by simplifying trirnming. Incontrast with the basic trim system, the trirnmers are provided with inductive pickups which measure the deflection of the trim springs from their neutral position and effect corresponding extension/retraction of the trim actuator spindles, thus relieving spring tension and removing cyclic stick pressure at its momentary position. 2. Description The follow-up trim system is located in the nose shell and on the instrument panel. The system consists of the following components (also refer to figure 847-1): 1 1 1 2 2 2 2

Circuit Breaker Mode Selector Unit Control Unit Four-way Switch Pushbutton Inductive Pickup Trim Actuators

1CC 22CC 21CC 2CC 23CC 26CC 6CC, 7CC

Mode Selector Unit 22CC The mode selector unit of the trim control is located on the center panel and has a toggle switch 3CC with ON, MAN and OFF switch positions. In the ON position the system is continually in operation so that every movement of the cyclic stick activates the trim actuator spindles which reduce stick control force s to zero. In the MAN position the equipment is on stand-by. Depression of the pushbutton 23CC (F/U-TRIM) on the cyclic stick activates the follow-up trim which remains operative until the pushbutton is released. Depression of the four-way switch 2CC (pilot has priority) by the pilot will result in the return to standard trirnming. In the OFF switch position the trim system is inoperative.

BO 105 CHAPTER 847 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Control unit 2lCC The control unit is located in the nose compartment between the blower and the right hand bulkhead. It contains the power supply, connector panel, and mode logic subassemblies, and the easily removable power amplifier, inductive pickup processor (inductive pickup SA) and sw~tching amplifier printed circuit boards. The equipment controls the directional rotation of the trim actuators in accordance with the input signals from the inductive pickups, four-way switch and the push-button switch. Trim actuators 6CC, 7CC The trim actuators are located in the nose compartment and are each connected by levers to the LAT and LONG trim spring rods. The trim actuators have a mechanical overrun stop, and under normal working conditions the respective limit switches control the extension and retraction of the actuator spindles. Inductive Pickup 26CC The inductive pickups are mounted on the LAT and LONG trim spring rods. The displacement of the trim springs is then transmitted as a signal to the control unit. 3. Operation (also refer to figure 847-2) Toggle switch 3CC set to MAN: Power is supplied to the control unit and from the control unit to the trim actuators from main bus PP2l through circuit breaker lCC and the closed contacts 5 and 6 of toggle switch 3CC. The control unit delivers a control voltage of 10V to the F/U-TRIM pushbutton 23CC, 4-way switch 2CC and toggle switch 3CC in the mode selector unit. The 10V control signal is transmitted to the FOLLOW-UP TRIM ON input on the control unit through closed contacts 2 and 1 thus inhibiting continuous follow-up trimming. Pressing the F/U-TRIM pushbutton 23CC completes the MAN circuit; the control unit controls the direction of rotation of the trim actuators 6CC and 7CC by means the FOLLOW-UP MAN signal and the signals produced by the inductive pickups. When the 4-way switch 2CC is moved to one of its switch positions i.e., RETR or EXT, LAT or LONG, the respective control unit circuit will be completed and the trim actuators 6CC and 7CC energized. The circuit will be deenergized if the 4-way switch 2CC is released or if the trim actuator spindles reach one of the limit switches.

BO 105 CHAPTER 847 Page 4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Toggle switch 3CC set to ON: The control unit and trim actuators are supplied with voltage from main bus PP21 through the circuit breaker 1CC and the closed contacts 5 and 6 of toggle switch 3CC. The 10V control signal is removed ¡rom the FOLLOW-UP TRIM ON input due to open contacts 2 and 1 of toggle switch 3CC, thus activating continuous follow-up trirnming. The inductive pickups continually measure trirnmer spring deflection caused by cyclic stick movements and transmit corresponding electrical signals to the pickup input s on the control unit. The control unit controls the direction of rotation of one or both actuators according to the input signals. The trim actuator spindles retractand/or extend thus unloading the springs and reducing cyclic stick forces to zero. 847 - 2

TROUBLESHOOTING - FOLLOW-UP TRIM

General Troubleshoot in conjunction with wiring diagram 847-1 in the Wiring Diagram Manual (WDM). Check all electrical connections for tightness and all switches and circuit breakers for proper mechanical functioning. Connect external power supply (EPU) and set 16P battery switch to BATT OFF/EPU ON. -

Depress circuit breaker 1CC.

BO 105 CHAPTER 847 Page 5

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

One of the trim actuators does not operate in switch position MAN or ON

Fuse defect on printed circuit board "power amplifier". Caused by faulty actuator or defective power supply

Test fuse Si 1 soldered on printed circuit board and replace board if fuse found faulty. Check motor. (Current consumption: max. 0.7A at 28 V). Check leads to motor. Replace motor

2

One of the trim actuators runs spontaneously to the limit switch when follow-up mode MAN or ON is selected, yet responds correctly to beep-cornrnands

Printed circuit board "inductive-pickup SA" faulty or lead connecting inductive pickup to control unit defective

Disconnect plug 21CCa and test connecting lead between control unit and inductive pickup. Wiring resistance values: 41 42 67 Ohm 67 Ohm 43 42 45

44 67 Ohm

67 Ohm 46

45

All wiring must be insulated against mass of helicopter Replace printed circuit board "inductive pick-up S.A. lI

3

4

Check four-way switch.

One of the trim actuators runs spontaneously to limit switch even in position MAN without Beep-cornrnands

Short in printed circuit board "power amplifier or fault in mode logic subassy.

Both trim actuators inoperative

Power supply subassy.

ll

Replace printed circuit board "power amplifier". Replace mode logic subassy. Check for voltage (10 at terminal junction 451VV Replace power supply subassy.

Table 847-1 BO 105 CHAPTER 847 Page 6

Troubleshooting (1 of 2)

V)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

Compensating resistance of motor power supply burned out

Test resistor R1 and R2 or printed circuit. board for signs of a previous overload Replace connector panel subassy together with mode logic subassy

5

stick forces in follow-up trim mode not symmetrical

Table

Toggle switch 3CC faulty

Check toggle switch and replace if necessary

Inductive pickup

Adjust inductive pick-up (refer to para 847-14)

847~1

Troubleshooting (2 of 2)

BO 105 CHAPTER 847 Page 7

EUROCOPTER

• 847 - 3

MAINTENANCE MANUAL 60 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 847 Page 8

Revision 18

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 847 - 4

INSPECTION FOR CONDITION - FOLLOW-UP TRIM

1. Inspect trim system for condition in accordance with Chapter 41. 2. Perform the following additional inspection items: a.

Inspect inductive pickups on longitudinal and lateral trim spring rods for external condition and security of installation. Inspect electrical connectors for tightness and corroded pins.

b.

Inspect control unit for external condition and security of installation, electrical connectors for tight fit and corroded pins, and bonding jumper connections for corros ion and tightness.

c.

Inspect associated electrical leads for external condition and stress-free installation. Replace harness if leads are chafed or broken through.

847 - 5

FUNCTIONAL CHECK - FOLLOW-UP TRIM

General Connect heiicopter to external power source (EPU). Set 16P battery switch to BATT OFF/EPU ON. Connect helicopter to hydraulic test stand. Depress circuit breaker lCC TRIM. NOTE

Stick trirn forces must be zero in any position at the following modes selected. If forces are not reduced to zero, adjustment of inductive pickups is not correct or the system is otherwise defective.

1. Mode Selector 3CC in ON position: a.

Press stick to left and right within operating range of trim actuator and hold for a few seconds in each position. Trim actuator LAT must follow up.

b.

Move stick back and forth within operating range of trim actuator and hold for a few seconds in eaeh position. Trim actuator LONG must rollow up.

BO 105 CHAPTER 847 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2. Mode selector switch 3CC in MAN position. a.

Press pushbutton 23CC F/U-TRIM. Press stick to left and right within operating range of trim actuator and hold for a few seconds in each position. Trim actuator LAT must follow up.

b.

Press pushbutton 23CC F/U-TRIM. Move stick back and forth within operating range of trim actuator and hold for a few seconds in each position. Trim actuator LONG must follow up.

c.

Move four-way switch 2CC COPILOT to all four position. Trim actuator must operate in any of the four positions and switching off must be effected by limit switch of trim actuator.

3. Pilot's four-way switch priority checkout: Move the copilot's 4-way switch to each switch position in turn, while each time moving the pilot's 4-way switch in the opposite direction. The affected actuator, LONG or LAT, must, in each case, reverse its direction of travel to comply with the inputs from the pilot's 4-way switch. The trim actuator is always switched off by its integrated limit switch. 847 - 6

Removal - control unit

1. Pull circuit breaker lCC TRIM.

2. Remove plug attaching screws (2, fig. 847-3) and remove plug (3). 3. Detach ground strap (4) at fuselage. 4. Remove control unit (1) attaching screws (5) and (6) and remove control unit. CAUTION

847 - 7

WHEN MAKING REPAIRS TO THE CONTROL UNIT 2lCC ALL CONTACT WITH STATIC CHARGES SHOULD BE PREVENTED. A STATIC CHARGE TO THE CONTROL UNIT WILL CAUSE DAMAGE TO THE ELECTRONIC COMPONENTS. Installation - control unit

1.

Installation is in reverse order of removal.

2.

Perform functional test as described in paragraph 847-5.

BO 105 CHAPTER 847 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS ----~-------­ MAINTENANCE MANUAL MBB - BO 105

847 - 8

Removal - control unit printed circuit boards

1. Unscrew and remove four screws (fig. 847-3) with washers (14). Take off housing cover (15). 2. Remove hexagon nut (16) with washer (17) from stud (18) on one side and extract stud (18) from opposite side. Remove spacers (19). Remove plugged-in printed circuit boards (7, 8 and 9). 847 - 9

Installation - control unit printed circuit boards

1.

Installation is in reverse order of removal.

2.

Perform functional test as described in paragraph 847-5.

847 - 10

Removal - control unit subassemblies

1. Remove screws (fig. 847-3) with washers (14) and remove cover (15). 2. Remove nuts (16) with washers (17) from studs (18) and pull out studs. Remove spacers (19) and remove printed circuit boards (7, 8 and 9) from their sockets. 3. Remove screws (20), washers (21), and spacers (22) in order to remove sub-assembly power supply (10). Unplug and remove subassembly. 4. Sub-assemblies mode logic (11) and connector panel (12) must be replaced together. Remove screws (23) on the rear support plate (24). Undo both screws (25) attaching control unit's receptacle. Remove screws (26) with washers (27), spacers (28) and rear support plate (24). Unplug and remove subassemblies.

BO 105

847 Page 11

CHAPTER

---------'------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 847 - 11

Installation - control unit subassemblies

Installation is in reverse order of removal. 847 - 12

Removal - inductive pickup

1. Loosen plug (29, fig. 847-3). 2. Unhook spring (30). 3. Bend down locking plate (31) and remove front nut (32). 4. Remove locking plate (31) and bracket (33). 5. Loosen clamp (34), and remove front segment (35). 6. Remove inductive pickup in direction of trirnmer end. 847 - 13

Installation - inductive pickup

1.

Installation is in reverse order of removal.

2.

It inductor pickup has been disassembled or replaced, adjust it as described in paragraph 847-14.

3.

Perform functional test as described in paragraph 847-5.

847 - 14 NOTE ------

Adjustment - inductive pickup Prior to adjustment of inductive pickup, adjustment of controls and break-out forces must be completed in accordance with Chapter 41 and 102.

1. Connect helicopter to external power source. Set 16P battery switch to BATT OFF/EPU ON. 2. Connect hydraulic test unit. 3. Press circuit breaker 1CC TRIM. 4. Select toggle switch 3CC to ON.

BO 105 CHAPTER 847 Page 12

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

NOTE

O

Wait approx. 5 min for control unit to warrn up.

o The adjustment procedure for both inductive pickups, LONG and LAT, is the same. Pull the plug out of one of the trim actuators and adjust the pickup of the other (connected) trim actuator. Follow same procedure with other trim actuator and inductive pickup. 5. Loosen clamp of first inductive pickup to be adjusted until lengthwise movement of the pickup is only possible by rotating it around its longitudinal axis. 6. To adjust the inductive pickup, position cyclic stick as follows: a.

Longitudinal control: From the stop PULL, move cyclic stick 150-1SSmm towards PUSH.

b.

Lateral control: Neutral (stick locking position) . NOTE

o Syrnmetrical setting of control forces must be checked (refer to MOM, Chapter 41) before commencing adjustment procedures. o If the follow up trim system is subsequently installed, a play of 0.5 mm must be set at the trimmer spring assy. (1/2 turn of adjusting screw) . (Refer to MOM, Chapter 41) .

7. When the cyclic stick is released, it moves either to the right or left or towards PRESS or PULL, depending on which trim actuator is connected. 8. Rotate and simultaneously shift the inductive pickup lengthwise until the cyclic stick no longer departs from its neutral position. Reset cyclic stick to neutral each time by adjusting the rods in the nose shell. 9. Establish force syrnmetry of stick within 1.0 N. Spontaneous deviation of stick necessitates readjustment of inductive pickup responsible for this particular range. In order to achieve required setting, position stick repeatedly within the range of 1.0 N and shift inductive pickup in minimal steps of 1/10 to 5/10 mm until stick remains in desired position.

BO 105 CHAPTER 847 Page 13

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 10. Adjust the other inductive pickup in the same way by connecting it to the corresponding trim actuator. 11. Check setting of both inductive pickups after tightening the clamps, and readjust as necessary. Refer to step 12. 12. Check inductive pickup setting as follows: Both inductive pickups are properly adjusted if, after pressing pushbutton 23CC in the MAN operating mode, with the cyclic stick within the force symmetry range of 1.0 N, cyclic force is trimmed to zero within a short space of time. When the pushbutton is released, the cyclic stick must not deviate by more than 2 mm from its trimmed zero stick-force position.

BO 105 CHAPTER 847 Page 14

- - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 6.7

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Circuit breaker 1CC Control unit 21CC Inductive pickup LAT 26CC Inductive pickup LONG 26CC Mode selector unit 22CC Four-way switch 2CC Pushbutton F/U TRIM 23CC Trim actuator LAT 7CC Trim actuator LONG 6CC Terminal junction 4S1VV Terminal junction 61VV

Follow-up trim BO 105 CHAPTER 847 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

MAIN BUS

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1 Control unit 2 Screw 3 Plug 4 Ground strap 5 Screw 6 Washer 7 Printed circuit board "Power Amplifier" 8 Printed circuit board "Inductive pickup S.A." 9 Printed circuit board "Switching amplifier" 10 Subassy "power supply" 11 Subassy "mode logic" 12 Subassy "connector panel" 13 Screw 14 Washer 15 Cover 16 Nut 17 Washer 18 Stud 19 Spacer 20 Screw 21 Washer 22 Spacer 23 Screw 24 Rear support plate 25 Screw 26 Screw 27 Washer 28 Spacer 29 Plug 30 Spring 31 Locking plate 32 Nut 33 Bracket 34 Clamp 35 Segment 36 Inductive pickup

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Fig. 847-3

Follow-up trim BO 105 CHAPTER 847 Page 17 /18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 848

SPERRY HELIPILOT

Table of Contents Paragraph

Title

848 - 1

DESCRIPTION - SPERRY HELIPILOT

3

848 - 2

TROUBLESHOOTING - SPERRY HELIPILOT

7

848 - 3

INSPECTION SCHEDULE - SPERRY HELIPILOT

10

848 - 4

INSPECTION FOR CONDITION - SPERRY HELIPILOT

12

848 - 5

Rernoval - control rod and actuator assemblies

15

848 - 6

Installation - control rod and actuator assemblies

16

848 - 7

Installation check - actuators

19

848 - 8

Zero position adjustrnent/test - control rod and actuator assemblies ..... . . . .

19

848 - 9

Rernoval - trirn actuator for tail rotor control

22

848 - 10

Installation - trim actuator for tail rotor control

22

848 - 11

Rernoval - position transrnitters

23

848 - 12

Installation - position transrnitters

23

848 - 13

Adjustrnent - position transrnitters

24

848 - 14

Replacernent - rubber boots/bellows

27

Page

BO 105 CHAPTER 848 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 848 - 1

DESCRIPTION - SPERRY HELIPILOT

1. General The Helipilot System functions as a three-axis controller providing helicopter attitude stabilization on the basis of pitch/roll attitude and yaw rate measurements received from the respective axes. 2. Description The Helipilot System consists of: 2 control rods, with two actuators each, for longitudinal and lateral control 1 control rod, with one actuator, for tail rotor control 1 trim actuator for tail rotor control 1 stop for longitudinal and lateral control 1 stop for tail rotor control 6 position transmitters and associated mechanical linkage 2 for longitudinal control, 2 for lateral control, 1 for tail rotor control and 1 for collective pitch control.

a.

Control rods with integral actuators The control system comprises three control rods with integral actuators. The actuators provide inflight length adjustment of the control rods; the relevant control signals are supplied by the Helipilot System. The two control rods for longitudinal and lateral control are each equipped with two actuators, that for tail rotor control with one actuator. The two longitudinal and lateral control rods are located in the left side shell on the port fuselage side, between the lower bellcranks and the tandem hydraulic booster. A rubber boot on the output rod immediately above the turbine deck, a rubber boot on the upper end of the upper actuator, and rubber bellows between the dual actuators protect each control rod from water condensation and ingress of rainwater.

b.

Trim actuator for tail rotor control. The trim actuator is attached to a bracket on the aft RH side in the baggage hold. The trim actuator acts on the aft bellcrank of the tail rotor control rod in the fuselage, via a lever and a rod with an integral spring unit biased to 98 N (10 kp). The Helipilot System, when in operation, overrides the spring bias.

BO 105 CHAPTER 848 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Travel stops for longitudinal and lateral control rods A stop plate is screwed to the structure where the vertical control rods protrude through the fuselage. The stop plate limits the travel of the control rods for longitudinal and lateral control. The travel range of the control rods with integral actuators is determined by stop flanges on the rods. Each rod has an adjustable flange above the stop plate, and a fixed one below. The cutout in the stop plate for the collective pitch control rod has been made bigger to enable the collective control rod to move freely.

d.

Travel stop for tail rotor control A stop mechanism installed on the intermediate bevel gear in the tail boom limits the travel of control rods for tail rotor control in both directions. The stop consists of two triangular sheet metal plates with blocks rivetted between them. The blocks accomodate stop screws which are provided with check nuts. The bellcrank is retained between the sheet metal plates. The stop screws limit the movement of the bellcrank and mark the end-of-travel positions of the rods.

e.

Position transmitters and relevant linkage To provide the Helipilot and Flight Director computers with control rod position data from all three helicopter axes and from the collective control, six position transmitters are installed in the flight controls: One each in the yaw and collective controls and two each in the pitch and roll controls. The two control and position transmitters, which transmit longitudinal control position data, are attached to a bracket which is screwed to the structure below the floor on the LH side of the fuselage. The actuating arm of each position transmitter is connected to one of the clamps attached to the longitudinal control rod by an adjustable rod. The two control rod position tránsmitters, which transmit lateral control positional data, and the position transmitter for collective pitch control are installed under the floor on the port fuselage side, adjacent to their corresponding bellcranks. The position transmitters are mounted on special brackets which are screwed to the structure. The actuating arm of each position transmitter is connected by an adjustable rod to an attachment lug bonded and rivetted to the corresponding bellcrank.

BO 105 CHAPTER 848 Page 4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The control rod position transmitter which transmits tail rotor control positional data is installed below the floor on the starboard fuselage side, adjacent to the aft bellcrank. Attachment to structure and connection to the corresponding bellcrank shaft are the same as for the lateral control and pitch control position transmitters. The control rod for tail rotor control is installed aft, in the right side shell of the fuselage, and is the vertical connection between the lower bellcrank of the control linkage on the RH side within the fuselage, and the upper bellcrank of the control linkage routed inside the tail boom. 3. Operation

a.

Attitude attitude attitude pressing

Hold (ATT) is the basic operating mode and enables a flight to be maintained indefinitely. If a change in heading or is required, the pilot can resume "hands-on" control by the cyclic-mounted beep trim switch.

b.

The SAS mode augments pilot effort during "hands-on".

c.

The YAW stabilizing mode can only be selected when Helipilot 1 is operative and the YAW/OFF switch is set to YAW. Lateral and roll vibrations are damped down in all flight conditions.

The conditions which determine the selection of either "hands on" or "hands-off" control are described in the Flight Manual.

BO 105 CHAPTER 848 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

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Mechanical installation of the Helipilot Systern

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 848 - 2

TROUBLESHOOTING - SPERRY HELIPILOT

General Troubleshoot in conjunction with wiring diagram 848-1 in the Wiring Diagram Manual. Check all electrical connections for tight and secure fit and all system switches and circuit breakers for unimpaired mechanical functioning. Connect external power supply (EPU) and set battery switch 16P on instrument panel to BATT OFF/EPU ON. Press circuit breakers No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

One Helipilot computer fails. Restarting not possible

Failure of power supply 28 VDC, 115 VAC or 26 VAC

Check circuit breakers; replace defective circuit breakers Check output voltage of Inverters 1 and 2; replace defective inverter

2

Automatic cutout computer HP 1 or HP 2 during turn in SAS mode

Failure of VG 1 or VG 2

Check circuit breaker

Automatic centering circuit in SAS panel 79 VE defective

Replace SAS panel 79 VE

Computer HP 1 or or HP 2 defective

Replace defective computer

Premature response of monitoring logic in centering circuit of SAS panel 79 VE (defective centering circuit)

Replace SAS panel 79 VE

Table 848-1

Troubleshooting (1 of 3)

BO 105 CHAPTER 848 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLEHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

3

Red warning light HP 1 or HP 2 in warning panel comes on during flight

Disengage unit of centering circuit in SAS panel 79 VE defective

Replace SAS panel 79 VE

4

Malfunctioning or failure of tail rotor control stabilisation in turn

Failure of Rate Gyro

Check circuit breakers and power supply Position helicopter so that it can move about vertical axis; switch on HP 1 and YAW - Rotate helicopter clockwise. Actuator in tail rotor control rod must increase rod length without considerable pedal travel being initiated - Rotate helicopter counterclockwise Actuator must reduce length without considerable pedal travel being initiated - If actuator does not respond as described above, replace Rate Gyro platform

With Helipilot disengaged, pedal forces excessive (stiffness of tail rotor blade pitch control) Table 848-2 BO 105 CHAPTER 848 Page 8

Refer to basic rigging of the main rotor and tail rotor controls chapter 102

Troubleshooting (2 of 3)

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLEHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

5

Malfunction or failure of stabilisation about longitudinal and lateral axes when flying with one Helipilot (HP 1 or HP 2)

VG 1 or VG 2 defective

Withdraw unit from I-console and check function of horizon sphere by tilting and rotating; replace defective ADI unit

Centering circuit in SAS panel 79 VE defective

With Helipilots HP 1 and HP 2 engaged, check that 28 VDC ± 1.SV is available at terminals PA 36 of computers. If voltage is not available, replace SAS panel 79 VE

Trim signal not available

Check circuit breaker. If o.k., check signal path

Trim actuator of tail rotor defective

Replace trim actuator

One of the computers defective

Replace defective computer

VG or YAW-Rate Gyros supply incorrect signals

Check gyros and replace equipment found to be defective

Positive feedback control circuit

Check synchro signals of actuators and synchros

Circuit breaker has triggered

Check circuit breakers, replace defective circuit breaker

Inverter 1 or 2 defective

Check inverters and replace defective inverter

6

7

8

Electrical trim function of tail rotor control inoperative

Actuators do not center when system is engaged

11SV AC and 26V AC supplies fail. INV 1 and/or INV 2 check lights are on

Table 848-1

Troubleshooting (3 of 3) BO 105 CHAPTER 848 Page 9

EUROCOPTER

• 848 - 3

MAINTENANCE MANUAL SO 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 848 Page 10

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

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Control rods with integral actuators (longitudinal and lateral control) BO 105 .CHAPTER 848 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 848 - 4

INSPECTION FOR CONDITION - SPERRY HELIPILOT

l. Inspect rubber bolts covering the control rod and actuator assemblies on

the upper surface of the turbine deck for damage and security. Replace damaged rubber boots. 2. Inspect pitch and roll control rod and actuator assemblies for proper installation, external condition and tight wire-locking. 3. Inspect rubber boots and rubber bellows on the pitch and roll control rod and actuator assemblies for damage and security. 4. Inspect slots connecting pitch and roll control rod actuators in series.

a.

Check coupler between both actuators for flexibility in the lateral direction, using the width of the slots in the spring sleeves as the basic for judgement. If the slot width does not change when the control rod is moved, replace coupler or, if necessary, control rod. (If the coupler is to be replaced, it is necessary to crack inspect the actuator shaft in the area of transition to the threads) .

b.

Check width of slots. If slots are less than 1 mm wide, remove control rod and replace coupler or, if necessary, control rod. (If the coupler is to be replaced, it is necessary, to crack inspect the actuator shaft in the area of transition to the threads) .

c.

Inspect for corros ion damage. Remove light corrosion damage, using 600 grit or finer abrasive cloth. If surfaces are heavily corroded, replace coupler or control rod.

d.

Inspect central area of spring sleeve, to within 6 mm of the upper and lower edges of the sleeve, for cracks and sratches (in particular, inspect for cracks in the vicinity of the slots). If such damage is detected in these areas, replace coupler or control rod.

e.

Apply corrosion preventive compound. Spray on corros ion preventive compound (CM 508) or equivalent material.

BO 105 CHAPTER 848 Page 12

fteurocopter

MAINTENANCE MANUAL M88 - 80105

s.

Inspect control rod and actuator assembly for tail rotor controls for proper installation, external condition, and tight wire-locking. Replace control rod according to external condition and renew impaired wire-locking.

6.

Inspect rams of all actuators for twisting. If the color coding on the actuator housing does not align with the groove in the actuator ram, remove control rod and replace actuator.

7.

Check trim actuator of tail rotor controls for proper installation and external condition. Replace trim actuator if external condition is poor or if trim actuator malfunctions.

8.

Inspect tail rotor control travel stop for damage and corrosion, and stop screws and associated safetying devices for tightness. If stop is badly dented, stop screws are deformed, or excessive corrosion is evident, replace affected parts; renew loose safetying devices.

9.

Check electrical leads along their entire length from the control rod actuators to the connectors in the left fuselage side shell for freedom of movement, external condition, and stress-free installation.

10.

Check position transmitters and associated mechanical linkages for proper installation, security"and external condition. Replace parts exhibiting excessive corros ion or external damage; tighten loose parts.

11.

Inspect pitch and roll travel stops for damage and corrosion, and adjustable stops and associated safetying devices for security. Replace stops if badly deformed or excessively corroded. Renew safetying devices as necessary.

12.

Check that play of bushings in actuators does not exceed 0.5 mm, by alternately applying a load of 8.9 N to various points around the circumference of all control rods. If play is excessive, replace affected control rod.

Revision 9

80 105 CHAPTER 848 Page 13

*

*

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_eurocopter

MAINTENANCE MANUAL MBB - BO 105

Dual gauge bracket

Actuator rod (rod end may remaln Installed) Actuator houslng

800379

Fig. 848-3

8.9 N applled to various points around clrcumference

Test for play - actuator bushings

13.

Check electrical leads from all position transmitters to terminal blocks for freedom of movement and unimpaired condition. If they have chafe marks or breaks, replace them.

14.

Check control rod with integral spring in tail rotor controls for correct installation and external condition¡ check spring tension: 9.2 daN.

15.

Inspect shafts of all actuators for cracks in the area of transition to the threads (i.e. undercut), using the X-ray or magnetic particle inspection methods. If cracks are detected, remove affected control rod and replace actuator.

BO 105 CHAPTER 848 Page 14

- - - - - - - - - - - - - M B B HEL1COPTER5 - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 848 - 5

Removal - control rod and actuator assemblies

1. Pitch and roll control rod and actuator assemblies. NOTE

The procedure for removing the control rod and actuator assemblies from the pitch control and roll control linkages is identical.

a.

Remove engine cowling.

b.

Remove interior panelling from the left wall of the cargo compartment.

c.

Remove copilot's seat, bench seat, if installed, and the rails of the litter or long range fuel tank, in order to unscrew and raise the floor panel.

d.

1f the actuators of the control rod to be removed still function, drive them to their zero positions.

e.

Disconnect electrical leads from the actuators.

f.

Remove the stop plate for the pitch and roll controls.

g.

Free the adjustable mechanical stop above the control rod and screw it fully down.

h.

Remove the cotter pins from the castellated nuts on both connecting bolts and remove the castellated nuts and washers. CAUT10N

o DURING REMOVAL DO NOT APPLY TORQUE BETWEEN OUTPUT ROO AND HOU51NG. o 1F A REMOVED CONTROL ROO 15 TO BE RE1N5TALLED, TAKE CARE NOT TO ALTER 1T5 OVERALL LENGTH ANO REFERENCE D1MENS10N (SEE FIGURE 848-2). o 1F A NEW CONTROL ROD 15 TO BE INSTALLED, TRANSFER TO 1T THE TOTAL LENGTH AND REFERENCE D1MENS10N OF THE REMOVED CONTROL ROD.

i.

While holding the control rod, remove the connecting bolts and then remove control rod from the fuselage.

2. Yaw control rod and actuator assembly.

a.

Remove right interior panelling of cargo compartment.

b.

If the actuator of the control rod to be removed still functions, drive it to its zero position.

c.

Disconnect electrical lead from actuator.

d.

Remove cotter pins from the castellated nuts on both connecting bolts and remove the castellated nuts and washers. BO 105 . CHAPTER 848 Page 15

- - - - - " ' - - - - - - - - - MEB HEL1COPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

CAUTION

o DUR1NG REMOVAL DO NOT APPLY TORQUE BETWEEN OUTPUT ROD ANO HOUS1NG. o 1F A REMOVED CONTROL ROD 1S TO BE RE1NSTALLED, TAKE CARE NOT TO ALTER 1TS OVERALL LENGTH AND REFERENCE D1MENSION (SEE FIGURE 848-2) . o IF A NEW CONTROL ROD 1S TO BE INSTALLED, TRANSFER TO 1T THE TOTAL LENGTH AND REFERENCE D1MENS10N OF THE REMOVED CONTROL ROD.

e.

While holding the control rod, remove connecting bolts and then remove control rod from the fuselage.

848 - 6

1nstallation - control rod and actuator assemblies

1. Control rod and actuator assemblies for pitch and roll control. CAUT10N

ACTUATORS WHERE THE GROOVE ON THE ROD 1S NOT AL1GNED W1TH THE MARK ON THE HOUS1NG MUST NOT BE INSTALLED.

a.

Check that actuators in the new control rods to be installed are at their zero position; if necessary, operate them to their zero position (refer to para 848-8).

b.

Transfer dimension L2 (see fig. 848-2) from the removed control rod to the control rod to be installed by rotating the fine adjustment on the lower rod end. Tighten jamnut on fine adjustment but do not safety at this time. CAUT10N

o DUR1NG REMOVAL DO NOT APPLY TORQUE BETWEEN OUTPUT ROD AND HOUS1NG.

c.

Transfer dimension L1 from the removed control rod to the control rod to be installed by rotating the upper rod end. Tighten and safety jamnut.

d.

Release the adjustable stop flange at the upper end of the control rod and screw it down fully.

e.

Locate adjusted control rod in position and insert connecting bolts; install washers and castellated nuts and provisionally tighten castellated nuts.

f.

Disconnect pitch and ro11 trirnmers from the cyclic stick and remove control linkage compartment access door.

g.

Rotate adjustab1e stop flange upward and screw stop plate to airframe structure.

BO 105 CHAPTER 848 Page 16

- - - - - - " " " - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 h.

Install adjusting device in accordance with Chapter 102 in the Maintenance Manual.

i.

Connect hydraulic ground servicing rig.

j.

Set pitch and roll controls to zero position in accordance with Chapter 102 in the Maintenance Manual.

k.

Check pitch control setting. If necessary, adjust according to Chapter 102.

l.

Check roll control setting. If necessary, adjust according to Chapter 102.

m.

Torque-tighten castellated nuts to 5-7 Nm and safety with cotter pins.

n.

Make electrical connection to actuators.

o.

Reconnect pitch and/or roll trirnmers to the cyclic stick.

p.

Inspect installed control rods for freedom of movement.

q.

Reinstall parts removed during control rod removal.

r.

If a new control rod has been installed, check zero position of actuator, refer to para 848-8.

s.

Install cargo compartment interior panelling; close control linkage compartment access door and install engine cowling.

2. Control rod and actuator assembly for tail rotor control. CAUTION

ACTUATORS WHERE THE GROOVE ON THE ROD IS NOT ALIGNED WITH THE MARK ON THE HOUSING MUST NOT BE INSTALLED.

a.

Check that the actuator on the new control rod to be installed is in the zero position; if necessary operate actuator to zero position (refer to para 848-8).

b.

Remove control linkage compartment access door, vertical fin fairing, and right interior panelling in cargo compartment.

c.

Locate control rod and actuator assembly in installed position and insert the connecting bolts; install washers and castellated nuts and provisionally tighten castellated nuts.

d.

Install pedal clamp assembly 105-31702 W20 on right (pilot's) pedals.

e.

Disconnect lower end of control rod in vertical fin from bellcrank.

BO 105 CHAPTER 848 Page 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - - ' - MAINTENANCE MANUAL MBB - BO 105 f.

Install tail rotor control rigging device. NOTE

Use rigging values for helicopters S/N 350 and prior to rig the tail rotor controls.

g.

Using the control rigging device with the pedals te parallel position, adjust the blade pitch angle in accordance with the chapter 102 in the Maintenance Manual.

h.

Adjust the disconnected control rod in the vertical fin so that the connecting bolt can be easily inserted though the bellcrank.

i.

Remove pedal clamp assembly from the right pedals.

j.

Back off tail rotor control stop screws on intermediate gearbox to full extent.

k.

Adjust nright yaw control n stop screw in control linkage compartment until the rigging pin in the rigging device on the tail rotor head fits into the corresponding groove.

l.

Back off the corresponding stop screw on the intermediate gearbox until it makes even contacto Tighten and safety jamnut.

m.

Perform steps k. and l. for the nleft yaw control n .

n.

Back off 'the forward stop screws so that they have at least 3 mm of play, tighten and safety jamnuts.

o.

Inspect installed control rod for freedom of movement and check for foreign objects.

p.

Make electrical connection to actuator.

q.

Install right interior paneIling in cargo compartment, vertical fin fairing, andcontrol linkage compartment access door.

BO 105 CHAPTER 848 Page 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 848 - 7

Installation check - actuators

1. Deenergize electrical system and depressurize hydraulic system.

2. Remove engine cowling and right interior panelling in cargo compartment. 3. Disconnect upper rod ends from control rods: - pitch and roll control from tandem hydraulic unit - tail rotor control from upper bellcrank. 4. Apply, at disconnected end of each control rod, a torque sufficient to take up the rotational play in the control rods. The torque required should not be more than 1,5 Nm. 5. Increase torque to 3 ± 0,5 Nm and check for rotation between output rods and actuators. CAUTION

THERE MUST BE NO ROTATION.

6. Repeat check for opposite direction of rotation. 7. Reconnect upper rod ends of control rods and safety castellated nuts with cotter pins.

8. Install engine cowling and right interior panelling of cargo compartment. 848 - 8

Zero position adjustment/test - control rod and actuator assemblies

1. General The zero position of the actuators is essential to transferring the reference dimension for the stops - on the longitudinal and lateral control rods - and the total length from the removed control rod to the replacement control rod. The zero position is automatically obtained, when the Helipilot System is operational, by switching on the system (HP1 and HP2 in position ON). The following instruction should be complied with to make sure that new control rods are in zero position before installation.

BO 105 CHAPTER 848 Page 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

NOTE

Zero position is defined as the central position between the maximum extension and maximum retraction of the actuator.

To accomplish zero adjustment, it is necessary that electrical and mechanical installations of the helicopter are in an advanced assembly state, so that all control rod indicating units function properly. 2. Perform adjustment as follows: a.

In helicopter, place Master Battery Switch in OFF position. Connect 28 V DC ground power unit and switch on.

b.

Remove left and right interior panelling in cargo compartment to provide access to longitudinal, lateral and tail rotor control rod and actuator assemblies.

c.

Disconnect electrical connection to control rod to be removed.

d.

Establish electrical connection to replacement control rod and position in helicopter so that it does not damage itself or any other equipment during operation.

e.

Press the following circuit breakers in circuit breaker panel 51VE In section 28 VDC

- HP 1 (Helipilot System 1) - HP 2 (Helipilot System 2) - YAW TRIM (Tail Rotor Actuator) - HELC (Helcis system)

In section EMERG BUS

- DG (Directional Gyro) - HOR 1 VALID (ADI 1 Pilot Valid)

In section 26 VDCd INV 1

- HSI/EXC (HSI - Excitation) - HOR 1 (ADI 1 Pilot Exitation) - XDU 1 (Transducer 1)

Insection 26 VDC INV 2

- COMP EXC (Compass Excitation) - HOR 2 (ADI 2 Copilot) Excitation) - XDU 2 (Transducer 2)

In section 115 VAC

- HP 1 (Helipilot System 1) - HP 2 (Helipilot System 2) - HELC (Helcis System)

BO 105 CHAPTER 848 Page 20

- - - - - - - - - ' - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 f.

Press three AVIONIC circuit breakers in switch panel 2VE.

g.

Switch on the following circuit breakers in Overhead & Circuit Breaker Panel 12 VE: In Section 1-INV-2

NOTE

28 VDC

- INV 1 (Inverter 1) - INV 2 (Inverter 2)

After switching on the circuit breakers INV 1 and INV 2, the warning lights INV 1 and INV 2 in Overhead & Circuit Breaker Panel 12 VE must go out.

h.

Place switch DG in Overhead & Circuit Breaker Panel 12 VE in ON position.

i.

Actuate HPl/OFF ATT/SAS YAW/OFF NOTE

j.

the following switches in the Center Pedestal: and HP2/0FF switches to HPl and HP2 switch to SAS switch to YAW The actuator position indicators (API 1 and API 2) in the instrument panel indicate the position of the actuators.

Check control rods as follows: - pitch control: - roll control: - tail rotor control: NOTE

slowly pull cyclic stick from forward to aft stop. Move cyclic stick from right to left stop. alternately press both pedals.

During above operation, actuators must travel through full range and indicators (API's) must move from stop to stop.

k.

Use pedals to move actuator in tail rotor control rod to center position, following indication on instrument panel.

l.

On Center Pedestal, place switch ATT/SAS in position ATT.

m.

Press and hold maneuver switch until center position of all actuators can be read at indicators in instrument panel. Release maneouver switch aúd press RELEASE BUTTON to switch off Helipilot System.

n.

Pull all system circuit breakers and disconnect electrical ground power supply from helicopter.

o.

Disconnect actuator(s) from helicopter wiring.

BO 105 CHAPTER 848 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 848 - 9

Removal - trim actuator for tail rotor control

1. Remove floor panel on aft RH side in cabin. 2. Open access door to baggage hold. 3. Disconnect electrical connection to trim actuator of tail rotor control. 4. Remove cotter pin from castellated nut on crank lever journal of trim actuator; remove castellated nut and washer. S. Withdraw spring unit from journal of crank lever on trim actuator. CAUTION

WITHIN FUSELAGE PROVIDE APPROPRIATE SUSPENSION OR SUPPORT FOR SPRING UNIT, SO AS TO AVOID DAMAGE TO EITHER SPRING UNIT OR OTHER EQUIPMENT.

6. Remove trim actuator attachment screws, press two support struts slightly apart and lift trim actuator from fuselage. 848 - 10

Installation - trim actuator for tail rotor control

l. Check that trim actuator is in center position. 2. Make certain that crank lever on trim actuator is normal to attachment flange. 3. Position trim actuator on bracket and attach with screws. 4. Connect support struts to trim actuator using forward attachment screws. S. Slide spring unit onto journal on crank lever of trim actuator, install washer on journal; install and tighten castellated nut and safety with cotter pino

BO 105 CHAPTER 848 Page 22

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 848 - 11

NOTE

Removal - position transmitters The removal procedure is identical for all position transmitters.

l. Gain access to position transmitter to be removed.

2. Disconnect electrical connection of position transmitter to be removed at relevant terminal board.

3. Remove cotter pin from castellated nut of connecting bolt between rod and attachment lug or clamp, remove connecting bolt. 4. Loosen setscrew in actuating lever on position transmitter shaft, and withdraw bellcrank together with rod from shaft. 5. Remove three position transmitter attachment screws. Remove position transmitter from bracket. 848 - 12

Installation - position transmitters

l. Place position transmitter on bracket and attach with screws and washers. 2. Slide actuating lever, with adjustable rod suspended from it, onto

position transmitter shaft. Tighten setscrew slightly so that position transmitter shaft can be rotated for adjustment purposes. 3. Insert connecting bolt to connect adjustable rod to attachment lug on bellcrank shaft or to associated clamp. Install washer on connecting bolt; install castellated nut, tighten and safety with cotter pino 4. Align installed position transmitter with associated system, refer to para. 848-13.

5. After aligning (adjusting), tighten setscrew in actuating lever. 6. Perform functional check of relevant control linkage and Helipilot System.

BO 105 .CHAPTER 848 Page 23

MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

----...,.------~...,..---

848 - 13

Adjustment - position transmitters

1. Position transmitters for longitudinal, lateral and tail rotor controls. a.

General The description of the adjustment of position transmitters is of a generally applicable nature, since the adjustment procedure is identical for all position transmitters. An adjustment is to be accomplished only after replacement of the position transmitter linkage or after detaching the position transmitter linkage on connection with the removal/installation of control rods or bellcranks. The position transmitter terminals to which an oscillograph must be connected, are listed in atable.

b.

Adjust position transmitter as follows: 1)

Place Master Battery Switch in helicopter in OFF position, connect 28 VDC ground power unit, and switch on.

2)

Connect hydraulic ground power unit and switch on.

3)

Press the following circuit breakers in Circuit Breaker Panel 51 VE:

4)

In section 28 VDC

-

In section EMERG BUS

- DG - HOR 1 VALlO

In section 26 VDC INV 1

- HSI/EXC - HOR 1 - XDU1

In section 26 VDC INV 2

- COMP EXC - HOR 2 - XDU 2

In section 115 VAC

- HP 1 - HP 2 - HELC

Press the following circuit breakers in Overhead and Circuit Breaker Panel 12 VE: In section l-INV-2

BO 105 CHAPTER 848 Page 24

HP 1 HP 2 YAW TRIM HELC

28 VDC

- INV 1 - INV 2

- - - - - - - ' - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5)

Press circuit breakers RADIO NAV 1, RADIO NAV 2 and AVIONICS in Switch Panel 2 VE.

6)

Switch on switch DG in Overhead and Circuit Breaker Panel 12 VE.

7)

Provide free access to position transmitters and associated terminal blocks.

8)

Connect a dual-trace oscillograph to the following terminals of the relevant position transmitter(s) .

Channnel of Oscillograph

Terminals of longitudinal control position transmitters

Terminals of lateral control position transmitter

Terminals of Tail Rotor Control position transmitter

Color code, cable

HP 1

HP 2

HP 1

HP 2

Channel 1

26CA1

26CA2

28CA1

28CA2

30C

black/ white (L)

Channel 2

26CA1

26CA2

28CA1

28CA2

30CA

blue (L)

9)

red/ white (H) yellow (H)

Lock affected control system (longitudinal, lateral or tail rotor control) in zero position, per Maintenance Manual, chapter 102.

10) Release setscrew in actuating lever of position transmitter so that position transmitter shaft can still follow the movement of the actuating lever. 11) Adjust position transmitter shaft until voltage display of second channel of oscillograph is O + 0.4 Vo1ts; then tighten setscrew. 12) Unlock the relevant control system and check position transmitter setting as follows: - Longitudinal control: - Lateral control: - Tail rotor control:

Pull cyclic stick aft Move cyclic stick right Press left pedal

BO 105 CHAPTER 848 Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 After operating the control device, the phase relation of the voltage at the second oscillograph channe1 shou1d not differ by more than lOA from the phase relation of the exciter voltage at the first channel. 13) If, during step 12), an oppositesignal is receivedat channel 2, repeat steps 9) through 13) with position transmitter shaft rotated through 180A. 14) After adjustment is completed, tighten setscrew on actuating lever of position transmitter. CAUTION

DURING ADJUSTMENT OF LONGITUDINAL CONTROL ACTUATORS BE SURE THAT THE ANGLE BETWEEN ACTUATING LEVER AND CONNECTING LEVER IS THE SAME FOR HELIPILOT SYSTEMS 1 AND 2. ADJUST LENGTH OF CONNECTING ROD, AS NECESSARY.

2. Position transmitter for collective pitch control. a.

Perform stops 1) thru 6).

b.

Press GO AROUND must come on.

c.

Remove right interior panelling in cargo compartment.

d.

Release setscrew in actuating lever of collective pitch control position transmitter so that position transmitter shaft can still follow the movement of the actuating lever.

e.

Move collective pitch stick to a position 290 mm above floor level. The 290 mm are measured between the floor and the underside of the control device.

f.

Adjust position transmitter shaft until collective pitch cornmand indicator is in center position.

g.

Move collective pith stick downward. The collective pitch command indicator must deflect downward.

h.

If collective pitch command indicator deflects upward, repeat steps 4) through 6) with position transmitter shaft rotated through 180A.

i.

After completion of adjustment, tighten setscrew on actuating lever of position transmitter.

j.

Reinstall right interior panelling of cargo compartment.

BO 105 CHAPTER 848 Page 26

button on collective pith stick. The GA light on ADl1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 848 - 14

Replacement- rubber boots/bellows

1. Remove control rod with damaged boot; refer to para 848-5. 2. Replace rubber boot on upper actuator as follows:

a.

Measure and record distance between fixed stop and housing of upper actuator.

b.

Remove lockwire from jamnut of fixed stop and back off jamnut.

c.

Unscrew and remove fixed stop together with rubber boot and rod end. Do not further disassemble fixed stop.

d.

Remove tab washer and unscrew and remove jamnut from thread.

e.

Remove damaged rubber boot and fit new boot in position on the actuator shaft and housing.

f.

Seal open end of rubber boot by tying it against the actuator shaft using twine.

g.

Screw fixed stop jamnut on threaded end of actuator as far as possible and install tab washer.

h.

Screw fixed stop on threaded end of actuator together with rubber boot and rod end.

i.

Screw fixed stop to its original installed position and lock in place with jamnut (torque-tightened to 5.7-6 Nm).

j.

Wire-lock jamnut to tab washer and tab washer to fixed stop.

3. Replace rubber bellows between series-connected actuators.

a.

Remove twine from rubber bellows.

b.

Cut open and remove rubber bellows.

c.

Measure and record distance between both actuators.

d.

Remove lockwire from one side only; baek off jamnut and remove eorresponding actuator.

e.

Fit new rubber bellows on assembled parts and eompress bellows.

BO 105 .CHAPTER 848 Page 27

------------'---'--MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 f.

Apply zinc chromate primer (CM 417) to threaded end of removed actuator, and screw on actuator.

g.

Screw·actuator to its installed position prior to removal and lock in place with castellated nut (torque-tightened to 5.7-6 Nm).

h.

Wire-lock jarnnut to tab washer.

i.

Pull rubber bellows back over connecting parts and seal by tying with twine.

4. Check zero position of control rod (see para 848-9). 5. Install control rod in accordance with para 848-6. 6. Functionally test pitch and roll control and Helipilot actuators.

BO 105 CHAPTER 848 Page 28

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 849

EXTENSION OF C.G. ENVELOPE 50 mm

Helicopter BO 105 CB . CB-2 CDN-B CBS CBS-2 CDN-BS DB DBS up to and including S/N 750 rnay be operated' with a C.G. envelope extended forward by 50 mm if following conditions are rnet (also refer to SB 80-67): 1. The logitudinal control range rnust be - 10.5° to + 5.5°. 2. Forward travel of the pilot seat rnust be reduced to ensure free rnovernent of the cyclic stick in the extended aft (pull) direction (appropriate stops provided on seat rails). For rigging of controls refer to chapter 102.

BO 105 CHAPTER 849 Page 1/2

MAINTENANCE MANUAL 80 105

EUROCOPTER

850 BLEED AIR HEATING Table of Contents

Paragraph Title

Page

850 -1

DESCRIPTION - BLEED AIR HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

850-2

TROUBLESHOOTING - BLEED AIR HEATING

5

850-3

INSPECTION SCHEDULE· BLEED AIR HEATING ....................•...•..... . .

7

850-4

INSPECTION FOR CONDITION • BLEED AIR HEATING

9

850-5

FUNCTIONAL TEST· BLEED AIR HEATING

10

850-6

Removal - Bleed Air System in Engine Compartment

12

850 -7

Installation - Bleed Air System in Engine Compartment

12

850-8

Removal - Bleed Air Valve Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

850-9

Installation - Bleed Air Valve Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

850 -10

Removal - Shut-off Valve

15

850 -11

Installation - Shut-off Valve

15

850 -12

Removal - Temperature Sensor and Temperature Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

850 -13

Installation - Temperature Sensor and Temperature Switch

17

850 -14

Removal - Axial Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

850 -15

Installation - Axial Fan

19

850 -16

Removal - Swivelling Nozzle

20

850 -17

Installation - Swivelling Nozzle

20

850 -18

Removal - Cabin Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

850 -19

Installation - Cabin Temperature Sensor

23

850 -20

Removal - Pipe Assemblies and Hose Pipes

23

850 -21

Installation - Pipe Assemblies and Hose Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Revision 17

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

CHAPTER 850 Page 1

MAINTENANCE MANUAL SO 105

EUROCOPTER

BLANK PAGE

CHAPTER 850 Page 2

Revision 17

EUROCOPTER

850 - 1

MAINTENANCE MANUAL 80105

DESCRIPTION - BLEED AIR HEATING

10 System Description The heating and ventilation system (see figo 850-1) comprises a bleed air heating subsystem and a fresh air ventilation subsystem having common air distribution ducting. The subsystems may be operated separately or together. Air is distributed via common ducting to outlets throughout the entire cabin area, Le., via two windshield distribution ducts with a nozzle each for the cockpit and two distribution ducts with two nozzles each for the passenger and cargo compartments. The individual air nozzles are adjustable in both flow rate and direction. 20 Ventilation The cabin may be ventilated with fresh air provided from a ram air inlet on the lower fuselage nose shell. A notched lever assembly on the lower right of the instrument panel operates a flap in the distribution duct to control the amount of fresh air entering the cabin and, when placed in the BLWR position, additionally activates an axial fan.

30 Bleed Air Heating Hot high-pressure bleed air, tapped from each engine's diffuser scroll, is mixed with outside air to obtain a desired temperature and then distributed via the common ducting to the cabin outletso Normally the temperature control operates automatically to regulate the selected temperature by sensing the air temperatures within the ducting and cabin area, and then adjusting the temperature control valve accordingly. Should the automatic control malfunction, adjustment of the valve may then be performed manually by means of the controls provided. Bleed air heating controls are on the overhead console switch panel. A three-position heating control toggle switch labeled MAN-AUTO and having a center-off position is used to select the desired heating control mode (manual or automatic). With this switch in the AUTO position, the desired cabin temperature may be selected using the TEMP CONTROL knob; clockwise rotation increases the temperature. With the heating control switch in the MAN position, the three-position DECR-INCR switch is activated so that displacing this switch from its spring-Ioaded center off position will respectively c10se or open the temperature control valve as long as the switch is held in that positiono The system is supplied 28V DC electrical power from the main bus via the HEATING circuit breaker on the center console switch panel. Placing the heating control switch to either the MAN or AUTO position will open a hot air supply valve which in turn activates the green caption HEATINGo Air f10wing in the distribution ducting is monitored by an overtemperature switch located downstream of the temperature control valve. Activation of this switch will cause the hot air supply valve to close and the green caption HEATING will go off.

Revision 17

CHAPTER 850 Page 3

EUROCOPTER

MAINTENANCE MANUAL 80105

OVERHEAD CONSOlE-SWITCH PANEL

r-----------------------.

I

DECR ,-- MAN

I

I

~

[Ul~@8 I I +t ---------------1 ,

o

O

I

INCR

1

AUTO - - " TEMP

HEATING:

CONTROL

L-----

1 L

I

l

-, I

I

I

I

Swivelling noz~

---

\ \ ~._t \ ;;"-::::\-:"'

~0\

\

I I I

-¡, /":;:::""J..

1_.1.. / Windshield nozzle --:

i

I

I I

-.~ I

I

Cabin temp. sensor

0---

Elt. ctrl. unit

r----J 11 I

I

I

,---

J

.Temp. bwitch

l'

I

II

~ Temp. s~n~or

--f---J I _.-1 -

Leverassy

I

-.J

JI ."

Shut-off valve

t

,/

Non·return valve Ambientair

Non-return valve

Engine 1 Figure 850-1

CHAPTER 850 Page 4

Óen9¡ne 2 Schematic Diagram - Bleed Air Heating

Revision 17

MAINTENANCE MANUAL 80105

EUROCOPTER

850 - 2

TROUBLESHOOTING - BLEED AIR HEATING

General - Perform troubleshooting in conjunction with wiring diagram in Wiring Diagram Manual (WDM). - Check all electrical connections tor secure attachment and all circuit breakers and system switches tor proper mechanical switching. - Atter circuit breaker (1, tig. 8S0-9) is depressed luminous covers to check the annunciator Iight (2) tor proper tunctioning (press to test). - Connect external power unit (EPU) or, when engines are running, switch on generators. - The circuit breaker (1) must remain depressed during troubleshooting. - The engines must be running during troubleshooting ot the bleed air heating system.

NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1.

Shut-off valve tails to open

Check continuity ot wiring using wiring diagram; repair or replace detective wiring as required. Check air shut-off valve tor electrical and mechanical tunction (reter para. 8S0-S): replace detective shut-off valve (reter para. 8S0-10 and 8S0-11 ).

Bleed air valve tails to open

Check continuity ot wiring using wiring diagram; repair or replace detective wiring as required. Check bleed air valve tor electrical and mechanical tunction (reter para. 8S0~S); replace detective actuator; replace detective bleed air valve (reter para. 8S0-8 and 8S0-9).

Control unit detective

Replace control unit.

Hose between bleed air valve and distribution duct (transmission compartment) detective or loosely connected

Replace or tighten hose connections.

Faulty wiring

Check continuity ot wiring using wiring diagram; repair or replace detective wiring as required.

Switch (4) (overhead console) detective

Replace switch.

Temperature control (S) (overhead console) detective

Replace temperature control.

Cabin temperature sensor detective

Replace cabin temperature sensor (reter to para. 8S0-18 and 8S0-19).

Temperature sensor in transmission compartment distribution duct detective

Replace temperature sensor (reter to para. 8S0-12 and 8S0-13)

2.

No heating in cabin and/or cargo compartment

No temperature control with switch (4, tig. 8S0-9) in AUTO position

Table 8S0-1 Troubleshooting (1 ot 2) Revision 17

CHAPTER 8S0 Page S

EUROCOPTER

MAINTENANCE MANUAL 80105

NO. TROUBLE SYMPTOM

3.

No manual temperature control with switch (4, fig. 850-9) set to MAN

PROBABLE CAUSE

CORRECTIVE ACTION

Temperature switch in transmission compartment distribution duct fails to actuate (actuating temperature is approx.180°C)

Replace temperature switch (refer to para. 850-12 and 850-13)

Faulty wiring

Check continuity of wiring using wiring diagram; repair or replace defective wiring as required.

Switch (4) (overhead panel) defective

Replace switch.

4.

No hot air from individual nozzle Hose to respective nozzle defective or detached

5.

Smell of burning in cabin

Winding in axial fan burnt through

Replace axial fan (refer to para. 850-14 and 850-15)

6.

No fresh air supply during f1ight (Iever assy (6, fig. 850-9) in RAM AIR position)

Flap in distribution duct (nose compartment) closed

Check the flap in distribution duct for functioning (opening,closing); repair as required.

7.

Caption fails to iIIuminate

Lamp defective

Replace lamp.

Faulty wiring

Repair or replace wiring.

Table 850-1 Troubleshooting

CHAPTER 850 Page 6

Attach or replace hose connections.

(2 of 2)

Revision 17

EUROCOPTER

• 850 - 3

Revision 18

MAINTENANCE MANUAL 80105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 850 Page7

MAINTENANCE MANUAL M88 80105

EUROCOPTER

BLANK PAGE

CHAPTER 850 Page 8

Revision 17

EUROCOPTER

850 - 4

MAINTENANCE MANUAL MBB B01 05

INSPECTION FOR CONDITION - BLEED AIR HEATING

1. Inspect bleed air valve as follows: a. Inspect bleed air valve assembly (fig. 850-3) for damage. If possible, remove damaged components si ngly, otherwise remove bleed air valve and attached components as a unit. For removal and installation of mixing valve and shut-off valve , refer to paragraphs 850-8 and-9 and 850-1 Oand -11, respectively. b. Inspect bleed air valve assembly for cleanliness. If dirty, c1ean using cleaning agent (CM 201). c.

Inspect attaching hardware tor tightness and presence of lockwires. Tighten loose attaching hardware and replace missing or damaged lockwires.

d. Inspect bonding jumpers (1 and 14) for condition and tight connection. Replace damaged bonding jumpers and tighten loose connections. e. Inspect electricalleads for condition and associated plugs (3,4,5,6,7 and 8) for tight connection. Replace chafed electricalleads and tighten plugs. f. 2.

Inspect electrical control unit (15) for tight installation and tighten as necessary.

Inspect all pipes and hose pipes in engine compartment for secure routing and damage. a. Secure loose pipes and hoses. b. Replace damaged pipes and hoses.

3. Inspect air inlets and nozzles for cleanliness and condition. a. Clean dirty air inlets and nozzles with cleaning agent (CM 201). Remove foreign matter. Replace damaged nozzles per paragraph 850-16 and 850-1 7. 4. Check air select lever for smooth movement to position "OFF, "RAM AIR" and "BLWR" , respectively. If there is binding, locate and remedy cause. If the flap in the distribution duct is faulty, remove distribution duct and repair the flap. NOTE 5.

The nose door has to be removed for the following steps.

Inspect axial fan as follows: a. Inspect elbows (7 and 8, fig. 850-6) for tight connection to axial fan. Tighten connections if loose. b. Inspect axial fan mounting brackets for tight installation and condition. Tighten loose screws (2) and replace damaged mounting brackets. c.

Inspect clamps (1) tor tightness and tighten it necessary

d. Inspect bonding jumper (3) for condition and tight installation. Replace damaged bonding jumper and tighten loose attaching hardware. e. Inspect electricallead for condition and associated plug for tight connection. Replace chafed electrical lead and tighten plug connection. 6.

Inspect all pipes and hose pipes tor secure routing and damage. a. Secure loose pipes and hoses.

Revision 17

CHAPTER 850 Page9

MAINTENANCE MANUAL MBB B0105

EUROCOPTER

b.

Replace damaged pipes and hoses.

7. Inspect ducts. elbows and distribution ducts tor condition and secure attachment. a. Replace parts with cracks. tighten loase parts. 8. Clase nose door.

850 - 5

FUNCTIONAL TEST - BLEED AIR HEATING

The tunctional test will be performed on the ground in the MANUAL and AUTOMATIC operating modes in the following 2 stages. Stage 1: Engines shut down Stage 2: Engines running 1. Test with engines shut down. a. Check axial tan: 1) Connect and switch on external power unit. 2) Push circuit breaker "HEATING" (1, tig. 850-9). 3) Move lever (6) to position "BLWR". a) Axial

tan

(cabin compartment) must run (audible check).

b) Air must come out of heating nozzles 4) Move lever (6) to position "OFF". a) Axial

tan must not run

(audible check).

b. Check manual system: 1) Move switch "AUTO/MAN" on overhead console to position "MAN". a) Shut-off valve (transmission compartment) must be open after approx. 30 secs. A red dot on the shut-oft valve comes into view when shut-off valve is open. b) Caption "HEATING" on the overhead console must illuminate as soon as the shut-oft valve begins to open. 2) Move switch "INCR/DECR" on overhead console to position "INCR" and hold in this position. a) Motor on bleed air valve (transmission compartment) must start running (audible check, piston retracts). 3) Release switch "INCR/DECR". 4) Move switch "INCR/DECR" on overhead console to position "DECR" and hold in this position. a) Motor of bleed air valve (transmission compartment) must run in the opposite direction. 5) Release switch "INCR/DECR". CHAPTER 850 Page 10

Revision 17

EUROCOPTER

MAINTENANCE MANUAL MBB 801 OS

6) Move switch "AUTO/MAN" on overhead console to center position. a) Shut-off valve must close. b) Caption "HEATING" must not i1luminate after valve is completely c1osed. 7) Switch off and disconnect external power unit. 2.

Check with engines running.

80th engines run at the maximum power allowable on the ground with both generators connected to the aircraft electrical system. a. Check automatic system: 1) Move switch "AUTO/MAN" on overhead console to position "AUTO". a) Motor of cabin temperature sensor must be heard to runo b) Caption "HEATING" must iIIuminate as soon as the shut-off valve begins to open. 2) The temperature of the air must be adjustable vía potentiometer "TEMP CONTROL" on the overhead console. Turning cw increases, ccw decreases the air temperature. b. Check manual system: 1) Move switch "AUTO/MAN" on overhead console to position liMAN". a) Motor of cabin temperature sensor must not runo b) Shut-off valve in the transmission compartment must be open after approx. 30 secs. A red dot on the shut-off valve comes into view when shut-off valve is open. c) Caption "HEATING" on the overhead console must iIIuminate as soon as the shut-off valve begins to open. 2) Set and hold switch "INCR/DECR" on overhead console in "INCR" position.. a) The temperature of the air must increase. 3) Set and hold switch "INCR/DECR" on overhead console in "DECR" position. a) The temperature of the air must decrease. 4) Set switch "AUTO/MAN" on overhead consoleto center position. a) Caption "HEATING" must be off after approx. 30 seconds. b) Shut-off valve is closed. c.

Final work 1) Pull"HEATING" circuit breaker and switch off heating system. 2) Stop engines.

Revision 17

CHAPTER 850 Page 11

EUROCOPTER

850 - 6

MAINTENANCE MANUAL M88 80105

Removal • Bleed Air System in Engine Compartment

1. Remove fastening clips and clamps.

2. Remove hose pipes (2 and 3, fig. 850-2).· 3.

Remove pipe assemblies (5) with unions (6). Blank off engine connections with caps.

4.

Remove non-return valves (4).

5.

Remove hose pipe (7) and bulkhead fitting (1). Blank off open connection on bleed air valve with cap.

850 - 7

Installation • Bleed Air System in Engine Compartment

1. Install in reverse order of removal.

3

5--------,

r------2

6-----,

800270

1 Bulkhead fitting 2 Hose pipe ENG 1 3 Hose pipe ENG 2 4 Non-return valve

Figure 850-2

CHAPTER 850 Page 12

5 Pipe assy

6 Union 7 Hose pipe to valve assy

Bleed air system in engine compartment

Revision 17

MAINTENANCE MANUAL MBB B0105

EUROCOPTER

850 - 8

Removal • Bleed Air Valve Assy

NOTE

Remove main rotor blades and main rotor head with main gearbox as required for removal of the bleed air valve assy.

1. Remove hose pipes from bleed air valve assy (fig. 850-3) at the disconnecting points .Blank off bleed air valve assy ports with caps.

2. Remove clamps as required. 3.

Disconnect bonding jumper (1) from transmission compartment floor. Remove plugs (3, 4, 5, 6, 7 and 8).

4. Remove screws (2) and bleed air valve assy (10).

850 - 9

Installation • Bleed Air Valve Assy

1. Install in reverse order ot removal.

2. Carry out functional test, reter to para. 850-5, step 2.

Revision 17

CHAPTER 850 Page 13

EUROCOPTER

MAINTENANCE MANUAL MBB B0105

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800271

Figure 850-3

CHAPTER 850 Page 14

Bonding jumper Screw Plug Plug Plug (temperature sensor) Plug (temperature switch) Plug (transmission compartment floor) Plug Clamp Bleed air valve Shut-off valve Clamp Actuator Bonding jumper Electrical control unit

Bleed Air Valve Assy

Revision 17

MAINTENANCE MANUAL MBB 80105

EUROCOPTER

Removal - 5hut~ff Valve

850 - 10

Remove main rotor blades and main rotor head with main gearbox as required for removal of the bleed air valve assy.

NOTE

1. Disconnect electricallead from receptacle (11, fig. 850-4). 2. Remove bonding jumper (5) from actuator (12). 3.

Unscrew hose (10) from elbow (9).

4. While holding shut-off valve (6) to prevent it from falling, unscrew nut (2) from connection on bleed air valve assembly and remove O-ring (1). Discard damaged o-ring (1). 5.

Loosen clamps (4 and 7) and detach elbow connector (3), elbow (9) and gaskets (8) from shut-off valve (6). Discard damaged gaskets (8).

850 -11

Installation - 5hut~ff Valve

1. Install shut-off valve in reverse order of removal. Replace damaged gaskets (8) and o-ring (1) with new ones. 2. Perform functional test per paragraph 850-5.....

Revision 17

CHAPTER 850 Page 15

EUROCOPTE.R

MAINTENANCE MANUAL MBB B0105

2

3

o

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9

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1 2 3 4 5 6

D-ring Nut Elbow connector Clamp Bonding jumper Shut-off valve

Figure 850-4

CHAPTER 850 Page 16

7 8 9 10 11 12

Clamp Gasket Elbow Hose Receptacle Actuator (with gear unít)

Shut-off valve

Revision 17

EUROCOPTER

850 -12

MAINTENANCE MANUAL MBB B010S

Removal- Temperature Sensor and Temperature Switch

1. Remove plugs (6 and 7, fig. 850-5). 2. Remove screws (4) with nuts (5) and remove temperature sensor (3) from distribution duct (1). 3. Remove screws (8) with washers (9) and remove temperature switch (2) with seal (10) from distribution duct (1).

850 -13

Installation - Temperature Sensor and Temperature Switch

1. Install in reverse order of removal. 2. Carry out functional test, refer to para. 850-5, step 2.

Revision 17

CHAPTER 850 Page 17

EUROCOPTER

MAINTENANCE MANUAL MBB B0105

ViewA \

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800272

1 Distribution duct

2 Temperature switch 3 Temperature sensor 4 Screw 5 Nut

Figure 850-5

CHAPTER 850 Page 18

6 7 8 9

Plug Plug Screw Washer 10 Seal

Temperature Sensor and Temperature Switch

Revision 17

EUROCOPTER

850 -14

MAINTENANCE MANUAL MBB B0105

Removal - Axial Fan

1. Remove nose door. 2. Remove c1amps (1, tig. 850-6). 3. Open electrical junction box cover (5) and disconnect axial tan electrical connections. Remove bonding jumper (3) trom axial tan (4). 4. Remove tan bracket screws (2) and remove axial tan (4) together with elbows (7 and 8). 5.

Remove screws (6) and detach elbows (7 and 8) trom axial tan.

850 - 15 NOTE

Installation - Axial Fan Observe direction ot f10w when installing the axial tan.

1. Install in reverse order ot removal. 2. Perform tunctional test per paragraph 850-5, step 1.

7

6

1 Clamp 2 Screw 3 Bonding jumper 4 Axial tan

Figure 850-6

Revision 17

4

5

3

5 6 7 8

2

6

Cover Screw Elbow Elbow

Axial Fan

CHAPTER 850 Page 19

EUROCOPTER

850 -16

MAINTENANCE MANUAL M8B 80105

Removal- Swivelling Nozzle

1. To remove swivelling nozzle (cockpit) (see fig. 850-7, detail A), remove screws (4) and detach swivelling nozzle (3) with seal (2) from windshield nozzle (1). 2.

3.

Remove swivelling nozzle (passenger compartment) as follows (see fig. 870-7, detail B): a.

Remove cowling as required.

b.

Remove screws (4) and detach swivelling nozzle (3) and seal (2) from bracket (9).

c.

If required, remove screws (8) and detach bracket (9) from elbow (7).

Remove swivelling nozzle (cargo compartment) as follows (see fig. 850-7, detail C): a.

Remove cowling as required.

b.

Remove screws (10) with washers (11).

c.

Remove clamp (6) and detach swivelling nozzle (3) together with bracket (11) and elbow (7).

d.

Remove screws (4) and nuts (13) anddetach swivelling nozzle (3) from bracket (12), seal (2) and elbow (7).

850 - 17

Installation - Swivelling Nozzle

1. Install in reverse order of removal.

CHAPTER 850 Page 20

Revision 17

MAINTENANCE MANUAL MBB B010S

EUROCOPTER

2

9-----..--

DETAlLe

1 Windshield nozzle 2 Seal 3 Swivelling nozzle 4 Screw 5 Hose 6 Clamp 7 Elbow 8 Screw, Washer 9 Bracket 10 Screw 11 Washer 12 Bracket 13 Nut 14 Nut

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Figure 850-7

Revision 17

Swivelling Nozzle

CHAPTER 850 Page 21

EUROCOPTER

850 -18

MAINTENANCE MANUAL MBB B0105

Removal· Cabin Temperature Sensor

1. Remove fairing as required. 2. Remove screw (3, fig. 850-8) and housing cover (2). 3. Unscrew plug (1). 4.

Remove screws (4 and 8), detach temperature sensor base plate (5) with seal (6) and socket (9) from bracket (7).

2

3

9----~~'

8----1-11

800276

7

I

6

5

4

Figure 850-8

CHAPTER 850 Page 22

1 2 3 4 5 6 7 8 9

Plug Housing cover Screw Screw Temperature sensor base plate Seal Bracket Screw Plug

Cabin Temperature Sensor

Revision 17

MAINTENANCE MANUAL MBB B0105

EUROCOPTER

850 -19

Installation· Cabin Temperature Sensor

1. Instan in reverse order of removal. 2. Carry out functional test, refer to para. 850-5, step 2..

850 - 20

Removal • Pipe Assemblies and Hose Pipes

1. Remove cowlings or fairings as required. 2. Slacken or remove clamps as required, and remove pipes or hoses.

850 - 21 NOTE

Installation • Pipe Assemblies and Hose Pipes Instan pipe assemblies and hoses so as to ensure that control system components can move freely and lines do not chafe.

1. Instan in reverse order of removal. 2. Torque value for hose clamps 1Nm.

Revision 17

CHAPTER 850 Page 23

EUROCOPTER

MAINTENANCE MANUAL MBB B0105

BLANK PAGE

CHAPTER 850 Page 24

Revision 17

MAINTENANCE MANUAL 801 OS

EUROCOPTER

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Revision 17

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Bleed Air Heating (1 of 2)

CHAPTER 850

Page25/26

15

Circuit breaker Caption Switch Switch Temperature control Lever assy Temperature sensor Distribution duct (transmission compartment) Hose Distribution duct Hose Hose Bracket Elbow with swivelling nozzle (cargo compartment) Clamp

16 Hose 17 Clamp 18 Elbow with swivelling nozzle (LH cabin) 19 Clamp 20 RAM AIR inlet 21 Wire cable 22 Adapter 23 Duct 24 Windshield nozzle 25 Elbowassy 26 Clamp 27 Duct 28 Clamp 29 Temperature switch 30 Temperature sensor 31 Hose

32 Plug (bleed air valve) 33 Actuator (bleed air valve) 34 Inlet t1ange (fresh air intake, transmission compartment) 35 Hose 36 Bleed air valve assy 37 Elbowassy 38 Hose 39 Elbow with swivelling nozzle (LH cabin) 40 Distribution duct 41 Clamp 42 Bleed air shut-off valve 43 Plug (shut-off valve) 44 Hot airduct 45 Clamp 46 Hose

MAINTENANCE MANUAL 80105

EUROCOPTER

49

47

50

56

55

54

53

51

57

59

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Figure 850-9 Bleed Air Heating (2 of 2)

CHAPTER 850 Page 27/28

68

69

47 Clamp 48 Distribution duct (nose compartment) 49 Flap 50 Elbow (RH) 51 Bracket (RH) 52 Clamp 53 Hose 54 Clamp 55 Hose 56 Non-return valve

Revision 17

60

57 58 59 60 61 62 63 64 65 66 67

Fitting (bleed air) Pipe Engine (RH) Hose Non-return valve Hose Engine (LH) Fitting (bleed air) Pipe Hose Clamp

67

65

66

68 69 70 71 72 73 74 75 76 77

64

Hose Axial tan Bracket (LH) Elbow (LH) Clamp CAB AIR inlet Hose (LH) Clamp Hose (RH) Clamp

63

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - " ' - - - - MAINTENANCE MANUAL MBB - BO 105

851

SEARCH- ANO LANDINGLIGHT 450 WATT

Table of Contents

Paragraph

Title

Page

851 - 1

DESCRIPTION - SEARCH- ANO LANDINGLIGHT 450 WATT . .

3

851 - 2

TROUBLESHOOTING - SEARCH- AND LANDINGLIGHT 450 WATT

4

851 - 3

INSPECTION SCHEDULE - SEARCH- ANO LANDINGLIGHT 450 WATT

7

851 - 4

INSPECTION FOR CONDITION - SEARCH- ANO LANOINGLIGHT 450 WATT

8

851 - 5

FUNCTIONAL TEST OF ELECTRICAL COMPONENTS SEARCH- AND LANDINGLIGHT 450 WATT ....

8

851 - 6

REMOVAL - SEARCH- ANO LANOINGLIGHT 450 WATT

10

851 - 7

INSTALLATION - SEARCH- ANO LANDINGLIGHT 450 WATT

10

851 - 8

Removal - landing light

10

851 - 9

Installation - landing light lamp

10

851 - 10

Removal - printed circuit card

11

851 - 11

Installation - printed circuit card

11

lamp

BO 105 CHAPTER 851 Page 1/2

- - - - - - - ' - - - - - - - MEB HELICOPTERS - - - - - - - - - - - ' - - - - - MAINTENANCE MANUAL MEB - BO 105 851 - 1

DESCRIPTION - SEARCH- AND LANDINGLIGHT 450 WATT

1. General The 450 Watt search- and landinglight is installed in the forward nose shell panel and replaces the standard landinglight. It is retractable and capable of 360 0 rotation to the left and right. Its movements are controlled by two motors. The motors are controlled via relays and cut off in their end positions by means of limit switches. Diodes and relays on the printed circuit card ensure copilot priority over the piloto The flip flop relay on the printed circuit card controls automatic light retraction into its stowed position from any extended position. The search- and landinglight 450 Watt mainly consists of the following components: -

Circuit-breaker LANDINGLIGHT CONT Circuit-breaker LANDINGLIGHT LAMP Annuncicator light LDG-LIGHT Switch ON-OFF-RETR (pilot) 4-way-switch EXT-RETR-L-R (pilot) Switch ON-OFF-RETR (copilot) 4-way-switch EXT-RETR-L-R (copilot) Printed circuit card Search- and landinglight

2. Operation

With circuit-breakers (1 and 2, figure 851-1) depressed, the light is switched on by setting switch (4) to ON; the LDG-LIGHT annunciator light (3) illuminates. The light is extended or retracted and/or rotated to the left or right by actuation of the 4-way switch (5) in the EXT-RETR-L-R positions. Movement takes place throughout operation of the switch. The copilot's switch has priority over the pilot's switch. If for short periods switch (4) is set to RETR, the light retracts, the lamp extinguishes and the light rotates to the right until it is switched off automatically in its stowed position.

BO 105 CHAPTER 851 Page 3

------------------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 851 - 2

TROUBLESHOOTING - SEARCH- AND LANDINGLIGHT 450 WATT

General Perform troubleshooting in accordance with wiring diagram in Wiring Diagram Manual (WDM). Check printed circuit card for snug fit. Check all associated switches on collective sticks and circuit-breakers for proper mechanical switching. Connect external power unit (EPU). Press circuit-breakers. No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Landinglight lamp fails to illuminate. Switch (4, fig. 851-1) pilot or copilot in ON position

Landinglight lamp defective

Check landinglight lamp for voltage. Replace if necessary (refer to paras 851-8 and 851-9)

Switch (4) pilot or copilot defective

Check for continuity with switch in ON position; replace defective switches

LANDINGLIGHT LAMP circuit breaker defective

Check circuit breaker for continuity; replace, if necessary

p/C card defective

Check p/C card for continuity i.a.w. wiring diagram . Replace PIC card, if necessary (refer to paras 851-10 and 851-11)

Lamp relay defective

Dismantle search- and landinglight and check lamp relay for function; replace landinglight, if necessary

Table 851-1

BO 105 CHAPTER 851 Page 4

Troubleshooting (1 of 3)

--.....;.....----------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

2

Search- and landing- 4-way-switch (5) pilot light fails to exor copilot defective tend/retract with 4-way-switch (5) pilot or copilot in EXT/RETR position Motor or motor relay defective

3

PROBABLE CAUSE

CORRECTlVE ACTION Check switch in EXT/RETR position for continuity; replace defective switches Check plug for voltage. If voltage is present, remove search- and landinglight and measure i.a.w. wiring diagram. Replace searchand landinglight, if necessary

P/C card defective

Check p/C card for continuity i.a.w. wiring diagram. Replace p/C card, if necessary (refer to paras 851-10 and 851-11)

LANDINGLIGHT CONT circuit breaker defective

Check circuit breaker for continuity; replace, if necessary

Search- and landing- 4-way-switch (5) pilot light fails to or copilot defective rotate to left/right with 4-way-switch (5) pilot or copilot Motor or motor in R/L position relay defective

p/C card loose or defective

Table 851-1

Check 4-way-switch in R/L position for continuity; replace defective switches Check connector for voltage. If voltage is present, remove search- and landing light and measure i.a.w. wiring diagram. Replace search- and landinglight, if necessary Check pIC card for snug fit and for continuity i.a.w. wiring diagram. Replace pIC card, if necessary (refer to . paras 851-10 and 851-11)

Troubleshooting (2 of 3) BO 105 CHAPTER 851 Page 5

-----------,-........;.---MBB HELICOPTERS ----------~--­ MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) No.

TROUBLE- SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

4

Search- and landinglight fails to move into stowed position with switch (4) pilot'or copilot set to RETR.

Flip flop relay RS1 defective

Check p/C card for continuity i.a.w. wiring diagram. Replace p/C card, if necessary (refer to paras 851-10 and 851-11)

Switch (4) pilot or copilot defective

Check switch for continuity in RETR position; replace defective switch

5

Copilot priority circuit without function

Relay RS2 defective

Check p/C card for continuity i.a.w. wiring diagram. Replace p/C card, if necessary (refer to paras 851-10 and 851-11)

6

Annunciator light fails to illuminate

Lamp defective

Replace lamp

Cables defective

Repair or replace cables

Table 851-1

BO 105 CHAPTER 851 Page 6

Troubleshooting (3 of 3)

EUROCOPTER

851 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 851

Page7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - - - ' MAINTENANCE MANUAL MBB - BO 105 INSPECTION FOR CONDITION - SEARCH- ANO LANOINGLIGHT 450 WATT

851 - 4

Check for condition with search- and landinglight in extended position.

NOTE

l. Inspect search- and landinglight for dirt. Clean with clear water and

cleaning agent (CM 218) as required. 2. Inspect search- and landinglight for secure screwed connection with nose door.Tighten slack screws (18, figure 851-1). 3. Inspect landing light lamp (15) for secure installation and condition.

a.

Tighten slack screws (13) of retaining ring (14).

b.

Replace damaged landing light lamp (refer to paras 851-8 and 851-9) .

4. Visually inspect cables and electrical connections (20) for proper 10-

cation, condition and secure attachment. a.

Secure loose cables and electrical connections.

b.

Repair or replace damaged cables.

851 - 5

FUNCTIONAL TEST OF ELECTRICAL COMPONENTS SARCH- ANO LANDINGLIGHT 450 WATT

l. Check all associated switches and circuit breakers for proper mechanical function.

2. Connect external power supply or battery. 3. Set master switch to EPU ON. 4. Press LANDING LIGHT CONT and LANDING LIGHT LAMP circuit breakers.

5. Set LDG-LIGHT switch (4, figure 851-1) on pilot's collective stick to ON. Search- and landinglight and LDG-LIGHT annunicator light (3) illuminate. 6. Set LDG-LIGHT switch (4) to OFF. Search- and landinglight and annunciator

light extinguish.

BO 105 CHAPTER 851 Page 8

- - - ' - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 7.

On pilots collective stick, set 4-way-switch LDG-LIGHT (5) to EXT and hold. Search- and landinglight must extend in direction of flight and stop automatically in the end position (duration of extension approx. 15 seconds). LDG-LIGHT annunciator light must (3) illuminate. Release 4-wayswitch LDG-LIGHT (5).

8.

Set LDG-LIGHT switch (4) to ON. Search- and landinglight illuminates.

9.

Set 4-way-switch LDG-LIGHT (5) to R and hold. Search- and landinglight turns to the right through 360 0 without any restriction. Time for one full 360 0 turn is approx. 20 seconds. Release 4-way-switch LDG-LIGHT (5). Search- and landinglight stops rotation.

10. Set 4-way-switch LDG-LIGHT (5) to L and hold. Search- and landinglight turns to the left through 360 0 without any restriction. Time for one full 360 0 turn is approx. 20 seconds. Release 4-way-switch LDG-LIGHT (5). Search- and landinglight stops rotation. 11. Set 4-way-switch LDG-LIGHT (5) to RETR in any position of rotation. Search- and landinglight retracts and cuts off automatically. Rotated position is maintained. LDG-LIGHT switch (4) is in OFF position. 12. Extend search- and landinglight to any position by means of 4-way-switch LDG-LIGHT (5) on pilot's collective stick. 13. Set LDG-LIGHT switch (4) to RETR. Light extinguishesi search- and landinglight retracts and turns in its casing to the right into zero position. 14. Repeat steps 3. through 11. with the respective switches on the copilot's collective stick. 15. Check switches on copilot's collective stick for priority as follows: a.

Copilot controls any movement of extension/retraction or rotation. The respective switches on the pilot's collective stick are without function.

b.

Pilot controls any movement of extension/retraction or rotation. Cornmands from the copilot's collective stick in opposite direction are carried out.

16. Pull LANDING LIGHT CONT and LANDING LIGHT LAMP circuit breakers. Disconnect battery or external power unit.

BO 105 CHAPTER 851 Page 9

------'----------'--- MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 851 - 6

REMOVAL - SEARCH- ANO LANOINGLIGHT 450 WATT

1.

Extend search- and landinglight approx. 45°.

2.

Disconnect battery or external power unit.

3.

Rernove nose door.

4.

Rernove screws (18, figure 851-1) and washers (17) and withdraw searchand landinglight (16) through nose. door.

5.

Disconnect plug.

851 - 7

INSTALLATION - SEARCH- AND LANDINGLIGHT 450 WATT

1.

Installation is accornplished in reverse order of rernoval.

2.

Connect battery or external power unit and carry out functional check of electrical cornponents (refer to para 851-5).

851 - 8

Rernoval - landing light larnp

1.

Extend search- and landinglight approx 45°.

2.

Disconnect battery or external power unit.

3.

Rernove screws (13, figure 851-1) and retaining ring (14).

4.

Carefully withdraw landing light larnp (15) frorn socket (19); rernove screws (21) and lock washers (22) and electrical connections (20).

851 - 9

Installation - landing light larnp

1.

Installation is accornplished in reverse order to rernoval.

2.

Connect battery or external power unit and actuate switch (4, figure 851-1) on pilot's or copilot's collective stick to check searchlight and landing for proper function (switch set to ON) .

3.

Using switch (4) rnove search- and landinglight into stowed position (briefly touching switch RETR position) .

BO 105 CHAPTER 851 Page 10

----------'-------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 851 - 10

Removal - printed circuit card

l.

Remove nose door.

2.

Disconnect battery or external power unit.

3.

Remove nuts (6, figure 851-1) with washers (7) and screws (8) to clear spacers (9).

4.

Carefully remove printed circuit card (10) and disconnect connection (11) .

851 - 11

Installation - printed circuit card

1.

Insert new p/C card (10, figure 851-1) and connect connection (11).

2.

Position spacers (9) between p/C card (10) and frame (12), and fasten P/C card using screws (8), washers (7) and nuts (6).

3.

Connect battery or external power unit and perform functional test of electrical components (refer to para 851-5).

BO 105 CHAPTER 851 Page 11/12

----------;:~~ HELI~P~:S _ MAINTENANCE MANU MBB

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20

DETAlL

Fig. 851-1

E

10 11

I

D

19

Searc h- and Landinglight 450 Watt BO 105

CHAPTER 851 Page 13/14

Nut Washer Screw Spacer p/c card Connection

PILOT

12 13

14 15 16 17 18 19 20 21 22

Frame Screw , Reta~nin? r~niamp Land1ngl1ghlandinglight Search and (450 Watt) Washer Screw Socket Electrical connections Screw Lock washer

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

852

COMPRES SOR RINSING EQUIPMENT

Table of Contents

Paragraph

Title

852 - 1

DESCRIPTION - COMPRES SOR RINSING EQUIPMENT

3

852 - 2

INSPECTION SCHEDULE - COMPRES SOR RINSING EQUIPMENT

4

852 - 3

INSPECTION FOR CONDITION - COMPRES SOR RINSING EQUIPMENT

5

852 - 4

DISASSEMBLY - COMPRES SOR RINSING EQUIPMENT

8

852 - 5

ASSEMBLY - COMPRES SOR RINSING EQUIPMENT

8

852 - 6

Compressor wash procedure

.

8

Page

BO 105 CHAPTER 852 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 852 - 1

DESCRIPTION - COMPRESSOR RINSING EQUIPMENT

During operation in industrial atmosphere, deposits build up on the compressor blades resulting in a loss of engine efficiency. During flights in salt laden atmosphere corroded residues are trapped in the engine. The compressor rinsing equipment enables such contamination to be removed easily, quickly and effectively. The installed equipment may be used for rinsing compres sor with water or for washing the compressor with a cleaning fluid in accordance with Allison "250-C20 engine Operating and Maintenance Manual". The compressor rinsing equipment consists of two rinsing tubes (one rinsing tube per engine) which are fastened to the gearbox supports with clamps and screws. One end of the rinsing tube is fitted with a connection for the water or cleaning fluid supply (Gardena Connection 1/2" No. 915), the other end has a spray nozzle which is directed towards the compressor. One cover eaeh on the right and left in the engine cowling ensures quick connection of water or cleaning fluid source without removal of engine cowling.

BO 105 CHAPTER 852 Page 3

EUROCOPTER

• 852 - 2

MAINTENANCE MANUAL 80105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 852 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSPECTION FOR CONDITION - COMPRESSOR RINSING EQUIPMENT

852 - 3

1.

2.

3.

Check cornpressor rinsing equiprnent for tight connection. a.

Tighten slack screws.

b.

Replace worn clarnps.

c.

Check spraying direction in accordance with figure 852-1 and adjust as required (refer to step 4.).

Inspect rinsing tube (4, figure 852-2) for chafing, deformation and cracks¡ in particular inspect welding searns for cracks: a.

Replace rinsing tubes exhibiting chafe rnarks and cracks.

b.

Straighten deforrned rinsing tubes if possible, or replace.

c.

Replace rinsing tube as follows: 1)

Rernove nuts (11) and washers (10) frorn screws (5). Rernove rinsing tube (4) with clarnps (12) frorn screws (5) and bushings (9).

2)

Take off clarnps (12) and rnount clarnps on new rinsing tube.

3)

Installation of new rinsing tube is accornplished in reverse order of rernoval.

4)

Check nozzle spraying direction in accordance with figure 852-1 and adjust as required (refer to step 4.) .

Inspect nozzle (1, figure 852-2) for blockage and firrn connection¡ check for proper safeting. a.

Clean nozzle (1) in installed condition using cornpressed air or suitable tool. If cleaning in installed condition proves to be irnpossible, rernove nozzle (1) and clean as follows: 1)

Rernove lockwire (3).

2)

Rernove nozzle (1) and sealing ring (2).

3)

Clean nozzle (1) using cornpressed air or suitable tool.

4)

Install nozzle (1) in reverse order of rernoval.

5)

Check spraying direction in accordance with fig. 852-1 and adjust as required (refer to step 4) .

b.

Tighten loose nozzles and renew lockwire.

c.

Install rnissing lockwire.

BO 105 CHAPTER 852 Page 5

--------.....,.......----MBB HELICOPTERS - - - - - - - - - - - - ' - - MAINTENANCE MANUAL MBB - BO 105 4.

Check nózzle (1, fig. 852-2) spraying direction. If necessary, adjust as follows: a.

Slacken screws (5 and 6).

b.

Insert plug gauge (fig. 852-1) in rinsing tube Vee groove and adjust rinsing tube in accordance with the dimensions shown in figure 852-1.

c.

Tighten screws (5 and 6, figure 852-2).

d.

Re-check adjustment. Plug gauge

-.l 1-:-------------_-__-_-_-_-_-_-._-_-_-_-_-_-_-~_l-l-4 I~

~o

~

A-----f I

I

;' I

Compressor axis

SECTIONA-A 2

800339

Dimension in mm 1 2

Figure 852-1 . Adjustment of spraying direction BO 105 CHAPTER 852 Page 6

Plug gauge Nozzle

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

----~--------MBB

DETAlL

DETAlL

A

B

14-

800280

1 Nozzle Sealing ring 3 Lockwire 4 Rinsing tube 5 Screw

2

6 7 8 9

la

Figure 852-2

Screw Clamp Rubber Bushing Washer

11

12 13 14 15

Nut Clamp O-ring Connection Cover

Compressor rinsing equipment BO 105 CHAPTER 852 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 852 - 4

DISASSEMBLY - COMPRESSOR RINSING EQUIPMENT

1.

Remove four nuts (11, fig. 852-2) and four washers (10).

2.

Remove screws (5), bushings (9) and take off rinsing tube.

3.

Remove two screws (6) and take off the two halves of the clamp (7).

4.

Remove rubber (8) as required.

852 - 5

ASSEMBLY - COMPRESSOR RINSING EQUIPMENT

1.

Temporarily fasten rinsing tube (4) with clamps (12), bushings (9) and screws (5 and 6) to clamp (7) and direct it to the compressor.

2.

Mark position of clamp (7).

3.

Remove the parts assembled in step 1.

4.

Bond rubber (8) at indicated position using adhesive (CM 605).

5.

Finally assemble compressor rinsing equipment in reverse order of disassembly.

6.

Adjust spraying direction of nozzle (refer to paragraph 852-3, step 4.).

852 - 6 1.

2.

Compressor wash procedure

Water rinse: a.

Open the upper flap located on the side of the left and right forward engine cowlings. Disconnect hose from exhaust duct of engine No. 1 and engine No. 2, refer to Chapter 61, figure 61-8.

b.

For contamination removal using water, refer to Allison OMM 10W2 (including the respective CSL's).

c.

Install hose to exhaust duct of engine No. 1 and engine No. 2 and secure with lockwire. Close flaps.

Cleaning: a.

Disconnect hose from exhaust duct of engine No. 1 and engine No. 2, refer to Chapter 61.

b.

Disconnect pipes of bleed air heating system (5, figure 850-2) and blank off.

c.

Compressor cleaning instructions using cleaning compounds, refer to Allison OPERATING and MAINTENANCE MANUAL NO. 10W2.

BO 105 CHAPTER 852 Page 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

d.

Install pipes (5, figure 850-2) to fittings and secure with lockwire.

e.

Install hose to exhaust duct of engine No. 1 and engine No. 2 and secure with lockwire.

BO 105 CHAPTER 852 Page 9/10

MAINTENANCE MANUAL 80 105

EUROCOPTER

853

FIRE EXTINGUISHING SYSTEM

Table of Contents Paragraph Title

Page

853 - 1

DESCRIPTION - FlRE EXTINGUISHING SYSTEM

3

853 - 2

TROUBLESHOOTING - FIRE EXTINGUISHING SYSTEM

4

853 - 3

INSPECTIONSCHEDULE - FlRE EXTINGUISHING SYSTEM

6

853 - 4

INSPECTION FOR CONDITION - FlRE EXTINGUISHING SYSTEM

7

853 - 5

FUNCTIONAL CHECK - FlRE EXTINGUISHING SYSTEM

8

853 - 6

Rernoval - fire extinguishing bottle

9

853 - 7

Installation - fire extinguishing bottle

10

853 - 8

Replacernent - explosive cartridge

10

853 - 9

Weighing - fire extinguishing bottle

lOA

853 - 10

Disposal - explosive cartridge

lOA

Revision 14

BO 105 CHAPTER 853 Page 1/2

* * * * *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 853 - 1

DESCRIPTION - FIRE EXTINGUISHING SYSTEM

1. General The purpose of the fire extinguishing system is to effectively suppress any engine fires that might occur, using fire extinguishing agent that does not impair engine operation. The extinguishing bottles and associated delivery lines are located aft of the engine bays.The contents of one bottle are discharged into both engine bays irrespective of the source of the fire, while the other bottle serves as a back-up. A fire extinguisher bottle can only be actuated through the associated fire switch on the fire extinguisher control panel located on the instrument panel. 2. Description Description and operation of the fire extinguishing system is basically the same for the two configurations described below. Two fire extinguisher bottles are attached to a support frame with clamps. The discharge swivels of the bottles are coupled through a double check tee valve, from which a discharge line branches out into two separate lines, each leading to a discharge nozzle in the aft firewall. Each bottle has a relief valve, a pressure gauge, and, installed in the discharge swivel, an electrically actuated explosive cartridge fitted with a discharge sensor. The configurations differ as follows: Configuration 1 (fig. 853-1): In this configuration the fire extinguisher bottles are located aft of the engine bays on the starboard side (port side on BO 105S). A thermal sensor (12) installed on the check thermal valve (13) actuates an amber annunciator (21) on the fire extinguisher control panel when the thermal va1ve opens. Each bottle is fitted with an overboard discharge line (14). Configuration 11 (fig. 853-2): In this configuration the fire extinguisher bottles are located aft of the engine bays on the port side. There is no thermal sensor on the thermal valve (3). The overboard discharge lines (6) of both bottles are interconnected through a tee (7) from which an overboard discharge line (8) connects to an outlet in the fuselage which is closed by a red rupture disk (4), the bursting of which indicates thermal discharge. 3. Operation The system is supplied with 28VDC from the main busbar PP21. Pressing circuit breaker FIRE-EXT 1 (11) 3WB (4WB) and then momentarily actuating fire switch 5WB (6WB) completes the circuit to the explosive cartridge in the extinguisher bottle, causing the explosive cartridge to detonate. Only one bottle is discharged when a fire switch is actuated.

BO 105 CHAPTER 853 Page 3

HELICOPTERS - - - - - - - - - - - - ' - - - MAINTENANCE MANUAL MBB - BO 105

----~---~----:.---MBB

The fire- extinguishing agent is discharged from the bottle and flows through the discharge swivel to the double check tee valve. There, the escaping agent pushes the free floating ball against the opposite inlet valve seat and flows out of the outlet and along the branched discharge line to the spray nozzle in each engine compartment. The circuits of the fire extinguisher system are checked using the amber annunciator 8WB on the fire extinguisher control panel, green annunciator 7WB on the overhead console, and cartridge test switch 13WB. If the pressure in a bottle should drop, due to either thermal or intentional discharge, the circuit of the associated sensor will open, causing the relevant amber annunciator (right or left) to come on. 853-2

TROUBLESHOOTING - FIRE EXTINGUISHING SYSTEM

General Refer to the appropriate wiring diagrams in the Wiring Diagram Manual (WDM)

Check all associated electrical connections for tight and secure fit. Check light bulbs and check circuit breakers for proper mechanical function. Connec:. external power supply (EPU). Set battery switch 16P on instrument panel to BATT OFF/EPU ON. Depress circuit breakers FIRE-EXT 1 and 11.

BO 105 CHAPTER 853 Page 4

EUROCOPTER

MAINTENANCE MANUAL BO 105

TROUBLESHOOTING (continued) No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Amber annunciators on fire extinguisher control panel 38VE do not illuminate when depressed

Light bulbs defective.

Replace bulbs.

One of the two explosive cartridges defective

Check continuity of cartridges (refer to para 853-5) and replace as necessary

Monitor module 9WB (lOWB) defective

Replace monitor module

Faulty wiring

Check continuity of wiring according to applicable wiring diagram in WDM; repair or replace faulty wiring

Light bulbs defective

Replace bulbs

One of the two explosive cartridges defective

Check continuity of cartridge (refer to para 853-5) and replace as necessary

Monitor module 9WB (10WB) defective

Replace monitor module

Faulty wiring

Check continuity of wiring according to applicable wiring diagram in ~~M; repair or replace faulty wiring

2

Green annunciators 7WB on overhead console do not illuminate when depressed

Table 853-1

Troubleshooting

BO 105 CHAPTER 853 Page 5

EUROCOPTER

• 853 - 3

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 853

Page6

MAINTENANCE MANUAL BO 105

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

DRUCK- TEMPERATUR VERGLEICHSTABELLE PRESSURE-TEMPERATURE CORRECnON TABLE

oc

TEt.4P

FO TEt.4P

INO PRESS

oc

TEt.4P

FO TEMP

IND PRESS

-51 -60 110 ·134 +4 +40 249 299

-40 -40 127 155 +16 +SO 304 354

-28 -20 148 180 +27 +80 367 417

-17 -7 O +20 174 207 212 251 +38 +49 +100 +120 442 532 492 5a2

800380

Table 853-2

853 - 4

Acceptable temperature and pressure values for fire extinguishing agent

INSPECTION FOR CONDITION - FlRE EXTINGUISHING SYSTEM

l. Read pressure indication on pressure gauge (6, fig. 853-1). If pressure is less than the minimum pressure (see Table 853-2), replace fire extinguisher bottle. 2. Inspect fire extinguisher bottles (7) for tight installation. Tighten loose nuts (9) on clamps (8).

3. Inspect support frame (18) for condition and tight installation. a.

Tighten loose attaching screws.

b.

Replace support frame if damaged.

4. Inspect wiring harness (13, fig. 853-2) and connections for damage and tight and secure fit.

a.

Replace damaged electrical cables.

b.

Tighten loose connections.

BO 105 CHAPTER 853 Page 7

------'---.......,.........,.....----MBB HELICOPTERS - - - - - - - - - - - - ' - - MAINTENANCE MANUAL MBB - BO 105 5. Inspect éonnector (5) for tight and secure fit. 6. Inspect spray nozzles (9) in firewall for condition. 7. Inspect overboard discharge lines for condition and security (different configurations) . a.

Replace damaged lines.

b.

Tighten loose lines.

8. Inspect discharge line (17, fig. 853-1) for condition and security. a.

Replace damaged tubes discharge lineo

b.

Tighten loose tubes discharge lineo

9. Check light bulbs; see para 853-5. 853 - 5

FUNCTIONAL CHECK - FIRE EXTINGUISHING SYSTEM DO NOT TEST THE CARTRIDGE WITH A CURRENT EXCEEDING

CAUTION

0 .. 1 AMP.

General Switch on electrical power supply. Press circuit breakers FlRE EXT I and II. 1. Lamp test

a.

Press amber annunciator 8WB (21, fig. 853-1); all four amber annunciators should illuminate. Release bulb test switch 8WB and all four lights should extinguish (bulb test) .

b.

Press ators nate. (bulb

c.

Set cartridge test switch 13WB (24) to I; LH side of green annunciator 7WB (25) should illuminate. Release spring-loaded test switch. It returns to position O and the lights should extinguish. Set switch to II and check that RH side of annunciator 7WB (cartridge test) .

BO 105 CHAPTER 853 Page 8

green annunciator 7WB (25); the four bulbs of green annunci7WB and the four bulbs of amber annunciator 8WB should illumiRelease bulb test switch and all eight bulbs should extinguish and electronics test) .

EUROCOPTER .

MAINTENANCE MANUAL BO 105

2. Cartridge test a.

Disconnect both connectors (119VV und 120VV) from fire extinguisher bottles and attach voltmeter to contacts B (+) and C of receptacle 119VV. The voltmeter must read OVo

b.

Raise switch guard of fire switch 1 (20, figure 853-1) and press fire switch 1 forward. The voltmeter should read approx. 28V.

c.

Close switch guard so that fire switch 1 returns to OFF position. The voltmeter should read OVo Detach voltmeter froro receptacle 119VV.

d.

Attach voltmeter to contacts B (+) and C of receptacle 120VV. The voltmeter roust read OVo

e.

Raise switch guard of fire switch 11 (22) and press fire switch forward. The voltmeter should read approx. 28V.

f.

Close switch guard so that fire switch 11 returns to OFF position. The voltmeter should read OVo Detach voltmeter from receptacle 120VV.

g.

Reconnect connectors 119VV and 120VV.

853 - 6 NOTE

11

Rerooval - fire extinguisher bottle

The removal procedures for configurations

1

and

11

are identical.

1. Pull out circuit breakers (19 and 23, figure 853-1) FIRE-EXT.I and FIRE-EXT.II (on fire extinguisher control panel in the instrument panel) and secure against unintentional pressing. WARNING

* * A JUMPER LEAn MUST BE CONNECTED BETWEEN THE CARTRIDGE TERMINALS TO * PREVENT UNINTENTIONAL DETONATION OF THE EXPLOSIVE CARTRIDGE. *

*

2. Connect jumper lead to cartridge terminals.

*

*

3. Remove electrical wires (12) from explosive cartridge (11). 4. Unscrew overboard discharge line (14) from fire extinguisher bottle.

5. Unscrew union nut froro discharge swivel (16). 6. Unscrew clamp nuts (9) and remove the extinguisher bottle (7).

Revision 14

*

BO 105 CHAPTER 853 Page 9

* * * * * * *

EUROCOPTER

853 - 7

MAINTENANCE MANUAL 80105

Installation - fire extinguisher bottle

* * NOTE The installation procedures for configuraton 1 (fig. 853-1) and 11 (fig. 853-2) are identical. * * * 1. The fire extinguisher bottle (7, figure 853-1) must be weighed per para

*

*

853-9 prior to its initial installation. 2. Check that fire extinguisher bottle (7) is in working order. 3. Position fire extinguisher bottle in both clamps (8). 4. Tighten union nut on discharge swivel (16) to 30 Nm. 5. Tighten nuts (9) on clamps.

* 6. Connect overboard discharge line (14). * * 7. Connect electrical wires (12) to explosive cartridge (11). * * 8. Remove jumper lead from cartridge terminals. 9. Perform functional check (refer to para 853-5). 853 -' 8

Replacement - explosive cartridge

* * 1. Pull out circuit breakers (19 and 23, figure 853-1) FlRE-EXT.I and

* * * * * * * * * * * * * * * * * *

FIRE-EXT.II and secure against unintentional pressing.

WARNING

A JUMPER LEAD MUST BE CONNECTED BETWEEN THE CARTRIDGE TERMINALS TO PREVENT UNINTENTIONAL DETONATION OF THE EXPLOSlVE CARTRIDGE.

2. Connect jumper lead to cartridge terminals. 3. Detach electrical wires (12) from explosive cartridge (11) andunscrew and

remove cartridge. 4. Connect jumper lead to terminals of new explosive cartridge. 5. Install new cartridge and torque-tighten to max. 20 Nm. 6. Connect electrical wires (12) to cartridge (11). 7. Remove jumper lead from cartridge terminals.

8. Perform functional check (refer to para 853-5).

BO 105 CHAPTER 853 Page 10

Revision 14

EUROCOPTER

853 - 9

MAINTENANCE MANUAL 80105

* *

Weighing - fire extinguisher bottle

*

1. Remove fire extinguisher bottle per para 853-6.

*

*

2. Weigh bottle together with the explosive cartridge.

* * 3. If the weight reading is more than 45.4 g (0.1 pound) less than the weight * recorded on the bottle identification plate, the bottle must not be *

reinstalled. * Instead, the removed fire extinguisher bottle shall be replaced with a new * one or returned to the bottle manufacturer for hydrostatic testing. *

* * * * 853 - 10 Disposal - explosive cartridge * * THE EXPLOSIVE CARTRIDGE SHALL BE DISPOSED OF AFTER ITS SERVICE * LIFE (COMBINED STORAGE AND IN-SITU TIME) HAS EXPIRED. ALL PERTI* CAUTION NENT SAFETY PRECAUTIONS SHALL BE STRICTLY OBSERVED. * CARTRIDGE DISPOSAL SHALL BE UNDERTAKEN ONLY BY AUTHORIZED PERSON- * NEL TRAINED IN THE HANDLING OF PYROTECHNIC EQUIPMENT. FOR THIS * PURPOSE, THE DEVICE SHOWN IN FIGURE 853-3 SHALL BE LOCALLY FABRI- * CATED. * * 1. Fabricate the disposal device as shown in fig. 853-3. Seat the end of the * pipe using one of the five possible closures shown in the figure. Use * firing leads that allow the cartridge to be detonated from a distance of * at least 1. 5 m. * * 2. Remove cartridge per para 853-8. * * 3. Screw cartridge into the pipe and connect the electrical leads. * * 4. Detonate cartridge by closing switch (2, figure 853-3). * * 4. Install fire extinguisher bottle per para 853-7.

*

Revision 14

BO 105 CHAPTER 853 Page 10A/B

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANU~L MBB - BO 105

-----VIEW

A

17

·7

6

7

'----9

n.1-----l0

5

4 VIEwD

17

800314

1

2

3

4 5 6 7 8 9

10 11

16

Overhead console -cartridge test switch 13WB -green lights 7WB Fire extinguisher bottles with delivery lines Spray nozzle Relay box 10VE Control panel Pressure gauge Fire extinguisher bottle Clamps Nut Discharge sensor Explosive cartridge

Fig. 853-1

15

14

13 12

11

12 Electrical wiresthermal relief sensor 13 Thermal valve 14 Overboard discharge line 15 Double check tee valve 16 Discharge swi vel 17 Discharge line (to spray nozzle) 18 Support frame 19 Circui t breaker 20 Fire switch 1 21 Amber annunciator 8WB 22 Fire switch 11 23 Circui t breaker 24 Cartr idge test switch 13WB 25 Green annunciator 7WB

Fire extinguishing system (configuration 1) BO 105 CHAPTER 853 Page 11/12

VIEwB VIEWC

19 3

20

21

22

23

24

I

25

EUROCOPTER

MAINTENANCE MANUAL 80 105

3

2 o

o

o

o ) o

el

.. ..

o

" " o

o

o

o

o

o

3

o

"

o

..

Sensor connectlon

c:

11

9

10

6

o

9

o

e

7

6

8

o

o

o

o

4

5

800315

1 2 3

4 5

6 7

8

Fire extinguisher bottle Support frame Thermal valve Rupture disk Connector Overboard discharge line Tee Overboard discharge line

Fig. 853-2

Revision 14

9 Spray nozzle 10 Bonding jumper 11 Explosive cartridge connection 12 Sensor connection (explosive cartridge) 13 Wiring harness 14 Conduit 15 Securing tape

Fire extinguishing system (configuration 11) BO 105 CHAPTER 853 Page 13

EUROCOPTER

MAINTENANCE MANUAL BO 105

*

8

'~

*

* *

Locking cap fabricated with external or internal thread or Locking cap welded on tube or cover welded in tube

* * *

, locking caps provided with one (3 + 0.2 mm dia.) hole and covers with one 3 + 0.2 mm día. hole or len l.Omm holes.

*

* * * * * * * * *

7-r~

~

9

~

/~

Thread type to match explosive cartridge thread

10

11

*

* * * * * * * * * * * *

*

* * * * * * * *

*

* * * * * * * * * * * *

2

BaUery, 28V Switch Eleetrieal wire A1llgator clip Explosive cartridge Pipe, wall thiekness 3.1 mm (Va ineh) Loeking cap or Loeking cap or Locking cap or Cover or Covar

800393

* *

Fig. 853-3

*

*

1 2 3 4 5 6 7 8 9 10 11

BO 105 CHAPTER 853. Page 14

Cartridge disposal device

Revision 14

MAINTENANCE MANUAL 80105

EUROCOPTER

854

MAIN ROTOR BLADE FOLDING SYSTEM

Table of Contents Page

Paragraph Title 854 - 1

DESCRIPTION - MAIN ROTOR BLADE FOLDING SYSTEM

3

854 - 2

INSPECTION SCHEDULE - MAIN ROTOR BLADE FOLDING SYSTEM

4

854 - 3

INSPECTION FOR CONDITION - MAIN ROTOR BLADE FOLDING SYSTEM

6

854 - 4

FOLDING ANO UNFOLDING OF MAIN ROTOR BLADES

7

Rev.~sion

10

BO 105 CHAPTER 854 Page 1/2

EUROCOPTER.

854 - 1

MAINTENANCE MANUAL BO 105

DESCRIPTION - MAIN ROTOR BLADE FOLDING SYSTEM

1. General The main rotor blade folding system (fig. 854-1) enables two opposite rotor blades to be swung through 90° in the direction of blade rotation so that a space-saving parallel arrangement of all four rotor blades along the fuselage centerline is obtained. 2. Description

NOTE

o The main rotor blades installed on the helicopter may be either type 1 or type 2 blades (these are described in more detail in chapter 14). The blade folding system to be used shall consist of blade folding cradles with blade supports which match the particular blade type. o The main rotor head may have either 4 secondary bolts or 4 locking lever assemblies installed. If 4 secondary bolts are installed, 2 opposing secondary bolts must be replaced with locking lever assemblies.

* * * * * * * * * *

The main rotor blade folding system comprises the following parts: - 2 locking lever assemblies (10, fig. 854-1)

- 1 forward blade folding cradle (2) with strut (12) - 1 rear blade folding cradle (3)

- fittings on fuselage and tail boom for attaching the blade folding cradles

* * * * *

*

- 1 demountable handling bar (1) for swinging the main rotor blades

folded position

*

- 2 clips (4) for retaining the folded main rotor blades

* *

Revision 10

RO 105 CHAPTER 854 Page 3

EUROCOPTER

• 854 - 2

MAINTENANCE MANUAL 80105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 854 Page4

Revision 18

EUROCOPTER

MAINTENANCE MANUAL 80 105

BLANK PAGE

Revision 18

CHAPTER 854 Page 5

EUROCOPTER

854 - 3

MAINTENANCE MANUAL BO 105

INSPECTION FOR CONDITION - MAIN ROTOR BLADE FOLDING SYSTEM

1. Inspect locking lever assembly (10, fig. 854-1). NOTE a.

b.

*

* * * * * * * *

Nickel-coated bolts P/N 105-13102.05 or salid-film lubricated bolts P/N 105-131035.05 may be installed. Inspect bolt (9) P/N 105-13102.05 with nickel plating for mechanical damage, corros ion and cracks. 1)

Minor mechanical damage to shank of bolts which does not prevent the bolts from being fitted by hand into bushes of blade mounting forks is acceptable and need not be reworked.

2)

More severe damage, for example scratch ridges and upset material at notches, which prevents easy assembly of the bolts, must be removed with polishing cloth. The nickel plating must not be removed down to the base metal of the bolt.

3)

Replace bolt if nickel plating of bolt is removed down to the base metal. Send unserviceable bolts to manufacturer (ECD) for re-coating. Repair by re-coating is permissible only if mechanical or corros ion damage to base metal of bolt does not exceed a depth of 0.05 mm.

4)

Perform a magnetic particle crack inspection in accordance with MIL-STD-1949 or dye penetrant crack inspection in accordance with MIL-STD-6866. If cracks are revealed, replace bolt or entire locking lever assembly.

Inspect bolt (9) coated with solid film lubricant (P/N 105-131035.05) for cracks, mechanical damage and condition of solid film lubricant coating. NOTE

When the penetrant method of crack inspection is used, the solid film lubricant coat must be removed completely from the bolt. If the solid film lubricant coat is to be retained, it is preferable to use the magnetic.particle method.

1)

Perform crack inspection using the magnetic particle method per MIL-STD-1949 or penetrant method per MIL-STD-6866, as applicable. Discard cracked bolt or complete locking lever assembly, as required.

2)

Mechanical damage such as individual scores, nicks and scratches which extend through the solid film lubricant coat and penetrate the base metal shall be polished out using 400 grit abrasive cloth.

3)

The solid film lubricant coat may be worn down to the base metal of the bolt on the entire coated surface. Polish out scores, nicks and scratches in the solid film lubricant coat using 400 grit abrasive cloth. The diameter of the bolt shank shall not be less than 17.965 mm.

BO 105 CHAPTER 854 Page 6

Revision 12

MAINTENANCE MANUAL BO 105

EUROCOPTER

c.

Inspect locking lever (11) for condition and sufficient spring tension. Replace if damaged or not enough spring tension.

d.

Inspect pip pin (5) for condition and correct functioning of self-locking mechanism. Discard pip pin if damaged.

e.

Inspect safety cord (7) for condition. Replace safety cord if damaged.

2. Inspect handling bar (1), main rotor blade folding cradles (2 and 3), strut (12) and clip assemblies (4) for darnage: a.

Polish out rnechanical damage and corrosion on clip assemblies with polishing cloth.

b.

Re-bond rubber strips on rnain rotor folding cradles and handling bar with adhesive (CM 601) or replace as necessary.

c.

Repair or replace deforrned rnain rotor blade folding cradles, strut or handling bar.

854 - 4 CAUTION

FOLDING AND UNFOLDING OF MAIN ROTOR BLADES DURING FOLDING AND UNFOLDING OF MAIN ROTOR BLADES DO NOT RELEASE ROTOR BRAKE. DO NOT SWITCH ON HYDRAULIC SYSTEM. IN FOLDED CONDITION OF BLADES DO NOT ACTUATE MAIN ROTOR CONTROLS SINCE CONTROL INPUTS WOULD RESULT IN SERIOUS DAMAGE. IF THE BLADE FOLDING SYSTEM IS FITTED FOR THE FIRST TIME,. TAKE CARE TO ADJUST MAIN ROTOR CONTROL RIGGING ACCORDINGLY PER CHAPTER 102.

1. Folding of main rotor blades.

a.

Position the two rnain rotor blades not to be folded along the helicopter centerline.

b.

Actuate rotor brake and lock in position.

C.

Push collective lever down to minimum pitch stop, and place cyclic stick in neutral position. NOTE

Do not lock collective lever or cyclic stick to ensure free movernent during folding procedure.

d.

Using pip pins (13) secure rnain rotor blade folding cradles (2 and 3, fig. 854-1) to mating fittings. Additionally secure forward blade folding cradle, using strut (12). Fit unfolded blades in lower blade support of blade folding cradles.

e.

Slide handling bar (1) over one of the two foldable rnain rotor blades.

Revision 12

BO 105 CHAPTER 854 Page 7

EUROCOPTER

MAINTENANCE MANUAL

eo 105

* *

f.

Fold open locking lever (11) of locking lever assy (10) to fu11 extent.

*

g.

Lift main rotor blade with handling bar (1) until bolt (9) can be removed by lightly turning the locking lever (11).

h.

Insert bolt (9) through mounting bore (8) of control lever into bore 0f oil seal retainer (6) and secure with pip pin (5).

i.

Using handling bar (1), carefully turn main rotor blade in the direction of rotor rotation until in line with the retained unfolded blade. Then fit it in the upper blade support of the blade folding cradle.

j.

Applya coat of grease (CM 101, CM 102 or CM 120) or corros ion preventive compound (CM 505) to bolt ends of clip (4), then install clip by inserting short bolt end in secondary bolt mating hole in inner sleeve and long bolt end in secondary bolt mating hole in blade root fitting. Rotor blade is secured.

k.

Remove handling bar from folded and secured main rotor blade.

l.

Fold second main rotor blade as described in steps e. to k.

*

* * * * * * * * * *

2. Unfolding of main rotor blades.

* * * * * * * * * * * * * * * * * * *

a.

Slide loop end of handling bar (1) over one of the two folded blades.

b.

Slightly lift main rotor blade and remove clip assembly (4).

c.

Carefully swing main rotor blade to its normal operation position and align bolt (9) mating holes.

d.

Remove pip pin (5) and withdraw bolt (9) from mounting bore (8).

e.

Prior installation of bolt (9) check pip pin (5) for correct function and locking lever (11) for sufficient spring tension.

f.

If bolt (9) is not coated with solid film lubricant, apply grease (CM 101, CM 102 or CM 120), corros ion preventive compound (CM 505) or lubricant (CM 146) .

g.

If new bolt (9) with solid film lubricant coating is installed, degrease mating bushing bores in blade mounting fork and blade root _fitting with acetone (CM 202) and dry install new bolt. Reinstall used bolt coated with solid film lubricant, using lubricant (CM 146) .

h.

Insert bolt (9) into flange bushing for secondary bolt.

BO 105 CHAPTER 854 Page 8

Revision 10

EUROCOPTER

MAINTENANCE MANUAL 80 105

i.

Fold locking lever (11) of locking lever assembly (10) full down. * Wrap safety cord (7) around locking lever (11) until remaining free * lenghth of safety cord is just sufficient to allow insertion of pip pino * Secure locking lever assembly with pip pino *

j.

Check locking lever and pip pin correct safetying.

k.

Remove handling bar from main rotor blade.

l.

Accomplish unfolding procedure for second main rotor blade in accordance with steps a. to j.

Revision 10

*

* *

*

BO 105 CHAPTER 854 Page 9/10

EUROCOPTER

MAINTENANCE MANUAL BO 105

DETAlL

A

3

1 Handling bar 2 Blade folding cradle, forward 3 Blade folding cradle, aft 4 Clip assembly 5 Pip pin 6 Oil seal retainer 7 Safety cord 8 Mounting bore for bolt (9) 9 BoH 10 Locking lever assembly (comprising items 5, 7, 9 and 11) 11 Locking lever 12 Strut 13 Pip pin 14 Blade support ~ 15 Blade support 1

13

4

,/'

-

,/

5 './

6 7

2-

DETAlL

~ Note different type blade supports for type 1 and type 2 main rotor blades. Refer to IPC for respective p/Ns.

DETAILB 1 10

9

8

800316

Fig. 854-1

Revision 10

Main rotor blade folding system BO 105 CHAPTER 854 Page 11/12

D

/

DETAlL

e

MAINTENANCE MANUAL BO 105

EUROCOPTER

855 GROSS MASS 2,500 KG 855 - 1

General

Helicopters SO 105 CS CS-2 CON-S CSS CSS-2 CON-SS OS OSS up to and including S/N 750 may be operated at a max. gross mass of 2,500 kg if equipped with 2.500 kg- kit 105-80026 or otherwise meet the following conditions (also refer to SS 80-77): 1. The longitudinal control range must be -10.5 o to +5.5 o • 2. The adjusting range of the pilot seat must be shortened to the front to ensure freedom of movement of cyclic stick with an extended travel in the "Pull" direction (respective stops provided on seat rails). 3. The tail rotor must be fitted with blades of the asymmetrical profile type (S 102E). 0

4. The tail rotor control range must be _8 to +17"30' . 5. The triple RPM indicator must have beside the green N2-RPM range of 95% - 102%, and additional green range of 98% - 102%. 6. The main rotor blades must be equipped with vibration absorbers. 7.

Bellcrank 105-43010 (crank lengths: 110/87.5 mm) must be installed on intermediate gearbox.

8.

For rigging of controls refer to chapter 102.

NOTE

Revision 17

Maintenance-related instructions are incorporated in the basic part of this maintenance manual. Special inspections are not required for "Gross Mass 2.500 kg".

CHAPTER 855 Page 1

I

EUROCOPTER

MAINTENANCE MANUAL BO 10S

BLANK PAGE

CHAPTER 855 Page 2

Revision 17

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 856

ATTACH FITTINGS - MULTIPURPOSE PYLON

Table of Contents

Paragraph

Titel

Page

856 - 1

DESCRIPTION - ATTACH FITTINGS-MULTIPURPOSE PYLON

3

856 - 2

INSPECTION SCHEDULE - ATTACH FITTINGS-MULTIPURPOSE PYLON

4

856 - 3

INSPECTION FOR CONDITION - ATTACH FITTINGS-MULTIPURPOSE PYLON .

5

BO 105 CHAPTER 856 Page 1/2

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

856 - 1

DESCRIPTION - ATTACH FITTINGS-MULTIPURPOSE PYLON

Attach fittings are installed at frames 7 and 9 on both sides of the helicopter for the installation of a multipurpose pylon. The support fittings located at frames 8 and 10 provide for attachment of the struts for the multipurpose pylon. The attach fittings at frame 7 are equipped with spherical bearings which are secured by means of cla~ bushings. Bushings are installed in the attach fittings of frame 9. The support fitting at frame 10 is equipped with a spherical bearing.

BO 105 CHAPTER 856 Page 3

EUROCOPTER

• 856 - 2

MAINTENANCE MANUAL BO 10S

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 856 Page4

Revision 18

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INSPECTION FOR CONDITION - ATTACH FITTINGS-MULTIPURPOSE PYLON

856 - 3

Special tool: Pressing-in tool l.

2.

3.

105-21832 W1

Inspect attach fittings (1, 2 and 5, figure 856-2) for deformation, cracks, corrosion and other mechanical damage. a.

Replace fitting if deformed or if cracks are evident.

b.

Polish out corrosion and mechanical damage, using polishing cloth 400. For damage and rework limits refer to figure 856-1.

Inspect spherical bearings (3, figure 856-2) of attach fittings (1 and 2) for play, ease of movement and corrosion. a.

If play is evident between spherical bearing and claw bushing, reseat claw bushing to ensure tight fit, using tool 105-21832 W1.

b.

Replace spherical bearing in the case of radial play (0.1 mm permissible) or corrosion, or if ease of movement is impaired (refer to chapter 02).

Inspect bushings (6, figure 856-2) of attach fittings (5) for mechanical damage and wear. a.

Polish out mechanical damage, using polishing cloth 400.

b.

Check dimensional accuracy after rework or if wear is suspected. Maximum permissible diameter 12.03 mm or 15.03 mm. It may be exceeded by 0.02 mm on one quarter of the circumference. If the maximum permissible diameter is exceeded, replace bushing as follows: 1)

Heat fitting to approx. 80 OC and remove bushing with a suitable tool. Make sure not to deform the fitting.

2)

Inspect bores in fittings for condition. Polish out minor mechanical damage, using polishing cloth 400. Maximum permissible diameter 16.02 mm or 19.03 mm. Local scratches or scores may be polished out, however, the reworked area must not exceed one quarter of the circumference. Replace fitting if specified dimensions are exceeded.

3)

Apply corrosion preventive paste (CM 510) to bore.

4)

Chill bushing to approx. -50 oC and fit it in such that the flange fully rests on the fitting.

5)

Hone bushing to the following diameters: 12.0 + 0.018 mm or 15.0 + 0.018 mm, respectively.

BO 105 CHAPTER 856 Page 5

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800329

TYPE OF DAMAGE

DAMAGE AND REWORK LIMITS ZONE 1

-

ZONE 2

ZONE 3

ZONE 4

111

Mechanical

0 .25 mm in depth on depth on 50% of the 50% of the zone surface zone surface

0.25 mm in depth on 50% of the zone surface

0.75 mm in depth on 50% of the zone surface

Corros ion

0.15 mm in O. 10 mm in depth before depth before and 0.25 mm and 0.15 mm after repair after repair on 50% of on 50% of the zone the zone surface surface

0.15 mm in depth before and 0.25 mm after repair on 50% of the zone surface

0.5 mm in depth before and 0.75 mm after repair on 50% of the zone surface

O. 15 mm in

Exfo1iation corros ion genera11y not allowed in all zones. Round off darnaged areas with a transition radius of at least 10 mm. Figure 856-1 BO 105 CHAPTER 856 Page 6

Attach Fittings - damage and rework limits

- - - - - - ' - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4.

5.

6.

7.

Inspect support fittings (4, figure 856-2) for deformation, cracks, corrosion, and other mechanical damage and inspect bores for wear. a.

Replace fitting if deformed or if cracks are evident.

b.

Polish out corrosion and mechanical damage, using polishing cloth 400. For damage and rework limits refer to figure 856-1, zone 3.

c.

Maximum permissible bore diameter 8.02 mm. It may be exceeded by 0.03 mm along one quarter of the bore circumference.

Inspect attach fittings (7, figure 856-2) for deformation, cracks, corrosion and other mechanical damage. a.

Replace fitting if deformed or if cracks are evident.

b.

Polish out corrosion or mechanical damage, using polishing cloth 400. For damage and rework limits refer to figure 856-1.

Inspect bushings (8, figure 856-2) of attach fittings (7) for mechanical damage and wear. a.

Polish out mechanical damage, using polishing cloth 400.

b.

Check dimensional accuracy after rework or if wear is suspected. Maximum permissible diameter 12.03 mm or 15.03 mm. It may be exceeded by 0.02 mm along one quarter of the circumference. If the maximum permissible diameter is exceeded, replace bushing as follows: 1)

Heat fitting to approx. 80 OC and remove bushing with a suitable tool. Make sure not to deform the fitting.

2)

Inspect bores in fittings for condition. Polish out minor mechanical damage, using polishing cloth 400. Maximum permissible diameter 16.02 mm or 19.03 mm. Local scratches or scores may be polished out, however, the reworked area must not exceed one quarter of the circumference. Replace fitting if specified dimensions are exceeded.

3)

Apply corrosion preventive paste (CM 510) to bore.

4)

Chill bushing to approx. -50 oC and fit it in such that the flange fully rests on the fitting.

5)

Hone bushing to the following diameters: 12.0 + 0.018 mm or 15.0 + 0.018 mm, respectively.

If the landing gear is removed, also inspect bushings (9, figure 856-2) according to step 6. The permissible diameter is 15.1 mm. It may be exceeded by 0.02 mm along one quarter of the circumference. If the bushing has been removed, hone replacement bushing to the following diameter: 15.0 + 0.018 mm.

BO 105 CHAPTER 856 Page 7

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - . . . , . . . . - - - MAINTENANCE MANUAL MEB - BO 105

8.

Inspect support fittings (10, figure 856-2) for deformation, cracks, corrosion and mechanical damage. a.

Replace fitting if deformed or if cracks are evident.

b.

Polish out corrosion or mechanical damage, using polishing cloth 400. For damage and rework limits refer to figure· 856-1, zone 3.

9.

Inspect spherical bearing (11, figure 856-2) of support fittings (10) for radial play (0.1 mm permissible), ease of movement and corrosion. If signs of the above mentioned damage are evident, replace support fitting together with spherical bearing.

10.

Inspect all fittings for damaged surface protection and touch up in accordance with chapter 02, if necessary, using the original lacquer coating of the helicopter.

BO 105 CHAPTER

Page 8

856

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Frame 7

...

Frame 8

Frame 9 rore Frame 9 aft

,

. Frame 10

"

"

"

" 5

Attach fitting Attach fitting 3 Spherical bearing 4 Support fitting 5 Attach fitting 6 Bushing 7 Attach fitting 8 Bushing Bushing 10 Support fitting 11 Spherical bearing 1

2

69

6

Figure 856-2

2

. . ..

Inspection of bushings (9) shall only be performed with the landing gear removed; refer to chapter 51

Attach fittings-multipurpose pylon BO 105 CHAPTER 856 Page 9/10

800328

VIEwA

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

---------'-----~MBB

857

C O N T I N U O U S I G N I T ION

S YS TEM

Table of Contents Page

Paragraph

Title

857 - 1

DESCRIPTION - CONTlNUOUS IGNITION SYSTEM . .

3

857 - 2

TROUBLESHOOTING - CONTlNUOUS IGNITION SYSTEM

4

857 - 3

INSPECTION SCHEDULE - CONTlNUOUS IGNITION SYSTEM

5

857 - 4

INSPECTION FOR CONDITION - CONTINUOUS IGNITION SYSTEM

6

857 - 5

FUNCTIONAL TEST - CONTINUOUS IGNITION SYSTEM

6

857 - 6

Removal - Noise Suppressor .

7

857 - 7

Installation - Noise Suppressor

7

Revision 1

BO 105 CHAPTER 857 Page 1/2

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - ' - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 857 - 1

DESCRIPTION - CONTlNUOUS IGNITION SYSTEM

The eontinuous ignition system is intended for flights in snow. It is designed to prevent the oeeurrenee of engine failure as a result of snow being ingested into the engines. To provide for eontinuous ignition the wlrlng of the standard starter and ignition system (see Chapter 92) has been modified and eaeh ignition system retrofitted with a noise suppressor to obtain eleetromagnetie eompatibility with the radio and navigation systeros. The noise suppressors are installed on the deek of eaeh engine bay at approximately STA 3900. The eontinuous ignition system is switehed on and off by means of toggle switehes CONT IGN ENG 1 (104J) and CONT IGN ENG 2 (204J) installed in the horizontal seetion of the instrument panel. The eontinuous ignition system is supplied with power froro main bus PP21 through the STARTER-IGNITION eireuit breaker 1J.

Revision 1

BO 105 CHAPTER 857 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 857 - 2

TROUBLESHOOTING - CONTINUOUS IGNITION SYSTEM

General Troubleshoot in conjunction with wiring diagrams 857 in the Wiring Diagram Manual (WDM). For additional information concerning starter and ignition system troubleshooting, refer to Chapter 92. . No.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Ignition of ENG 1 or ENG 2 not possible

Defective ignition switch 104J or 204J

Check ignition switch and replace as necessary

Faulty wiring

Check wlrlng according to wiring diagram and repair or replace as necessary

Defective noise suppressor

Check filter output voltage (28 VDC) and replace noise suppressor as necessary (refer to paras 857-6 and 857-7)

Defective ignitionbox

Check output signal of ignition-box and replace ignition-box as necessary

Defective spark igniter

Check spark igniter (refer to para 857-4) and replace as necessary

Defective noise suppressor

Replace relevant noise suppressor (refer to paras 857-6 and 857-7)

2

Interference in a radio or navigation system, or in engine monitoring system during operation of the continuous ignition system

Table 857-1

BO 105 CHAPTER 857 Page 4

Troubleshooting

Revision 1

EUROCOPTER

857 - 3

Revision 18

MAINTENANCE MANUAL BO 105

•

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 857 Page5

------'----------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 857 - 4 l.

INSPECTION FOR CONDITION

3.

CONTINUOUS IGNITION SYSTEM

Clean spark igniters and inspect for fretting wear and chafe marks (refer to Allison 250-C20, C20B Series Operation and Maintenance Manual) . IF THE SEMICONDUCTOR MATERIAL OF THE INSULATOR EXHIBITS FRETTING WEAR IN EXCESS OF 3 mm, REPLACE SPARK IGNITER.

CAUTION 2.

~

Inspect noise suppressor for damage and security. a.

Replace damaged noise suppressor (refer to paras 857-6 and 857-7) .

b.

If ignition noise filter is loose, tighten attaching hardware.

Wherever possible, inspect electrical leads, connectors and connecting hardware for correct routeing, condition and tight and secure fit. a.

Remove corrosion from lug terminals and connecting hardware or replace affected parts.

b.

Tighten loose connections and loose attaching hardware.

c.

Repair or replace damaged electrical leads.

857 - 5

FUNCTIONAL TEST - CONTINUOUS IGNITION SYSTEM

l.

Energize external power source and press STARTER-IGNITION circuit breaker 1J in instrument panel.

2.

Switch on CONT-IGN ENG 1 toggle switch 104J. Ignition noises (chattering) must be clearly audible at No. 1 engine.

3.

Switch off toggle switch 104J and switch on CONT-IGN ENG 2 toggle switch 204J. Ignition noises (chattering) must be clearly audible at No. 2 engine.

4.

Switch off toggle switch 204J, pull circuit breaker 1J, and deenergize external power source.

BO 105 CHAPTER 857 Page 6

Revision 1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 857 - 6 NOTE

Removal - Noise Suppressor Removal and installation is identical for both noise suppressors. The following instructions apply to the noise suppressor in the left engine bayo The identification codes in parentheses apply to the noise suppressor in the right engine bayo

1.

Remove engine cowlings and panelling of the cargo compart roof.

2.

Disconnect lead 10SJ (20SJ) (refer to fig. 857-1) and associated shield (3) by removing the lug terminals (4 and 5) on the ignition-box.

3.

Cut through lead J1F20 (J2F20) at splice (2) 104SVV (1046VV).

4.

Remove sealing compound (10) from between noise suppressor (8) and engine bay deck.

5.

Remove attaching hardware (9, 11 and 12) and remove noise suppressor (8) from engine bay. Note installed position.

6.

Using hot air gun, heat solder sleeve (6) on lead 10SJ (20SJ) and pull out shield (3) from under solder sleeve.

857 - 7

Installation - Noise Suppressor

1.

Provide output lead of replacement noise suppressor with lead-identifying shrink sleeve (7, fig. 857-1) marked 10SJ (20SJ).

2.

Siide new solder sleeve (6) over lead 10SJ (20SJ) and push previously removed shield (3) under solder sleeve. Shrink on solder sleeve, using hot air gun.

3.

Provide lead 10SJ (20SJ) with replacement lug terminal (5).

4.

Attach noise suppressor (8) to engine deck with screws (9), washers (11) and nuts (12).

5.

Connect lead 10SJ (20SJ) and shield (3) to ignition-box using lug terminals (4 and 5) .

6.

Connect noise suppressor input lead to lead J1F20 (J2F20) using replacement splice (2) 104SVV (1046VV).

7.

Perform functional test (refer to para 857-5).

8.

Fill gap between noise suppressor (8) and engine deck on all sides with sealing compound (CM 635) (10).

9.

Coat connection of shield (3) to ignition-box with corrosion preventive lacquer (CM 501) .

10. Install cargo compartment roof panelling and engine cowlings.

Revision 1

BO 105 CHAPTER 857 Page 7

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

3

4

2

ZUENDBOX IGNITIONBOX

J1F20 (J2F20)

105J (205J) 7

6

5

FILTER

8

9

0857-1

Lead-identifying shrink sleeve 104SVV (1046VV) 2 Splice 104SVV (1046VV) 3 Shield 4 Lug terminal 5 Lug terminal 6 Solder sleeve 1

Figure 857-1

BO 105 CHAPTER 857 Page 8

Lead-identifying shrink sleeve 10SJ (20SJ) 8 Noise suppressor 9 Screw 10 Sealing compound 11 Washer 12 Nut 7

Removal and Installation - Noise Suppressor

Revision 1

EUROCOPTER

MAINTENANCE MANUAL BO 105

858

YAW B RAKE

(Standard equipment in helicopters S/N 890 and subsq., and is retrofitted per SB-B0105-30-103 in helicopters S/N 889 and prior)

Table of Contents Paragraph

Title

858 -

DESCRIPTION - YAW BRAKE

3

INSPECTION ANO MAINTENANCE - YAW BRAKE

3

1

858 - 2

Revision 11

Page

BO 105 CHAPTER 858 Page 1/2

EUROCOPTER

858 - 1

MAINTENANCE MANUAL BO 105

DESCRIPTION - YAW BRAKE

The yaw brake prevides tor improved helicopter yaw stability in torward tlight with teet off the pedals. It consists mainly ot the plates to which brake Iining is bonded and ot the lever. Tightening ot the Nylstop nuts creates triction between both plates and the lever, which affects the pedal breakout torces. The yaw brake is only required tor tail retor blades with a 1-degree coning angle, not tor tail rotor blades with a Q-degree coning angle.

858 - 2

NSPECTION AND MAINTENANCE - VAW BRAKE

•

1. For Inspection Schedule, reter to Chapter 101, Tail rotor control. 2. For removal, inspection tor condition and installation, reter to Chapter 42. 3. For adjustment ot the yaw brake, reter to Chapter 102.

Revision 18

CHAPTER 858 Page3

EUROCOPTER

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 858 Page4

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

859

WlRE

STRIKE

PROTECTION SYSTEM

(WSPS)

Table of Contents

Page

Paragraph

Title

859 - 1

DESCRIPTION - WSPS

3

859 - 2

INSPECTION SCHEDULE - WSPS

4

859 - 3

INSPECTION FOR CONDITION - WSPS

6

859 - 4

REMOVAL - WSPS

7

859 - 5

INSTALLATION - WSPS

8

Revision 13

BO 105 CHAPTER 859 Page 1/2

EUROCOPTER

859 - 1 1.

MAINTENANCE MANUAL 80 105

DESCRIPTION - WSPS

General The purpose of WSPS is to deflect and cut wires encountered by the helicopter in forward flight. WSPS installation provides the helicopter with a measure of frontal protection against impact damage from horizontally strung mechanical, power and cornrnunication wires and cables.

2.

Description The WSPS consists of the following components: - upper deflector and cutter assembly (1, Fig. 589-1) - windshield centerpost deflector (2) - windshield wiper deflector (3) - nose deflector (4) - lower deflector and cutter assembly (5) - skid gear deflector (6).

Revision 13

BO 105 CHAPTER 859 Page 3

EUROCOPTER

11

859 - 2

MAINTENANCE MANUAL 80 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 859 Page 4

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MAINTENANCE MANUAL BO 105

EUROCOPTER

859/1-01

1 Deflector and cutter assembly, upper 2 Windshield centerpost deflector 3 Windshield wiper deflector

4 Nose deflector Deflector and cut ter assembly, lower 6 Skid gear deflector

5

Figure 859-1 General view - WSPS

Revision 13

BO 105 CHAPTER 859 Page 5

EUROCOPTER

859 - 3

MAINTENANCE MANUAL

eo 105

INSPECTION FOR CONDITION - WSPS

1.

Inspect cutter blades (16 and 38, figure 859-2) for notches and sharpness of cutting edges. Replace notched or dulled blades. Install new cutter blades with sealing compound (CM 622). See figure 859-2 for torque values.

2.

Inspect WSPS for mechanical and corrosion damage, deformation and cracks. Replace cracked or deformed components. Polish out mechanical and corrosion damage and sharp-edged notches using 400-grit abrasive cloth.

3.

Check individual WSPS components for security of attachment. Apply sealing compound to areas where sealing compound is missing and tighten loose attaching hardware. See figure 859-2 for torque values.

4.

Inspect WSPS for damaged protective finish. Touch up damageo areas per Chapter 02.

BO 105 CHAPTER 859 Page 6

Revision 13

EUROCOPTER'

859 - 4

MAINTENANCE MANUAL BO 105

REMOVAL - WSPS

1.

Remove upper deflector and cutter assembly (1, figure 859-2), shims (2), and stabilizer struts (3 and 7) by removing attaching hardware (5, 6 and 8, 10, 11).

2.

Remove windshield wiper deflector (19) and insert (23) by removing attaching hardware (20, 21, 22 and 24, 25, 26).

3.

Remove insert (4) and windshield centerpost deflector (17) by removing attaching hardware (47, 48 and 9, 10, 11).

4.

Remove nose deflector (28) by removing quick-release pin (27) and bolt (29), washer (30) and cotter pin (31).

5.

Remove slotted strip (12) by removing screws (18).

6.

Remove lower deflector and cutter assembly (39) and stabilizer struts (36 and 37) by removing attaching hardware (32, 33 and 34, 35).

7.

Remove skid gear deflectors (40) by removing attaching hardware (41, 42, 46 and 43, 44, 45).

Revision 13

BO 105 CHAPTER 859 Page 7

EUROCOPTER

859 - 5

MAINTENANCE MANUAL BO 105

INSTALLATION - WSPS

1.

Install skid gear deflectors (40, figure 859-2) on skids with attaching hardware (41, 42, 46 and 43, 44, 45). See figure 859-2 for torque values.

2.

Install lower deflector and cutter assembly (39) and stabilizer struts (36 and 37) on fuselage with attaching hardware (32, 33 and 34, 35). See figure 859-2 for torque values.

3.

Install slotted strip (12) on fuselage with screws (18).

4.

Install nose deflector (28), using bolt (29), washer (30), cotter pin (31) and quick release pin (27).

5.

Apply sealing compound (CM 622) to faying surfaces of windshield centerpost deflector (17). Pesition insert centerpost deflector in slotted strip (12) and secure hardware (9, 10, 11 and 47, 48). See figure 859-2 for

6.

Apply sealing compound (CM 622) te faying surfaces of insert (23) and windshield wiper deflector (19). Attach windshield wiper deflector (19) and insert (23) to slotted strip with attaching hardware (20, 21, 22 and 24, 25, 26). See figure 859-2 fer torque values.

7.

Apply sealing compound (CM 622) to faying surfaces of shims (2) and deflector and cutter assembly (1), as applicable. Pesition shims and deflector and cutter assembly with the attached stabilizer struts (3 and 7) in slotted strip and secure to fuselage and slotted strip with attaching hardware (5, 6 and 8, 10, 11, respectively). See figure 859-2 for torque values.

BO 105 CHAPTER 859 Page 8

insert (4) and and windshield with attaching terque values.

Revision 13

MAINTENANCE MANUAL BO 105

EUROCOPTER 1

2 3

4 5 6 7 8 9

10 11 12

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37

38

39 40

41 42 43

44 45 46

47 48

Deflector and cutter assembly, upper Shim Stabilizer strut, upper RH Insert Screw Washer Stabilizer strut, upper LH Screw Screw Washer Nut Slotted strip Screw Washer Nut Cutter blades (4 off) Windshield centerpost deflector Screw Windshield wiper deflector Screw Washer Nut DETAlL Insert Screw \\----28 Washer Nut 29 ------:~."'_A Quick release pin Nose deflector Bolt Washer Cotter pin 38------... Washer Screw 37----.----""'""'lClI1~ Washer Screw ' - - - - - 15--../ Stabilizer strut, 14 lower LH Stabilizer strut, lower RH Cutter blades (3 off) Deflector and cutter assembly, lower 14 13 38 Skid gear deflector 35 Bolt Washer Bolt Washer 39 Nut Nut Screw Washer

A

11.5·l Nml I

16

L-15-~~~ 14

~'.::WJ.i.'

2----tl~~~

14-----'

13---'"

,,

e

.~.•.J.

Figure 859-2 Revision 13

DETAlL

Removal and Installation - WSPS

DETAlL

,,

,,

,

10

B

"

1111.5-2.1 Nml " , ,

,

10

25

11

12

.

~1.5-2,1 Nml

16.8-Y Nml 44 45

34

'" / Ji ......

" ""

Nml

BO 105 CHAPTER 859 Page 9/10

28

",

,

",'"

. i-, '-o

.... , \

l, o

'\

:JI

' ..... "'-1,

/,

..... '1

' ......

." ",

, ," '

DETAlL

O

--- ---~2

461 16 -22 Nml 859/2-01

EUROCOPTER

MAINTENANCE MANUAL BO 105

860

ENGINE AIR CLEANER - BLOWER PURGE

Table of Contents

Page

Paragraph

Title

860 - 1

DESCRIPTION - ENGINE AIR CLEANER

3

860 - 2

TROUBLESHOOTING - ENGINE AIR CLEANER

4

860 - 3

INSPECTION SCHEDULE - ENGINE AIR CLEANER

6

860 - 4

INSPECTION FOR CONDITION - ENGINE AIR CLEANER

9

860 - 5

FUNCTIONAL TEST - ENGINE AIR CLEANER

860 - 6

REMOVAL - ENGINE AIR CLEANER

. .

12

860 - 7

INSTALLATION - ENGINE AIR CLEANER

12

Revision 14

10

BO 105 CHAPTER 860 Page 1/2

EUROCOPTER

860 - 1 1.

MAINTENANCE MANUAL BO 105

DESCRIPTION - ENGINE AIR CLEANER

General The engine air cleaner separates solid particles, such as sand and dust, from the engine intake air, thus protecting engine parts, especially the compressor, from erosiono The separated contaminants are sucked out of the air cleaner housing and discharged overboard.

2.

Description The system comprises a roof-mounted particle separator with 2 electric scavenge blowers, a SANDFILTER switch, a SANDF. caution light, an enlarged oil cooler with modified air intake and a seal assembly to cover openings in the cowling around the main rotor mast and control rods. The particle separator housing and the swirl tube panels are fitted with an electrically-driven bypass door on the forward face.

3.

Operation Dirt particles are separated from the air flowing through the swirl tubes and then discharged overboard by two electrical blowers. The SANDFILTER switch on the overhead console supplies power to a bypass-door actuator, mounted in the separator housing, for opening and closing functions and to the two scavenge blowers. When power is supplied to the system, the LH blower (I) comes irnmediately while the bypass door begins to close. After approx. 2 seconds, the bypass door reaches its closed position and the RH blower (II) comes on. During normal functioning the SANDF. caution light will come on momentarily whenever the bypass door is in transito The system is supplied 28 V DC from the Main Bus PP21 (or Emergency Bus PP20 if installed) via the SANDFILTER circuit breaker on the center console switch panel. The scavenge blowers are powered from the Main Bus PP21 each via separate circuit breakers. SANDF. BLWR I and SANDF. BLWR II also located on the center console switch panel. Therefore, should both generators fail, the blowers will no longer be powered as indicated by the SANDF. caution light coming on. However, the bypass door will continue to function. Whenever the helicopter is on the ground for an extented period of time, close the particle bypass door and install the particle separator protective cover.

Revision 14

BO 105 CHAPTER 860 Page 3

MAINTENANCE MANUAL BO 105

EUROCOPTER

860 - 2

TROUBLESHOOTING - ENGINE AIR CLEANER

General -

Refer to wiring diagram 860-1 in the Wiring Diagram Manual (WDM). Inspect electrical connections to actuator and blowers for tight installation.

-

Check mechanical functioning of switches and circuit breakers. Connect external power supply (EPU). Set battery switch on instrument panel to BATT OFF/EPU ON.

-

Push in circuit breaker 1KC.

NO.TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1. High engine exhaust temperature (T4)

Dirty separator tubes

Inspect air cleaner panels and clean as necessary

2. Bypass door opens or does not close

Defective circuit breaker 1KC

Check continuity of circuit breaker and replace as necessary

Defective toggle switch 4KC

Check toggle switch and replace as necessary

Faulty wiring between main busbar PP21 or emergency busbar 20 and bypass door actuator

Check continuity of wiring using wiring diagram; repair or replace wiring as necessary

Poorelectrical connector contact

Check connector; remove any corrosion; replace connector as necessary

Either one of the actuator limit switches defective

Inspect limit switches, and replace actuator as necessary

Defective actuator winding

Check continuity of actuator; replace actuator if defective

Table 860-1

BO 105 CHAPTER 860 Page 4

Troubleshooting (1 of 2)

Revision 14

EUROCOPTER

MAINTENANCE MANUAL 80 105

TROUBLESHOOTING (continued) NO.TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

3. Blower 1 or Blower II not working

Defective circuit breaker SKC or 8KC

Check continuity of circuit breaker and replace as necessary

Defective relay 9KC or 10KC

Check relay for continuity and replace as necessary

Defective blower motor 6KC or 7KC

Check blower motor and replace as necessary

Faulty wiring between main busbar 21 and blower motor

Check continuity of wiring using wiring diagram; repair Qr replace wiring as necessary

Defective diode 16KV or 17KC

Check diode for continuity and replace as necessary

Defective toggle switch 4KC

Check toggle switch and replace as necessary

4. Blower 1 and Blower II not working

Table 860-1

Revision 14

Troubleshooting (2 of 2)

BO 105 CHAPTER 860 Page 5

EUROCOPTER

860 - 3

MAINTENANCE MANUAL 80 105

INSPECTION SCHEDULE (refer to Chapter 101)

CHAPTER 860 Page6

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

BLANK PAGE

Revision 18

CHAPTER 860

Page7

EUROCOPTER

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 860 Paga 8

Revision 18

EUROCOPTER

INSPECTION FOR CONDITION - ENGINE AIR CLEANER

860 - 4 l.

MAINTENANCE MANUAL BO 105

Inspect air cleaner housing and bypass door for mechanical damage, corrosion, and secure installation. a.

Replace cracked parts.

b.

Polish out corroded areas with 400 grit abrasive cloth, and restore surface protection.

c.

Tighten loose screws.

d.

Apply grease (CM 101) to bypass door mounting.

2.

Inspect cleaner panel swirl tubes for clogging or dirt. If either condition exists, remove cleaner panel and flush swirl tubes with water.

3.

Replace air cleaner panel if more than approx. 5% of the swirl tubes are damaged.

4.

Inspect blowers for general condition and secure installation; tighten loose attaching screws.

5.

Inspect electrical wiring on bypass door and blowers for loose contacts and evidence of damage; tighten or replace as necessary.

6.

Inspect bonding jumpers for corroded connections and secure installation; remove corros ion and tighten loose bonding jumpers as necessary.

7.

Inspect seals of rotor mast and control rods for general condition and secure installation. Replace damaged seals as necessary; tighten loose studs.

Revision 14

BO 105 CHAPTER 860 Page 9

MAINTENANCE MANUAL

EUROCOPTER

eo 105

860 - 5

FUNCTIONAL TEST - ENGINE AIR CLEANER

NOTE

o The functional test is carried out with the engines shut down. o For the functional test, a properly charged battery is to be installed, a 28 VOC external power unit of sufficient capacity is to be provided and, unless specified otherwise, connected to the helicopter power system. 1KC "SANDFILTER" SKC "SANDFILTER BLWR 1" (LH) 8KC "SANDFILTER BLWR Ir" (RH)

1.

Press circuit breakers:

2.

Set battery switch 16 P to EPU ON/BAT OFF position and "SANDFILTER" switch 4KC (overhead panel) to fwd. position (ON).

3.

-

Blower 1 6KC (LH) should start up irnmediately. At the same time the bypass door 3KC should move in the closed direction.

-

During the closing process (approx. 1.5 sec.) the caution light "SANDF." 2KC should light up on the indicator panel.

-

When the bypass door reaches its end positon (CLOSED), blower 11 7KC (RH) should start up. The caution light "SANDF." will extinguish.

Set battery switch 16 P to BAT ON/EPU OFF. Blower 1 and 11 will shut down. -

Bypass door remains closed.

-

Caution light "SANDF." will light up.

BO 105 CHAPTER 860 Page 10

Revision 14

EUROCOPTER

4.

MAINTENANCE MANUAL 80 105

Set "SANDFILTER" switch 4KC to the rear position (OFF). -

Bypass door should move in the open direction.

-

Caution light "SANDF." will extinguish.

5.

Repeat step 2.

6.

Pul! circuit breaker "SANDFILTER BLWR I".

7.

8.

9.

-

Blower I will shut down.

-

The caution light "SANDF." wil! light up.

Press circuit breaker "SANDFILTER BLWR I". -

Blower I will start again.

-

The caution light "SANDF." wil! extinguish.

Pul! circuit breaker "SANDFILTER BLWR Ir". -

Blower II will shut down.

-

The caution light "SANDF." wil! light up.

Press circuit breaker "SANDFILTER BLWR Ir". -

Blower II will start again.

-

The caution light "SANDF." wil! extinguish.

10. Set "SANDFILTER" switch 4KC to the rear position (OFF). -

Blower I will shut down. At the same time the bypass should move in the open direction.

-

During the opening process (approx. 1.5 sec.) the caution light "SANDF." should light up. When the bypass door reaches its end position (OPEN), blower II will shut down. The caution light "SANDF." extinguishes.

11. Pull circuit breakers:

Revision 14

1KC "SANDFILTER" SKC "SANDFILTER BLWR I"(LH) 8KC "SANDFILTER BLWR Ir" (RH)

BO 105 CHAPTER 860 Page 11

EUROCOPTER

860 - 6

MAINTENANCE MANUAL 80 105

REMOVAL - ENGINE AIR CLEANER

1.

Ensure that helicopter is grounded and disconnect battery.

2.

Remove bonding jumper between blower (5, figure 860-1) and bracket (14) on cabin roof.

3.

Disconnect plug of blower (5) from bracket (14) and cover receptacle on bracket (14) with protective cap.

4.

Remove blower (5) with diffusor ducts (8) and sheet (12) from bracket (14), engine cowling (7) and air cleaner housing (2). Retain attaching hardware for reinstallation.

5.

Remove air cleaner panel (4) on right or left side from air cleaner housing to access the electrical connection of bypass door actuator.

6.

Disconnect plug from bypass door actuator on cabin roof and cover receptacle on cabin roof with protective cap.

7.

Remove screws and detach air cleaner housing (2) from mounting support (1) .

8.

If necessary, remove sealing (6) from engine cowling (7).

9.

If necessary, remove clamps (9) and disconnect blower (5) from diffusor ducts (8). Remove sheet (12) from blower, if necessary.

860 - 7 1.

INSTALLATION - ENGINE AIR CLEANER

If removed, reinstall sheet (12) on blower (5), (torque value for nuts 4.5 to 5 Nm), and reinstall diffusor ducts (8) with clamps (9) on blower (5) •

2.

If removed, install sealing (6) on engine cowling (7).

3.

Secure air cleaner housing (2) to mounting support (1) on cabin roof with screws (10).

4.

Connect plug of bypass door actuator to receptacle on cabin roof. Put protective cap on dummy socket.

5.

Install air cleaner panel (4) on air cleaner housing (2).

6.

Install blower (5) with diffusor ducts (8) and sheet (12) on bracket (14), engine cowling (7) and air cleaner housing (2).

BO 105 CHAPTER 860 Page 12

Revision 14

EUROCOPTER

MAINTENANCE MANUAL 80105

7.

Connect plug of blower (5) to receptacle on bracket (14). Put protective cap on dummy socket.

8.

Install bonding jumper between bracket (14) and blower (5).

9.

Perform functional test per para 860-5.

Revision 14

BO 105 CHAPTER 860 Page 13

MAINTENANCE MANUAL BO 105

EUROCOPTER

1 2 3

4 5 6 7

8 9 10 11 12 13 14 15 16

Mounting support Air cleaner housing Bypass door actuator Air cleaner panel Blower Sealing Engine cowling Diffusor duct Clamp Screw Screw Sheet Electrical cable Bracket Washer Nut

Fig. 860-1 Engine air cleaner - blower purge

105 CHAPTER 860 Page 14

(1 of 2)

B0

Revision 14

MAINTENANCE MANUAL 80 105

EUROCOPTER

765

8

4

9

10

~'----------4

4-------~

It-~__"d~~------

3

~JJr7>'----11

o o

'-..

'(~'"

800394

Figure 860-1 Engine air cleaner - blower purge ( 2 of 2)

Revision 14

BO 105 CHAPTER 860 Page 15/16

EUROCOPTER

MAINTENANCE MANUAL 80105

861

EMERGENCY FLOTATION SYSTEM (Fl05-85189)

The supporting documentation for the emergency flotation system has been prepared by its manufacturer, AIR CRUISERS COMPANY and by the American Eurocopter Corporation (AEC) , not by ECD. If this documentation is required, it may be ordered from the manufacturero The following documentation shall be used to support maintenance of this system: - AEC Maintenance Manual Supplement 105-MMS-003 - Air Cruisers Overhaul Manual with Illustrated Parts List 25-60-95.

Revision 15

BO 105 CHAPTER 861 Page 1/2

EUROCOPTER

MAINTENANCE MANUAL 80105

862

WEATHER RADAR SYSTEM

The supporting documentation for the weather radar system has been prepared by its manufacturer, Allied Signal, not by ECD. If this documentation is required, it may be ordered from the manufacturero The following documentation shall be used to support maintenance of this system: - Maintenance Manual I.B.214 OOOC for Receiver and Indicator RDR-1400/IN-2025 - Maintenance Manual I.B. 2100A for Antenna AA-4512A - Bendix Publication ACS-927

Revision 15

BO 105 CHAPTER 862 Page 1/2

EUROCOPTER

MAINTENANCE MANUAL 80 105

863

FLIR SYSTEM

The supporting docurnentation for the FLIR system has been prepared by its manufacturer, Broadcast and Surveillance System Ltd, not by ECD. If this documentation is required, it may be ordered from the manufacturero The following documentation shall be used to support maintenance of this system: -

Revision 15

BSS 400 Dual Safire Operators Manual, Drawing No. A1/159-101

BO 105 CHAPTER 863 Page 1/2

EUROCOPTER

MAINTENANCE MANUAL SO 105

867 CARTRIDGE-TYPE FUEL PUMP Table of Contents

Paragraph Title

Page

867-1

DESCRIPTION - FUEL PUMP

3

867-2

TROUBLESHOOTING - FUEL PUMP •........••.•.•.••••.....•.••.....•...•....

3

867-3

INSPECTION FOR CONDITION - FUEL PUMP ...•..•..•.•••••....•..•.••.••••.••

3

867-4

REMOVAL AND INSTALLATION - FUEL PUMP .•..•.•...........•.......•..•....

4

867-5

REMOVAL AND INSTALLATION - PUMP CARTRIDGE ........••..........•......

6

Revision 19

CHAPTER 867 Page 1

EUROCOPTER

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 867 Page2

Revision 19

EUROCOPTER

867 - 1

MAINTENANCE MANUAL 80105

DESCRIPTION - CARTRIDGE-TYPE FUEL PUMP

1. General The fuel pump is driven by a motor housed in the pump cartridge. When it becomes necessary to replace the pump motor, the pump cartridge can be removed without having to remove the entire tuel pump. 2.

Oescription The fuel pump consists of a sealed pump housing and a pump cartridge incorporating the motor and impeller.

3. Operation ·Fuel is drawn in through a valve installed in the pump housing and is then pumped into the fuelline by the impeller housed in the pump cartridge. The pump delivers 7.5Iiters/min. at 1.7 bar (25 psi) maximum.

867 - 2

TROUBLESHOOTING - FUEL PUMP

Troubleshooting shall be performed in conjunction with fuel system troubleshooting per Chapter 62, para. 62-2.

867 - 3

INSPECTION FOR CONDITION - FUEL PUMP

1. Remove screws (22, tig. 867-1) and remove cover plata (21). 2. Visually inspect fuel pump for leakage in the mounting area. If leakage is evident, remove pump cartridge per para. 867-6 and replace G-rings (24 and 25). 3.

Inspect screws (14, 16, 17 and 20) and nuts (27) tor tightness. It necessary, retighten screws and nuts and secure with lockwire. For torque on nuts reter to tig. 867-1.

4.

Inspect bonding jumpers (5) and (9) and electrical lead (6) tor damage and tight connection. Replace it damaged.

5. Attach cover plate (21) to bottom shell with screws (22).

Revision 19

CHAPTER 867 Page3

MAINTENANCE MANUAL 80 105

EUROCOPTER

867 - 4

REMOVAL AND IN5TALLATION - FUEL PUMP

WARNING

TO AVOID FIRE ANO EXPLOSION HAZARDS DUE TO SPARKING, ALL REGULATIONS ANO PRECAUTIONS REGARDING HANDLING OF HIGHLY FLAMMABLE MATERIALS SHALL BE STRICTLY OBSERVED.

1. Remove fuel pump. a. Defuel the helicopter per Chapter 06. b. Disconnect battery and EPU from aircraft electrical system (refer to Chapter 92). WARNING

BEFORE THE FUEL PUMP IS REMOVED IT IS NECESSARY TO PURGE THE ASSOCIATED FUEL TANK OF FUEL VAPORS TO AVOID FIRE ANO EXPLOSION HAZARDS.

c. Purge fuel cell with air or nitrogen: 1) Open all drain valves by pushing up and turning the valve stem. 2) Remove fuel filler cap and insert the purging medium delivery hose ¡nto the fuel cell. Seal the gap between the delivery hose and the filler neck with adhesive tape (CM 614). 3) Purge the fuel tank using either fi/tered, compressed air for apprax. 2 hours at 2 to 4 bar or nitragen for 2 hours at a flow rate of 0.5 kg/min. 4) When purging has been completed. remove the delivery hose and wait approx. 1 hour before continuing with the removal procedure. d. Remove screws (22, fig. 867-1) and remove cover plate (21). e. Unscrew and remove Allen screw (17) together with electricallead (6). f.

Remove lackwire (7).

CAUTION

TO AVOID DAMAGING THE FUEL PUMP VALVE, DO NOT SET THE PUMP DOWN ON THE VALVE ANO DO NOT TOUCH THE VALVE WITH SHARP OBJECTS.

g. Remove Allen screw (16), ratate fuel shutoff lever arm (8) away from the pump cartridge, and remove bonding jumper (9) and washer (15). h. Detach connecting piece (4) and attached fuelline by removing screw (14), washer (13), o-rings (1 0,12) and spacer (11). Discard D-rings (10, 12). i.

Remove nuts (27) together with washers (28) and bonding jumper (5), and detach pump housing (3) togetherwith pump cartridge (26) and gasket (2) from bolt ring (1 )offuel cell.lfconnecting piece (4) is hard to dislodge fram the fuel pump, force it up off its seat by threading an M6 screw of suitable length into the bore.

NOTE

CHAPTER 867 Page4

If the fuel pump is to be sent for repair. be sure to ¡nclude the connecting piece. Instead of removing the connecting piece lacated in the tank, you are recommended to send the connecting piece of the replacement fuel pump to the repair facility. Revision 19

EUROCOPTER

MAINTENANCE MANUAL BO 10S

2. Install fuel pump. CAUTION

TO AVOIO OAMAGING THE FUEL PUMP VALVE, DO NOT SET THE PUMP OOWN ON THE VALVE ANO DO NOT TOUCH THE VALVE WITH SHARP OBJECTS.

a. Inspect gasket (2) for condition and replace if found to be damaged. b. Lubricate gasket with grease (CM 101) and fit it on the mounting flange of pump housing (3). c. Secure connecting piece (4) togetherwith attached fuelline to pump housing (3), using screw (14), new O-rings (10, 12), spacer (11) and washer (13). d. Fit pump housing (3) together with pump cartridge (26) and gasket (2) in fuel tank and attach to bolt ring together with bonding jumper (5), using screws (27) and washers (28). For torque on nuts refer to fig. 867-1. e. Rotate fuel shutoff lever arm back in line with its mating hole in the pump cartridge. f.

Press upward on the connected end of the fuel shutoff lever arm so that valve spring bottoms and install washer (15), bonding jumper (9) and Allen screw (16).

g. Wire-Iock Allen screw (16) to screw (14). h. Connect electricallead (6)and secure with Allen screw (17). i.

Apply a coat of corresion preventive lacquer (CM 501) to bonding jumper (9).

j.

Refuel fuel system according to Chapter 06 and functionally test fuel pump per Chapter 92, para. 92-79.

k. Visually inspect fuel pump for leakage in mounting area.

1.

Attach cover plate (21) to bottom shell with screws (22).

Revision 19

CHAPTER 867 Page 5

eeurocopter 867 - 5

REMOVAL ANO IN5TALLATION - FUEL PUMP CARTRIOGE

Special tools:

WARNING

I

MAINTENANCE MANUAL BO 105

Cartridge pulling tool E2-10-1 (Airborne Freight Corporation)

TO AVOID FIRE ANO EXPLOSION HAZARDS DUE TO SPARKING, ALL REGULATIONS ANO PRECAUTIONS REGARDING HANDLING OF HIGHLY FLAMMABLE MATERIALS SHALL BE STRICTLY OBSERVED. • Befare replacing a pump cartridge in the main fuel tank, 25 Iiters of fuel shall be removed from the supply tank (refer to defueling in Chapter 06).

NOTE

• Defueling is not required when replacing a pump cartridge in the supply tank. 1. Remove pump cartridge. a. Disconnect battery and EPU from aircraft electrical system (refer to Chapter 92). b. Remove screws (22, fig. 867-1) and removecover plate (21). c. Unscrew Allen screw (17) and remove together with electricallead (6). d. Remove lockwire (7). e. Remove Allen screw (16), rotate fuel shutoff lever arm (8) 180° away from the pump cartridge, and remove bonding jumper (9) and washer (15). f.

Catch fuel spillage in a suitable container.

g. Remove lockwire from blanking screw (20). h. Unscrew and remove blanking screw (20) while holding drain boss (23). i.

Remove cartridge retaining ring (18).

j.

Thread pulling tool E2-10-1 into drain boss.

k. Remove pump cartridge (26) from pump housing (3) by pulling down the heavy slider of pulling tool E2-10-1 sharply against the bolt head. 2. Install pump cartridge. a. Inspect D-rings and screws for condition and replace as necessary. b. Lubricate D-rings (24 and 25) on new pump cartridge (26) and cartridge seating surface in the pump housing (3) with grease (CM 101). NOTE

• The arrow on pump housing (3) must align with the arrow on pump cartridge (26) to within ±3°. • Do not use pulling tool E2-10-1 to install the pump cartridge. Use hands only.

c. Insert pump cartridge (26) by hand into pump housing (3) and ensure it iscorrectly seated. CHAPTER 867 Page6

Revision 21

EUROCOPTER

MAINTENANCE MANUAL BO 105

d. Install cartridge retaining ring (18). e. Lubricate new ~ring (19) with grease (CM 101). f.

Install blanking screw (20) together with ~ring (19) in drain boss (23) and wire-Iock blanking screw to pump housing (3).

g.

Rotate fuel shutoff lever arm (8) back in line with its mating hole in the pump cartridge

h.

Press upward on the connected end of the fuel shutoff lever arm so that valve spring bottoms and install washer (15), bonding jumper (9) and Allen screw (16).

i.

Wire-lockAllen screw (16) to screw (14).

j.

Connect electricallead (6) and secure with Allen screw (17).

k.

Apply a coat of corrosion preventive lacquer (CM 501) to bonding jumper (9).

1.

Functionally test fuel pump per Chapter 92, para. 92-79.

m. Visually inspect fuel pump for leakage in mounting area. h. Attach cover plate (21) to bottom shell with screws (22).

Revision 19

CHAPTER 867 Page7

MAINTENANCE MANUAL SO 105

EUROCOPTER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Bolt ring on fuel tank Gasket Pump housing Connecting piece Bonding jumper Electrical lead Lockwire Fuel shutoff lever arm Bonding jumper O-ring Spacer O-ring Washer Screw Washer Allen screw Allen screw Retaining ring O-ring Blanking screw Cover plate Screw Drain boss O-ring Q-ring Pump cartridge Nut Washer Valve stem Pulling tool E2-1D-1

Figure 867-1

CHAPTER 867 Page8

Cartridge-type fuel pump (1 of 2)

Revision 19

EUROCOPTER

MAINTENANCE MANUAL 80 105

Pump cartridge with pulling tool 0

0

00

m

O

O

O

O

O

O

26 2

t-----3

t---30

Installed condition Viewed from below

..n - - - 1 8

~~::v

~---:--19

J.,l----20

7

&.

Figure 867-1

Revision 19

Aligning arrows

Fuel pump (2 of 2)

CHAPTER 867 Page9

MAINTENANCE MANUAL 80 10S

EUROCOPTER

BLANK PAGE

CHAPTER 867

Page 10

Revision 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91

INSTRUMENT SYSTEMS

Table of Contents

Paragraph

Title

91 - 1

GENERAL

5

91 - 2

Location - instruments

5

91 - 3

1 n s t r u me n t

5

91 - 4

Inspection for condition - instruments

11

91 - 5

FLIGHT INSTRUMENTS

11

91 - 6

P i t o t

91 - 7

Troubleshooting - pitot-static system

15

91 - 8

Removal and installation - pitot-static system

16

91 - 9

Inspection for condition - pitot-static system

19

91 - 10

Functional test - pitot-static system

20

91 - 11

Draining - pitot-static system

22

91 - 12

Cleaning - pitot-static system

22

91 -13

Ai r s p e e d

23

91 - 14

Removal and installation - airspeed indicator

23

91 - 15

A 1 t i m e ter

25

91 - 16

Removal and installation - altimeter

25

91 - 17

Ver t i c a 1

26

91 - 18

Removal and installation - vertical speed indicator

26

91 - 19

Ma s t

27

91 - 20

NAVIGATION INSTRUMENTS

27

91 - 21

M a g n e tic

27

91 - 22

Troubleshooting - magnetic compass

Page

pan e 1

s t a tic

s y s t e m

i n d i c a t o r

s p e e d

mo me n t

i n d i c a t o r

i n d i c a t o r

c o mp a s s

11

29 BO 105 CHAPTER 91 Page 1

- - - - - - - - - - - - , - - - - MBB HELICOPTERS------------MAINTENANCE MANUAL MBB - BO 105 Paragraph

Title

91 - 23

Rernoval and installation - rnagnetic cornpass

29

91 - 24

Inspection for condition - rnagnetic cornpass

29

91 - 25

Functional test - rnagnetic cornpass

30

91 - 26

Cornpensation - rnagnetic cornpass

31

91 - 27

ENGINE AND MAIN TRANSMIssrON INSTRUMENTS

37

91 - 28

Tri pIe R P M i n die a t ion s y s t e rn, N2 a n d NR

38

91 - 29

Troubleshooting - triple RPM indication systern, N2 and NR

41

91 - 30

Rernoval and installation - triple RPM indication systern N2 and NR ....

42

91 - 31

R P M i n die a t ion

43

91 - 32

Troubleshooting - RPM indication systern N1

46

91 - 33

Rernoval and installation - RPM indication systern N1

46

91 - 34

Tri pIe o i 1 P r e s s u r e l n die a t ion s y s t e rn

49

91 - 35

Troubleshooting - triple oil pressure indication systern

52

91 - 36

Rernoval and installation - triple oil pressure indication systern . . . . . . ..

53

91 - 37

Functional test - triple oil pressure indication systern

53

91 - 38

Tri pIe o i 1 t e rn p e r a t u r e l n die a t ion s y s t e rn

54

91 - 39

Troubleshooting - triple oil ternperature indication systern

57

91 - 40

Rernoval and installation - triple oil ternperature indication systern ....

58

91 - 41

T O T i n die a t ion

s y s t e rn

59

91 - 42

Tro~bleshooting

- TOT indication systern

62

91 - 43

Removal and installation - TOT indication systern

63

91 - 44

F R E E

63

91 - 45

BO 105 CHAPTER 91 Page 2

Page

s y s t e rn N1

.Calibration - TOT indication systern

63

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Paragraph

Title

91 - 46

Du a 1

Page

f u e 1 q u a n t i t Y i n die a t ion s y s t e m

67

91 - 47

Troubleshooting - dual fuel quantity indication system

70

91 - 48

Removal and installation - dual fuel quantity indication system .

71

91 - 49

Du a 1

f u e 1 s y s t e m

p r e s s u r e

i n die a t ion 72

91 - 50

Troubleshooting - dual fuel pressure indication system

75

91 - 51

Removal and installation - dual fuel pressure indication system . . . . . . ....

76

Du a 1 t o r q u e e n g i n e s

77

91 - 52

i n die a t ion

s y s t e m

91 - 53

Troubleshooting - dual torque indication system, engines

80

91 - 54

Removal and installation - dual torque indication system, engines .

81

Inspection for condition - dual torque indication system, engines . . . . .. . .

83

91 - 56

Functional test - dual torque indication system, engines

83

91 - 57

Ventilation - dual torque indication system, engines

84

91 - 58

MISCELLANEOUS INSTRUMENTS

85

91 - 59

Arnmeter and voltmeter

85

91 - 60

C loe k

89

91 - 61

Troubleshooting - clock

90

91 - 62

Removal and installation - clock

90

91 - 63

Functional test - clock

91

91

ou

91 - 55

64

t s

l

d e

a i r

t e mp e r a t u r e

i n die a t o r

91

65

91 - 66 91 - 67

Troubleshooting

92 outside air temperature indicator

93

Removal and installation - outside air temperature indicator . . .. .

94

Functional test - outside air temperature indicator

94 BO 105 CHAPTER 91 Page 3/4

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

91 - 1

GENERAL

The instruments are divided into the following groups: - Flight instruments - Navigation instruments - Engine and main transmission monitoring instruments - Miscellaneous instruments

91 - 2

Location - instruments

The instruments are located in the instrument panel, on the center beam and in the canopy.

91 - 3

1 n s t r u me n t

pan e 1

The instrument panel is installed in the center of the cabin in front of the pilot's seats. The instrument panel is a rack assembly with a vertical and a horizontal section. The whole instrument panel has a panelling, the upper part consists of a glareshield. The vertical section (figure 91-1 and figure 91-2) mainly accomodates instruments and warning lights. The horizontal section (figure 91-3, figure 91-4 and figure 91-5) is essentially equipped with circuit breakers and toggle switches, a voltmeter and an arnmeter. A fuse board (refer tochapter 92) with fuses is installed at the bottom of the RH or RH and LH side, respectively.

BO 105 CHAPTER 91 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

S/N 7-60 2

3

3

4

2

5

6

18

7 . 17

@

16

'¡' ......o

15

8

6

--+---l,..... 9

14

--+---41"-----~'"'-_+-

10

13 --4--411-

900161

12

1 2 3 4 S 6 7 8 9 10 11 12 13 14 15 16 17 18

11

Dirnmer for instrument lighting 10LC Pushbutton "test fire warning·system" LH/RH 103WG/203WG Warning light fire warning LH/RH 104WG/204WG Warning light panel Control light for pitot tube heating 2HG Warning light test switch Altimeter Vertical speed indicator TOT indicator LH/RH 10SEL/20SEL RPM indicator NI 108EN/208EN Triple oil pressure indicator 4ED Triple oil temperature indicator SED Dual fuel pressure indicator 2EA Dual fuel quantity indicator SEB Dual torque indicator Mast moment indicator 2WM Airspeed indicator Triple RPM indicator 7EN Figure 91-1

BO lOS CHAPTER 91 Page 6

Instrument panel (vertical section) (typical)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 EFFECTIVITY

S/N 61 and subsequent and series D

2

3

2

D

19

18

5

4

17

6

~ \~

7

_8

16

9

15 --+-H~··I~'«':'·.~~I

11 14 900159

13

1 Pushbutton "test fire warning" LH/RH 103WG/203WG 2 Warning light fire warning LH/RH 104WG/204WG 3 Warning light panel 4 Control light for pitot tube heating 2HG 5 Warning light test switch 6EB 6 Altimeter 7 Vertical speed indicator 8 Triple RPM indicator 7EN 9 Dual torque indicator 10 TOT indicator LH/RH 10SEL/20SEL Figure 91-2

12

RPM indicator N1 108EN/208EN 12 Dual fuel pressure indicator 2EA 13 Dual fuel quantity indicator SEB 14 Triple oil pressure indicator 4ED 15 Triple oil temperature indicator SED 16 Mast rnornent indicator 2WM 17 Clock 18 Dirnmer for instrurnent lighting 10LC 19 Airspeed indicator 11

Instrurnent panel (vertical section) (typical) BO 105 CHAPTER 91 Page 7

- - - - - - - - - . , . . . . - - - - M B B HELICOPTERS - - - - - - - - - - - - - -

MAINTENANCE MANUAL MEB - BO 105 EFFECTIVITY

S/N 7-160

,-L

---. ..J

- - - - - - - - ¡ //

/-_._---

I

J

\

I \.1 )1

1,

/1 (1

"'o ~~F1·~A

)1 ON CASIN

<:

~--------

~

O"

~

lR

"-------

ENG I (NG 11 STAATt:A/Go!~I!RATOA

OH

CAeN

AlA

or

I

91M

1

.EN

TAPlT

ENG I

ENG 11

STARlE~/GENEAATOA

900162

Figure 91-3 BO 105 CHAPTER 91 Page 8

Instrument panel (horizontal section) (typical)

- - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

S/N 161 and subsequent

BUS.AR

START SlARTEA'GEHERA TOR

@®~======V 900160

Figure 91-4

Instrument panel (horizontal section) (typical)

BO 105 CHAPTER 91 Page 9

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

Series D

©

(±) , r - - - - - - - , .

©®'--

---J

+@-------

900189

Figure 91-5

BO 105 CHAPTER 91 Page 10

Instrument panel (horizontal section) (typical)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 4

Inspection for condition - instruments

l.

Inspect instruments for security, general condition, damaged cover glasses and presence of dirt. tighten mounting hardware, clean oe replace instruments as necessary.

2.

Inspect instruments for damaged scale markings. replace instrument ar necessary.

3.

Check for presence, legibility and secure attachment of decals. replace missing, loose or illegible decals as necessary.

4.

Inspect range markings and slippage marks on cover glasses of instruments for condition. replace markings as necessary. (AIso refer to FLM, section 2.)

91 - 5

FLIGHT INSTRUMENTS

The flight instruments consist of: -

pitot-static system airspeed indicator altimeter vertical speed indicator mast moment indicator

91 - 6

P i t o t - s t a tic

s y s t e m

The pitot - static system (figure 91-7) comprises a tube/hose line assembly together with a pitot tube, two static ports, a tee, and an optional static pressure selector valve. Static pressure is exerted on the instruments via the static ports and the tube/hose line assembly. The pitot tube additionally supplies dynamic pressure to the airspeed indicator. It can be heated to prevent the formation of ice (refer to chapter 92). A tee with cap assembly is installed in the tube/hose line assembly to drain condensatione water and to connect test equipment.The static pressure selector valve cnables static pressure to be taken either from the static ports or from the cabin.

BO 105 CHAPTER 91 Page 11/12

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

.. r Pf

0_.-

~'i \m~'

-J-.

.

,--.~.

~/ r~r-· I i¡=+'Ó-'5i) " \ ]

I . ¡.

.

(.~::..

,-.

.

! LL..~..

lIt!

.

j.r¡

I . . .. -G'_.~'I 1_.---/_._._._.. n n ./" 11 ____ ._~

O'

I---'!~'

.'

'.-=.. ---=.:-~~

.d.b

4

900116

5

1 Instrument panel 2VE Airspeed indicator Altimeter Vertical speed indicator Static pressure selector valve 2 Tee 3 Pitot tube 4 Static port, RH 5 Static port, LH Figure 91-6

Component location - pitot-static system BO 105 CHAPTER 91

Page 13

- - - - - - - - - , - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

VERTICAL AIRSPEED ALTIMETER SPEED INDICATOR INDICATPR

REVERSING VALVE

.--1---.----

Cilr'!

a.:

~==:

STATIC PORTS 900117

Figure 91-7

BO 105 CHAPTER 91

Page 14

PITOT TUBE

,--)

6

Only Installed wlth optlonally equipment

Pitot - static system

- - - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 7

Troubleshooting - pitot-static system

No. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Leak in dynamic pressure lineo

Apply pressure to the dynamic pressure system and check dynamic pressure line for leaks using a weak soap solution. Replace leaky tubing/hose lines, if necessary or retighten connections.

During the leakage test of the dynamic pressure system, the value drops more than 3 kts within 1 minute.

Airspeed indicator Check airspeed indicator for leaking. leaks and replace if necessary. 2

3

During the leakage test of the static pressure system, the value drops more than 150 ft within 1 minute.

No or incorrect indication of instruments.

Leak in static pressure lineo

Disconnect hoses from instruments and plug hose ends. Apply pressure to static lines and check for leaks, using a weak soap soluation. Replace leaking tubing/hose lines,if necessary or retighten connections.

Instruments leaking.

Check instruments for leaks and replace if necessary.

Leak in tube/ Check tube/hose line hose line assembly. assembly leaks; seal if necessary. Tube/hose line assembly clogged.

Check pitot tube, static ports and tube/hose line assembly for contamination; clean if necessary.

Pitot tube or static ports damaged.

Check pitot tube or static ports for damage and replace if necessary.

Leak in instrument housing.

Check instruments for leaks and replace if necessary.

Table 91-1

Troubleshooting

80 105 CHAPTER 91 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - S

1.

Removal and installation - pitot-static system

Removal - pitot tube a.

Cut off power supply.

b.

Remove countersunk screws (S, figure 91-S) and detach pitot tube (9).

c.

Feed hose line (4) and electric wiring (11) outward through flange (2) and fuselage (12).

d.

Remove lockwire from hose connection and loosen union nut (5). Blank off hose line.

e.

Disconnect contact plugs (10) from contact pins (7) of the pitot tube heating, protect with caps and remove pitot tube. i'r---1

+--2

1 Threaded adapter 2 Flange

3

3 4 5 6

4

5

7

6

S 9 10 11 12

7

Bore Hose line Union nut Connection nipple Contact pins Countersunk screw Pitot tube Contact plugs Electric wiring Fuselage

&---8

9--......,"--

900104

Figure 91-S 2.

Pitot tube

Installation - pitot tube a.

Install hose line (4, figure 91-S) to connection nipple (6), using union nut (5). Secure bolted joint with lockwire.

b.

Connect contact plugs (10) and contact pins (7) of the pitot tube heating.

BO 105 CHAPTER 91 Page 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Remove access cover above the RH static port.

d.

Align threaded adapters (1) of flange (2) and bores (3) in fuselage (12) through access hole. Fasten pitot tube (9) with countersunk screws (8), with the opening pointing towards direction of flight.

e.

Install access cover.

f.

Inspect pitot system for leakage per para. 91-10 and perforrn functional check of the pitot tube heating in accordance with chapter 92.

3.

Removal - static port NOTE

Removal procedure is identical for LH and RH static ports.

a.

Loosen countersunk screws (9, figure 91-9), remove ram plate (8) and detach static port (7).

b.

Feed hose line (1) outward through flange (4) and fuselage (5).

c.

Secure flange (4) to prevent it from falling in to the belly of the helicopter.

d.

Loosen hose clamp (2), disconnect hose line (1) from nipple (6) and protect with cap.

0-'

tfJ}-2 I

ft:

C~3 I

5

1 2 3

6

4 5 7

6 7 8

~---8 900105

9

4--9 Figure 91-9

Hose line Hose clamp Threaded adapter Flange Fuselage Nipple Static port Ram plate Countersunk screw

Static port BO 105 CHAPTER 91 Page 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4.

Installation - static port

NOTE

The installation procedure is identical for LH and RH static ports. a.

Remove protective cap from hose line (1, fig. 91-9).

b.

Connect hose line to static port nipple (6) with hose clamp (2).

c.

Remove temporary holding device from flange (4).

d.

Align threaded bores in flange (4) with holes in fuselage (5).

e.

Align bores in static port (7) and ram plate (8) with holes in fuselage (5) and assemble aligned parts with countersunk screws (9).

f.

Perform leakage test according to para 91-10.

BO 105 CHAPTER 91 Page 18

- - - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5.

6.

Removal - tube/hose line assembly a.

Remove access cover above RH static port.

b.

Remove instrument panel fairing.

c.

Disconnect instruments of the pitot-static system from tube/hose line assembly.

d.

Remove the respective floor plates with seat, seat guide rails, cyclic stick bellows and, if necessary, floor covering.

e.

Loosen clamps or union nuts at the respective connections and remove hose lineo

f.

Blank off openings.

Installation - tube/hose line assembly a.

Fasten hoses with clamps or union nuts to the respective connections. Replace O-rings, if installed.

b.

Connect instruments and perform leak test in accordance with paragraph 91-10.

c.

Re-install previously removed parts, such as access cover, etc. in the reverse order of removal.

91 - 9

Inspection for condition - pitot-static system

1.

Check instruments in accordance with para. 91-4.

2.

Inspect tube/hose line assembly as follows: a.

Inspect pitot tube and static ports for secure installation, dirt and damage. Perforrn following as necessery: - tighten loose parts, - clean dirty parts, - replace damaged parts.

b.

Inspect hose lines for secure installation, damage, deformation (kinks) and porosity. Fasten or replace hose line, if necessary.

BO 105 CHAPTER 91 Page 19

- - - - - - - - - - - - - M B B HELICOPTER5 - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 10 1.

Functional test - pitot-static system

General The following equipment or consumable material is required for the functional test: - commercially available test units for the leak test of the pitot-static system, - pitot adapter, 16.7 mm dia. - adhesive vinyl tape (CM 714 or similar) to seal the static ports.

NOTE

Operate test unit for leak test of pitot-static system in accordance with the operating instructions.

Drain the tube/hose liné assembly per para. 91-11 prior to each leak test. 2.

Leak test - pitot system a.

Using the adapter, connect pressure port P of the test unit to the pitot tube (figure 91-10).

b.

Carefully pressurize the pitot tube to produce an airspeed indicator reading of 140 kts.

c.

Close the shut-off valve at port P of the test unit to maintain a constant pressure.

d.

Check pressure indication on airspeed indicator. The indication on the airspeed indicator must not decrease more than 3 kts within 1 minute.

3.

e.

Open shut-off valve of port P and slowly de-pressurize the system.

f.

Remove adapter from pitot tube.

Leak test - static system

CAUTION a.

ALL READING CHANGE5 OCCURRING WH1LE THE PITOT - STATIC SYSTEM 15 BEING LEAK TESTED MUST NOT EXXEED 5000 FT/MIN.

Connect low pressure port S of the test unit to the tee and to the pitot tube with the adapter (figure 91-10).

BO 105 CHAPTER 91 Page 20

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

AIRSPEED IND.

REVERSING VALVE

'--..--

~ ~--

PITOT TUBE

'--~

6

VERT. SPEED INDICATOR

ALTIMETER

ADAPTER

~_~-I---:o----I§ RH STATIC PORT

LH STATIC PORT

s o o p

@

6

Only Installed wlth optlonally equlpment

TESTER 900132.1

Figure 91-10

Leak test setup

b.

Tightly seal LH and RH static port, using vinyl tape (CM 714 or similar) .

c.

Carefully produce a vacuum to obtain an altimeter reading of 12000 feet, plus the actual elevation of the helicopter.

d.

Close shut-off valve at port S of the test unit to maintain a constant vacuum.

e.

Check pressure indication on altimeter. The altimeter indication must not decrease more than 150 ft within 1 minute. The pointer of the airspeed indicator must not leave its zero position during this periodo

f.

Open shut-off valve at port S and release vacuum slowly.

g.

Disconnect hose lines between test unit and helicopter and remove vinyl tape fram static ports.

BO 105 CHAPTER 91

Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

91 - 11

Draining - pitot-static system

1.

Remove nose door of the control room.

2.

Remove cap assembly (2, figure 91-11) from tee (1).

3.

Drain condensation water.

4.

Install cap assembly and tighten.

5.

Install nose door of the control room.

91 - 12

Cleaning - pitot-static system

1.

Disconnect pitot and static pressure lines from instruments.

2.

Blank off open instrument connections.

3.

Clear tube/hose line assembly using filtered compressed airo

4.

Remove blanks from instrument connections.

5.

Connectpitot and static lines to instruments.

6.

Perform leak test in accordance with para. 91-10.

2

Figure 91-11

BO 105 CHAPTER

Page 22

91

1 Tee 2 Cap assembly

Tee

HELICOPTERS - - - - - - , - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

----------.-----MBB

91 - 13

Ai r s p e e d i n d i c a t o r

The airspeed indicator (figure 91~12) is installed in the instrument panel and is designed to measure dynamic pressure. It indicates the speed of the helicopter relative to the ambient aire The scale is color-coded (refer to FLM) .

Dynamic pressure is exerted through the opening of the pitot tube and the connected tubing on the aneroid capsule of the airspeed indicator. In addition, static pressure is exerted on the capsule via the static ports and the tubing system so that the capsule measures the difference between static and dynamic pressures. By means of a pointer the measured pressure difference is indicated as airspeed in "KNOTS".

900136

Figure 91-12

Airspeed indicator (typical)

91 - 14

Removal and installation - airspeed indicator

NOTE

Removal and installation is identical for airspeed indicator, altimeter and vertical speed indicator.

Removal and installation of the airspeed indicator is accomplished in the sequence of the index numbers as outlined in figure 91-13.

BO 105

CHAPTER 91 Page 23

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 6

4

9 4

5

900135.1

Figure 91-13 105 CHAPTER 91 Page 24

BO

7

1 2 3 4 5 6 7 8 9

Pressure hose Screw Lamp socket Eyebrow light Shade Electric wiring Screw Airspeed indicator Instrument panel

Removal and installation - airspeed indicator

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

91 - 15

A 1 t i m e ter

The altimeter is installed in the instrument panel and is designed as a barometric altimeter which converts static pressure values into an altitude indication. The altimeter is supplied with static pressure via thé static pressure ports and the tube/hose assembly. The thin pointer indicates 1000 feet with each revolution, while one revolution of the ring pointer indicates 10000 feet. The rotating scale on the right side counts the number of ring pointer revolutions and has a red cross-hatched warning section in the O - 10000 feet sector. By turning the knob on the lower left-hand side deviations from the standard atmosphere, for which the altimeter is calibrated, can be corrected. The value can be read off the millibar-calibrated indication on the scale located on the lower part of the dial. 91 - 16

Removal and installation - altimeter

Removal and installation of the altimeter is performed in accordance with para. 91-14.

9DD137

Figure 91-14

Altimeter

BO 105 CHAPTER 91 Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAlNTENANCE MANUAL MBB - BO 105

91 - 17

Ver t i c a 1 s p e e d

i n d i c a t o r

CONFlGURATION 1

The vertical speed indicator (figure 91-15) is installed in the instrument panel and displays the helicopter's rate of climb or descent. The housing of the indicator, which is designed as a pressure equalizing chamber, contains a diaphragm capsule which is directly connected to the static pressure systern. A capillary constriction is installed in the static pressure line leading to the diaphragm capsule in the housing. This causes a delay in pressure equalization between the interior of the diaphragm capsule and the housing while the helicopter climbs or descends. The short-time differential pressure causes a change on the diaphragm capsule which is rnechanically transrnitted to the pointer. The indication rernains until pressure is equalized via the capillary constriction between the interior of the diaphragm capsule and the housing. The scale is calibrated in "1000 FT/MIN". CONFIGURATION II

An instantaneous vertical speed indicator rnay be installed as an alternative to configuration 1. lt incorporates a mechanisrn which practically elirninates the delay in indication. lt displays arate of climb or dive up to ± 6000 ft/min at altitudes of between - 1000 ft and + 40 000 ft. The scale is graduated in 100 ft/rnin increments to ± 1000 ft/min and in 500 ft/rnin incrernents from ± 1000 ft/min to ± 6000 ft/rnin. The scale is internally illurninated. The pointer can be readjusted on the ground to zero by rneans of the adjusting screw located in the lower left corner of the indicator face. Rernoval and installation - vertical speed indicator

91 - 18

Rernove and install vertical speed indicator in accordance with para. 91-14.

CONFIGURATION 1

Figure 91-15 BO 105 CHAPTER 91 Page 26

CONFIGURATION 2

Vertical speed indicator

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 19

Ma s t

mo me n t

i n d i c a t o r

For description of mast moment indicator refer to chapter 705.

91 - 20

NAVIGATION INSTRUMENTS

91 - 21

M a g n e tic

c o mp a s s

The magnetic compass (figure 91-16) is mounted above the instrument panel at the center beam of the cabin frame and serves as an auxiliary compass. It operates on the principle of a liquid-dampened magnetic compass arid indicates the heading of the helicopter relative to magnetic north. The compass card (2) is located on a float with markings at 10 deg intervals. The cardinal directions are marked N, E, S and W, and numbers indicate the heading in 30 deg increments. The float is free to move in all three dimensions with silicone fluid as the damping medium. Deflections caused by interfering magnetic fields are compensated by the compensation device (3).

2--

1 2 3

900140

Figure 91-16

Lamp socket Compass card Compensationdevice

Magnetic compass

BO 105 CHAPTER 91 Page 27/28

------~------MBB

HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO 105

91 - 22

Troubleshooting - magnetic compass

No. TROUBLE SYMPTOM Magnetic compass indicates incorrectly.

1

Compass light defective.

2

PROBABLE CAUSE

CORRECTlVE ACTION

External magnetic interference; improper compensation.

Compensate magnetic compass in accordance with para. 91-26.

Magnetic compass defective.

Replace magnetic compass.

Lamp defective.

Replace lamp per fig. 91-17.

Table 91"""2

91 - 23

NOTE

Troubleshooting

Removal and installation - magnetic compass

o Use antimagnetic tools when removing and installing the magnetic compass. o Replace lamp with antimagnetic lamp only.

1.

Removal and installation of the magnetic compass is performed in the sequence of the index numbers shoen in figure 91-17.

2.

Compensate magnetic compass in accordance with para. 91-26 after installation.

91 - 24

Inspection for condition - magnetic compass

1.

Inspect magnetic compass for cleanliness, damage, haziness, discoloration, and contamination of the damping fluid.

2.

Inspect magnetic compass and electrical connector for secure installation.

3.

Check expiration date of compass card (figure 91-19).

BO 105 CHAPTER 91 Page 29

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 2 3 5

4 5

6 7

Nut Washer BoU Magnetic cornpass . Electric connector Larnp socket Larnp

900141

Figure 91-17

Functional test - rnagnetic cornpass

91 - 25 l.

Rernoval and installation - rnagnetic cornpass

General A deflector rnagnet is required for the functional test.

2.

Scale check a.

Rotate cornpass card by 360 0 with deflector rnagnet and inspect scale rnarks, figures and letters for discoloration and darnage.

b.

The cornpass card should rotate easily without binding.

BO 105 CHAPTER 91 Page 30

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

Friction error test a.

Using the deflector magnet, deflect the compass card through 10 deg and maintain the deflection for 10 seconds to allow the liquid to settle. Remove the deflector magnet and allow the compass card to settle. Record the settling position.

b.

Repeat this deflection procedure in the opposite direction. The difference between the two values must not exceed 2.5°.

91 - 26 1.

Compensation - magnetic compass

General The compensation site must meet the following requirements:

2.

a.

There should be no sources of magnetic interference within 50 m of the site (e.g. aircraft or road vehicles, rails, steel posts, iron fences, high-voltage lines, etc.).

b.

The ground must be level and the subsoil must be free from ferrous magnetic material (e.g. pipes, current cables, heating systems, etc.) .

Preparation Prior to compensation make sure to observe the following points: a.

All equipment (also magnetic material) must be at the location it has in flight.

b.

Personnel must not carry magnetic material on their persono

c.

Additional equipment which could influence the compass has to be removed from the cabin.

d.

Anti-magnetic tools have to be used.

BO 105 CHAPTER 91

Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3.

Helicopter alignment To determine the deviation, the helicopter has to be aligned with the magnetic course (MC), using one of the following methods: - alignment with a compensating turntable; - alignment with a compensating bearing dial; - alignment with a hand-held bearing compass; - alignment with marked directional lines; - alignment to a slaved directional gyro.

4.

Example of a compass compensation procedure

NOTE

o The two engines must be running and all electrical systems required for normal helicopter operation must be switched on. o A second or third compass correction card shall be made for non- continuously operating optional equipment with high power consumption and/or energized emergency bus. o Lift off the wiper blades to preventthem from running dry. a.

Determination of deviation Align the helicopter to the magnetic north, east, south and west. Record the magnetic course (MC) and the compass course (CC) and calculate the deviation based on these two values.

MC

CC

Dev.

N

360 0

349 0

+1P

E

90 0

100 0

-100

S

180 0

185 0

- 50

W

270 0

258 0

+12 0

BO 105 CHAPTER 91 Page 32

A copy of the compensation report shown in figure 91-18 can be used for this purpose

- - - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Type:

M88

Compensation Data Sheet

Ident: serial No.:

SIN

Compass: Compensated. date: Place:

Devlatlon

c

15° -000°

10

+

0° -

5°

5°

15°

10°

mw Kurs

Deviation

Compass course

6

000·

030·

030°

060°

060°

090°

OSOO

120°

120° 150°

150°

180°

180°

210:

210°

240:

240°

270:

270°

I

300"

300°

330: 330· 360·

360·

A=

B =

( 6N ) + ( 6 O ) + ( 6S I + ( 6W )

(60) -( 6 W)

A=

) +1

(

)+ (

e '"

2

4 )+(

)

B =

(

)-(

)

e '"

2

4

2 (

)- (

)

2

e

B =

A-

(6N )-1 bS)

=

The compass has been compensated with engines running Following instruments have been swilched on: VHf 1 VHF 2 NAVl NAV 2 ADF I ADF 2

XPDR

DME

RA

WXR

ANTI· COLL

NAV· LT5

Remarks:

Dale:

Tester:

Stamp:

900223

Figure 91-18

Compensation data sheet BO 105 CHAPTER 91

Page 33

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Calculation of the A, B and C error The errors (coefficients) are calculated from the deviation results as follows: (N)+(E)+(S)+(W) A error =

+11°-10°-5°+12° =

4

4

(E)-(W) B error =

-10°- (+12°) =

2

- 22° =

= -11° 2

+11°- (-50) =

2

c.

4

2

(N)-(S) C error =

8° = +-"= +2°

+ 16° = +8°

= 2

2

Error compensation 1)

A error: - Align the helicopter with magnetic course (MC) 360°. - Loosen bolts (4, figure 91-17) and turn compass such that"the lubber line moves by +2° from 349° to 351°. - Tighten bolts.

2)

B and NOTE

e errors: To adjust the B and C corrector, the triangular wrench supplied with the magnetic compass is required.

- Align the helicopter with magnetic course 360° and turn the C corrector such that the compass points exactly to 360°. - Align the helicopter with magnetic course 90° and turn the B corrector such that the compass points exactly to 90°. - Align the helicopter with magnetic course 180° and turn the C " corrector such that half of the indicated error is compensated. - Align the helicopter with magnetic course 270° and turn the B corrector such that half of the indicated error is compensated. - Align the helicopter again with MC 360°, 90°, 180° and 270° and read the compass indications. The readings must not deviate more than ± 5° from the MC values. If a value exceeds ±5° repeat the ·compensation.

BO 105 CHAPTER 91 Page 34

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

Determination of residual deviation Align the helicopter with MC 360 0 and continue in 30 0 turns. Read off compass indications and enter the values in a compass correction card (figure 91-19), column "TO STEER". Repeat this procedure with the heating or with optional equipment having similar high power consumption switched on, and with the emergency bus connected, if installed. Make a new compass correction card for each procedure. Then check compass correction cards for completeness and attach them on the centre beam of the cabin frame above the magnetic compass. File all written records or the compensation report respectively for the next magnetic compass compensation in the Historical Record of the helicopter.

COMPASS

--------------TO FLY O' 30' 60' 90' 120' . ISO' 180' 210' 240' 270'

TO srEER

u.

~D

fa

a:

300' 330' SWUNG BY:

DATE:

MeB 900552

Front side

Figure 91-19

Reverse side

Compass correction card

BO 105 CHAPTER 91 Page 35/36

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 27

ENGINE ANO MAIN TRANSMISSION INSTRUMENTS

Engine and rnain transrnission instruments cornprise: Triple RPM indication systern, N2 and NR - RPM indication systern N1 - Triple oil pressure indication systern - Triple oil ternperature indication systern - TOT indication systern - Dual fuel quantity indication systern - Dual fuel pressure indication systern - Dual torque indication systern

BO 105 CHAPTER 91 Page 37

- - - - - - - - - - - - - M B B HELICOPT8RS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 28

Tri p 1 e RPM a n d NR

i n die a t ion

s y s t e m , N2

The triple RPM indication system N2 and NR (figure 91-20) consists of: - triple RPM indicator - two tachogenerators N2 (ENG 1 and ENG 11) - RPM tachogenerator NR (main transmission) - electrical wiring and connectors

TO RPM WARNING DEVICE 1 EW

TRIPLE RPM INDlCATOR 7 EN

R

111-+__"":'

MAINROTOR

ENGINE 1

RPM TACHOGENERATOR 101 EN

2

11""""__"': I

IL.

ENGINE 2 _

RPM TACHOGENERATOR201 EN 900195.1

Figure 91-20 BO 105 CHAPTER 91 Page 38

Triple RPM indication system

- - - - - - - - - - - - - M B B HELICOPTERS'----------MAINTENANCE MANUAL MBB - BO 105

~~~~==~=--===-=-' . \._-~

"

-I-~' / :r::1r t--+ 'l' " 11

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n r'1 --ir-----p--~_ji........_ - -=..Jl.~

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~·.Y ..r-~-" ~~. ~L·~·-:-.:.=:-· .. ~.~ 4

900110.B

1 2 3 4

Figure 91-21

Triple RPM indicator 7EN RPM tachogenerator 201EN RPM tachogenerator 101EN RPM tachogenerator 3EN

Component location - triple RPM indication system, N2 and NR BO 105 CHAPTER 91 Page 39

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The tachogenerators generate an alternating voltage with frequencies proportional to the speed of their respective power turbine. The alternating voltage controls one of the three synchronous motors in the triple RPM indicator, respectively. The triple RPM indicator (figure 91-22) accomodates three independent measuring circuits with one synchronous motor each. Each synchronous motor actuates a pointer. RPM is displayed in "PER CENT". A 100% N2 indication by pointer "1" (ENG 1) or by pointer "2" (ENG 2) corresponds to the rated output oí the respective power turbine. A 100% indication by pointer "R" corresponds to the normal main rotor RPM during flight.

"'"=",,,,",-H---2

"''''-:::-HI+--- 3

900072.A

1 Pointer 2 (N2 - ENG 2) 2 Pointer 1 (N2 - ENG 1) 3 Pointer R (main rotor)

Figure 91-22

BO 105 CHAPTER 91 Page 40

Triple RPM indicator

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 29

Troubleshooting - triple RPM indication system, N2 and NR

No. TROUBLE SYMPTOM 1

2

No N2 RPM indication, or erratic or sluggish indication of pointer 1 or pointer 2.

No RPM indiction of NR, or erratic or sluggish indication.

PROBABLE CAUSE

CORRECTlVE ACTION

Loose connector plate of tachogenerator.

Replace tachogenerator.

Respective tachogenerator defective.

Measure voltage output. With rotor RPM 100%: 21 ± 5 YAC (70.0 Hz)¡ replace tachogenerator, if necessary.

Faulty contact of electric connector

Check electric connector for contact, replace, if necessary.

Electric Wlrlng interrupted.

Check electric wlrlng per wiring diagram (refer to WDM), repair or replace if necessary.

Triple RPM indicator defective.

Check RPM indicator by provisionally replacing it¡ replace triple RPM indicator, if necessary.

Loose connector plate of tachogenerator.

Replace tachogenerator. Accomplish SB 90-24.

Respective tachogenerator.

Measure voltage output. with 100% RPM: 21 ± SVAC (70.0 Hz)¡ replace tachogenerator, if necessary.

Faulty contact of Check electric connector for electric connector. contact¡ replace, if necessary. Electric Wlrlng interrupted.

Check electric wiring per wiring diagram (refer to WDM)¡ repair or replace, if necessary.

Triple RPM indicator defective.

Check triple RPM -indicator by provisionally replacing it¡ replace triple RPM indicator, if necessary.

Table 91-3

Troubleshooting BO 105 CHAPTER 91 Page 41

- - - - - - - - - - - - - M B B HELICOPTERS"-------------MAINTENANCE MANUAL MBB - BO 105

91 - 30

Rernoval and installation - triple RPM indication systern, N2 and NR

1.

Rernoval and installation of the triple RPM indicator is perforrned in the sequence of the index numbers shown in figure 91-23.

2.

Rernove and install tachogenerator N2 in accordance with chapter 61.

3.

Rernove and install tachogenerator NR in accordance with chapter 11.

YI--H---- 4 ~'t---7 ~,,~!L_-~_!i~--

2

rra.-----2

900081

~----5

Figure 91-23

BO 105 CHAPTER 91 Page 42

1 Electrical connector 2 Screw 3 Shade 4 Electric wiring 5 Screw 6 Triple RPM indicator 7 Instrurnent panel

Rernoval and installation - triple RPM indicator

- - - - - - - - - - - - - - - M B B HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO 105

91 - 31

R P M i n die a t ion s y s t e m NI

The RPM indication system N1 (figure 91-24) is identical for both engines. The RPM indication system consists of: - tachogenerator N1 - RPM indicator NI - electric wiring and connectors

TO RPM WARNING DEVICE RPM INDICATOR N1 108 EN

ENGINE 1 RPM TACHOGENERATOR 102 EN

TO RPM WARNING DEVICE

RPM INDICATOR N1 208 EN

ENGINE 2

900511

Figure 91-24

RPM indication system N1 BO 105 CHAPTER 91

Page 43

- - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

900110.(

1 RPM indicator N1 108 EN, 208 EN 2 Tachogenerator NI 202 EN 3 Tachogenerator NI 102 EN Figure 91-25 BO 105 CHAPTER 91 Page 44

Component location - RPM indication system NI

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 A tachogenerator N1 is installed on the RH side of each engine gearbox. Tachogenerator N1, driven by the engine gearbox, generates an alternating voltage with a frequency proportional to the gas producer turbine RPM.

A synchronous motor in the RPM indicator N1 (figure 91-26) operated by the alternating voltage indicates the compressor RPM in per cent. 100 per cent corresponds to the maximum continous power of the compressor.

Figure 91-26

RPM indicator N1

BO 105 CHAPTER 91 Page 45

- - - - - - - - - - - - - M B B HELICOPTERS---------'----MAINTENANCE MANUAL MBB - BO 105 91 - 32

Troubleshooting - RPM indication system N1

No. TROUBLE SYMPTOM No N1 RPM indication, or erratic or sluggish indication.

PROBABLE CAUSE

CORRECTlVE ACTION

Connector plate of Replace tachogenerator. respective tachogenerator loose. Respective tachoge- Measure voltage output. At nerator defective. RPM 4200/min: 21 ±S YAC (70 Hz); replace tachogenerator, if necessary. Faulty contact of Check electric connector for electric connector. contact, replace, if necessary. Electric wiring interrupted.

Check electric wlrlng per wiring diagram (refer to WDM), repair or replace, if necessary.

RPM indicator defective.

Check RPM indicator by provisionally replacing it, replace RPM indicator, if necessary.

Table 91-4

91 - 33

Troubleshooting

Removal and installation - RPM indication system N1

1.

Removal and installation of the RPM indication system is performed in the sequence of the index numbers as outlined in figure 91-27.

2.

Remove and install tachogenerators N1 in accordance with chapter 61.

BO 105 CHAPTER 91 Page 46

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3

2

5 4

900083

1 Electric connector Screw RPM indicator 4 Instrument panel 5 Lamp

2 3

Figure 91-27

Removal and installation - RPM indicator

BO 105

CHAPTER 91 Page 47/48

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

91 - 34

Tri p 1 e o i 1 P r e s s u r e s y s t e m

i n die a t ion

The triple oil pressure indication system (figure 91-28) consists of: - 3 oil pressure transmitters - triple oi1 pressure indicator - fuse, e1ectric wiring and connectors MAIN BUS

PP21

28V-

FUSE 5E

r

---

I

I

TRIPLEOIL -, PRESSURE INDICATOR 4 ED

OIL PRESSURE TRANSMITTER 101 ED

r---""

I

I

I I

I ENGINE

1

I _.J

--

OIL PRESSURE TRANSMITTER 201 ED

r---l I

I

I ENGINE 2 I

--

J

OIL PRESSURE TRANSMITTER 301 ED

. r-

--l

I I

900S0S

Figure 91-28

-- -

I MA1N I TRANSMISSION I _.J

--

Triple oil pressure indication system BO 105 CHAPTER 91

Page 49

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

900110.D

Triple oil pressure indicator systern 4 ED 2 Oil pressure transrnitter 301 ED 3 Oil pressure transrnitter 201 ED 4 Oil pressure transrnitter 101 ED

1

Figure 91-29

BO 105 CHAPTER Page 50

91

Cornponent location - triple oil pressure indication systern

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The oil pressure transmitters 101 ED and 201 ED of engines 1 and 2 are connected to the respective oil pressure lines in the bottom of the engine compartment. The oil pressure transmitter 301 ED of the main transmission is connected to the transmission pressure line on the engine deck between fire wall and main transmission. The oil pressure transmitters are pressure sensitive potentiometers, whose resistance varies proportional to the oil pressure. This resistance value influences the voltage supplied to the triple oil pressure indicator (figure 91-30). The oil pressure is indicated in ftbar ft (kp/cm2 ). The triple oil pressure indicator is supplied with voltage from main bus PP21 via fuse 5E.

Figure 91-30

Triple oil pressure indicator

BO 105 CHAPTER 91 Page 51

- - - - - - - - - - - - - M B B HELICOPT:E:RS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 35

Troubleshooting - triple oil pressure indication systern

No. TROUBLE SYMPTOM 1

No indication on triple oil pressure.

PROBABLE CAUSE

CORRECTlVE ACTION

Fuse SE blown.

Check fuse; replace if necessary indicator.

Triple oil pressure Check triple oil pressure indicator defective.indicator by provisionally replacing it; replace triple oil pressure indicator, if necessary.

2

End scale deflection of pointer(s) on triple oil pressure indicator.

Respective oil transmitter defective.

Short electric connector of oil pressure transmitter; if pointer is deflected replace respective oil pressure transmitter.

Faulty contact of an electric connector.

Check electric connector for contact; replace if necessary.

Electric wiring interrupted.

Check electric wlrlng per wiring diagram (refer to WDM); repair or replace, if necessary.

Grounded electric wiring.

Check electric wiring per wiring diagram (refer to WDM); repair or replace if necessary.

Respective oil pressure transmitter grounded.

Check oil pressure transmitter; replace if necessary.

Table 91-5

BO 105 CHAPTER 91 Page 52

Troubleshooting

- - - - - - - - - - - - - M B B HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO 105

91 - 36

Removal and installation - triple oil pressure indication system

1.

Remove and install triple oil pressure indicator in accordance with paragraph 91-33.

2.

Remove and install oil pressure transmitters of the engines in accordance with chapter 63.

3.

Remove and install oil pressure transmitter of main transmission in accordance with chapter 11.

91 - 37

Functional test - triple oil pressure indication system

Perform functional test of triple oil pressure indication system during ground run .

BO 105 CHAPTER 91

Page 53

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

91 - 38

Tri p 1 e o i 1 t e m p e r a t u r e s y s t e m

i n die a t ion

The triple oil temperature indication system (figure 91-31) consists of: - 3 oil temperature bulbs, - triple oil temperature indicator, - fuse, electric wiring and connectors. MAIN BUS PP21

28V-

í - - - - - ---1 I

I I I I

TRIPLE OIL TEMPERATURE INDICATOR 5 ED

U-~---"""'V1VV'+--tI11

I

I I I

o------+-"v1~v'+_ .... 11

L

ENGINE

2

OIL TEMPERATURE BULB 302 ED

I I

ENGINE 1

OIL TEMPERATURE BULB 202 ED

I I

OIL TEMPERATURE BULB 102 ED

u------+J' V1¡J v'+-""'"

1I ~:Á~SMISSION

-1

900506

Figure 91-31 BO 105 CHAPTER 91

Page 54

Triple oil temperature indication system

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

&

EFFECTIVITY

S/N 7-160

1 Triple oil temperature indicator 5 ED 2 Oil temperature bulb 302ED

&

EFFECTIVITY

S/N 161 and subsequent

3 Oil temperature bulb 202ED 4 Oil temperature bulb 102ED

Figure 91-32

Component location - triple oil temperature indication system

BO 105 CHAPTER 91 Page 55

- - - - - - - - - - - - - M E B HELICOPTERS'-------------MAINTENANCE MANUAL MEB - BO 105

The oil temperature bulbs of engine 1 and engine 2 are installed to the respective oil lines in the LH and RH upper sections of the engine cornpartrnent. The oil ternperature bulb'of the rnain transrnission is installed to the oil line at the inlet of the fine filter. EFFECTIVITY

S/N 161 and subsequent: The oil ternperature bulb of the rnain transrnission is installed to the oil pump below the rnain transrnission.

The oil ternperature bulbs accornrnodate a heat sensitive resistor whose resistance varies proportional to the oil ternperature. This resistance influences the voltage supplied to the triple oil ternperature indicator (figure 91-33). The oil ternperature is indicated in "OC". The triple oil ternperature indication systern is supplied with voltage frorn rnain bus PP21 via fuse 6E.

Figure 91-33

BO 105 CHAPTER 91 Page 56

Triple oil ternperature indicator

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 39

Troubleshooting - triple oil pressure indicating system

No.TROUBLE SYMPTOM 1

2

No indication on triple oil temperature indicator.

Full-scale deflection of pointer(s) of triple oil temperature indicator.

PROBABLE CAUSE

CORRECTlVE ACTION

Fuse 6E blown.

Check fuse; replace if necessary.

Triple oil temperature indicator defective.

Check triple oil temperature indicator by provisionally replacing it; replace triple oil temperature indicator, if necessary.

Respective oil temperature bulb defective.

Short electric connector of oil temperature bulb; if pointer is deflected, replace respective oil temperature bulbo

Faulty contact of electric connector.

Check electric connector for contact; replace if necessary.

Electric wlnng interrupted.

Check electric wiring per wiring diagram (refer to WDM) ; repair or replace, if necessary.

Electric wiring short to ground.

Check electric wlrlng per wiring diagram (refer to WDM); repair or replace, if necessary.

Respective oil temperature bulb short to ground.

Check oil temperature bulb; replace if necessary.

Table 91-6

Troubleshooting

BO 105 CHAPTER 91 Page 57

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

91 - 40

Removal and installation - triple oiltemperature indication system

1.

Remove and install triple oil temperature indicator in accordance with para. 91-33.

2.

Remove and install engine oil temperature bulbs in accordance with chapter 63.

3.

Remove and install main transmission oil temperature bulb in accordance with chapter 11.

BO 105 CHAPTER

Page 58

91

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 41

T O T i n d i c a t ion

5

y

5

t e m

The TOT indication system (figure 91-34) consists of: - 2 thermocouple harnesses - 2 TOT indicators - 2 trim resistors

- electric wiring and connectors

THERMOCOUPLE HARNESS 101 EL TRIM RESISTOR 104 EL

ENGINE 1 TOT INDICATOR 105 EL

THERMOCOUPLE HARNESS 201 EL TRI M RESISTOR 204 EL

ENGINE 2

900512

TOT INDICATOR 205 EL

Figure 91-34

Tor indication system

BO 105 CHAPTER 91 Page 59

HELICOPTERS - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-----------MBB

=~== . =~.=._=-=' ~._..

/. /.

1/

I

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/1

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2

3

900110.F

1 TOT indicators 105 EL and 205 EL Trirn resistors 104 EL and 204 EL 2 Therrnocouple harness 201 EL 3 Therrnocouple barness 101 EL Figure 91-35 BO 105 CHAPTER 91 Page 60

Cornponent location - TOT indication systern

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The TOT of eaeh engine is measured in the third power turbine stage by a thermoeoup1e harness. The thermoeouple harness eonsists of four thermoeouples eonneeted in parallel. When heated they generate a voltage proportional to the average TOT value. The voltage for eaeh engine is separately displayed in "OC" in a. TOT indieator (figure 91-36). Adjustment of the TOT indieation is aeeomplished with an adjustable trim resistor whieh is installed in the instrument panel.

TOT indieator with linear seale

* * *

TOT indieator with spread seale

* Figure 91-36 . TOT indieator

Revision 2

BO 105 CHAPTER 91 Page 61

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 42

Troubleshooting - TOT indication system

No.TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

TOT indicator defective.

Check TOT indicator¡ replace if necessary.

Trim resistor defective.

Check trim resistor¡ replace if necessary.

Electric wiring interrupted.

Check electric wlrlng per wiring diagram (refer to WDM)¡ repair or replace if necessary.

Thermocouple harness defective ..

Check thermocoup1e harness¡ replace if necessary.

Maladjusted TOT indication.

Adjust TOT indioation.

Thermocouple harness defective.

Check thermocouple harness; replace if necessary.

TOT indicator defective.

Check TOT indicator; replace if necessary.

2

No indication on TOT indicator.

Wrong indication on TOT indicator.

Table 91-7

BO 105 CHAPTER 91 Page 62

Troubleshooting

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Removal and installation - TOT indication system

91 - 43 l.

Remove and install TOT indicators in accordance with para. 91-33.

2.

Remove and install thermocouple harnesses in accordance with Allison Operation and Maintenance Manual.

3.

Trim resistor a.

Remove fairing from instrument panel as necessary.

b.

Disconnect electric wiring from respective trim resistor.

c.

Loosen fastening screws and detach trim resistor.

d.

Install trim resistor in reverse order of removal.

91 - 44

F REE

91 - 45

Calibration - TOT indication system

l.

Calibrate thermocouple harnesses. a.

Disconnect thermocouple leads from terminal box (figure 91-37) 138VV (Eng 1) and 236VV (Eng 2) .

b.

Measure resistance of thermocouple harnesses 101 EL (201 EL) of both engines. 1)

Resistance with 635 mm lead: 0.5 - 0.6 Ohm.

2)

Resistance with 812 mm lead: 0.65 - 0.75 Ohm.

BO 105 CHAPTER 91 Page 63

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Measure insulation resistance with 500 V between thermocouple harness and connecting flange (shield). Insulation resistance must be at least 2.0 kOhm.

d.

Remove TOT indicators 105 EL (205 EL) and short circuit the chromel and alumel lines with a clamping screw.

e.

Connect alumel line (green) to junction box 138VV (236VV).

f.

Connect precision resistance bridge to chromel line (white) disconnected in step a.

g.

Calibrate thermocouple harness 101 EL (201 EL) to a total resistance of 8 ± 0.10 Ohm, using trim resistor 104 EL (204 EL).

h.

Re-connect and re-install both TOT indicators 105 EL (205 EL) .

i.

Disconnect resistance bridge on chromel line (white) from terminal junction 138VV (236VV).

* * 2. Calibrate TOT indicator with linear scale (see figure 91-36). * a.

Connect a DC power source (mV) in accordance with figure 91-37. TERMINAL JUNCTION

THERMOCOUPLE HARNESS 101 EL (201 EL)

ALUMEL LINE GREEN

TOT INDICATOR 105 EL (205 EL)

138 W (236 W)

r-,

I I ~--------t-QJ

CHROMEL LINE WHITE

TRIM RESISTOR 104 EL (204 EL)

OC POWER SOURCE (mV) 900205

Figure 91-37

BO 105 CHAPTER 91 Page 64

Calibration - TOT indication system

Revision 2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Measure ambient temperature. NOTE

*

c.

Adjust DC power source (mV) to 29.14 mV.

d.

The r~spective TOT indicator must indicate 700 oC ± 7 oC plus ambient temperature. Re-adjust TOT indicator, if necessary.

e.

Check the following indications:

Ambient temperature

mV setting

Nominal TOT oC

20 oC 20 oC 20 oC

36.56 19.84 11. 41

900 ± 20 500 ± 20 300 ± 20

A deviation change of A deviation change of + f.

3.

Ensure that the ambient temperature does not fluctuate during the calibration procedure.

of + 0.04 of 0.04

1 °Cfrom the ambient temperature equals an mV setting mV. 1 oC from the ambient temperature equals an mV setting mV.

Disconnect DC power source (mV) and reconnect thermocouple leads (alumel lead has terminal with larger bore) .

Calibrate TOT indicator with spread scale (see figure 91-36). a.

Connect DC power source (mV) as shown in fig. 91-37.

b.

Measure ambient temperature. NOTE

Ensure that the ambient temperature does not fluctuate during the calibration procedure.

c.

At an ambient temperature of 20 oC, set DC power source (mV) to 32.91 mV ± 0.01 mV.

d.

The respective TOT indicator reading shall be 810 oC ± 2°C. If necessary, adjust TOT indicator by turning the adjusting screw located on the back of the indicator. At other ambient temperatures, correct the nominal TOT reading for the amount of deviation from 20°C.

Revision 3

BO 105 CHAPTER 91 Page 65

* *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 e.

verify the following readings:

. Ambient temperature 20 oc 20 oC 20 oC 20 oC A deviation change of A deviation change of +

f.

of + 0.04 of 0.04

mV setting

Nominal TOT oC

36.56 34.55 32.51 30.43

900 850 800 750

±

0.01

± 0.01 ± ±

0.01 0.01

± ± ± ±

20 20 -5 5 5

1 oC from the ambient temperature equals an mV setting mV. 1 oC from the ambient temperature equals an mV setting mV.

Disconnect DC power source (mV) and reconnect thermocouple leads (alumel lead has terminal with larger bore) .

BO 105 CHAPTER 91 Page 66

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

91 - 46

D u a 1 f u e 1 q u a n t i t Y i n die a t ion s y s t e m

The dual fuel quantity indication system (figure 91-38) consists of - fuel quantity transmitter in main tank, - fuel quantity transmitter in supply tank, - dual fuel quantity indicator, - fuse, electric wiring and connectors.

MAlN BUS

PP21

2SV-

r--------, I DUAL FUEL aUANTITY I I

INDICATOR 5 EB

I I

~

I I

I all--C~

A

FUEL aUANTITY TRANSMITTER 1 EB

I

s

MAINTANK

I

I

L __ 900510

.1.....o,v,lO I

[=1 Figure 91-38

FUEL aUANTITY TRANSMITTER 2 EB

SUPPLYTANK

Dual fuel quantity indication system

The dual fuel quantity indication system indicates the fuel quantity in the main and supply tank. Fuel quantity transmitter 1 EB is installed in the main tank, fuel quantity transmitter 2 EB in the supply tank. The fuel quantity transmitters are float gages with the resistance varying proportionally to the fuel level. BO 105 CHAPTER 91

Page 67

- - - - - - - - - - - M B B HELICOPTER5'----------MAINTENANCE MANUAL MBB - BO 105

1 Fuse dual 2 Fuel 3 Fuel

Figure 91-39 BO 105 CHAPTER 91

Page 68

3 E and fuel quantity indicator 5 EB quantity transmitter 2 EB quantity transmitter 1 EB

Component location - dual fuel quantity indication system

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 A change in the applied voltage is indicated in "kp x 10" on the dual fuel quantity indicator. The left "M" scale indicates the fuel quantity of the rnain tank, the right "S" scale indicates the fuel qUantity of the supply tank. EFFECTIVITY

o

S/N 7 - 120 A red warning light is located in the bottorn section of the dual fuel quantity indicator 5 EB. It comes on together with the warning light 7 EB "LOW FUEL" when the low fuel warning systern is activated.

o

S/N 121 and subsequent Indication only by warning light 7 EB "LOW FUEL" (refer to chapter 92).

The dual fuel quantity indication systern is supplied with electrical power frorn rnain bus PP21 and, if installed, frorn ernergency bus PP20 via fuse 3 E.

Figure 91-40

Dual fuel quantity indicator

BO 105 CHAPTER 91 Page 69

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 91 - 47

Troubleshooting - dual fuel quantity indication system

No.TROUBLE SYMPTOM 1

2

3

No reading on dual fuel quantity indicator.

No pointer indication on scale M of dual fuel quantity indicator.

No pointer indication on scale S of dual fuel quantity indicator.

PROBABLE CAUSE

CORRECTIVE ACTION

Fuse 3 E blown.

Check fuse; replace if necessary.

Dual fuel quantity indicator defective.

Check dual fuel quantity indicator; replace if necessary.

Electric Wlrlng interrupted.

Check electric wlrlng per wiring diagram (refer to WDM); repair or replace, if necessary.

Fuel quantity transmitter 1 EB defective.

Check fuel quantity transmitter 1 EB; replace if necessary.

Dual fuel quantity indicator defective.

Check dual fuel quantity indicator; replace if necessary.

Electric wiring interrupted.

Check electric wiring per wiring diagram (refer to WDM); repair or replace, if necessary.

Fuel quantity transmitter 2 EB defective.

Check fuel quantity transmitterr 2 EB, replace if necessary.

Dual fuel quantity indicator defective.

Check dual quantity indicator; replace if necessary.

Electric wiring interrupted.

Check electric wiring per wiring diagram (refer to WDM); repair or replace, if necessary.

Table 91-8

BO 105 CHAPTER 91 Page 70

Troubleshooting

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

91 - 48

Removal and installation - dual fuel quantity indication system

1.

Remove and install dual fuel quantity indicator in the sequence of the index numbers outlined in figure 91-41.

2.

Remove and install fuel quantity transmitters in accordance with chapter 62.

3

900157

4

5

2

1 2 3 4 5

Figure 91-41

Screw Dual fuel quantity indicator Connector Electric connector Instrument panel

Removal and installation - dual fuel quantity indicator BO 105 CHAPTER 91 Page 71

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

91 - 49

Du a 1 f u e 1 p r e s s u r e s y s t e rn

i n die a t ion

The dual fuel pressure indication systern (figure 91-42) consists of: - 2 fuel pressure transrnitters - dual fuel pressure indicator - fuse, electric wiring and connectors

MAIN BUS PP21

28V-

1 - - - - - - --1 I I

I DUAL FUEL PRESSURE INDICATOR 2 EA

I I I I I

I

I

I ENG 1

I

FUEL PRESSURE TRANSMITTER 101 EA

I I

I I I

ENGINE 1

I

I 1 I

900509

L

Figure 91-42 BO 105 CHAPTER

Page 72

91

FUEL PRESSURE TRANSMITTER 201 EA

ENG 2

1

-.J

8

111'-<"""0

Dual fuel pressure indication systern

ENGINE2

- - - - - - - - - - - M B B HELICOPT"E:RS'----------MAINTENANCE MANUAL MBB - BO 105

~·---=.-_·~---·.==-·---~'-=:3~·· ~ _'~' i \ ._--~.

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( I ~'

//

L....j

.

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.

.

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--l..-:-:7'

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900112

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L . ' - . = .j!/ "

/

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._.._. .~.-=c:::=\

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... --.11_.-/_.___

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-

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~:::i~==-..,....--,-.d.b

1.

'~~:J

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o

-':"'-:JC'=:(

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. I!'

,

~':.-'

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.

.

."

3

<:2~.c::==.:.=-::=:_' =::ñJn> .~

1 Fuse 7 E and dual fuel pressure indicator 2 EA 2 Fuel pressure transmitter 201 EA 3 Fuel pressure transmitter 101 EA

Figure 91-43

Component location - dual fuel pressure indication system BO 105 CHAPTER 91 Page 73

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The dual fuel pressure indication system (figure 91-42) indicates the pressure in the supply lines between supply tank and both engines. The fuel pressure transmitters are installed in the respective supply lines. Each fuel pressure transmitter comprises a pressure sensitive resistor, whose resistance varies proportionally to the fuel pressure in the supply lines. Resistance variation produces variations of the voltage which is supplied to the dual fuel pressure indicator (figure 91-44) and indicated in "kp/cm21 . The red pointer on scale "1n indicates the fuel pressure for engine 1, the green pointer on scale "2" indicates the fuel pressure for engine 2. Voltage for the dual fuel pressure indication system is supplied from main bus PP21 and, if installed, from emergency bus PP20 via fuse 7 E.

900233

Figure 91-44

BO 105 CHAPTER 91 Page 74

Dual fuel pressure indicator

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 50

Troubleshooting - dual fuel pressure indication system

No.TROUBLE SYMPTOM 1

2

3

No reading on dual fuel pressure indicator.

No indication of red pointer on dual fuel pressure indicator.

No indication of green pointer on dual fuel pressure indicator.

PROBABLE CAUSE

CORRECTIVE ACTION

Fuse 7 E blown.

Check fuse¡ replace if necessary.

Dual fuel pressure indicator defective.

Check dual fuel pressure indicator¡ replace if necessary.

Fuel pumps in the supply tank do not operate.

Switch on fuel pumps per chapter 92.

Both emergency fuel valves closed.

Open emergency fuel valves per chapter 92.

Electric wiring interrupted.

Check electric wiring per wiring diagram (refer to WDM)¡ repair or replace if necessary.

Dual fuel pressure indicator defective.

Check dual fuel pressure indicator¡ replace if necessary.

Emergency fuel valve "1" closed.

Open emergency fuel valve "1" per chapter 92.

Fuel pressure mitter 101 EA dedefective.

Check fuel pressure transmitter; replace if necessary.

Electric wiring interrupted.

Check electric w~r~ng per wiring diagram (refer to WDM)¡ repair or replace, if necessary.

Dual fuel pressure indicator defective.

Check dual fuel pressure indicator; replace if necessary.

Emergency fuel valve "11" closed.

Open emergency fuel valve "n" per chapter 92.

Table 91-9

Troubleshooting (1 of 2) BO 105 CHAPTER 91 Page 75

- - - - - - - - - - - - - MBB HELICOPTERS·------------MAINTENANCE MANUAL MBB - BO 105 Troubleshooting (continued) No.TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

Fuel pressure Check fuel pressure transtransmitter 201 EA mitter; replace if defective. necessary. Electric wiring interrupted.

Table 91-9

91 - 51

Troubleshooting

Check electric wlrlng per wiring diagram (refer to WDM); repair or replace, if necessary.

(2 of 2)

Removal and installation - dual fuel pressure indication system

l.

Remove and install dual fuel pressure iridicator in accordance with paragraph 91-48.

2.

Remove and install fuel pressure transmitters in accordance with chapter 62.

BO 105 CHAPTER 91 Page 76

----~--------MBB HELICOPTERS'-------------

MAINTENANCE MANUAL MBB - BO

91 - 52

D u a len g i n e t o r q u e

105

i n die a t i n g s y s t e m

The dual engine torque indicating system (figure 91-45) consists of: - dual torque indicator - hose/tube lines

,-----------,

HOSE UNE

I

I

I I

I DUAL TOROUE INDICATOR

I I

I

I

I

I

I I

'-~---i--1

HOSE UNE

I 1-----'--..... I

I I _ _ _ _ --.l

TUBE UNE

TUBE UNE

HOSE UNE

HOSE UNE

•

•

ENGINE 1

ENGINE 2

900507

Figure 91-45

Dual engine torque indicating system

BO 105 CHAPTER 91

Page 77

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

4

1 2 3 4

Hose line Dual torque indicator Tube line Torque pressure connection engine 1 5 Torque pressure connection engine 2

Figure 91-46 BO 105 CHAPTER

Page 78

91

Component location - dual engine. torque indicating system

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The dual engine torque indicating system provides indication of the torque of the No. 1 and No. 2 engines. The torque measuring shaft of the reduction gearbox of each engine supplies hydraulic pressure which is proportional to the torque of the drive shaft. This hydraulic pressure is transferred via a hose and tube assembly from the torque pressure connection on the reduction gearbox of each engine to the dual torque indicator (figure 91~47) mounted in the instrument panel, where it is displayed in "% TORQUE". The pointers, one for each engine, are labelled "1" and "2" and indicate No. 1 and No. 2 engine torque respectively. To prevent the pointers on the dual torque indicator from fluttering, it is necessary to build up an air cushion in their respective tube and hose lines. This air cushion is built up by purging the tube and hose lines of all oil. Purging must be uniform to prevent torque split indications.

Figure 91-47

Dual torque indicator

BO 105 CHAPTER 91 Page 79

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 53

Troubleshooting - dual engine torque indication system

No.TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

No reading on dual torque indicator.

Dual torque indicator defective.

Check dual torque indicator; replace if necessary.

2

Sluggish indication on dual torque indicator.

Dual torque indicator defective.

Check dual torque indicator; replace if necessary.

Hose/tube lines clogged.

Check hose/tube lines for free passage. Remove obstructions or replace lines, as necessary.

3

Pointer flutter on dual torque indicator.

No air cushion in hose/tube line(s) or air cushion is inadequate.

Purge hose/tube line(s) of aH oil.

4

Dual torque indicator pointers do not superimpose.

Differing air cushions in hose/ tube lines.

Purge both hose/tube lines of aH oil.

Hose/tube line circuit leaks.

Check hose/tube line for leakage; seal or replace, as necessary.

Table 91-10

BO 105 CHAPTER 91 Page 80

Troubleshooting

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 54

Rernoval and installation - dual engine torque indicating systern

1.

Rernove and install dual torque indicator as shown in figure 91-48.

2.

Catch escaping oil in a suitable container.

3.

Blank off open hose lines and connections.

900443

Figure 91-48

Screw Dual torque indicator 3 Instrurnent panel 4 Hose lines

1 2

Rernoval and installation - dual torque indicator

BO 105 CHAPTER 91 Page 81

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4.

Removal - hose line (2, fig. 91-49) a.

Remove battery and instrument panel fairing to extent necessary for access.

b.

Remove attaching screws of dual torque indicator (1).

c.

Unscrew and remove union (4), discard gasket, and catch escaping oil in a suitable container.

d.

Blank off tube line (5).

e.

Withdraw dual torque indicator (1) from instrument panel (6) und unscrew and remove union (3).

f.

Discard gasket and remove hose line (2). Blank off hose connection on dual torque indicator.

4 6---f-

-+- -1- +- + 1 -+- -4- -t- -'- +, : -+- -t- -1- ...... +1 1

Vi.:r---- 5

-l-

: -l--+_+~+:

: -+- + -+-- -1- -1- 1

: ..¡... -+- -l- -1- -1- : : --l- -4- -+- -1- + I

, ~-l--+-++: : +++++1

'+;-++--+'

'¿

900442

Figure 91-49 BO 105 CHAPTER 91 Page 82

... Dual torque indicator Hose line Union Union 5 Tube line 6 Instrument panel

1 2 3 4

Removal and installatipn - hose lines

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

5.

Installation - hose line (2, fig. 91-49) a.

Connect hose line to tube line (5) together with a new gasket.

b.

Provide hose/tube lines with air cushion by purging lines of all oil according to para 91-57.

c.

Screw hose line to dual torque indicator (1) together with new gasket.

d.

Install dual torque indicator securely in instrument panel (6).

e.

Install previously removed instrument panel fairings and battery.

f.

Check oil,level in both engines and replenish as necessary (refer to Chapter 63).

g.

Perform functional test according to para 91-56.

91 - 55

Inspection for condition - dual engine torque indicating system

1.

Inspect dual torque indicator for cleanliness, damage, secure fit and leaks.

2.

Inspect hose/tube line connections for leaks and secure installation; retighten if necessary.

3.

Check electrical connector for secure installation.

91 - 56

Functional test - dual engine torque indicating system

ii!spec~ dual engine tOLque indicaL~ng sjsLem conjunction with ground run or test flight.

{OI proF~r

functioning in

BO 105 CHAPTER 91

Page 83

MAINTENANCE MANUAL BO 105

EUROCOPTER

91 - 57

Purging - dual torque indicator (engines)

NOTE

To obtain torque readings from both engines without pointer vibration, the respective torque Iines attached to the dual torque indicator must be air purged. To avoid mixing up the torque line connections, only one torque line shall be disconnected at one time.

1. Disconnect hose end of one of the torque lines (2, fig. 91-49) from dual torque indicator (1). Catch escaping oi! in a suitable container. 2. Disconnect tube end of the same torque line from the connection on the transmission deck. When unscrewing the attaching hardware, hold the fitting to prevent rotation. Catch escaping oil in a suitable container. 3. Using protective cap, blank off open end of torque tine leading to the engine. 4. Using compressed air, carefully blow through the combined hose/tube line until all oi! has been expelled. Catch escaping oi! in a suitabJe container. 5. Remove protective cap and reconnect torque line on the transmission deck. 6. Reconnect hose end of torque line to the dual torque indicator. 7. Repeat step 1 thru step 6 with the other torque line. 8. Perform inspection for condition (refer to para 91-55).

9. Perform functional test (refer to para 91-56). NOTE

CHAPTER 91 Page 84

If the pointers on the dual torque indicator indicate vibration, repeat air purge until torque readings are obtained without pointer vibration.

Revision 18

- - - - - - - - - - - - - - M B B HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO 105 91 - 58

MISCELLANEOUS INSTRUMENTS

Miscellaneous instruments consist of the following: - Arnmeter and voltmeter - Clock - Outside air'temperature indicator

91 - 59

Arnmeter and voltmeter

Arnmeter and voltmeter are the monitoring instruments of the helicopter's electrical system (figure 91-50). They are installed in the horizontal section of the instrument panel (figure 91-4, 91-5, 91-6).

BO 105 CHAPTER 91 Page 85

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

,--------1 I

I

I I I

MAIN BUS •

PP21

28V;

VOLTMETER 18P

I

0

I

I I

I

I I

I I I

I I I

AMMETER 19P

I

I

I

I

I i

L ___

...

...

I

- - - ___ J

+

GEN 1 BAT GEN 2

STARTERGENERATORl

1II

~-

-- --

AMMETER SELECTOR SWITCH 24P

~ 1] L

STARTERGENERATOR 2

MAIN BUS PP21

900508

Figure 91-50

BO 105 CHAPTER 91 Page 86

Monitoring instruments of the helicopter's e1ectrical system

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Depending on the position of the toggle switch DC LOAD (refer to chapter 92) the arnmeter (figure 91-51) indicates the current at the following measuring points: - main bus PP21, - starter-generator 1, - starter-generator 2. If the arnmeter not operated the pointer is in zero center position.

900225

o Figure 91-51

o Arnmeter

The voltmeter (figure 91-52) indicates the voltage of main bus PP21.

900225.A

o Figure 91-52

o Voltmeter BO 105 CHAPTER 91

Page 87/88

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 60

C1 o c k

The clock (figure 91-53) is installed in the center of the horizontal section of the instrument panel (figure 91-2). The clock is a chronometer with hands for hours and minutes·and a mechanical stop device for seconds and minutes. A knurled knob (4) is used to wind and set the clock. To set the correct time, lever (2) on the RH side next to the knurled knob has to be pulled downward. The start/stop/reset knob (3) of the stop device is below the knurled knob. During the stopping, hand (5) counts the seconds and the hand of the auxiliary scale (1) the number of rotations of the second hand up to the maximum of 15 minutes. The stopping can be interrupted with the lever as required. In addition, the clock has an adjustable setting ring (6) with minute increments.

6

---+---,~

~----2

+-------3

900143

1 2

3 4 5

6

Auxiliary scale Lever Start/stop/reset knob Knurled knob Second hand Setting ring

Figure 91-53

Clock BO 105 CHAPTER 91 Page 89

-----------~-MBB

HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS

91 - 61 No.

Troubleshooting - clock

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

Clock inoperative or incorrect indication of local time.

Clock defective.

Replace clock.

Table 91-11

91 - 62

Troubleshooting

Removal and installation - clock

Remove and install clock in sequence of the index numbers as outlined in figure 91-54. 2 3 11

10

6

'1

¡!

I.•

8

1 2 3 4 5 900145

9

6 7 8 9

la

11

Figure 91-54 BO 105 CHAPTER 91 Page 90

Electric cable Connector Nut Washer Instrument lamp Spacer Nut Washer Bolt Clock Instrument panel

Removal and installation - clock

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

91 - 63

Functional test - clock

l.

Wind up clock.

2.

Set clock to local time. - The clock must indicate the respective local time.

3.

Testing the stop function. a.

Push start-stop-reset knob (3, figure 91-53). - Second hand (5) must runo - After one minute the hand of auxiliary dial (1) must be over the first radial lineo

b.

Pull lever (2) downward. - Second hand must stop.

c.

Push lever upward. - Second hand must run again.

d.

Push start-stop-reset knob. - Second hand must stop.

e.

Push again start-stop-reset knob. - Second hand and hand of the auxiliary dial must fly back to zero .

•

BO 105 CHAPTER 91

Page 91

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 64

Ou t s i d e a i r i n die a t o r

t e mp e r a t u r e

The outside air temperature indicator (figure 91-56) is installed in the canopy, forward RH side, above the pilot's seat (figure 91-55).

9DD442.A

Figure 91-55

Location - outside air temperature indicator

The outside air temperature indicator is a rod-shaped bimetallic thermometer. The temperature sensor (5, figure 91-57) is located in a protective tube (1). Two rubber seals (3 and 6) prevent the ingress of humidity and dirt into the cockpit . The outside air temperature is indicated in "OC" and "OF".

BO 105 CHAPTER 91 Page 92

- - - - - - - - - - - - - M B B · HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

900142

Figure 91-56

91 - 65 No.

Outside air temperature indicator

Troubleshooting - outside air temperature indicator

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

Incorrect temperature indication.

Outside air temperature indicator defective.

Replace outside air temperature indicator.

Table 91-12

Troubleshooting

BO 105 CHAPTER 91 Page 93

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 91 - 66

Removal and installation - outside air temperature indicator

1.

Remove and install outside air temperature indicator in the sequence of the index numbers as outlined in figure 91-57.

2.

Inspect both rubber seals (3, 6, figure 91-57) for damage prior to installation of the outside air temperature indicator; discard if necessary.

3.

The outside air temperature indicator must be installed such that it can be easily read by the piloto

~--2

~--3

....., ' y - - - - - 4

1 2

3

4 5 900144

Figure 91-57

91 - 67

6 7

Protective tube Washer Rubber seal Outside air temperature indicator Temperature sensor Rubber seal Canopy

Removal and installation - outside air temperature indicator

Functional test - outside air temperature indicator

Check the accuracy of the indicator by comparing its reading with a calibrated thermometer.

BO 105 CHAPTER 91 Page 94

HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO 105

-------------MBB

92

E LEC TRI CAL

S Y S T E MS

Table of Contents

Page

Paragraph

Title

92 - 1

GENERAL

9

92 - 2

Cornmon electrical components of the electrical systems

9

92 - 3

Removal and installation - ,cornmon electrical components

9

92 - 4

Inspection - cornmon electrical components

10

92 - 5

Main relay box 1VE

14

92 - 6

Relay box 10VE

20

92 - 7

DC POWER SYSTEM

23

92 - 8

Component location - DC power system

25

92 - 9

DC power system controls

31

92 - 10

Generator operation

41

92 - 11

Operation - battery power

48

92 - 12

Operation - external power

48

92 - 13

Power distribution

49

92 - 14

Protection of DC power system circuits

53

92 - 15

Troubleshooting - DC power system

55

92 - 16

MAINTENANCE - DC POWER SYSTEM

60

92 - 17

Check and adjustment of generator voltage

60

92 - 18

Gen e r a t o r

92 - 19

Starter generators

65

92 - 20

Removal and installation - starter-generators

67

92 - 20A

Inspection and maintenance - starter-generators

69

92 - 21

Voltage regulators

.

70

s y s t e m

.... -

62

BO 105 CHAPTER 92 Page 1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Paragraph

Title

92 - 22

Removal and installation - voltage regulators .

71

92 - 23

Inspection and maintenance - voltage regulators

72

92 ,.. 24

Functional test - generator system

..

72

92 - 25

B a t ter y p o w e r

92 - 26

Battery

76

92 - 27

Removal and installation - battery

76

92 - 28

Inspectiori and maintenance - battery

77

92 - 29

Functional test - battery power system

79

92 - 30

E x ter n a 1

81

92 - 31

External power receptacle

83

92 - 32

Inspection and maintenance - external power receptacle

83

92 - 33

Functional test - external power system

83

92 - 34

Mo n i t o r i n g - D C P o w e r

85

92 - 34A

Voltmeter and arnmeter

85

92 - 34B

Generator failure warning

87

92 - 34C

External power engagement warning

87

92 - 34D

Generator overheat warning

88

92 - 34E

Battery temperature warning

88

92 - 35

Battery temperature switches

89

92 - 36

Removal and installation - battery temperature switches90

92 - 37

Inspection and maintenance - battery temperature switches

92 - 38

Functional test -

92 - 39

STARTER AND IGNITION SYSTEM

91

92 - 40

Locations - starter and ignition system.

92

92 - 41

Protection of circuits of starter and ignition system

97

92 - 42

Troubleshooting - starter and ignition system

97

92 - 43

Inspection - starter and ignition system

BO 105 CHAPTER 92 Page 2

Page

p o we r

De

75

s y s t e m

s y s t e m

s y s t e m

power system monitoring equipment

90 90

100

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Paragraph

Title

Page

92 - 44

S t a r ter

92 - 45

Functional test - starter system

105

92 - 46

1 g n i t ion

107

92 - 47

Functional test - ignition system

108

92 - 48

ENGINE AND MAIN TRANSMISSION SYSTEMS

109

92 - 49

Locations - engine and main transmission systems

110

92 - 50

Protection of engine and main transmission systems

112

92 - 51

Mo n i t o r i n g

s y s t e ms

118

92 - 52

RPM monitoring - engines and rotor

118

92 - 53

RPM warning NI and NR

119

92 - 54

N2 overspeed warning

121

92 - 55

Troubleshooting

RPM monitoring, engines and rotor

122

92 - 56

Functional test - RPM monitoring, engines and rotor

124

92 - 57

Chip detector system

126

92 - 58

Oil pressure monitoring

127

92 - 59

Temperature monitoring

133

92 - 60

N 2 G o ver n o r

134

92 - 61

Troubleshooting - N2 governor

139

92 - 62

Functional test - N2 governor

141

92 - 63

En g i n e

92 - 64

Troubleshooting - engine anti-icing system

146

92 - 65

Functional test - engine anti-icing system

146

92 - 66

En g i n e

147

92 - 67

Troubleshooting - engine fire detection system

s y s t e m

101

s y s t e m

a n t i -

1 C

i n g

s y s t e m

f i r e d e t e c t ion

s y s t e m

142

151

BO 105 CHAPTER 92 Page 3

MAINTENANCE MANUAL BO 105

Paragraph Tltle

Paga

92-68

Functional test - engine fire detection system

.

151

92-69

Removal and installation - engine fire detection system

.

152

92-70

011 cooler fan fallura warning system ••••••.•.•••.•.•••.••••••••••••.•••.•••

155

92-71

Troubleshooting - oil caoler fan failure warning system .....................•.....

156

92-72

Functional test - oil caoler fan failure warning system

.

156

92-73

Removal and installation - oil caoler fan failure warning system

.

156

92-74

FUEL SYSTEM •••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••••

157

92-75

Locations - fuel system

.........................................•.•.........

157

92-76

Protection of circuits of fuel system ...............•....................•....•..

158

92-n

Fuel supply system .•.......••.••••••.•••.•••••••••.••••.••••••••••••••••••

161

92-78

Troubleshooting - fuel supply system

.

162

92-79

Functional test - fuel supply system .....................•.....................

162

92-80

Fuel shutoff system ...••.....••••••••.••••••••••.••.••••••..•••••••••••.•••

163

92-81

Troubleshooting - fuel shutoff system ......................•..............•....

167

92-82

Functional test - fuel shutoff system ..........................................•

167

92-83

Leakage test - fuel shutoff system

.

168

92-84

Monltorlng - fuel supply system .•.•••••••..•••••••••••.•••••••••.•••••••••.

169

92-85

Low fuel waming system

.....................•..............................

169

92-86

Differential fuel pressure (BYPASS) warning system •............................

173

92-87

CONTROL SYSTEMS •••••.••••.••••••••••••••••••••••••••••••••••••••••••••

175

92-88

Locations - control systems

.

176

92-89

Protection of circuits of control systems ....................•...................

1n

CHAPTER 92 Page4

Revision 21

e

eurocopter

MAINTENANCE MANUAL 80 105

Paragraph TItle

Page

177

92-90

Hydraullc system

92-91

Hydraulic pressure monitoring system

.

178

92-92

Electrically initiated system switch-over - hydraulic system

.

180

92-93

Cyclic stlck trim ..•••••••••••.••••••••••••.••••••••••••••. ••••.•••.••••••••

185

92-94

Troubleshooting - cyclic stick trim

.

189

92-95

Functional test - cyclic stick trim

.

191

92-96

Cyclic stick grlp •••••••••.•••••••.•••••••.•••••••••••••••••••••••••..••...•

193

92-97

Removal and installation - cyclic stick grip

.

194

92-98

Removal and installation - four-way beeper switch 2CC

.

195

92-99

Removal and installation - PTI button 14RT

.

197

92 -100

Removal and installation - push button switch

.

200

92 -101

Control unlt on collective pltch stick· •••••••..••.•••••••••..•..•••.•..•••.•.•

201

92 -102

Removal and installation - components of control unit on collective pitch stick

.

203

92 -103

Removal and installation - four-way switch (8KA) and switches 11 MF, 20LA, 24LA and 2MD

.

203

92 -104

Removal and installation - switch 13MF

.

204

92-105

LIGHTING SYSTEMS ••••••••••••••••••••••••••.•••••••••••.••••••••••••••••

205

92 -106

Locations - Iighting systems

.

205

92 -107

Protection of Iighting systems

.

206

92-108

Position IIght system •••••••••••.•••••••••••.•.••••••••••••••••••••••••••••

207

92 -109

Troubleshooting - pesition Iights

.

207

92-110

Inspection and maintenance - position Iights

.

208

92 -111

Removal and installation - position Iights

.

211

92 -112

Removal and Installation - tail Iight

.

212

Revision 22

CHAPTER 92 Page5

1

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 Paragraph

Title

92 - 113

Functional test - position light system

92

A n t i - col 1 i s ion

114

Page

1 i g h t

215 s y s t e m

215

92 - 115

Troubleshooting - anti-collision light system

219

92 - 116

Inspection for condition - anti-collision lights 4LA, 5LA

220

92 - 117

Removal and installation - anti-collision light system

221

92 - 118

Removal and installation - anti-collision light 4LA

221

92 - 119

Removal and installation - anti-collision light SLA

222

92 - 120

Removal and installation - flasher unit 21LA

224

92 - 121

Functional test - anti-collision lighting

224

92

1 n ter n a 1

225

122

1 i g h t i n g

s y s t e m

92 - 123

Troubleshooting - internal lighting

228

92 - 124

Inspection and maintenance - internal lighting

229

92 - 125

Removal and installation - internal lighting

229

92 - 126

Functional test - internal lighting

230

92 - 127

1 n s t r u me n t

231

92 - 128

Troubleshooting - instrument lighting

235

92 - 129

Removal and installation - eyebrow lights and post lights

235

92 - 130

Removal and installation - light control unit 9LC

236

92 - 131

Removal and installation - potentiometer 10LC

237

92 - 132

Functional test - instrument lighting

238

92 - 133

Wa r n i n g

238

BO 105 CHAPTER 92 Page 6

1 i g h t i n g

1 i g h t

s e g me n t s

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Paragraph

Title

92 - 133A

M 1 S C E L L A N E O U S E LEC TRI CAL S Y S T E MS

241

92 - 134

P i t o t

241

92 - 135

Troubleshooting - pitot tube heating

242

92 - 136

Functional test - pitot tube heating

242

92 - 137

a ver h e a d pan e 1 12VE

243

92 - 138

C e n t e r pan e l . . .

247

Page

t u b e

h e a t i n g

Ba 105 CHAPTER 92 Page 7/8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 1

GENERAL

The electrical systems of the helicopter BO 105 are: -

DC power system Starter and ignition system Engine and main transmission systems Fuel system Control systems Lighting system Miscellaneous electrical systems

Troubleshoot in conjunction with the Wiring Diagram Manual (WDM) 92 - 2

Cornmon electrical components of the electrical systems

The cornmon electrical components are installed in the following equipment as shown in figures 92-1 to 92-3: -

Main relay box 1VE (see figures 92-4 thru 92-6) Instrument panel 2VE (see chapter 91) Relay box 10VE (see paragraph 92-6) Overhead panel 12VE (see chapter 92-137) Center panel (see paragraph 92-138) External power receptacle 2P (see paragraph 92-31)

92 - 3

Removal and installation - cornmon electrical components NOTE

1.

Perform maintenance with proper tools, using antimagnetic ones if necessary. Blank off plugs with protective caps. Insulate wire ends with electrical tape and inspect solder connections for integrity.

Removal a.

Pull all circuit breakers and set all switches to OFF.

b.

Remove battery connector 1P and secure against inadvertent reconnection.

c.

Remove attaching hardware.

d.

If necessary, identify wiring to aid reconnection.

e.

Remove component.

BO 105 CHAPTER 92 Page 9

- - - - - - - - - - - - - - - - - ' . MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2. Installation a.

Install new component using attaching hardware.

b.

Connect wiring or electrical connectors (safety as necessary).

92 - 4

Inspection - cornmon electrical components

1.

Inspect electrical wiring for correct routeing, security, damage, and evidence of overheating or burns. repair, reroute or secure wiring.

2.

Inspect electrical terminals for corrosion, looseness and damage. remove corrosion, tighten or replace terminals.

3.

Inspect all bonding jumpers for condition. repair or replace.

4.

Disconnect plugs and inspect contact pins fOr condition. Visually inspect shrink sleeves for porosity. replace corroded or damaged pins, replace shrink sleeve or plug.

5.

Visually inspect shock mounts for damage. replace shock mounts.

6.

Inspect parts for security, damage, corrosion.and burns. tighten or replace parts, remove corrosion.

BO 105 CHAPTER 92 Page 10

- - - - - - - - - - - - - M B B HELICOPTERS'-------------MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY Series A, C, D S/N 7 - 160

5 ~::-......__

900093

1 Engine Starter-generator

~

j

2 Main Relay Box 1VE Voltage regulator Voltage regulator Power supply relay Reverse-current relay Generator relay Generator relay Shunt Circuit breaker Fuse

& &

Fuse Generator control relay Diode Starter bus 3 Instrument Panel 2VE Battery External power receptacle External power relay Battery relay Auxiliary bus relay

&

EFFECTIVITY

103P, 203P 104P, 204P 108P, 208P 8P 10SP, 20SP 109P, 209P 107P, 207P 110P, 210P 21P, 22P 128P, 228P 29P, 33P, 34P, 3SP 36P 39P 106P, 206P 112P, 212P, 111P, 211P PP1

&

&

&

& &

1P

&

2P 7P 6P 10P

Emergency bus relay Battery switch Generator control switch, Generator control switch Voltmeter Ammeter Generator failure warning light EMERG. DC BUS pushbutton indicator Ammeter selector switch EPU ON indicator light Shunt Auxiliary relay Fuse Fuse Main bus Auxiliary bus Emergency bus 4 Overhead Panel 12VE Generator field cutout switch

40P 16P 117P, 217P 118P, 218P 18P 19P 23P 41P 24P 27P 20P 26P 11P, 2SP, 30P, 32P 13P, 38P PP21 PP22 PP20

104P, 204P

5 Relay box 10VE

D series only Figure 92-1

&

&

EFFECTIVITY

A and C series only

Electrical equipment location BO 105 CHAPTER 92 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS

EFFECTIVITY

3

900094

1 Engine Starter-generator 2 Main Relay Box 1VE Voltage regulator Reverse-current relay Power supply relay Generator relay Shunt Circuit breaker Fuse Generator control relay Starter bus

EFFECTIVITY

3 Instrument Panel 2VE Battery External power receptacle 104P, 204P Battery relay 10SP, 20SP External relay 8P Battery master switch 109P, 209P Starter-generator 21P, 22P control switch 128P, 228P Voltmeter 33P, 34P, 3SP Armneter 29P, 36P, 37P Generator 38P warning light Armneter selector 106P, 206P switch EPU ON indicator PP1 light Shunt Fuse

103P, 203P

Optional emergency bus

Fuse EMERG. DC BUS pushbutton indicator Auxiliary bus relay Main bus Auxiliary bus Emergency bus Emergency bus relay 4 Relay. box 10VE

Figure 92-2 BO lOS CHAPTER 92 Page 12

Electrical equipment location

1P 2P 6P 7P 16P 117P, 217P 18P 19P 23P 24P 27P 20P 11P, 2SP, 30P, 3lP, 32P 13P lSP 10P PP21 PP22 PP20 14P

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY Series S

I

I 3

5

2

I

1 Engine Starter-generator 2 Main Relay Box 1VE Voltage regulator Reverse-current relay Power supply relay Generator relay Shunt Circuit breaker Fuse Generator control relay Starter bus

103P, 203P 104P, 204P 105P, 205P 8P 109P, 209P 21P, 22P 128P, 228P 33P, 34P, 35P, 36P 106P, 206P PP1

3 Instrument Panel 2VE External power 2P receptacle External power 7P relay Auxiliary bus 10P relay Figure 92-3

Battery master switch Starter-generator control switch Voltmeter Arnmeter Generator warning light Arnmeter selector switch EPU ON indicator light Shunt Fuse Main bus Auxiliary bus Starter relay

16P 117P, 217P 18P 19P 23P 24P 27P 20P 30P, 31P, 32P 25P, 26P PP21 PP22 103J, 203J

4 Engine Deck (aft right) lP Battery 6P Battery relay 5P Strip fuse 5 Relay box 10VE Electrical equipment location BO 105 CHAPTER 92 Page 13

---------------'--MBB HELICOPTERS·------------MAINTENANCE MANUAL MBB - BO 105

92 - S

Main relay box lVE

The main relay box lVE is installed in the aft RH side of the cargo compartment (see figures 92-1 to 92-3). The following components of the main relay box are accessible after removal of the cover. - voltage regulator 104P, 204P, 108P and 208P - generator relays 107P, 109P, 207P, 209P, 110P and 210P - generator control relay 106P, 206P - reverse-current relay 10SP, 20SP - power supply relay 8P - circuit breaker 128P, 228P - junction box 1VV - diodes 111P, 112P, 211P, 212P - shunts 21P, 22P, 129P -.fuses 29P, 33P, 34P, 3SP, 36P, 37P, 38P, 39P - starter bus PP1 As shown in figures 92-4 thru 92-7, the configuration of the main relay box 1VE varies with the helicopter series A, e, D and S.

BO

lOS

CHAPTER

Page 14

92

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY Series A, C S/N 181 and subsequent

o

900500

~.@

~-

...

Figure 92-4

--

Main relay box 1VE BO 105 CHAPTER 92 Page 15/16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY Series A, C S/N 81 - 180

205P

l04P

lOSP

204P

9005Dl

Figure 92-5

Main relay box 1VE

BO 105 CHAPTER 92 Page 17

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

Series A, C, S S/N 7 - 80

+ 104P

10SP

20SP

_

:~;

:lf:J

.·.:_~~!i

204P

+1 1~----""7f<1 +: ~

1

1

I 1

I

! o~~ ~_~~ '._. . _._.

~t~~~ :

!

•

•

.

4~"

Figure 92-6

Page 18

_.

.

o

tf~~:

4t)f ,fI-To

900502

BO 105 CHAPTER 92

-=:=".

Main relay box lVE

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

Series A, C, D S/N 7 - 160 ~ ~

{-~

~

é

u I

I I1

, 900499

--------------~--------:----

....

------------.......,.-=-...:=.~=-== 1 -

.¿ffif.-

@:~-

Figure 92-7

1-- i -

L JL....J

-----'"

,~~--.7""------

l.-l.-!~~

Main relay box 1VE

BO 105 CHAPTER 92 Page 19

----------------"MBB HELICOPTERS"------------MAINTENANCE MANUAL MBB - BO lOS 92 - 6

Relay box 10VE

The relay left side Access to door (see

box 10VE is installed in the front end of the nose shell, on the below the cabin floor (see figures 92-1 to 92-3). the components of the relay box is obtained by opening the nose figures 92-8 and 92-9) .

The following components are installed: l.

For N2 governor: - relays 4KA, SKA and 6KA - diode matrix 10KA

2.

For cyclic stick trim: retraction relays 8CC, 10CC - extension relays 9CC, llCC

3.

Additional relays can be installed for optional equipments.

BO lOS CHAPTER 92 Page 20

- - - - - - - - - - - - - M B B HELICOPTERS··------------MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

S/N 4 - 100

O ___

\1

1: 1:

l~~---i--, J I

.

I~~~1..~ __ C~.~ ~ ~

+

+

+ r+

+ t

+ +

+ r+-

..li

~ I

+

i

~

900S03 ' - -

+

+

+ +

+

+ Figure 92-8

~ I

;;

1

T

ro

I

>

!

I

T

i

T ~ 1

+

+

J.. I

+ + J-I I

T

+ +-.:...

t·

+ ~

Relay box 10VE

BO 105 CHAPTER 92

Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY S/N 101 and subsequent and series D

[±r

-------------'*-'

f-¡

~

+

I

¡

+ +

~

+~

K- • ~

+ + 900504

~

+

H-~

+.

+ +•

+ +•

~

+ +

+ Figure 92-9

BO 105 CHAPTER 92 Page 22

EJ ~ ~+

.=--a;-=-t--"I

+

~

+~

'"'--l+f--);--t--'+

L.r+----+---J

+

+ ®t + +~ +

+ Relay box 10VE

+

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 DC POWER SYSTEM

92 - 7 l.

General The DC power system (see figure 92-10) mainly consists of the following: generator system battery systern external power receptacle rnonitoring system In order to produce and distribute de power to the electrical loads, the electrical system rnust include relays, controls and busses. Engines 1 and 2 are started one after the other by rneans of two startergenerators. Voltage is supplied by the airborne battery or by an external power source. When an engine has reached idle speed, its associated starter-generator will produce power for the electrical system. Each starter-generator is connected to a voltage regulator which maintains a constant generator output voltage. The connected loads are supplied via the busses. System voltage and current consumption are indicated by the voltrneter and amrneter respectively, installed in the horizontal section of the instrument panel (see figures 92-11 thru 92-13 and chapter 91). Both generators and the airborne battery can be switched on and off and the generator fields still activated can be switched off. The consumers are protected by circuit breakers (see paragraph 92-14). warning lights are used to warn of generator failure, overheating of the airborne battery and overheating of the starter-generators (D series only). Utilization of external power is also indicated.

2.

Technical data a.

Airborne battery (see VARTA Maintenance Manual) -

nominal voltage nominal capacity design rnax. permissible discharge rnanufacturer

24V 25 Ah 20 cells (nickel-cadmium) 800 A VARTA

BO 105 CHAPTER 92 Page 23

- - - - - - - - - - - - - M B B HELICOPTERS·------------MAINTENANCE MANUAL MBB - BO 105 EXTERNAL POWER RECEPTACLE

VOLTAGE REGULATOR

1---.

'---4

BATTERY

-::

-

VOLTAGE REGULATOR

PP1

PP21

STARTER BUS

MAIN BUS

900133

13

I ....---r::( PP22 )J I AU~UARYBUS

'-o

&

EFFECTIVITY

D series or when the optional emergency bus is installed Figure 92-10 BO 105 CHAPTER

Page 24

92

DC Power Supply (General)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Starter-generator (see LEAR SIEGLER Maintenance Manual) 28V 150A 4,5 kW

-

nominal voltagé nominal current nominal power permissible current consumption at start: - rnanufacturer c.

200 700A at 23V Lear Siegler

Voltage regulator (see LEAR SIEGLER Maintenance Manual) 27 28,OV 27,5V + O.lV DC voltage regulator with protection and monitoring function Lear Siegler

- adjusting range - adjusted voltage - design - manufacturer

92 - 8

Component location - DC power system

COMPONENT

LOCATION

Starter-generators 103P, 203P

Engine 1 and 2 (see chapter 61)

Airborne battery 1P

Nose section, forward of the instrument panel 2VE

92-1 to 92-3

External power receptacle 2P

Nose section

92-1 to 92-3

DC power system controls

Instrument panel 2VE

92-1 to 92-3

Indicators (voltmeter 18P and armneter 19P)

Instrument panel 2VE (see chapter 91)

92-1 to 92-3 92-11 to 92-13

Warning lights

Instrument panel 2VE, vertical section (see chapter 92-133)

Starter bus PP1

Series C, D, S, IFR Main relay box lVE

Table 92-1

FIGURE

92-4 to 92-7

Component location - DC power system (1 of 2)

BO 105 CHAPTER 92 Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

COMPONENT

LOCATION

Emergency bus PP20

Series D, S/N 7 - 160 92-1 Main relay box 1VE Series A, C S/N 161 and subsq. 92-2 Optional equipment, main relay box 1VE

Main bus PP21

Series A, C, D, S Main relay box 1VE

92-1 to 92-3

Auxiliary bus PP22

Series A, C, D, S Instrument panel 2VE

92-1 to 92-3

Shunts 20P, 21P, 22P

Series A, C, D, S Main relay box 1VE

92-1 to 92-3

Voltage regulator 104P, 204P, 108P and 208P

Main relay box 1VE

92-4 to 92-7

Generator relays 107P, 109P, 207P, 209P, 110P, 210P

Main relay box 1VE

92-4 to 92-7

Circuit breakers

See paragraph 92-14

Fuse 25P (300A)

Series C, D Instrument panel 2VE

92-1

Fuse 5 P (300A)

Series S Below the engines next to battery

92-3

Flight essential bus relay 10P

Series A, C, D and S Instrument panel 2VE

92-1 to 92-3

Battery relay 6P

92-1 Series A, C, D, S/N 7 - 160 Series A, C S/N 161 and subsq. 92-2 Instrument panel 2VE Series S 92-3 Engine deck, aft right

External power relay 7P

92-1 Series A, C, D S/N 7 - 160 Series A, C S/N 161 and subsq. 92-2 92-3 Series S Instrument panel 2VE

Junction box 1VV

Series A, C, D, S Main relay box

Table 92-1 BO 105 CHAPTER 92 Page 26

Component location - DC power system

FIGURE

92-4 to 92-7

(2 of 2)

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-~-----------MBB

EFFECTIVITY

S/N 7 - 160

-

I

......

\

,",,,

, ..... '1 \J J\

'-" _.- -,

·---------, ", '< F /,k ~j r -- -

L-

"-t rJ I

I

L. __ .J

~--

-..,

~_---'

I

°n QU: ON

e:,:'

/-

•.~~~

/

" '- O ,

I

¡

'.

\

I E:J ~~~r--l

(q).-

Ir ---------( ~, __

J~ _/

¡",;;;-'"--"",¡~::;;;:::...::::;::::;::=., ---: E"ft: I ENG 1: S"'AATECllGENfAA'rOR

CA.... AlA

or

ENG I

900162

Figure 92-11

tNG

5T "A'!'Elllt/GENE".uoa

Instrument Panel 2VE (Horizontal Section) BO 105 CHAPTER 92 Page 27/28

- - - - - - - - - M B B HELICOPTERS - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

S/N 161 and subsequent

@~--~"(X)®~--~J)C) ~r;;;;;;;=

ITA'" IfAFt~"/G!N!"ATO"

900160

Figure 92-12

Instrument Panel 2VE (Horizontal Section)

BO 105 CHAPTER 92 Page 29

-----------........;.-MBB HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

Series D

© E) ' - - - - - - - - / 900189

Figure 92-13

BO 105 CHAPTER

Page 30

92

Instrument Panel 2VE (Horizontal Section)

- - - - - - - - - - - - - M B B HELICOPT:E:RS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 9 l.

DC power system controls

General The switches of the DC power system are located on the lower RH side of the instrument panel 2VE (see figures 92-11 to 92-13). The DC power system is controlled by the following switches: battery switch, labelled BATTERY MAST SWITCH (S/N 7 - 160), BAT EPU (S/N 161 and subsq.) and BATTERY MASTER (Series D), EMERG. DC - BUS pushbutton indicator (only S/N 161 and subsq. and Series D) generator switch, labelled ENG. 1 and ENG. 11 STARTER-GENERATOR (S/N 7 - 160), START STARTER-GENERATOR (S/N 161 and subsq.) and ENG. 1 and ENG. 11 GENERATOR (Series D) .

2.

Battery switch BATTERY MAST SWITCH; BAT EPU; BATTERY MASTER This 2-pole toggle switch has the positions EPU ON/BATT OFF and EPU OFF/BATT ON. In the EPU ON/BATT OFF position (see figures 92-16 and 92-17), the positive terminal of the battery is disconnected, and the starter bus PP1 and main bus PP21 are connected to the positive terminal of external power receptacle 2P. Simultaneously, the EPU ON segment will illurninate on A, C and S series, S/N 161 and subsequent, and on S/N 7 thru 160. In the EPU OFF/BATT ON position, the battery switch energizes battery relay 6P and auxiliary relay 26P. In turn, external power relay 7P de-energizes and disconnects the positive terminal of external power receptacle 2P from starter bus PP1 and main bus PP21 (see figures 92-14 thru 92-18). During generator operation, power from the generators will charge the battery. In the event of their failure, the battery will supply the buses (except for auxiliary bus) with power.

3.

EMERG. DC - BUS pushbutton indicator 41P (D series or optional equipment) In position ON (push button depressed), the emergency bus relay 40P (S/N 7 - 160 and series D) and emergency bus relay 14P (S/N 161 and subsequent, and series S) are energized, thus connecting the positive terminal of aircraft battery 1P to emergency bus PP20 (see figures 92-19 thru 92-21). All other busses are disconnected. In position OFF (switch released), the emergency operating mode is switched off.

4.

Generator switch ENG 1 (ENG 11) STARTER/GENERATOR; START STARTERGENERATOR; ENG 1 (ENG 11) GENERATOR. This switch is used to connect or disconnect generator 1 and 2 to or from the helicopter electrical system. However, connection is only possible if the respective generator is operating.

BO 105 CHAPTER 92 Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 EFFECTIVITY

Series A, C, D S/N 7 - 160

1---1 ON

BATTERY1P

EXTERNALPOWER RECEPTACLE 2P

+ +

OFF BATTERY SWITCH 16P

AUXILlARY RELAY

BATTERY RELAY

EXTERNALPOWER RELAY 7P

26P

6P

--

-EPU ON INDICATOR L1GHT 27P

--

REFER TO SWITCHING ON GENERATORS POWER SUPPLy RELAY 8P AUXILIARY BUS RELAY 10P

AUXILlARY BUS

I:(PP22 28V)=

MA1N BUS

•

-----

__-4[JI

STARTER BUS

PP 21 28 V ~"'''''''JI PP1 28 V.

900219

Figure 92-14 BO 105 CHAPTER 92 Page 32

Connection of external power to the line

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

Series A, C, S S/N 161 and subsequent

EXTERNAL POWER RELAY 2P

BATTERY1P

I--~

+

BATTERY SWITCH 16P

+

--

EPU OFF BAT ON

--

o EXT. POWER RELAY 7P

~

BATTERY RELAY 6P

EPU ON INo. 27P ~

--

--

REFER TO SWITCHING ON GENERATORS POWER SUPPLy RELAY 8P

AUXILlARY RELAY 26P

__r-O----tll

I I

I I

E( PP 22

28 V)J--y

AUXILIARY BUS

l __"""11:. !

PP 21 28 V ID-.-cJl PPl 28 V MAIN BUS

STARTER BUS

900220

Figure 92-15

Connection of external power to the line BO 105 CHAPTER 92

Page 33

- - - - - - - - - - - - - - ' - M B B HELICOPTERS . - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY S/N

7 - 160 EXTERNAL POWERRECEPTACLE 2P

OFF

BATTERY 1P

BATTERY MASTER SWITCH 16P

•

--

~-BATTERY RELAY 6P

--

AUXILIARY RELAY 26P

--~ EXTERNAL POWER RELAY 7P

EMERGENCY BUS

-- fO-("p;;;-;8~:\O-' & L..:_' 1_ ~

PP1

28V- -.:;. .-

STARTER BUS

...~-otl:. PP21

28V-

MAIN BUS

900182

~

EFFECTIVITY

Series D Figure 92-16

BO 105 CHAPTER

Page 34

92

Connection oí battery to the line

---~---------MBB

HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

S/N 161 and subsequent EXTERNAL POWERRECEPTACLE 2P

BATTERY MASTER SWITCH 16P

BATTERY1P

~--I

+

o

+

BAT ON EPU OFF

--

--

--------~

~-BATTERY· RELAY 6P

EXTERNAL POWERRELAY 7P

EMERGENCY BUS ~------ - - - r.::O- I PP20 28V - -::-l \ e,

~

PP1

-, - -- - - - - ~_.

28V- I :...- - - - 4 I.....- - -...::JI PP21

STARTER BUS

-'

&,

28V-

MAIN BUS

900183.1

&

EFFECTIVITY

With optional emergency bus installed Figure 92-17

Connection of battery to the line BO 105 CHAPTER 92

Page 35

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

Series S BATTERY MASTER SWITCH 16P

BATTERY1P

EXTERNAL POWERRECEPTACLE 2P

BAT ON EPU OFF

~--I

BAT OFF EPU ON

+

o

+

--

---

--------~

~-BATTERY RELAY 6P

EXTERNAL POWER· RELAY 7P

EMERGENCY BUS r.::-..-.------~

- - - - LO

I PP20

28V- ,

-'.------"-

PP1

2BV-

I : l l - - - -...----~

STARTER BUS

PP21

MAIN BUS

900183

&

EFFECTIVITY

With optional emergency bus installed Figure 92-18 BO 105 CHAPTER 92 Page 36

28V-

Connection of battery to the line

1:\

0-, ~

---------------,--MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY S/N 7 - 160

41P

OFF

-T _~ _~ ~ _0_~ _ c:.

EMERG

'Ii-

¡

~

DC BUS

I

b

-

ON

BATIERY MASTER SWITCH 16P

~

(

OFF-ON GEN CONTROL SWITCH 118P

~-}:~

lO.

f

O

~

)

iUJ lO. 2 a:OO

j ) rg~

O

POWER SUPPLY RELAY 8P

----<--1tlO.

-1

oZ llo

II

VOLTAGE REGULATOR 108P

( ()

I

1~C;l1 D

VOLTAGE REGULATOR 208P

FUSE 38P

~~

Uu , UJ 2. t-en W w3: a: (!)en


~~

i

-

40P

VOLTMETER 18P

V

....

PP20

,.

II I '1

I

C~ ,.., I

EMERG. BUSBAR AELAY

1

~~ ON

II

INDICATOA LIGHT 27P

I

11P

I

'"FUSE

'V

I

\

I

~

~-

1

EMERGENCY BUS

ID[

1

....

PP21

~

MAIN BUS

PP' STARTEA BUS EXTERNAL POWER RECEPTACLE 2P

--+ +

FUSE 30P ,..,

',.,. I ·1

BATTERY 1P FUSE 25P

~.... ~I I

I

~

l'

¡: ~-~ ~II I

BATIERY RELAY8P

EXTERNAL POWER· RELAY 7P 900186

Figure 92-19

Application oí power to emergency bus BO 105 CHAPTER 92 Page 37

- - - - - - - - - - - - - ' - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY S/N

161 and subsequent

EXTERNAl POWERRECEPTAClE BATIERY 1P BATIERY RElAY 6P

EMEAG.14P BUSBAA RElAY

FUSE 30P

PUSH-BUTION SWITCH 1SP

EXTERNAl POWERAElAY 7P

EMERG. OC BUS

--

o

--

BATIERY MASTER SWITCH 16P

tNDICATOR lIGHT 27P

REVERSE CURAENT RElAY GEN 10SP

o

GEN 20SP

-

~ ~

EXTERNAl POWER RECEPTACLE 2P

STARTER BUS

-3P

PP1

MAIN-BUS

EMERGENCY BUS

PP21

PP20

117P

-¡ ~""

~ ISTARTER/GENERATOR· CONTROL SWITCH I I L _ _ .J

Iro

VOLTMETER 1SP 206P GENERAiOR CONTROL RElAY .....- - - - - - - 106P GEN.

~

•

~

ANl.

900214

Figure 92-20 BO 105 CHAPTER

Page 38

92

Application of power to emergency bus

--

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

--

EFFECTIVITY

--¡-

Series S

I

.J.. EXTERNAL POWERRECEPTACLE

BATTERY lP

EMERG. 14P BUSBAR RELAY

FUSE 30P

PUSH-BUTTON SWITCH 1SP EMERG. OC BUS

BATTERY RELAY 6P

EXTERNAL POWERRELAY 7P

--

o

--

..L

--

REVERSE CURRENT RELAY

o

GEN 105P

GEN 205P

--

~ ~

INDICATOR L1GHT 27P

--

EXTERNAL POWERRECEPT ACLE 2P

STARTER BUS PPl

EMERGENCY BUS

3P

MAIN-BUS PP21

PP20

--~ ~ - -...l217P

117P

"'1 I 1 II L. _ _ -.J L

t]STARTEROGENERATORO CONTROL SWITCH

I

__ .J

VOLTMETER 1SP 206P

"'------__l_ 106P GEN.

~

•

GENERATOR CONTROL RELAY

. , ANL.

--

900215

Figure 92-21

Application of power to emergency bus BO 105 CHAPTER 92 Page 39/40

- - - - - - - - - - - - - M B B HELICOPTtRS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

o S/N 7 - 80 The generator switch has three positions marked GEN, OFF (center position) and START. The position START is spring-loaded and safetied with a cover against inadvertent activation. o S/N 81 and subsequent The generator switch has three positions marked GEN (or GEN ON), OFF (cent~r position) and START. The position START is spring-loaded and protected against inadvertent activation by a mechanical stop, which may be released by pulling the toggle. o Series A, C, S With the engine running and the generator switch set to position GEN or GEN ON, the voltage supplied by the generator is fed to the reverse-current relay via the generator switch and the energized generator control relay. If the generator voltage exceeds the battery voltage by 0.3SV to 0.6SV, the reverse current-relay will connect the generator to the main bus. o Series D With the engine running and the generator switch set to position GEN or GEN ON, the voltage supplied by the generator is fed to the voltage regulator via the generator switch and the generator field cutout switch. If the voltage exceeds the battery voltage by 0.35 to 0.65V, the generator relay will connect the generator to the main bus.

92 - 10 1.

Generator operation

Both generators operating (see figure 92-22 to 92-24) Under normal operating conditions the DC power system is supplied by both generators. After the generators have built up the required voltage, they are connected to the helicopter electrical system as described in paragraph 92-9.4. The two red warning 1ights GEN 1 and GEN 2, installed in the instrument panel 1VE (vertical section, figure 92-97), then extinguish. The voltage regulators provide for equal distribution of the load between both generators. A1l busses are supplied with power (refer to paragraph 92-13 for power distribution). Battery power can also be connected to the electrical system thru battery switch BATTERY MAST SWITCH, BAT EPU, or BATTERY MASTER (depending on effectivity). The battery will be charged and, if both generators should fail, will irnmediately provide battery power to the system (refer to Operation-battery power, paragraph 92-11) .

BO 105 CHAPTER 92 Page 41

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 a.

Connecting the generators to the line

NOTE

O

The methods of activation and operation of the No.1 and No.2 generators are the same for both generators.

o For S/N 7 thru 80, the auxiliary bus is automatically energized when one generator is connected to the lineo o For S/N 81 and subsequent, power supply to the auxiliary bus is ensured only after both generators have been connected to the lineo o Battery master switch set to position EPU OFF-BATT ON (ON position for D series).

EFFECTIVITY

o Series A, C, S only After generator control switch 117P (217P) is set in position GEN ON or GEN, the generator voltage is routed to the excitation winding of the generator control relay 106P (206P). The relay will close, thereby routing the generator voltage via closed contact of the power supply relay 8P to the terminal SW of tbe reverse-current relay 105P (205P). When the generator voltage exceeds the battery voltage by 0.35 to 0.65V, the reverse-current relay routes the generator voltage to the helicopter electrical system. Closing of the reverse-current relay energizes the related generator relay 109P (209P) and interrupts the circuit to the generator failure warning light 23P. o S/N 7 - 80, series A, e, S Via a contact of the energized generator relay 109P (209P), the auxiliary bus interconnect relay is energized allowing the auxiliary bus PP22 to be supplied with voltage. o S/N 81 and subsequent, series A, C, S Via a contact of the energized relay 109P (209P), voltage is routed to the contact, connected in series, of the energized relay 209P (109P). As soon as both contacts are closed (both generators are connected to the line) , the auxiliary bus relay is energized, allowing the auxiliary bus PP22 to be supplied with power.

BO 105 CHAPTER 92 Page 42

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

......------------I~

see

92-31

POWER SUPPLY RELAY 8P

EFFECTIVITY

·1...-.---0-;--

Series A, C SIN 7 - 80

I

~

·1, . Á ) - - - - - - - -•20SP (sw) ....¡........¡O

•

GENERATOR CONTROL RELA Y 106P

EOUALlZING L1NE

GENERATORCONTROL RELAY 206P

r--+--o-....~~STARTER/

II

GENERATOR CONTROL SWITCH 217P

~ ~ GENERAT. RELAY 109P

--

GENERATOR RELAY 209P

(s. 9-6)

VOLTAGE REGUlATOR 204P

VOlTAGE REGUlATOR

STARTER/ GENERATOR 103P

--

--

REVERSE CURRENT RELAY AUXILIAAY BUSBAR RELAY 205P 10P

REVERSE CURRENT RELAY 10SP

-ot-C)-----fla PP1

PP21

-.--tt:

PP22

XI

900216

Figure 92-22

Connection of generators to the line BO 105 CHAPTER 92

Page 43

- - - - - - - - - - - - - - ' - M B B HELICOPTERS . - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

,--------------11- see 92-31 EFFECTIVITY

POWER SUPPLY RELAY 8P

Series A, C, S S/N 81 and subsequent

'I.----o--¡-1

~) 205P

(sw)

YI ~()

.-1.: rel="nofollow">---------

y EQUALlZING LINE

GENERATOR CONTROL RELAY 206P

STARTER/GEN' I CONTROL SWITCH 217P

I

,.--+-o-.....-~

1I

I STARTER/GENERATOR CONTROL SWITCH 117P

~

GEN.ON

EJ -

TART¡ I I

GENERAT'l RELAY 109P

ft--

(see start/ignition syst.) VOLTAGE REGULATOR 104P

--

GENERATOR RELAY 209P

-

STARTER/ GENERATOR 103P

I

I

isw:D

I

I

REVERSE CURRENT RELAY 105P

O:sw --

REVERSE CURRENT RELAY 205P AUXILlARY BUS RELAY 10P

-;-c:>------tl. PPl

PP21

-•....--~a:

900217

Figure 92-23 BO 105

CHAPTER 92 Page 44

Connection of generators to the line

PP22

~

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

Series D

GENERATOR CONTROL SWITCH RESET OFF

118P

t

...

,.._ _O_N.. ;

•

I ,

218P

RESET GENERATOR FIELD OFF SWITCH TOFF

, ON

•

.204P

l04Pt

,r

+ t

I---t--;I· GEN 2 23P

110P

210P

lo I a---+----J t--I----f-e-lo BATTEF.lY I MASTER SWITCH l06P

&~

II~'

206P

-.--<,~

'1~ 8P

POWER SUPPLY RELAY

~ o: EMERGENCY BUS RELAY 38P 40P EM. OC BUS PUSH

rro-

(~II I I

...L~

STARTER BUS

&

PP 1 S. Starter and Ignition System

900184

Figure 92-24

Connection of generators to the line BO 105 CHAPTER 92

Page 45

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 o Series D After generator control switch 118P (218P) is set in position GEN ON or GEN, generator voltage is routed via the EMERG. DC BUS pushbutton indicator 4lP and both the voltage regulator 108P (208P) and the normally closed contact of the power supply relay 8P back to the voltage regulator. When the generator voltage exceeds the battery voltage by 0.35 to 0.65V, the voltage regulator routes the energizing voltage to the generator relay 107P (207P) and the generator voltage is connected to the helicopter electrical system. Simultaneously, the generator relay 110P (2l0P) is energized. A contact of the energized dual-pole relay is interrupted, causing the generator failure warning light 23P to extinguish. The second contact connected in series with generator relay 210P (110P) is closed when generator 2 is connected to the line, thereby energizing the auxiliary bus relay 10P. The relay closes allowing auxiliary bus PP22 to be energized. b.

Operation of the generators in parallel

EFFECTIVITY

o Series A, C, S When both generators are connected to the line, the equalizing circuit of the voltage regulator 104P and 204P is closed via generator control relay 106P and 206P, which are connected in series. The voltage regulators now ensure an equal load sharing between the generators. o Series D When both generators are connected to line, the equalizing circuit of the voltage regulators 108P and 208P is closed. The voltage regulators now provide for an equal load sharing between the generators.

c.

Disconnecting the generators from the line

The generator is manually disconnected froro the starter bus by setting the starter-generator control switch to OFF (center position) . The generator is disconnected automatically by the corresponding reversecurrent relay when the generator voltage drops below a certain value. EFFECTIVITY

BO 105 CHAPTER 92 Page 46

Series D The generator is disconnected autornatically by the corresponding generator relay 107P (207P) when the generator voltage drops below a certain value.

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 In all cases the corresponding generator failure warning segment will illuminate to indicate the disconnection or failure of the generator. 2.

Single generator operation. If a generator fails or is disconnected, main bus PP21 will continue to be supplied with power. All equipment and systems essential to normal helicopter operation, are connected to the main bus PP21 (see figure 92-25). In case one generator should fail, the electrical power produced by the second generator is sufficient to meet all of the loads.

EFFECTIVITY

o Series D or when the optional emergency bus is installed. Should both generators fail, the main bus may be disconnected by pressing the EMERG. DC BUS pushbutton indicator. The emergency bus is then supplied with electrical power from the battery. For connected loads, see figure 92-25.

Auxiliary bus The auxiliary bus PP22 is supplied with electrical power during the following system operating modes: a.

EPU operation

EFFECTIVITY b.

Single generator operation and dual generator operation

EFFECTIVITY c.

o Series A, C (S/N 7 - 80)

o Series D and series A, C, S S/N 81 and subsequent

Dual generator operation only For connected loads, see figure 92-25.

BO 105 CHAPTER 92 Page 47

MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

_ _ _ _ _ _ _ _ _ _ _--'------'0

Emergency bus EFFECTIVITY

o Series D or when optional emergency bus is installed.

The emergency bus PP20 is supplied with electrical power during operation of any of the three power supply sources. In case both generators should fail, battery power is supplied to all vital equipment through the emergency bus. The battery is activated as an emergency power source via EMERG. DC BUS pushbutton indicator 41P (S/N 7 - 160 and series D) or lSP (S/N 161 and subsequent, and series S) and emergency bus relay 40P (S/N 7 - 160 and series D) or 14P (S/N 161 and subsequent, and series S), respectively, which illuminates as soon as the emergency bus is energized (refer to figures 92-19 thru 92-21). NOTE

92 - 11

with EMERG DC BUS pushbutton indicator depressed, neither the generators nor an external power source can be connected to the electrical system. Operation - battery power (see figures 92-16 to 92-1B)

As the battery has a limited capacity, it is only used as a power source for starting the engines (see paragraph 92-39) if external power is not available, or to provide emergency power i f both generators fail. The BATTERY SWITCH, described in paragraph 92-9.2, is used to energize battery relay 6P, causing external power relay 7P to de-energize (all Series). The starter bus PP1 and the main bus PP21 are then supplied with power from the battery 1P. When changing to emergency operation, i.e., push button indicator EMERG DC BUS in ON (see figures 92-19 thru 92-21), the emergency bus relay 40P or 14P is energized and connects the positive terminal of the battery 1P to emergency bus PP20 or PP22, as applicable. In this case, the starter bus PP1 and the main bus PP21 are de-energized. 92 - 12

Operation - external power (see figures 92-14 to 92-15)

For starting the engines and during ground maintenance, a 2BV external power llnit is normally connected to the aircraft system. The n~ximum current input of the external power source is 400A. In position EPU ON (pushbutton switch depressed) and BATTERY MASTER switch OFF, battery 1P is disconnected and the external power receptacle 2P is connected via contact of relay 7P to the busses PP1 and PP21. In addition, power supply relay 8P is actuated and connects auxiliary bus PP22 to the other busses. When external power is connected and switched on, the indicator light 27P (S/N 7 - 160 series A,C,D) or the indicator light EPU ON illuminates (S/N 161 and up, series A,C,S) . Since both generator relays 109P, 209P and 110P, 210P have dropped out, red warning lights GEN 1 and GEN 2 located in instrument panel 2VE will illuminate. BO 105 CHAPTER 92 Page 48

- - - - - - - - - - - - - M B B HELICOPTERS"-------------MAINTENANCE MANUAL MBB - BO 105 92 - 13 1.

Power distribution

General Distribution of the eleetrieal power supplied by any of the three power sourees (generators, battery and external power unit) is aeeomplished via three or four busses to the individual loads. The latter are proteeted by fuses or eireuit breakers. For eireuit breaker loeation, refer to para 92-14.

2.

Starter bus The starter bus PP1 is supplied with eleetrieal power during operation of any of the three power sourees, and is primarily used for supplying the starter-generators during engine starting. In addition, high-power-eonsuming optional equipments may be conneeted to it. For loads eonneeted to the starter bus, refer to figure 92-25.

3.

Main bus The main bus PP21 is supplied with eleetrieal power during the following operating modes: al

EPU operation

b)

Battery operation

e)

Single generator operation

d)

Dual generator operation

All equipment and systems essential to normal helieopter operation, are , eonneeted to the main bus (refer to figure 92-25). In case one generator should fail, the eleetrieal power produeed by the seeond generator is suffieient to supply all of the eonneeted loads. In case both generators fail, the main bus is supplied with eleetrieal power from the battery. EFFECTIVITY

Series D or when the optional emergeney bus is installed. Should both generators fail, the main bus is de-energized by pressing the EMERG. DC BUS pushbutton indieator. The emergeney bus is then supplied with battery power. For eonneeted loads, refer to figure 92-25.

4.

Auxiliary bus The auxiliary bus PP22 is supplied with eleetrieal power during the following operating modes:

BO 105 CHAPTER 92 Page 49

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

a.

EPU operation

EFFECTIVITY b.

Single generator and dual generator operation

EFFECTIVITY c. 5.

Series A, C (S/N 7 - 80)

Series D and series A, C, S S/N 81 and subsequent

Dual generator operation only For connected loads, refer to figure 92-25.

Emergency bus EFFECTIVITY

Series D or when optional ernergency bus installed.

The emergency bus PP20 is supplied with electrical power during operation of any of the three power supply sources. In case both generators should-fail, the ernergency bus provides battery power to all vital equipment. The battery is activated as an ernergency power source via EMERG DC BUS pushbutton indicator 41P (S/N 7 - 160 and series D) or 15P (S/N 161 and subsequent, and series S) and emergency bus relay 40P (S/N 7 - 160 and series D) or 14P (S/N 161 and subsequent, and series S) respectively, which illuminates as soon as the ernergency bus is energized (refer to figures 92-19 thru 92-21). NOTE

6.

With EMERG DC BUS pushbutton indicator depressed, neither the generators nor an external power source be connected to the system.

Circuit breakers The circuit breakers for the loads are located on instrument panel l2VE (refer to figures 92-11 thru 92-13), in the overhead panel 12VE (see fig. 92-100), and in the center panel (see fig. 92-101). The fuses are installed on the left and right sides in the bottom of the instrument panel 2VE (see fig. 92-~0).

7.

DC socket The socket 2VEG is located on the lower left side of the instrument panel 2VE. When the access hole cover is removed from the instrument panel fairing, external 28V DC loads can be connected to the socket. The DC socket is supplied with electrical power from the emergency bus via 20A circuit breaker 1U "DC SOCKET".

BO 105 CHAPTER 92 Page 50

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- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 14 l.

Protection of DC power system circuits

Protection of internaI circuits The following fuses are instaIIed to protect the internaI wiring circuits of the DC power suppIy system: ·a.

Fuses

FUSES

PROTECTION

INSTALLATION

EFFECTIVITY

Starter bus overload (battery switching circuit)

Engine deck

Series S

NOM.

CAP.

SP

300A

llP

4A

Energizing circuit of reIay 6P and 26P

2VE

AH helicopters S/N 7 - 160

llP

4A

Energizing circuit of reIay 6P

2VE

AlI helicopters S/N 161 and subsequent

13P

4A

Emergency bus overload

2VE

Seri~s D or with the optional emerg.bus installed

25P

l30A

Main bus overload

2VE

Series S

2SP

300A

Starter bus overload

2VE

Series A, C, D S/N 7 and subsequent

26P

80A

Emergency bus overload

2VE

Series S

29P

4A

Energizing circuit of lVE reIay 7P , 8P and 10P and circuits of warning Iights GEN 1 and GEN 2

TabIe 92-2

Series A, C, S S/N 7 and subsequent

Protection of De power system circuits (1 of 2)

BO 105 CHAPTER 92 Page 53

- - - - - - - - - - - - - - - - MBB HELICOPTE'RS"------------MAINTENANCE MANUAL MBB - BO 105

FUSES NOM.

PROTECTION

INSTALLATION

EFFECTIVITY

1VE

Series D

CAP.

29P

4A

Energizing circuit of relay 7P, 8P and 10P and circuit of warning light GEN 1

30P

4A

Control circuit of 2VE external power supply and EPU ON indicator light circuit

AH helicopters S/N 7 and subsequent

3lP 32P

4A 4A

Electrical circuit (shunt 20P) bus, battery

2VE

AH helicopters S/N 7 and subsequent

33P 34P

4A 4A

Electrical circuit (shunt 21) generator 1

2VE

AH helicopters S/N 7 and subsequent

3SP 36P

4A 4A

Electrical circuit (shunt 22) generator 2

2VE

AH helicopters S/N 7 and subsequent

37P

4A

Energizing circuit of generator relay 109P

1VE

Series A, C, S S/N 7 and subsequent

38P

4A

Energizing circuit of generator relay 209P

1VE

Series A, C, S S/N 7 and subsequent

39P

4A

Electrical circuit of generator failure warning light GEN 2

1VE

Series D

Table 92-2

b.

Protection of DC power system

(2 of 2)

Circuit breakers Two circuit breakers 128P and 228P are located in main relay box 1VE and are used to protect the circuits which control the connection of the respective starter-generators to the electrical system.

BO 105 CHAPTER 92 Page 54

HELICOPTtRS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

-------------MBB

92 - 15 1.

Troubleshooting - DC power system

General In order to perform troubleshooting, the circuit breakers must be powered and depressed, and the fuses intacto A lamp test shall be carried out to ensure that the annunciators are not defective. Prior to replacement of any system component, check electrical wiring for continuity, insulation faults andproper connections. Also check for proper connection of electrical connectors to the units. The respective wiring diagrams are contained in the Wiring Diagram Manual. CAUTION

2.

BEWARE OF SHORT CIRCUITING WHEN MEASURING LlVE COMPONENTS.

Troubleshooting - generator system

NO. TROUBLE SYMPTOM 1

PROBABLE CAUSE

Defective circuit Starter-generator switch GEN 1 breaker 128P (228P). (GEN 2) is in position GEN or GEN ON, but generator is isolated from electrical system although the engines are running. Battery master switch 16P is ON.

Table 92-3

CORRECTIVE ACTION Using a multimeter, check for presence of 27,SV* at both connection points of the circuit breaker against ground. Replace circuit breaker, as . necessary. * see adjustab1e voltage regulator

Defective startergenerator control switch.

Check control switch for continuity. Replace switch, as necessary.

Generator supplies no voltage.

Check generator and replace as necessary.

Defective voltage regulator.

Interchange voltage regulators. Replace, as required.

Troubleshooting - DC power system

(1 of 5)

BO 105 CHAPTER 92 Page 55

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) NO. TROUBLE SYMPTOM

2

PROBABLE CAUSE

CORRECTIVE ACTION

Faulty reversecurrent relay 105P (205P) .

Using a multimeter, check reverse-current relay for presence of voltage at terminal SW. (Starter-generator switch in position GEN) . If voltage is present, replace reverse-current relay. If voltage is not present, generator control relay 106P (206P), or power supply relay 8P is defective. Replace defective components.

Arnmeter (19P) pointer Defective ammeter. does not deflect to the left, although both generators are connected to the line, ammeter selector switch set is in position BATT and Defective ammeter loads are being selector switch. carried.

Set ammeter selector switch to another position. Check for correct indication. Replace ammeter, if necessary.

Defective or incorrectly connected shunt.

3

EPU ON indicator light Defective lampo does not illuminate with external power source connected and energized and . Defective wiring. battery master switch 16P set in position EPU ON - BATT OFF

Table 92-3

BO 105 CHAPTER 92 Page 56

Set ammeter selector switch to another position. Check for correct indication. Replace ammeter selector switch, if necessary. Set ammeter selector switch into another position. Check for correct indication. Replace shunt or connect it correctly. Check lamp operation by depressing light cover. Replace lamp, if required .. Check for continuity using the applicable wiring diagramo

Troubleshooting - DC power system

(2 of 5)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) NO. TROUBLE SYMPTOM 4

5

6

PROBABLE CAUSE

EPU cannot be connec- Inadequate voltage ted to the line, supply from exteralthough battery nal power source. master switch l6P is in EPU ON Defective wiring. BATT OFF or OFF.

Battery is not connected to the line, although battery master switch l6P is set in position EPU OFF - BATT ON or ON.

Check external power source.

Check w~r~ng for continuity, using the applicable wiring diagram.

Defective fuse 30P.

Check fuse and replace as necessary.

Defective external power relay.

Checkrelay for continuity and replace, as necessary.

Battery not connected, or improperly connected.

Connect battery

Battery voltage nil or too low.

Check battery voltage. Charge or repl~ce battery.

Defective wiring.

Check wiring for continuity, using the applicable wiring diagram.

Defective fuses (llP, 2SP).

Check fuses for continuity and replace, as required.

Defective battery relay 6P.

Check relay for continuity and replace, as required.

Defective battery master switch l6P.

Check relay for continuity and replace, as required.

Auxiliary bus is not One generator is energized although not connected to the both generators are lineo connected to the lineo EPU still connected to the lineo

Table 92-3

CORRECTlVE ACTION

Using the ammeter, check whether both generators are connected to the lineo Check generator failure warning light. Check EPU ON indicator light. Disconnect EPU.

Troubleshooting - De power system

(3 of 5) BO 105 CHAPTER 92 Page 57

-----------'---·MBB HELICOPTERS·------------MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) NO. TROUBLE SYMPTOM

7

S

9

Auxiliary bus is not energized; external power source is energized.

Emergency bus is not energized

Voltage fluctuations at a constant load.

PROBABLE CAUSE

CORRECTlVE ACTION

Defective auxiliary bus relay 10P.

Check for continuity, using the applicable wiring diagramo Replace, as required.

Defective power supply relay SP.

Check for continuity and replace, as necessary.

Defective auxiliary bus relay 10P.

Check for continuity and replace, as necessary.

Defective wiring.

Check for continuity, using the applicable wiring diagramo

Defective fuse llP.

Check fuse and replace, as necessary.

Defective EMERG DC BUS pushbutton indicator.

Check for continuity using wiring diagram and replace indicator as required.

Defective emergency 'bus relay.

Check for continuity using wiring diagram and replace, as necessary.

Defective voltage regulator.

Interchange voltage regulators and replace defective regulator.

10 Warning light GEN 1 Defective generator (GE 2) does not failure warning illuminate when light 23P. generator is switched off or fails. Defective generator relay 109P (209P).

Table 92-3

BO 105 CHAPTER 92 Page 58

Check lamps by depressing warning light test switch 6EB. Replace faulty lamps or warning light, as necessary. Check wiring for continuity. Replace relay as necessary.

Troubleshooting - DC power system

(4 of 5)

- - - - - - - - - - - - - M B B HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

11 Warning light GEN 1 (GEN 2) illuminates when the generator is connected to the lineo

Defective reversecurrent relay 105P (20SP) .

Using a multimeter, check reverse-current relay for presence of voltage at terminal APP (on S/N 9 - 80), or terminal IND on S/N 81 and subsq.). If voltage is not present, replace reverse-current relay. If voltage is present, replace generator relay.

12

Defective voltmeter 18P.

Replace voltmeter.

Faulty wiring

Check continuity of wiring, using applicable wiring diagram.

No voltage indication when battery, EPU or generator is connected to lineo

Defective arnmeter. 19P does not deflect to the right, although the generator selected by the arnmeter selec- Defective arnmeter tor switch is conselector switch. nected to the electrical system and loads are being carried.

13- Pointer of arnmeter

Defective or incorrect1y connected shunts (21P = Generator 1) (22P = Generator 2)

Table 92-3

Set arnmeter selector switch to another position. Check for correct indication. Set arnmeter selector switch to another position. Check for correct indication. Replace arnmeter selector switch. Set arnmeter selector switch to another position. Check for correct indication. Replace shunt or connect correctly.

Troubleshooting - DC power system

(5 of 5)

BO 105 CHAPTER 92 Page 59

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 16

MAINTENANCE - De POWER SYSTEM

92 - 17

Check and adjustment of generator voltage

1.

General Generator voltage must be checked and adjusted after replacement of a generator, voltage regulator, reverse-current relay and associated wiring. Check and adjustment shall be performed on the ground with engines running.

2.

Test equipment 1

3.

4.

Voltmeter O - 30v, 0.3% accuracy (error

~

O.lV)

Preparatory steps a.

Connect voltmeter to starter bus PP1 and connect ground jumper to main relay box.

b.

Run engines at ground idle speed.

c.

Set battery switch to ON.

d.

Set ammeter selector switch to center position.

e.

Set generator 1 and 2 switches to ON. - GEN 1 and GEN 2 warning lights must not come on.

f.

If present, switch off EMERG DC BUS pushbutton indicator.

Measurement and adjustment of generator No. 1 and No. 2 voltages. CAUTION

BEWARE OF SHORT CIRCUITING WHEN MEASURING LlVE PARTS.

NOTE

Adjustments shall be made after the generators and voltage regulators have had time to warm up. Therefore, the generators shall be operated under load for at least 5 minutes.

a.

Pull circuit breaker 228P (lVE). - warning light GEN 2 shall come on.

b.

Switch on electrical equipment connected to main bus PP2l, e.g. fuel pumps, landing light, interior lights. The applied load shall be between 15 and 30 amperes.

BO 105 CHAPTER 92 Page 60

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Read voltmeter indication. - Nominal values: 19-cell battery: 20-cell battery:

27.SV ± O.lV 28.0V ± O.lV

If the reading on the voltmeter differs from the nominal value, turn the voltage regulating screw on the voltage regulator 104P (see fig. 92-26) to set the correct value. d.

Depress circuit breaker 228P and pull circuit breaker 128P (lVE) - Warning light GEN 2 must go out, warning light GEN 1 must come on.

e.

Repeat step c. If necessary, adjust voltage regulator 204P to obtain the nominal value. NOTE

o The maximum difference between both generator voltages must not exceed 0.2V. Example: Gen. No. 1 = 27.9V, Gen. No. 2= 28.1V If max. difference is exceeded, repeat adjustment. o If the BAT 60 warning occurs frequently as a result of the max. ambient temperature being exceeded , the required nominal values can be decreased by O.SV by resetting the voltage regulator. o At extremely low ambient temperatures, the voltage regulator can be reset to increase the required nominal value by O.SV.

f.

Depress circuit breaker 128P again. - warning light GEN 1 must go out.

g.

Shut down engines.

h.

Swivel the protective caps in place over both voltage regulator adjusting screws and tighten.

i.

Disconnect voltmeter, install cover on main relay box 1VE, and install cargo compartment panels.

BO 105 CHAPTER 92 Page 61

- - - - - - - - - - - - ' - M B B HELICOPTERS;'"- - - - - " " " " - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Potentiometerfor _ _ voltage regulation

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Figure 92-26

92 - 18

Gen e r a t o r

Vo1tage regulator

S y s t e m

The generator system consists of: -

two starter-generators 103P and 203P one voltage regulator each 104P or 204P (108P or 208P on series D) one generator relay each 109P and 209P (107P/207P or 110P/210P on series D) one shunt field re1ay 106P and 206P (series A, C only) one power supply relay 8P auxiliary start relay 101J and 201J (106P and 206P on series D) warning lights for generator overheating (see paragraph 92-34).

Location see paragraph 92-8

BO 105 CHAPTER

Page 62

92

- - - - - - - - - - - - - M B B HELICOPTERS------------MAINTENANCE MANUAL MBB - BO 105 1.

General With the engines running, the generator system supplies the DC power system with regulated 28V power and charges the airborne battery (see paragraph 92-10).

2.

Generator relay EFFECTIVITY

Series A, C to S/N 80

The generator relays 109P (LH generator) and 209P (RH generator) are located in the main relay box 1VE. These relays control the related warninglights (GEN 1 and GEN 2) and the auxiliary bus relay 10P (see figures 92-22 thru 92-24). Both relays are energized when the corresponding reverse-current relays have connected the generators to the busses. a.

Generator relay 109P When de-energized (generator 1 failed or disconnected froro the line) , the single-pole generator relay connects voltage to the GEN 1 failure warning light. When energized, it routes voltage to the control circuit of the auxiliary bus relay.

b.

Generator relay 209P When de-energized (generator 2 failed or disconnected froro the line), the dual-pole generator relay connects voltage via a contact to the GEN 2 failure warning light. The second contact disconnects the control line ofthe auxiliary bus relay.

EFFECTIVITY

Series A, C S/N 81 and subsequent The relay contacts (109P and 209P) for the control of the auxiliary bus relay 10P are connected in series, i.e. on failure of a generator, the relay 10P is de-energized and thus disconnects the auxiliary bus PP22 froro the helicopter electrical system.

c.

Generator relay (107P, 207P, 110P, 210P)

EFFECTIVITY

Series D Each starter-generator is controlled bytwo generator relays which are located in the roain relay box 1VE. The generator relays 107P and 207P connect the generators to the roain bus and disconnect them in case a reverse current occurs. Control of the relays is via the excitation line o~.the voltage regulators 108P and 208P. BO 105 CHAPTER 92 Page 63

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The generator relays 110P and 2l0P are also in the excitation line of the voltage regulators and energize respectively the GEN 1 and GEN 2 failure warning lights and the auxiliary bus relay lOP. 3.

Generator control relay EFFECTIVITY

Series A, C, S

The generator control relays 106P (LH generator) and 206P (RH generator) are located in the main relay box 1VE. The dual pole relays control the energizing of the reverse-current relays, as well as the equalizing circuit of the voltage regulator. The generator control relays are energized by the starter-generator control switch (position GEN ON or GEN) . When energized, the generator control relays feed voltage to the respective SW terminals of the reverse-current relays via the corresponding closed contacts of the power supply relay 8P (contacts are closed if external power source is not connected). The second contacts (in series) close the equalizing circuit of the voltage regulator. 4.

Power supply relay The power supply relay 8P is located in the main relay box 1VE. This triple-pole relay controls the connection of the generators to the line and the actuation of the auxiliary bus relay. The power supply relay is energized when an external power source (EPU) is connected to the helicopter electrical system (see paragraph 92-12). When energized, the power supply relay interrupts the control line of the reverse-current relay (two contacts), i.e. generators cannot be connected to the line during EPU operation. The third contact closes the energizing circuit of the auxiliary bus relay.

5.

Shunt field relay 106P and 206P EFFECTIVITY

Series D

Each generator comprises a shunt field relay located in t~e main relay box 1VE, which ensures constant generator field excitation. With the generator control switch in position ON or START, the starter relay (see paragraph 92-39) and the shunt field relay are energized. BO 105 CHAPTER 92 Page 64

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The shunt field relay interrupts the power supply to the field excitation winding of the generator with one contact, and simultaneously shortcircuits the field excitation winding with the other contacto 92 - 19 l.

Starter-generators

Starter-generator 103P, 203P A starter-generator is flanged to the lower, aft right side of each engine (I - II) gearbox. The starter-generator incorporates a shunt winding which is located in the shunt circuit of the voltage regulator, thus controlling the excitation (RPM output voltage) of the generator. In the starter mode (engine starting) a series winding is connected in series with the armature. To compensate for an armature reaction (brush arcing during load), an interpole winding and a compensation winding is connected in series with the armat ure . At 100% N2 engine RPM the generator speed is 12070 rpm. The normal speed range is 7200 to 12100 rpm but an overspeed of up to 14000 rpm is permissible for a shorttime. The nominal output of the starter-generators is 28V, 1S0A. A fan attached to the armature shaft is used for self-cooling the unit. Additional cooling of the starter-generators is provided by ram air (refer to chapter 65).

o

---------------0

2--~

SHUNT WINDING

A+

...--"""-"J..........r--~--------o

REGULATOR

E REGULATORINTERPOLEWINDING

COMPENSATION WINDING

-B+

SERIES WIND_IN_G

;.

-8"

" ' - - - - - - - - -.....v..AA-J

900187

7

! 5 4

3

1 2 3 4 Figure 92-27

Drive Shaft Terminal Fan Brush holder

5 Cornmutator 6 Armature 7 Windings

Cross-Sectional View and Schematic Diagram of the Starter-Generator BO 105 CHAPTER 92 Page 65/66

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 20 1.

Removal and installation - starter-generators

Removal a.

Disconnect the battery or, if connected, the external power source from the helicopter electrical system, and secure against inadvertent reconnection.

b.

Remove engine cowlings.

c.

Disconnect wiring from terminal block (5).

d.

Loosen V-clamp (2) of the starter-generator and carefully lift starter-generator (4) or (9) from mounting pad (1). EFFECTIVITY

SB 60-31 or SiN 321 and subsequent o Loasen hose clamp (7) on GRP fan cover (6) of starter-generator and pull off cooling air hose (8). o Loosen V-clamp (2) of starter-generator and lift starter-generator (4) or (9) from mounting pad (1). o Unscrew GRP fan cover from starter-generator and retain for later re-installation (clean. the fan cover) .

2.

Installation CAUTION

o INSTALL STARTER-GENERATOR WITH "WET SPLINE" DRIVE SHAFT (p/N 32032-027, ALSO TO BE RECOGNIZED BY THE PACKING GROOVE BEHIND DRIVE SPLINES) ONLY TO ENGINE GEARBOX MODIFIED FOR THIS PURPOSE (REFER TO SERVICE INFORMATION NO. 50). o APPLY GREASE (ITEM 101) TO DRIVE SPLINES OF STARTER-GENERATOR WITH "DRY SPLINE n DRIVE SHAFT (p/N 23032-022, NO PACKING GROOVE BEHIND THE DRIVE SPLINES) .

o ON STARTER-GENERATORS WITH ftWET SPLINE n DRIVE SHAFTS, CHECK O-RING (3, FIGURE 92-28) INSTALLED BEHIND THE DRIVE SPLINES FOR DAMAGE ANO REPLACE O-RINGS, IF NECESSARY.

BO 105 CHAPTER 92 Page 67

-----------------'---'" MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

CAUTION

INSTALL STARTER-GENERATOR WITH "WET SPLINE" DRIVESHAFT ONLY ON ENGINE GEARBOXES MODIFIED BY ALLISON CEB 179 OR CEB 1082. (Refer to 2. Installation)

8

7

6

4

3 2 90051.4

9

1 Mounting pad 2 V-clamp 3 O-ring

CAUTION

4 Starter-generator ("wet spline" drive shaft) 5 Terminal block

INSTALL STARTER-GENERATOR WITH "DRY SPLINE" DRIVESHAFT ONLY ON ENGINE GEARBOXES NOT MODIFIED BY ALLISON CEB 179 OR CEB 1082. (Refer to 2. Installation)

7 Hose clamp 8 Cooling air hose 9 Starter-generator ("dry spline" drive shaft) Figure 92-28 BO 105 CHAPTER 92 Page 68

Removal and Installation of the Starter-generator

MAINTENANCE MANUAL 80 105

EUROCOPTER

a.

Inspect starter-generator for visible damage.

EFFECTIVITY b.

SB 60-31 or S/N 321 and subsequent. Install GRP fan cover (6) to starter-generator.

Push starter~generator (4) or (9), together with V-clamp (2), in mounting pad until drive splines are fully engaged with splines in I.D. of engine gearbox bushing.

CAUTION

PRESS STARTER-GENERATOR FIRMLY AGAINST MOUNTING PAD (1) TO PREVENT SCREW HEADS FROM SLIDING OUT OF THE PAD RECES SES (DAMAGE TO SPLINES OF DRlVE SHAFT) .

c.

Align screw heads on starter-generator with recesses on pad so that the terminal block (5) comes to seat at the lower side, as shown in figure 201.

d.

Tighten "T" boH nut and torque to 4-6 Nm.

e.

Re-connect wiring to terminal block (refer to wiring diagram) .

f.

If a new or overhauled starter-generator is installed, or the carbon brushes have been replaced, functionally test the generator system and adjust the generator voltage as necessary (refer to para 92-24).

92 - 20A NOTE

Inspection and maintenance - starter-generators For shop maintenance or overhaul of the startergenerators refer to LEAR SIEGLER Manuals.

1.

Check for warped or cracked terminal block or damaged terminals.

2.

Check fan cover for dents and broken spot welds.

3.

Clean exterior surfaces of unit with a clean cloth moistened with cleaning solvent (CM 202). Wipe unit with a dry, clean cloth~ Dry and clean splines of drive shaft.

4.

Remove fan cover and check for oil, carbon and copper dust, dirt and other foreign objects. CAUTION

o DO NOT USE COMPRESSED AIR FOR INTERNAL CLEANING OF STARTER-GENERATORS. o DO NOT WIPE COMMUTATOR, BRUSHES ANO BRUSH HOLDERS.

5.

Remove deposits with a cloth moistened with cleaning solvent (CM 202), and remove foreign objects with a vacuum cleaner only.

Revision 14

BO 105 CHAPTER 92 Page 69

* *

*

EUROCOPTER

MAINTENANCE MANUAL BO 105

6. Visually inspect fan for bent blades, friction marks, cracks or loose connections. NOTE

Check bearings for condition only with brushes removed from holders.

7. Rotate armature slowly with your fingers to feel bearing condition.

s.

Check brushes for cracks, chips, frayed leads and loose rivets. -

* * *

The remaining service life of the brushes must be more than one quarter of the total service life, otherwise the brushes must be replaced.

9. Reinstall brushes in their initial positions making sure that they are properly seated on cornmutator surface (100% in direction of rotation and at least 75% in axial direction is mandatory) . 10. Inspect cornmutator for surface condition. The Cornmutator must have a bright appearance and a thin film on the surface. 11. Reinstall fan cover. 92 - 21

Voltage regulators

The two voltage regulators 104P and 204P or 10SP and 208P are installed in the main relay box 1VE (see figure 92-1 to 92-3). The voltage regulators perform the following functions: 1.

Voltage regulation Generator voltage is regulated to the adjusted nominal value of 27.5V or 2S.0V respectively using the exciter current in the regulator. Voltage fluctuations because of load and speed changes must not be greater than ± O.lV.

2.

Parallel operation control During parallel operation, the generators are regulated by the voltage regulators so that they are equally loaded. The voltage regulators are controlled mutually via a equalizing lineo

3.

Generator relay control/reverse-current protection The generator relays are energized or de-energized by the voltage regulators depending on the condition of the DC power system. The generator relay is automatically energized when the voltage of the respective generator almost equals that of the helicopter electrical system (minus 0.3V of the adjusted voltage). This is to prevent reverse current during lock-on. The respective generator is deenergized if reverse current flows.

BO 105 CHAPTER 92 Page 70

Revision 14

EUROCOPTER

4.

MAINTENANCE MANUAL BO 105

Overvoltage protection

*

EFFECTIVITY: All helicopter models except model D, DBS-5, CB-5 and CB5-5. * The voltage regulator opens the generator relay and generator field if an * overvoltage condition occurs. The generator is not automatically reconnected to the helicopter electrical system but must be reactivated by momentarily setting the toggle switch GEN CONTROL to OFF, then to GEN.

* * * * * EFFECTIVITY: Helicopter models CB-5 and CBS-5. Helicopter models C and S * EFFECTIVITY: Helicopter models D and DB5-5. In D series each generator is switched on by setting the GEN CONTROL toggle switch to RESET and then to ON.

after accomplishment of ASB-B0105-80-118 and/or 5B-B0105-80-119. * Two switches are installed in the overhead panel by means of which * generators, shut off as a result of overvoltage, can be switched on again * individually. * 5.

* *

Short-circuit protection The voltage regulator opens the generator relay and generator field if the generator feeder or starter bus PP1 shorts to ground.

92 - 22 1.

2.

Removal and installation - voltage regulators

Removal a.

Disconnect battery or, if connected, the external power source from the helicopter electrical system and secure against inadvertent reconnection.

b.

Remove cover on lower right side of the cargo compartment panelling.

c.

Open four quick-release fasteners of main relay box 1VE cover. Remove cover.

d.

Disconnect electrical connector from voltage regulator.

e.

Remove four mounting screws from voltage regulator.

f.

Lift voltage regulator from main relay box 1VE.

Installation a.

Inspect voltage regulator for visible damage.

b.

Position voltage regulator in its installation location and secure in place with the four mounting screws.

C.

Re-connect electrical connector to voltage regulator.

d.

Perform functional test of the DC generator system (refer to 92-24 Functional Test) .

e.

Inspect main relay box 1VE for foreign objects.

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EUROCOPTER

MAINTENANCE MANUAL 80 105

f.

position cover on main relay box 1VE and secure with the four quickre1ease fasteners.

g.

Re-install cover on cargo compartment panelling.

92 - 23

Inspection and maintenance - voltage regulators

NOTE

Refer to paragraph 92-17 for checking and adjustment of the generator voltage.

l.

Check voltage regulator for external damage and damaged plug contacts.

2.

Check monitoring and fault protection functions of voltage regulator and carry out functional test of generator system (see paragraph 92-24).

92 - 24 1.

Functional test - generator system

General The functional test must be carried out after having changed one or more electrical components, cables, electrical connections, etc. of the generator system. This test shall be performed on the ground with the engines running.

2.

Test equipment - test voltmeter, 0-30V DC, class 0.5

3.

4.

Preparations a.

Connect test voltmeter to main bus PP21.

b.

Connect test voltmeter or test lamp to auxiliary bus (DC socket 2VEG) .

c.

Start engine with an external power source. Both starter-generator control switches must be in OFF.

d.

Switch on battery switch 16P.

e.

Disconnect external power source from helicopter. EPU ON indicator light must extinguish.

Connection of generator 1 to the line (engines running at approx. 100% N2, but with identical NI idle speed) a.

* * * *

Set starter-generator control switch 117P (118P) to position GEN. Generator warning light panel GEN 1 must extinguish. The test voltmeter connected to main bus PP21 and voltmeter 18P must indicate identical voltage, 27.0 - 28.0V. In case the reading deviates from the specified voltage value, adjust voltage (refer to para. 92-17). The test voltmeter connected to auxiliary bus PP22 must not indicate voltage or the test lamp must not illuminate.

* BO 105 CHAPTER 92 Page 72

Revision 16

MAINTENANCE MANUAL 80 105

EUROCOPTER

5.

Connection of generator 2 to the line (engines running at approx. 100% N2, but with identical Nl idle speed). a.

b.

Set starter-generator control switch 2l7P (218P) to position GEN or ON, and set starter-generator control switch ll7P (l18P) to position OFF. Generator warning light GEN 2 must extinguish. Generator warning light GEN 1 must illuminate. The test voltmeter connected to main bus PP21 and voltmeter 18P shall both indicate 27-28V. In case the reading deviates from the specified voltage value, adjust voltage (refer to para. 92-17). The test voltmeter connected to the auxiliary bus PP22 must not indicate voltage or the test lamp must not illuminate.

* * * * *

Deleted

* * *

c.

6.

Set arnmeter selector switch 24P to position GEN 2 and switch on a suitable load. The arnmeter must indicate the load current by a pointer deflection to the right.

Connection of generator 1 and 2 (parallel operation) to the line (engines running at approx. 100% N2, but with identical N1 idle speed). a.

Set both starter-generator control switches to position GEN or ON. Both generator warning lights must extinguish. The Test voltmeter connected to the main bus PP21 and voltmeter 18P must both indicate 27.0 - 28.0V. In case the reading deviates from the specified voltage value, adjust voltage (refer to para. 92-17). The test voltmeter connected to the auxiliary bus PP22 must also indicate the same voltageor the test lamp must illuminate, whichever is applicable.

- With emergency bus installed - Depress EMERG. DC BUS pushbutton indicator l5P (41P). It must illuminate. With an external power source connected, the EPU ON indicator light must extinguish. Check that there is no voltage present on the main, auxiliary and starter busses. Check voltage supply to emergency bus on voltmeter 18P. Voltmeter must indicate battery voltage. - Set starter-generator control switch to OFF, then return it to position GEN or ON. Activation of the generators shall not be possible (main, auxiliary and starter busses still de-energized) . - Reset pushbutton indicator lSP (41P). Check that generators are connected to the line, and all busses are energized.

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BO 105 CHAPTER 92 Page 73

* * * * * *

EUROCOPTER

b.

7.

8.

MAINTENANCE MANUAL

eo 105

Set arnmeter selector switch 24P to center position and switch on a load. - The arnmeter must indicate the total current GEN 1 and GEN 2 by pointer deflection to the left.

Functional test of activated generators a.

Switch battery switch 16P to ON and OFF. Check that both generators keep on operating without interruption.

b.

Set battery switch 16P to OFF and switch generator 1 on the starter-generator control switch. Generator 2 shall operate without any interruption, and generator warning shall illuminate when the generator is removed from the extinguish as soon as it is reconnected to the lineo

and off with continue to light GEN 1 line and then

Disconnection of the generators from the line by reverse current

* * * * *

NOTE

On helicopter models D and DBS-S with respect to steps b. and e., the generators are disconnected from the line by generator relays 107P and 207P, when the latter are actuated by the respective voltage regulators.

a.

Set arnmeter selector switch 24P to position GEN 1.

b.

Shut down engine 1. The arnmeter 19P momentarily current of approx. S-lOA (pointer deflection to reverse-current relay 10SP then disconnects the heliéopter electrical system. Generator warning illuminate.

c.

Re-start engine 1 and reconnect generator 1 to the lineo The generator warning light GEN 1 must extinguish.

d.

Set arnmeter selector switch 24P to position GEN 2.

e.

Shut down engine 2. The arnmeter 19P momentarily current of approx. S-lOA (pointer deflection to reverse-current relay 20SP then disconnects the helicopter electrical system. Generator warning illuminate.

f.

Re-start engine 2 and reconnect generator 2 to the lineo The generator warning light GEN 2 must extinguish.

BO 105 CHAPTER 92 Page 74

indicates a reversethe left). The generator 1 from the light GEN 1 must

indicates a reverse the left). The generator 2 from the light GEN 2 must

Revision 16

EUROCOPTER

9.

MAINTENANCE MANUAL 80105

Functional test of switches 110P and 210P

* * * NOTE The functional test is only necessary on helicopter * models Ca-5 and CaS-5. Helicopter models C and 5 after * accomplishment of A5B-BOI05-80-118 and/or 5B-B0105-80-119. * * a. Press switches 110P and 210P in overhead panel momentarily to "GEN * TRIP". Both indicators "GEN1" and "GEN2" in instrument panel must * come on. * The main busses PP21 in the main relay box 1VE are conducting battery * voltage. * The test voltmeter connected to the auxiliary bus PP22 must not * indicate voltage or the test lamp must not illuminate.

b.

c.

*

Press and hold switch 11 OP for approx. 2 sec. in "GEN1 RE5" position. Indicator "GEN1" goes off. The main bus ses PP21 are conducting generator voltage. The test voltmeter connected to the auxiliary bus PP22 must not indicate voltage or the test lamp must not illuminate. Press and hold switch 210P for approx. 2 seco in "GEN2 RE5" position. Indicator "GEN2" goes off. The main busses PP21 are supplied by both generators The test voltmeter connected to the auxiliary bus PP22 must not indicate voltage or the test lamp must not illuminate.

Revision 16

BO 105 CHAPTER 92 Page 74A/B

* * * * * *

*

* *

* *

* * *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 25

B a t ter y p o w e r

s y s t e m

The battery power system comprises: -

battery battery battery battery

1P relay 6P switch 16P overheat warning light (see paragraph 92-34) .

For locations refer to paragraph 92-26 1.

General The battery power system provides power to the DC power system when both generators are disconnected, when the external power source is disengaged, and during emergency operation (refer to paragraph 92-11).

2.

Battery relay 6P

EFFECTIVITY

o Series A, C, D The battery relay 6P is located on the battery block in the nose section. o Series S The battery relay 6P is located underneath the engine deck (in flight direction forward of the battery) .

When energized, the battery relay (battery switch set to EPU OFF-BATT ON) routes the battery voltage to the main bus PP21 and starter bus PP1. 3.

Battery switch (master switch) 16P The battery switch is located on the lower right side of the instrument panel. The single or dual-pole toggle switch is used to energize the battery relay 6P and the auxiliary relay 26P or the external power relay 7P respectively (for effectivity see figures 92-16, 92-17 and 92-18). With the single-pole toggle switch set in position ON, the battery relay 6P and the auxiliary relay 26P are simultaneously energized. The energized battery relay completes the batterypower circuit to the helicopter electrical system and the auxiliary relay simultaneously . interrupts the exciter circuit of the external power relay 7P. This ensures that no externalpower source can be connected to the line simultaneously. With the dual-pole toggle switch installed and set to position EPU OFF-BATT ON, the battery relay 6P is energized and the exciter circuit of the external power relay 7P interrupteq at the same time, thereby preventing the external power source from being connected to the line simultaneously.

BO 105 CHAPTER 92 Page 75

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 92 - 26

Battery

The battery serves as an emergency power source and provides engine starting power and back-up power for the generators, which charge the battery during normal operation. The battery consists of 19 or 20 (optional) plastic cells with nickel cadmium plates, with a rated voltage of 24V when fully charged. Ventilation of the battery is via vent tubes which are routed overboard. A temperature warning system (refer to para 92-34) ensures safe operation of the battery. EFFECTIV1TY

o Series A, C, D The battery is located in the nose section forward of the instrument panel 2VE and is accessible through a cover on the front of the helicopter. o Series S The battery is located on the aft RH side of the engine deck and is accessible through a cover in the engine cowling.

92 - 27

Removal and installation - battery

CAUTION

l.

IT 1S ESSENT1AL TO AV01D SHORT-C1RCUIT1NG THE BATTERY CONNECTORS. SHORT CIRCUIT CURRENTS OF MORE THAN 1400A ARE POSS1BLE.

Removal (see fig. 92-29) a.

Set battery switch to OFF.

b.

Open battery access door.

c.

Unlock connector (11) and disconnect from battery.

d.

Disconnect connector (12) of the battery temperature warning system.

e.

Loosen clamps (5) and disconnect vent tubes from battery case.

CAUT10N

f.

SECURE VENT TUBES W1TH OPEN ENDS UP OR P1NCH OFF OPEN ENDS SO THAT NO ELECTROLYTE RESIDUE CAN DR1P ON TO STRUCTURAL PARTS.

Loosen both wing nuts (3) after removal of the spring (2).

BO 105 CHAPTER 92 Page 76

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

CAUTION g. 2.

Lift battery from support (9).

Installation a.

Inspect battery for visible damage.

b.

Inspect battery support and vent tubes prior to the installation of the battery, and clean, as required.

c.

Install battery in support (9).

d.

Insert hold-down bolts (8) through slotted lug on battery cover (1), secure with wing nuts (3) (channel positioned with flanges down) , and install the spring (2).

e.

Slide on vent tubes and secure with clamps (5).

f.

Re-connect connector for battery temperature warning system.

g.

Re-connect and lock battery connector (11).

h.

Perform functional test of the DC power system, battery (refer paragraph 92-17).

i.

Inspect working area for foreign objects.

k.

Close battery access door.

92 - 28 l.

AVOID TILTING THE BATTERY UPON REMOVAL. DO NOT OPEN BATTERY COVER WHEN ~ATTERY I5 STILL INSTALLED IN THE HELICOPTER.

to

Inspection and Maintenance - battery

General a.

Check battery connector (figure 92-29, 11) and cables for faulty insulation and other damage.

b.

Check battery receptacle for unimpaired condition.

c.

Check that battery case is free from spilled electrolyte or alkaline deposits. If these are present, remove the battery and clean the battery case (see VARTA Battery Maintenance Manual) .

NOTE

Maintenance of nickel-cadmium batteries shall be performed at battery shops on1y. Refer to VARTA Battery Maintenance Manual.

BO 105 CHAPTER 92 Page 77

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

6---~.

5----

"'-.. ~

7

5

1 2 - -......

~a.:.-_-+-_-6

1~---:7'e..----7

11------8 .>"'1+----9

l' 5

900073

Battery cover 2 Securing spring 3 Wing nut 4 U-plate 5 Clamp 6 Vent tube elbow

1

Figure 92-29 BO 105 CHAPTER

Page 78

92

Vent tube Hold-down bolts Battery support 10 Screw 11 Battery connector 12 Connector 7

8 9

Removal and installation - battery

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Testing the battery charge a.

Set battery switch respectively BATT EPU or BATTERY MASTER toggle switch to ON. - The voltmeter on instrurnent panel 2VE must indicate between 24V and 28V.

b.

Energize allfour fuel purnps via switches on overhead panel 12VE. - The indicated battery voltage must not drop below 24V within one minute.

c.

Switch off fuel purnps.

92 - 29 1.

Functional test - battery power system

General The functional test must be carried out each time one or more electrical components, cables, electrical connections, units etc. of the battery power system are replaced. This test shall only be performed on the ground with the engines operating or shut down.

2.

Test Equipment - 1 Test - 1 VTVM - 1 Load - 1 Test

3.

voltmeter 0-30V, class 0,5 with automatic polarity switch over bank 50-l00A lamp

Functional test a.

Battery operation 1)

Check that all fuses are installed in the main relay box and instrurnent panel.

2)

Set battery switch 16P to ON position. Check that battery voltage indicated on the voltmeter 18P is 24V.

3)

To check voltage on the auxiliary bus PP22, connect test volt-. meter to DC socket 2VEG and push circuit breaker DC SOCKET. There must be no voltage indication on the voltmeter.

BO 105 CHAPTER 92 Page 79

- - - - - - - - - - - - - M B B HELICOPTERs . - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

b.

c.

4)

To check battery current, pull all circuit breakers and place arnmeter selector switch 24P to each of its three positions in turn.Ammeter °19P must not indicate current in any of the three switch positions.

5)

Set arnmeter selector switch to center position and switch on a load (e.g. main tank fuel pump). Amrneter 19P must indicate the load current (pointer deflection to the left). No current indication must be present in~he two other switch positions.

EPU operation 1)

Set battery switch 16P to position ON or EPU ON - BATT OFF.

2)

Connect an external power source to the external power receptacle 2P. The EPU ON indicator light and both generator warning lights GEN 1 and GEN 2 must illuminate.

3)

Check that the applied external power source voltage (approx. 27.SV) is indicated on the voltmeter lSP.

4)

To check voltage on the auxiliary bus PP22, connect test voltmeter to DC socket 2VEG and push circuit breaker DC SOCKET. The voltage indication on the test voltmeter must correspond to that on the voltmeter lSP.

5)

Place battery switch 16P to position ON or BATT ON - EPU OFF. The voltmeter lSP must indicate the battery voltage (24V). (The external power supply is disconnected from the helicopter electrical system by setting the battery switch to ON). No voltage must be present on the auxiliary bus PP22 (test voltmeter) . .

Emergency bus supply (if installed), (with battery and external power source connected). 1)

Switch off EMERG. DC BUS pushbutton indicator lSP (41P) and set battery master switch 16P to OFF or EPU ON - BATT OFF. Check that voltmeter lSP indicates the external power source voltage (approx. 27.SV). The EPU ON indicator light 27P and GEN l/GEN 2 warning lights must illuminate.

2)

Connect test voltmeter to main bus PP21 (refer to wiring diagram) and to auxiliary bus PP22 (DC socket). Both busses must be supplied with voltage. Check voltage supply to emergency bus on the voltmeter 18P.

3)

Set battery master switch 16P to position ON or EPU OFF - BATT ON.The main bus and emergency bus must be supplied ~ith battery .power, whereas no voltage must be present on the auxiliary bus.

BO 105 CHAPTER 92 Page SO

-----------......;,.-··MBB HELICOPTERS------------MAINTENANCE MANUAL MBB - BO 105

92 - 30

4)

Depress EMERG. DC BUS pushbutton indicator lSP (41P). It must illuminate, and the EPU ON indicator light must extinguish. No voltage must'be present on the main bus, auxiliary bus and starter bus (generator warning lights must extinguish). Check voltmeter for indication of battery power on emergency bus.

S)

Set battery master switch 16P in position OFF or EPU ON - BATT OFF.The main, auxilary and starter busses must remain de-energized (Disconnection of the external power source is not possible) .

6)

Set battery master switch 16P in position ON or EPU OFFBATT ON. The main, auxiliary and starter buses must remain deenergized (Normal battery connection interrupted) .

7)

Set battery master switch 16P to OFF or EPU ON/BATT OFF

8)

Switch off EMERG. DC BUS pushbutton indicator lSP (41P). It must extinguish, and EPU ON indicator light illuminate. Check that all busses are supplied from the external power source.

9)

Remove all test equipment and wiring required for functional testing. E x ter n a 1 p o w e r

s y s t e m

The external power system comprises: -

external power receptable 2P external power relay 7P power supply relay 8P auxiliary relay 26P EPU indicator light 27P battery switch 16P

For locations of components, refer to paragraph 92-8. l.

General The external power system supplies power froro an external power source to the busses (refer also to paragraph 92-12). This power supply is used for ground maintenance and as the normal source of power for starting the engines.

BO lOS CHAPTER 92 Page 81

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

External power relay 7P The relay 7P is located on the battery block. When the relay is energized, it connects the external power supply to the main bus PP21 (figures 92-14 and 92-15).

3.

Power supply relay 8P When energized, the relay feeds control voltage to the auxiliary bus relay 10P, thus connecting external power to the auxiliary bus as well (see figures 92-14 and 92-15) .

4.

Battery switch 16P The battery switch controls the actuation of the auxiliary relay and battery relay. These relays control changeover from battery to external power (figures 92-14 and 92-15).

5.

Auxiliary relay

EFFECTIVITY

S/N 7 - 160

The auxiliary relay 26P is located on the battery block (nose section). The dual-pole relay, when de-energized (battery switch in the OFF position), connects the control voltage from the external power receptacle to the EPU ON indicator light and to the field coil of the external power relay 7P and the power supply relay 8P (figure 92-14). 6.

EPU ON indicator light NOTE

External power can only be connected to the line when the battery switch is set to BATT OFF position.

The EPU ON indicator light 27P is located on the lower right side of the instrument panel, and illuminates whenever the battery switch is set to BATT OFF and an external power source is connected to the external power receptacle and energized (figures 92-14 and 92-18) .

BO 105 CHAPTER 92 Page 82

- - - - - - - - - - - - - M B B HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 92 - 31

External power receptacle

The external power receptacle is located on the battery block in the nose section. 1t is the plug-in point for a 28Vdc external power source which delivers 700 amp starting power and 200 amp continuous power. The external power connector has one negative and two positive pins~ The shorter of the two positive pins controls the external power relay and does not energize it until the external power source is connected tightly to the other positive pin, thus preventing charring of the contacts. 92 - 32

Inspection and maintenance - external power receptacle

CAUTION

WHEN WORK1NG ON THE EXTERNAL POWER RECEPTACLE MAKE 5URE THAT BATTERY CONNECTOR 1P 15 REMOVED AND THAT NO EXTERNAL POWER 50URCE 15 CONNECTED~ PROTECT AGA1N5T 1NADVERTENT CONNECT10N.

1.

Check attachment of busses for proper seat.

2.

Check insulation of busses and cables for charring and other damage.

3.

Check condition of fuses 2SP and 30P.

92 - 33 1.

Functional test - external power system

General The functional test must be carried out each time one or more electrical components, cables, electrical connections, etc. of the external power receptacle are replaced. This test shall be performed on the ground with the engines shut down.

2.

Test equipment - Test voltmeter, 0-30 V DC, class 0.5

BO 105 CHAPTER 92 Page 83

- - - - - , - - - , - - - - - - - - - " MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

Preparations - engines must be shut down - battery switch respectively BATT EPU or BATTERY MASTER set to OFF - generator switches STARTER/GENERATOR respectively ENG.I - ENG.II set to OFF - external power unit disconnected.

4.

Performance of test a.

Connect the external power unit to the external power receptacle 2P and switch on. - External control light 27P (series A, C, D S/N 7-160) and EPU ON indicator (series A, C, S S/N 161 and subsq.) illuminate

b.

Set battery switch respectively BATT EPU or BATTERY MASTER toggle switch to ON. warning lights GEN 1 and 2 illuminate in red (only S/N 61 and subsq. and Series D) - voltmeter 18P on instrument panel 2VE indicates application of external power (28V) - connect test voltmeter to pin lOor 11 of receptacle 2VEP and ground - Test voltmeter indicates external voltage if circuit breakers lR and 2R are depressed

c.

Press EMERG. DC BUS pushbutton indicator (only S/N 161 and subsq. and Series D) to activate emergency power mode. - warning lights GEN 1 and GEN 2 illuminate red (only S/N 161 and subsequent and Series D) - voltmeter 18P on instrument panel 2VE indicates the battery voltage (24V - 28V).

d.

Press EMERG. DC BUS pushbutton indicator again to deactivate emergency power mode. Set battery switch respectively BATT EPU or BATTERY MASTER toggle switch to OFF. - warning lights GEN 1 and GEN 2 must extinguish voltmeter 18P on instrument panel 2VE indicates no voltage

e.

Disconnect voltmeter.

f.

Disconnect external power supply from external power receptacle 2P.

BO 105 CHAPTER 92 Page 84

- - - - - - - - - - - - - ' M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 34

MO n i t

O

r i n g DC P

O

we r

s y s t e m

The following monitoring'systems are installed in the DC power system: ,-

voltmeter and arnmeter generator failure warning external power engagement warning generator overheat warning battery temperature warning

92 - 34A

Voltmeter and arnmeter (see figure 92-30)

The monitoring system comprises the voltmeter 18P, arnmeter 19P, a test point selector switch 24P, and three shunts 20P, 21P and 22P. For component locations refer to paragraph 92-8. 1.

Voltage measuring equipment The voltmeter 18P is located on the upper right side of the instrument panel 2VE right above the arnmeter. The voltmeter is connected to main bus PP21 and indicates the momentary value of the connected power source. Battery operation: Externa1 power operation: Generator operation:

2.

battery voltage check = 24V EPU voltage check = 28V system voltage check = 27V and 29V

Current measuring equipment The arnmeter 19P is located on the upper right side of the instrument panel 2VE. Depending upon the position of the arnmeter selector switch 24P, the arnmeter will indicate either the power supply by or the load current of the generator 1, generator 2 or the main bus PP21. The arnmeter has a measuring range of -150A to +150A with a zero indication in the center of the scale.

3.

Arnmeter selector switch The arnmeter selector switch 24P is located directly below the arnmeter. It is a toggle switch with three positions for connecting the arnmeter to the respective circuits (refer to table) .

4.

Shunts Three shunts 21P, 22P and 20P are located in the main circuits of generator 1 (21P) and generator 2 (22P), and main bus respectively (20P) . To measure one of the circuits a shunt is connected in parallel to the arnmeter via the arnmeter selector switch.

BO 105 CHAPTER 92 Page 85

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 STARTERlGENERATOR 1 103 P

STARTER/GENERATOR 2 203 P

EXTERNAL POWER· RECEPTACLE 2P

BATIERV 1P

--

see 92·31

VOLTAGE· REGULATOR

R--~r

REVERSE CURRENT· RELAV 10SP .

R-~ ~-R

~-R

REVERSE CURRENT· RELAY 205P

BATIERV RELAY 6P

EXTERNAL POWER· RELAY 7P

SHUNT 21P SHUNT

SHUNT

22P

20P STARTER BUS

MAIN BUS PP21

28V I :...-I----~__.

AUXILlARV BUS RELAY 10P

~

R--~

109P

-f1

GENERATOR RELAV

GEN 1

H. 209P

GEN 2

1-'

íAüXiLIAAY RElAY I

-!Rif

iI AMMETER·

- ...

GEN1 BATI GEN2

; SELECTOR SWITCH 24P

BUS

VOLTMETER 18P

AMMETER 19P

--

:

I

I ~¡::=oI

I

L

900221

Figure 92-30 BO 105 CHAPTER 92 Page 86

E~pu="1

'\

Voltmeter and arnmeter

1

I

-:' ..J

"""""1

ON

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

------------~MBB

AImneter Selector Switch Setting

Arnmeter Left Scale Range -lSOA to O Generator operation (parallel) : Reverse current GEN 1 Reverse current GEN 2 GEN 1 Total current and GEN 2

Generator operation: GEN 1 (left) GEN 2 (right) BAT or BUS (center position)

EPU operation: Current supplied by EPU

BAT or BUS

Battery operation: Load current

BAT or BUS

Table 92-4 92 - 34B

AImneter Right Scale Range O to +lS0A

Current generated by GEN 1 Current generated by GEN 2

AImneter selector switch

Generator failure warning

The warning light 23P is located on the warning panel in the center of the instrument panel 2VE. It contains two display captions marked GEN 1 and GEN 2, which will illuminate red, when a generator fails or is switched off. Operation of the lamps is tested by depressing the warning light test switch 6EB. 92 - 34C EFFECTIVITY

External power engagement warning o S/N 7 - 160 The yellow, round EPU ON-indicator light 27P is located on the instrument panel above the battery master switch 16P. During EPU operation with battery switch set to BATT OFF/EPU ON, voltage is fed via a contact of the auxiliary relay 26P to the indicator light, which will illuminate yellow.

BO 105 CHAPTER 92 Page 87

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 o S/N 161 and subsequent and S series The yellow, square EPU ON indicator light 27P is located on tne instrument panel above the battery master switch 16P. When the external power supply is engaged and switched on, the four lamps of the indicator light will be energized and light up the EPU ON caption. Operation of all four lamps is tested by depressing the warning light test switch 6EB. o D series and IFR Same as S/N 161 and subsq., except that the EMERG. DC BUS pushbutton indicator switch 41P/15P must not be depressed. 92 - 34D

Generator overheat warning

EFFECTIVITY

D series only

This warning indicates overheating of generators. It consists of two thermo-switches 3DA and 4DA on the two generators and a red warning light 2DA installed in instrument panel 2VE. If the generator temperature exceeds 205 oC, the respective warning light "GEN 1 O/H or GEN 2 O/H" is switched on by the thermo switch. 92 - 34E

Battery temperature warning (see figure 92-31)

Purpose of the system is to indicate any overheating of the battery. Indication is via two warning lights marked BAT 60 and BAT 70, which are controlled by two temperature switches installed in the battery. These switches activate at different battery temperatures. NOTE -----a.

When the warning light BAT 60 illuminates, the battery must be disconnected from the electrical system. Warning light EFFECTIVITY

o S/N 7 - 60 The warning light 1WP is located on the instrument panel next to the arnmeter selector switch 24P. o S/N 61 and subsequent and D series The warning light 1WP is located on the warning panel of the instrument panel 2VE.

When a battery temperature of 60°C (140°F) BAT 60 illuminates red. If 70°C (lGO°F) is light BAT 70 will additionally illuminate. functionally tested by pressing pushbutton BO 105 CHAPTER 92 Page 88

is reached, warning light reached the red warning The 4 lamp bulbs are /indicator GEB.

------------------:.-'MBB HELICOPTERS------------MAINTENANCE MANUAL MBB - BO 105

MAIN BUS

.PP21

2BV

XI

! ~ FUSE

~

BE

, WP

,

4 WP

'"'l p-

.4

•

L

11

BAT 60

W

BAT 70

I

I

WARNING LIGHT

... 3WP

:>

...

(

70°

60°

2WP

BATTERY1P 9DD221

Figure 92-31 92 - 35

Battery Temperature Warning System

Battery temperature switches

Both temperature switches 2WP and 3WP (see figure 92-31) are screwed onto two cell connectors within the battery. Temperature switch 2WP is set to a temperature of 60°C (140°F). If the battery temperature reaches 60 oC, the temperature switch will close and complete the circuit to the light BAT 60, which will illuminate. The temperature switch 3WP is set to close at 70 oC (160 F), thereby activating both warning lights BAT 60 and BAT 70. NOTE

At high ambient temperatures and/or as a result of incorrect maintenance of the battery, the BAT 60 warning may occur frequently a)

Check battery and temperature switch (see paragraph 92-28 and 92-37) .

b)

Check generator voltage setting. Reduce voltage in case of high ambient temperatures (see paragraph 92-17) .

BO 105 CHAPTER 92 Page 89

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 36

Removal and installation - battery temperature switches

WARNING

THE ELECTROLYTE (POTASSIUM HYDROXIDE SOLUTION) IS A STRONG ALKALINE SOLUTION THAT IS VERY CORROSIVE AND NOXIOUS. IF ANY IS SPILLED ON CLOTHING, HANDS OR OTHER OBJECTS IT SHOULD BE NEUTRALIZED WITH BORIC ACID SOLUTION OR FLU5HED AWAY WITH WATER IMMEDIATELY. WEAR RUBBER GLOVES, RUBBER APRON AND FACE SHIELD WHEN HANDLING THE ELECTROLYTE.

CAUTION

NOTE THAT THE INTERNAL RESISTANCE OF NICKEL-CADMIUM BATTERIES IS VERY LOW. THE CURRENT FLOW 15 EXTREMELY HEAVY (MORE THAN l400A) IF A FULLY CHARGED BATTERY 15 SHORTED.

NOTE

The electrolyte level of the cells must not be adjusted without knowing the state of battery charge. The electrolyte level of the cells shall be only adjusted if the battery is fully charged.

1.

Remove battery and open cover.

2.

Remove cell connector bars and temperature switches.

3.

Remove temperature warning receptacle with temperature switches.

92 - 37

Inspection and maintenance - battery temperature switches

Remove temperature switches and check them for proper functioning, using an oven, oil bath or water bath. Temperature switch 2WP must close at 60°C. Temperature switch 3WP must close at 70°C. Subsequently, clean the temperature switches to remove residual oil or water. 92 - 38 1.

Functional test - DC power system monitoring equipment

General The respective portion of the functional test must be carried out after having changed one or more electrical components, cables, electrical connectors, etc. of the monitoring systems. The tests are to be performed on the ground only with the engines running or shut down.

BO 105 CHAPTER 92 Page 90

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Preparations - engines must be shut down - BATTERY MASTER switch or BAT EPU or BATTERY MASTER switch set to OFF EMERG. OC BUS push indicattor set OFF

3.

Testing of voltmeter and arnmeter a.

Set BATTERY MASTER switch resp. BAT EPU or BATTERY MASTER switch to ON. - Voltmeter indicates battery voltage.

b.

Start engines and let run in GROUND IOLE. Lock-on generators. - warning light GEN 1 and GEN 2 extinguish.

c.

Connect consumers, like both main fuel pumps. - set arnmeter selector switch 24P (see figure 92-30) to GEN 1 - Arnmeter indicates consumer current

d.

Set Arnmeter selector switch to GEN 2 - Arnmeter indicates consumer current

e.

Set Arnmeter selector switch to BATT - Arnmeter indicates no consumer current.

f.

Switch off engines and consumers. Set BATTERY MASTER switch resp. BAT EPU switch to OFF.

4.

Functionally test battery temperature and generator overheat warning lights. Refer to paras 92-340 and 92-37.

5.

Functionally test external power engagement warning light. Refer to paragraph 92-34C.

6.

Functionally test generator failure warning light. Refer to paragraph 92-34B.

92 - 39

STARTER ANO IGNITION SYSTEM

Each engine has its own starter and ignition system (see figures 92-33 and 92-34) . These systems are used to start both engines, one after the other, but not both at the same time.

BO 105 CHAPTER 92 Page 91

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 40

Locations - starter and ignition system

Starter-generators 1 and 2, 103P and 203P

Engines 1 and 2 (see chapter 61)

92-32

Starter relays 1 and 2 103J and 203J

Main relay box 1VE

92-4 to 92-7

Warning lights 3J

Instrument panel 2VE only Series D

92-32

Toggle switches STARTERGENERATOR resp. GENERATOR ENG. 1 and ENG. 11, 117P and 217P

Instrument panel 2VE

92-32

Circuit breaker 1J Circuit breaker 1J, 2J

Instrument panel 2VE only Series D

92-33

Diodes D102J, D202J

Main relay box 1VE

92-4 to 92-7

Ignition units 10SJ, 20SJ

Engine 1 and 2

92-4 to 92-7

Ignition switch 104J, 204J

Instrument panel 2VE

92-32

Starter/Ignition switch 108J, 208J

Only Series D

92-34

Ignition plugs 106J, 206J

Engine 1 and 2 (see chapter 61)

92-34

Table 92-S

BO lOS CHAPTER 92 Page 92

Location, Starter and ignition system

- - - - - - - - - - - - - M B B HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105

1 1nstrument panel (2VE) Circuit breaker "STARTERS" lJ "STARTER-GENERATOR" switch (117P, 2l7P) EFFECT1V1TY

Series D

Circuit breaker "STARTERS 1-11" (lJ, 2J) "STARTER/1GN1T10N" switch (lD8J, 208J) Warning light (3J)

Figure 92-32

2 Main relay box (lVE) Starter relays (103J, 2D3J) 3 Starter-generator (203P) 4 Spark igniter (206J) 5 19nition exciter (20SJ) 6 Spark igniter (106J) 7 Starter-generator (103P) 8 19nition exciter (lOSJ)

Starter and 19nition Systern BO 105 CHAPTER 92 Page 93/94

- - - - - - - - - - - - - M B B HELICOPTERS"------------MAINTENANCE MANUAL MBB - BO 105

MAIN BUS PP21 28V-

CIRCUIT BREAKER 1J

117P

1=4=t===1 SWITCH GEN 4

o o o

IGNITION SWITCH 204J

217P

STARTER/GENERATOR

~

o

••

I

OFF START

see 92·7 STARTER BUS PPl 28VIGNITION EXCITER 105J ,

D102J

o e

- --~

-.

STARTERRELAY 103J

" ·11

~----

IGNITION EXCITER 205J

o

o STARTERRELAY 203J

SPARK I

IGNITER 206J STARTER-GENERATOR

900126

Figure 92-33

Starter and Ignition System

BO 105 CHAPTER 92

Page 95

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

Series D

EFFECTIVITY

I

rl,t\ó,

I

I

I I

1"

I

I

¡

10~

r---+--------

2J

STARTERIIGNITION SWITCH

~

(j

ON

2WW

OFF VENT

VENT OFF

ON

--,

':;:. 1

20SJ

--....----

-o---

~-

..

CIRCUIT

~ lJ

..JI

~.

28V-D

~ BREAK~

WARNING L1GHT 3J

11

MAIN BUS

PP21

I

' ¡;:__

...JI

see 92·7

STARTER BUS

PP1

28V-

-

D~

IGNITION EXCITER

105~ 11

.&

-

rB--STARTER RELAY 103J

---~

-

I

1- - - -

SPARK IGNITER 206J

10~ ~

.

STARTER-GENERATOR

900153

Figure 92-34

Page 96

IGNITION EXCITER 205J

__--+.....JSTARTER RELAY 203J

SPARK IGNITION,

BO 105 CHAPTER

D202J

92

Starter and Ignition Systern

-

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 41

Protection of circuits of starter and ignition system

The following circuit breakers are provided to protect the starter and ignition system. PROTECTED CIRCUIT

LOCATION

IDENTIFICATION

3A

Ignition system engine 1 and 2, starter relay 103J, 2D3J

Instrument panel 2VE

STARTERS

3A 3A

Ignition system engine 1 and 2, starter relay 103J, 203J, and warning light 3J

Instrument panel 2VE

STARTERS I-II

CIRCUIT BREAKER CODE PROTECTION 1J

Series D 1J 2J

Table 92-6

92 - 42

Protection, Starter and ignition system

Troubleshooting - Starter and Ignition System

NO.

TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Starter-generator 103P (LH engine) fails to operate during starting procedure. Ignition is not possible

Defective circuit breaker lJ

Replace

nSTARTER-GENERATOR n switch 117P defecttive

Replace

Table 92-7

Troubleshooting - Starter and ignition system (1 of 4)

BO 105 CHAPTER 92 Page 97

- - - - - - - - - - - - - · M B B HELICOPTERS------------MAINTENANCE MANUAL MEB - BO 105 TROUBELSHOOTING (continued) NO.TROUBLE SYMPTOM

CORRECTlVE ACTION

PROBABLE CAUSE

EFFECTIVITY

Series D

Replace. Defective "STARTER/ IGNITION" switch 10SJ.

2 Starter-generator 103P fails to operate during starting procedure.Ignition of engine is possible.

3 Starter-generator 203P (RH engine) fails to operate during starting procedure. Ignition is not possible.

Defective starter relay 203J.

Replace.

Defective electrical wiring.

Check w~r~ng for continuity using the applicable wiring diagrarn (refer to WDM) . Replace defective wiring.

Defective starter relay 103J.

Replace.

Defective startergenerator 103P.

Defective electrical wiring.

Check wiring for continuity using the applicable wiririg diagrarn (refer to WDM). Replace defective wiring.

Defective circuit breaker 1J.

Replace.

Defective "STARTERGENERATOR" switch 217P.

Replace.

EFFECTIVITY

Series D

Defective circuit breaker 2J.

Table 92-7

BO 105 CHAPTER 92 Page 98

Remove starter-generator and repair or replace, as necessary (refer to 92-20, . check brushes for general condition) .

Replace.

Troubleshooting - Starter and ignition system (2 of 4)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

Defective "STARTERGENERATOR" switch 20SJ.

Replace.

Defective starter relay 103J.

Replace.

Defective electrical wiring.

Check wiring for continuity using the applicable wiring diagram (refer to WDM). Replace defective wiring.

Defective starter 4 Starter-generator 203P (RH engine) fails to relay 203J. operate during starting 'procedure. Ignition of Defective starterengine is possible. generator 203P.

5 Ignition of LH engine is not possible, although startergenerator 103P is operating.

Replace. Replace.

Defective electrical wiring.

Check w~r~ng for continuity using the applicable wiring diagram (refer to WDM. Replace defective wiring.

Defective "IGNITION switch l04J.

Replace.

Defective ignition exciter lOSJ.

Replace.

Defective spark igniter lOGJ.·

Replace.

Defective electrical wiring.

Check w~r~ng for continuity using the applicable wiring diagram (refer to WDM). Replace defective wiring.

EFFECTIVITY Series D Defective "STARTER/ IGNITION" switch lOSJ.

Table 92-7

Replace.

Troubleshooting - Starter and ignition systern (3 of 4)

BO 105 CHAPTER 92 Page 99

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 TROUBLESHOOTING (continued) NO.TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

6 Ignition of RH engine is not possible, although startergenerator 203P is operating.

Defective ftIGNITION ft switch 204J.

Replace.

Defective ignition exciter 20SJ.

Rep1ace.

Defective spark ignitor 206J.

Replace.

Defective electrical wiring.

Check wiring for continuity using the applicable wiring diagram (refer to WDM). Replace defective wiring.

EFFECTIVITY

Series D

Defective ftSTARTER/ IGNITION ft switch 208J.

Table 92-7

92 - 43

WARNING

1.

Replace switch

Troubleshooting - Starter and ignition system (4 of 4)

Inspection - starter and ignition system

SWITCH OFF ANY ELECTRICAL POWER SUPPLY PRIOR TO WORKING ON THE STARTER AND IGNITION SYSTEM. MAKE SURE THAT IGNITION LEADS ARE PROPERLY CONNECTED. TAKE ALL SAFETY MEASURES REQUIRED FOR WORK ON HIGH VOLTAGE INSTALLATIONS.

Check the ignition system regularly for - defective insulation of high voltage leads - condition of ignition plugs - condition of high voltage connectors.

2.

Check starter-generators for proper seating of terminals.

BO 105 CHAPTER 92 Page 100

- - - - - - - - - - - - - M B B HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 92 - 44

S t a r ter

s y s t e m

The starter system consists of: 1.

two two one one

starter-generators, 103P and 203P starter relays, 103J and 203J starter warning light 3J each (only Series D) toggle switch each, STARTER/GENERATOR resp. ENG.1 and ENG.11

General The engines are started by means of two starter-generators operated as series motors for this purpose. This design makes own starters unnecessary. The starter-generators 103P/203P (see figures 92-32 and 92-33) are mounted on the gearbox of the LH and RH engine. Control of the startergenerators is via two starter relays 103J/203J installed in the main relay box 1VE, which provide connection of starter-generators to the starter bus PP1. Starter relays are supplied with electrical power from the main bus PP21 via circuit breaker 1J "STARTERS"" and "STARTER/GENERATOR" switch 117P/217P (on the instrument panel). Diodes 102J/202J which are connected in parallel to the starter relay coils are used for arc suppression .. EFFECTIV1TY

Series D (figures 92-32 and 92-34) Starter relays are supplied with electrical power from main bus PP21 via circuit breakers 1J/2J "STARTERS 1-11" and "STARTER/IGN1T10N" switches 108J/208J (on the instrument panel). Warning light 3J (on the instrument panel) with legends "START 1" and "START 2" indicates operation of the respective starter system by illumination.

With circuit breaker 1J pushed and switch 117P in position "START", control voltage flows via normally-closed contact of the starter relay 203J to energizing coil of starter relay 103J. Starter relay 103J is energized and completes the circuit between starter-generator 103P and starter bus PP1. The starter-generator 103P will operate. In addition, starter relay 103J opens the control circuit of starter relay 203J, thus rendering a simultaneous starting of engine 2 impossible.

BO 105 CHAPTER 92 Page 101

- - - - - - - - - - - - - · M B B HELICOPTERS------------MAINTENANCE MANUAL MEB - BO 105

EFFECTIVITY

Series D (figures 92-32 and 92-34) With circuit breakers 1J/2Jpushed and switch 10SJ in position "VENT" or "START", control voltage flows via normally-closed contact of the starter relay 203J to the energizing coil of starter relay 103J. The starter relay 103J is energized and completes the circuit between starter-generator 103P and starter bus PP1. The starter-generator 103P will operate. In addition, the starter relay 103J opens the control circuit of the starter relay 203J, thus rendering a simultaneous starting of engine 2 impossible. Furthermore, the circuit of the warning light 3J "START 1" is completed and operation of the starter-generator 103P is indicated respectively.

2.

Starter relays (see figure 92-35) The two starter relays 103J and 203J are installed in main relay box 1VE (see figure 92-4 to 92-7). The starter relays connect the respective starter-generators to the main bus PP21.

BO 105 CHAPTER 92 Page 102

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~""--2

) o

~

~-I' /

15

900148

1 2 3

4 5 6 7

8

'

~ i

/

I! 14~ 12

'}, 9

~ ¡

11

10

13-i

Nut Washer Electrical wiring Jumper Washer Screw Clamp Starter relay Figure 92-35

9 Bracket 10 Screw 11 Washer 12 Electrical wiring 13 Screw 14 Washer 15 Diode 16 Main relay box lVE Starter Relay BO 105 CHAPTER 92 Page 103/104

- - - - - - - - - - - - - M B B HELICOPTERs·-------------MAINTENANCE MANUAL MBB - BO 105 92 - 45 1.

Functional test - starter system

General The functional test must be carried out after having changed one or more components, cables, electrical connections, etc. of the starter system. This functional test is performed on the ground using external power. NOTE

2.

As the engines are not started, the starter-generators must be disconnected from power supply. They are thus not subjected to testing.

Test equipment - Voltmeter, 0-30V, DC

3.

Preparations (see figure 92-36) a. 'b.

Switch off electrical power supply. Disconnect below listed leads from terminal nC+ n of starter-generators 103P/203P:

EFFECTIVITY

Starter-Generator Lead

J9F4

Jl1F4

o S/N 161 and up

Lead

J9F2

Jl1F2

o Series D S/N 1 - 160

Lead

J20F2

J21F2

Lead

J9E2

Jl1E2

Connect a test voltmeter between disconnected lead (+) and ground (-), (measuring range: 30V DC).

CAUTION d.

203P

o S/N 7 - 160

S/N 161 and up c.

103P

ISOLATE DISCONNECTED LEADS FROM GROUND.

Switch on electrical power supply and push circuit breaker 1J nSTARTERS" (or circuit breakers 1J and 2J nSTARTERS I-II" for series D) .

BO 105 CHAPTER 92 Page 105

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

LJUUL

DDD[

DDDD[

Figure 92-36 4.

Terminal Strip of Starter-Generator

Testing of the starter system NOTE

a.

Testing of the starter system is identical for the LH and RH engine, and is subsequently described for the LH engine only. Set switch 117P ftSTARTER/GENERATOR, ENG. IR to position ftSTART ft and hold in position.

EFFECTIVITY

b.

Reading on test voltmeter, connected to the disconnected lead of LH starter-generator, shall be approx. 2SV.

EFFECTIVITY c.

Series D Set switch 10SJ ftSTARTER/IGNITION R to position ftVENT ft .

Series D Legend ftSTART 1 ft on warning light shall illuminate.

Set switch 217P ftSTARTERGENERATOR, ENG. 11 ft to position ftSTART ft and hold in position.

EFFECTIVITY

BO 105 CHAPTER 92 Page 106

Series D Set switch 20SJ ftSTARTER/IGNITION R to position ftVENT ft .

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

There shall be no pointer deflection on the test voltmeter, connected to the disconnected lead of RH starter-generator. Series D Warning light nSTART 2 n shall not illuminate.

EFFECTIVITY e.

Release switch 117P and 217P (10SJ and 20SJ for series D)

f.

Release circuit breakers 1J and 2J and switch off power supply. Disconnect test voltmeter and reconnect leads to terminal nC+ n of starter-generators 103P and 203P.

92 - 46

I g n i t ion

s y s t e m

The ignition system (see figures 92-33 and 92-34) consists of: - one ignition exciter 10SJ and 20SJ each - one spark igniter 106J and 206J each - one ignition cable per engine 1.

General The ignition systems are activated by setting toggle switches 104J and 204J nIGNITION n and 10SJ/20SJ nSTARTER/IGNITION n (Series D) on instrument panel 2VE (see figures 92-11 to 92-13) to START. When the required ignition voltage is reached, energy stored in the ignition exciter is discharged at the related spark igniter 106J/206J in forro of an electric are. After the discharge, this procedure is repeated for as long as the ignition exciter is under power. WARNING

2.

WHEN WORKING ON THE IGNITION SYSTEM, DISCONNECT ELECTRICAL POWER SUPPLY AND SECURE BEFORE SWITCHING ON AGAIN. DANGER OF HIGH VOLTAGE!

Ignition exciter The ignition exciters 10SJ/20SJ are mounted on the gearbox of the LH and RH engine. They are connected via shielded ignition leads to the spark igniters 106J/206J, which are screwed into the combustion chambers. The ignition system and the starter system are interconnected such that ignition is only possible during the starting procedure.

BO 105 CHAPTER 92 Page 107

- - - - - - - - - - - - - - · M B B HEL!COPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 3.

Spark igniter The spark igniters 106J and 206J are installed in the engines. They are used to ignite the engines by means of an arc discharge. NOTE

4.

For removal and installation of spark igniter refer to ALLISON Operating and Maintenance Manual (DDA) 250-C20, C20B.

Ignition cable The two ignition cables are mounted to the engines. They connect the respective ignition exciter with the appropriate spark igniter. NOTE

For removal and installation of ignition cable refer to ALLISON Operating and Maintenance Manual.

92 - 47

Functional test - ignition system

1. ·General Test of the ignition system is made after test of the starter system. Therefore, observe preparations for functional test of the starter system (see paragraph 92-45). 2.

Preparations Refer to

92-45.

Disconnect lead from terminal nC+ n as in paragraph 92-45.

NOTE 3.

p~ragraph

Performance of test CAUTION

DISCONNECTED LEADS MUST BE PROTECTED AND MUST NOT CONTACT GROUND. DANGER OF SHORT CIRCUITS!

NOTE

Testing of the ignition system is identical for the LH and RH engine, and is subsequently described for the LH engine only.

a.

Set switch 117P nSTARTER/GENERATOR, ENG. In to position nSTART n and hold in position.

BO 105 CHAPTER 92 Page lOa

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Set switch 104J nIGNITION n to the ON position. Ignition noise (loud crackling) shall be clearly audible at ignition exciter 10SJ and spark igniter 106J of LH engine. Set switch 104J to the OFF position.

c.

Set switch 204J nIGNITION n to the ON position. There shall be no ignition noise on RH engine. Set switch 204J to the OFF position and release switch 117P nSTARTER/GENERATOR, ENG. In.

d.

Pull circuit breaker 1J and switch off electrical power supply. Disconnect test voltmeter and re-connect leads to terminal nC+ n of starter-generators.

EFFECTIV;I:TY

Series D

e.

Set switch 108J nSTARTER/IGNITION n to position ·ON n . Ignition noise (loud crackling) shall be clearly audible at ignition exciter 10SJ and spark igniter 106J of the LH engine.

f.

Functionally test ignition systern of the RH engines as described for LH engine.

g.

Pull circuit breaker lJ and 2J and switch off electrical power supply. Disconnect test voltmeter and re-connect leads to terminal nC+ n of starter-generators.

92 - 48

ENGINE ANO MAIN TRANSMISSION SYSTEMS

The electrical system of engine and main transmission systems comprises: - monitoring systems

- engine fire detection system

- N2 governor

- oil cooler fan failure warning systern

- engine anti-icing

BO 105 CHAPTER 92 Page 109

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Locations - engine and main transmission systems (see figures 92-37 and 92-39)

Component

Location

Fig.No. or Chapter

Warning lights

Instrument panel 2VE (vertical part)

See paragraph 92-77

Circuit breakers

Instrument panel 2VE

See paragraph 92-50

Instruments

Instrument panel 2VE

See paragraph 91

RPM warning unit 1EW

Instrument panel 2VE

See paragraph 91-53

Pushbutton 2EW

Cyclic stick grip 3/4VE

See paragraph 92-49

Tachogenerators N1 102EN and 202EN

Engine 1 and 2

See chapter 61

Tachogenerators N2 101EN and 201EN

"

"

Chip detectors 101EV and 201EV

"

"

Thermocouple 101EL and 201EL

"

"

Oil pressure transmitter 101ED and 201ED

"

"

Oil temperature transmitter 101ED and 201ED

"

"

Chip detector 102EV and 202EV

"

"

Oil temperature transmitter 102ED and 202ED

"

"

Monitoring systems

Chip detector SEV

Table 92-8

BO 105 CHAPTER 92 Page 110

Main transmission

See chapter 11

Locations, engine and main transmission systems (1 of 2)

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

Locations - engine and main transmission systems (continued) Location

Fig.No. or Chapter

Engines 1 and 2

see chapter 61

Relay box 10VE

Fig. 92-8, 92-9

Collective pitch stick 5VE

Fig. 92-51

Toggle switch ENG ANTI ICING 1 and 2 resp. ENG. ANTI-ICING 1 and 11 (Series D)

Instrument panel 2VE

Fig. 92-11 to 92-13

Actuators 21VE

Engines 1 and 2

see chapter 61 and Fig. 92-54

Component

N2 Governor Actuators 103KA, 203KA Relay 4KA, 5KA and 6KA Diode board 10KA Four-way switch 8KA Engine anti- icing system

Table 92-8

Locations, engine and main transmission systems (2 of 2)

BO 105 CHAPTER 92 Page 111

- - - - - - - - - - - - - ' MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 50

Protection of engine and main transmission systems

The following circuit breakers are installed to protect the engine and main transmission systems: CIRCUIT BREAKER Code Protection

PROTECTED CIRCUIT

LOCATION

4E

lA

Engine RPM indicator

Fig. 92-40

5E

lA

Oil pressure indicator Engine 1 and 2 and transmission

Fig. 92-40

6E

lA

Oil temperature indicator Engine 1 and 2 and transmission

Fig. 92-40

lOE

lA

Chip detector warning engine

Fig. 92-40

lHL

3A

Anti icing, engine 1

Fig. 92-11 to 92-13

11HL

3A

Anti icing, engine 2

Fig. 92-11 to 92-13

lWB (lWG)

lA

Fire warning, engine 1

Fig. 92-40

2WB (2WG)

lA

Fire warning, engine 2

Fig. 92-40

Table 9f-9

BO 105 CHAPTER 92 Page 112

Protection of engine and main transmission systems

- - - - - - - - - - - - - M B B HELICDPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BD 105

Dil temperature transmitter 102ED 1 Instrurnent Panel 2VE Chip detector 102EV Triple RPM indicator 7EN Triple oil temperature 4 Chip Detector 10lEN indicator SED Triple oil pressure indicator 4ED 5 N2 RPM tacho-generator lOlEN N1 RPM indicator 10BEN, 20BEN TDT indicator lOSEL, 20SEL 6 Engine 11 (right side) Variable trim resistor 104EL,204EL N1 RPM tacho-generator 202EN RPM warning unit EW Thermocouple 201EL Warning light 3EW Dil pressure transmitter 20lED Dil temperature transmitter 202ED 2 Cyclic stick Grip 3/4V Chip detector 202EV 3 Engine 1 (left side) N1 RPM tacho-generator 102EN Thermocouple 101EL Dil pressure transmitter 101ED Figure 92-37

7 Chip Detector 20lEV B N2 RPM tacho-generator 20lEN Engine Monitoring BD 105 CHAPTER 92 Page 113

- - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 Circuit Breaker lKA 2 Relay Box lOVE Relay 4KA Relay SKA Relay 6KA Printed circuit board lOKA

4 Collective Stick Grip (Copilot) 6VE Four-way switch (beeper) 8KA 5 Actuator (ENG.I) 103KA 6 Actuator (ENG. Ir) 203KA

3 Collective Stick Grip (Pilot) SVE Four-way switch (beeper) 8KA Figure 92-38

BO 105 CHAPTER 92 Page 114

Engine Monitoring (N2 control)

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 Nl RPM indicator l02EN (202EN) 2 N2 RPM indicator 101EN (201EN) 3 Chip detector 101EV (201EV) 4 Chip detector 102EV (202EV) 5 Thermocouple assy 101EL (201EL) Figure 92-39

Location of Components

BO 105 CHAPTER 92 Page 115/116

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL. MBB - BO 105

EFFECTIVITY

S/N 7-160

B

8el e

I mw I f::\811NSTRUMENT PANEL

INSTRUMENT PANEL RH SIDE

_V

+

FLlGHT

OIREellON

::

rI I

LHSIDE

&

+

EFFECTIVITY

S/N 161 and subsequent

INSTRUMENT PANEL RH SIDE

&

EFFECTIVITY

For series D only

Figure 92-40

Fuse Panel BO 105 CHAPTER 92

Page 117

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 51

Mo n i t o r i n g s y s t e m s

The following monitoring systems are installed to ensure the proper function of main transmission and engines and to continually check engine performance: RPM control, engines and rotor RPM monitoring NI and NR engine RPM monitoring N2 chip warning systems for engines and main transmission oil pressure monitoring for engines and main transmission (refer to chapter 91) - oil temperature monitoring for engines and main transmission (refer to chapter 91) - TOT monitoring, (refer to chapter 91) - torque monitoring, (refer to chapter 91)

-

The associated instruments and the procedures for removing and installing them are described in chapter 91. 92 - 52

RPM monitoring - engines and rotor

Each engine is provided with two tacho-generators, see figure 92-40. They generate an alternating voltage whose frequency changes proportionally with the RPM. Tacho-generator 102EN (202EN) is used to control the compres sor RPM NI and tacho-generator 101EN (201EN) to control tbe power turbine RPM N2. The AC voltage produced by this tacho-generator is also used to drive the synchronous motors of the triple RPM indicator 7EN. The main transmission is also provided with a tacho-generator 3EN. The AC voltage produced by this tacho-generator is used to drive the triple RPM indicator 7EN i,nstalled in the instrument panel 2VE and is fed to the RPM warning unit 1EW. For remova1 and installation of the engine tacho-generator refer to chapter 61 and for main transmission to chapter 11.

BO 105 CHAPTER 92 Page 118

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RPM warning N1 and NR (rotor RPM) (see figure 92-41)

RPM warning is controlled by the RPM warning unit 3EW installed on the instrument panel 2VE. The AC voltage produced by the tacho-generators is fed into the RPM warning unit 1EW. The RPM warning signal is released if there is an N1 RPM difference between the engines. An intermittent warning sound (600 Hz) is audible in the headset and the warning light "RPM n flashes. 1.

N1 RPM warning The RPM warning (sound and flashes) is generated if the N1 RPM difference between the engines is greater than 12% ± 0.8%, in the range from idle to ful! power. The warning can be reset using push-button switch RPM 2EW on the pilot's (copilot's) cyclic stick.

2.

NR RPM warning a.

Rotor underspeed The RPM warning is released if the rotor RPM is between 75% ± 0.8% and 95% ± 0.8%. An intermittent warning sound is audible in the headset and the warning light "RPM" flashes.

b.

Rotor overspeed The RPM warning is released if the rotor RPM exceeds 103% ± 0.8%. In this case only the warning light nRPM n 3EW flashes (S/N 7 - 160). EFFECTIVITY

o S/N 161 and subsequent If the rotor RPM exceeds 103% ± 0.8%, the warning light nRPM" flashes. If the rotor RPM exceeds 108% ± 0.8%, a continuous warning tone is audible.

BO 105 CHAPTER 92 Page 119

MAINTENANCE MANUAL 80 105

EUROCOPTER

MAINBUS PP21

28V=

HEADSET WARNING SOUND

re!. to RadiolNav. System

TRIPLE INDICATOR

1-------,

MAIN TRANSMISSION TACHOGENERAT. 3EN

ENGINEN1 TACHOGENERAT. 102EN 1202EN

INSTRUMENT PANEL 2VE

..--tI...--.I I 1

..--tI...--.I

RPM-WARNING UNIT 1EW

I

1 1

T-QiI

1

ENGINEN2

1

..--tI...--.I

I L

r--11

PUSH BunON 2EW

L

Figure 92-41

CHAPTER 92 Page 120

1 RPM

I I

1

1

I

N1·INDICATOR

TRIPLE INDICATOR

TACHOGENERAT. 101EN/201EN

..

1 WARNING L1GHT 3EN

1

I · __ J

---l CYCLlC STICK

1

J

1

RPM monitoring - engine and rotor

Revision 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 54

N2 overspeed warning (see figure 92-42)

A tacho-generator (ENG.I 101EN, ENG.II 201EN) is installed on the left side (in flight direction, forward) of each engine gearbox (refer to figure 92-40) and generates alternating current, the frequency of which varies in proportion to the power turbine speed (N2). The AC voltage drives a synchronous motor inside the triple RPM indicator 7EN, causing a display of N2 speed in per cent via pointer 1 (ENG.I) and 2 (ENG.II) . (Refer to chapter 91). One hundred percent corresponds to the nominal power output of the power turbine.

TRIPLE N2 RPM INDICATOR 7EN

r

'IH

I

~---------

TACHO-GENERATOR 101EN (201EN)· 900195

Figure 92-42

a.

N2 overspeed warning

Removal - Disconnect the electrical connector from the tacho-generator and protect with a cap. - Remove the four self-locking nuts (nylstop) with washers. Detach tacho-generator and protect opening on engine gearbox with a cap.

b.

Installation - Lightly grease drive pinion with item 101. - Installation is essentially the reverse of the removal.

BO 105 CHAPTER 92 Page 121

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Troubleshooting - RPM monitoring, engines and rotor PROBABLE CAUSE

NO. TROUBLE SYMPTOM

CORRECTlVE ACTION

RPM-Indicators NI, N2 and NR See Chapter 91. RPM warning - N1 At an RPM differential of 12%: 1

- warning light RPM does not flash, intermittent warning sound is audible

Wiring between RPM warning unit 3EW and warning light defective

Check wiring and connector contacts for continuity and good electrical contacto Repair or replace defective components as necessary.

2

- warning light RPM does not flash, intermittent sound is not audible

RPM warning unit 3EW defective

Replace RPM warning unit

3

- warning cannot be reset

Push button RPM WARN 2EW on pilot's (copilot's) cyclic stick grip defective

Test push button and replace if necessary.

RPM warning unit 3EW defective

Replace RPM warning unit.

Wiring between RPM warning unit 3EW and warning light defective

Check wiring and connector contacts for continuity and good electrical contacto Repair or replace defective components as necessary.

RPM warning unit 3EW defective

Replace RPM warning unit.

RPM warning - NR At a rotor speed between 75% and 95%: 1

warning light RPM does not flash, intermittent sound is audible

2

- warning light does not flash, intermittent sound is not audible

Table 92-10 BO 105 CHAPTER 92 Page 122

Troubleshooting

(1 of 2)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Troubleshooting (continued) NO. TROUBLE SYMPTOM

PROBABLE CAUSE

3

RPM warning light does not flash at a rotor RPM of 102%

Same as item 1 and 2

4

Continuous warning sound not audible at a rotor RPM of 108%

Headset defective

CORRECTlVE ACTION

Check headset and replace, if necessary.

Engine N2 RPM monitoring No RPM indication or pointer 1 or 2 indication is erratic or sluggish.

Table 92-10

Loose receptacle plate on tachogenerator 101EN (201EN) .

Replace tacho-generator.

Defective tachogenerator 101EN (201EN) .

Measure output voltage. 100% rotor RPM, 21 +SVAC (70.0 Hz) -

Intermittent contact at plugs 101ENa, 2VEd, 111VVa, 7ENa, (102ENa, 2VEd, 211VVa, 7ENa).

Check electrical connection for good electrical contacto Repair or replace defective components.

Defective triple RPM indicator 7EN.

Check triple RPM indicator by temporarily replacing it with new indicator.

Troubleshooting

(2

of

2)

BO 105 CHAPTER 92 Page 123

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 56 l.

Functional test - RPM monitoring, engines and rotor

General The applicable portion of this functional test must be carried out after each replacement of one or more electrical components, cables, electrical connections, etc. of a RPM monitoring system. NOTE

2.

The functional test of RPM indicators is described in paragraph 91.

Functional test - RPM monitoring Nl and N2 a.

With engines off - Indication - Pointers on RPM indicator lOSEN and 20SEN must read O ± 0.5.

b.

With engines running at 100% N2 RPM - Indication - Pointers on RPM indicator lOSEN and 20SEN must read S6%. - Warning CAUTION

WHEN ACTUATING THE FOUR-WAY SWITCH, MAKE -SURE COLLECTIVE PITCH STICK REMAINS IN ITS LOCKED POSITION.

- Move four-way switch SKA in position L+. Nl RPM of ENG. 1 must increase; Nl RPM of ENG. 11 must decrease. EFFECTIVITY

o When trim actuator circuitry is modified (refer to figure 92-51). o Move four-way switch in position L+. Nl RPM of ENG. 1 must increase; Nl RPM of ENG. II remains unchanged.

- At a NI RPM differential exceeding 12% ± 1, acoustic and optical warning shall come on (continuous warning sound in headset and flashing indication on warning light 3EW "RPM"). NOTE

Make sure N2 RPM does not decrease.

- Perform same work steps for ENG. 11 (position R+) .

BO 105 CHAPTER 92 Page 124

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Functional test - RPM monitoring rotor a.

With engines off - Indication - Pointer 1 and 2 of the triple RPM indicator 7EN must read O ± 1.

b.

With engines running (power lever in position "FLIGHT") - Indication - Pointer 1 and 2 of the triple RPM indicator must read 100%.

c.

Warning NOTE

If RPM warning unit P/N KDW02-1 is installed, y warning light "RPM" may briefly illuminates once or several times when electrical power is switched on.

- Low RPM warning Slowly reduce rotor RPM from 100%. Within a rotor RPM range of 95% ± 0.8% to 75% ± 3%, the warning light 3EW shall illuminate. with a flashing indication and intermittent audio tone warning signals shall be present in headsets. (Refer to chapter 105 and FLM.) - Rotor overspeed warning (can be tested in flight only). (Refer to chapter 105 and FLM.) EFFECTIVITY

o For helicopters up to and including S/N 160, the warning light 3EW shall flash at a rotor speed of 103% ± 0.8%. o For helicopter S/N 161 and subsequent, the warning light 3EW shall flash at a rotor speed of 103% ± 0.8% and an additional continuous set at a rotor speed of = 108% ± 0.8%.

BO 105 CHAPTER 92 Page 125

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 57 1.

Chip detector system (see figure 92-40 to 92-43)

Engines Magnetic chip detectors 101EV, 102EV, (ENG. I) and 201EV, 202EV (ENG. II) installed in the engine gearbox, attract metallic particles (chip particles, gear debris and fragments etc.) from engine lubricating oil by a detector magneto When the contact gap on the detector magnet is bridged by accumulated metallic particles, an electrical ground is provided to complete the warning light 3EV circuit and warning light 3EV "MAG. PLUG 1" and/or "MAG. PLUG 2" illuminates, indicating excessive metallic particle accumulation in the oil. MAIN BUS PP21

101 EV, 102 EV

28V-

ENG, I

CHIP DETECTOR MAGo PLUG 1 MAGo PLUG 1 WARNING L1GHT --I3 EV

~

MAGo PLUG 2 201 EVo 202 EV 900201

MAGo PLUG 2 CHIP DETECTOR

Figure 92-43

ENGolI

~-~

II

Chip Detector System - engines

For removal and installation of the chip detector refer to Allison Operation and Maintenance Manual. 2.

Main transmission The chip detector 5EV (see figure 92-44) installed in the oil drain opening of the main transmission attracts metal particles from the transmission oil by a detector magneto The metal particles accumulated (chip particles, gear debris, fragments etc.) bridge the contact gap on the detector magnet and complete the electric circuit of thewarning light 4EV to ground. The warning light 4EV "T PLUG" on the instrument panel 2VE illuminates, indicating metal accumulation in the transmission oil.

BO 105 CHAPTER 92 Page 126

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

MAIN BUS

28V-_ _

4A

~

WARNING LIGHT

FUSE 'E

OIL COOL

10 ED

T PLUG

4 EV

900080

!

Figure 92-44

CHIP DETECTOR 5 EV

,I I

J

Chip Detector System, Main transmission

For removal and installation of the chip detector 5EV refer to chapter 11 main transmission.

92 - 58 l.

Oil pressure monitoring (see figures 92-46 and 92-47)

Oil pressure monitoring - engines (see figure 92-45) The oil pressure transmitter 101ED (ENG. I) and 201ED (ENG. II) is 10cated in the oil pressure line on lower left or right side in the engine compartment (refer to figures 203 and 204). The transmitter comprises a pressure controlled potentiometer, whose resistance varies relative to the oil pressure changes, causing rotational movement of the armature in the cross coil of the triple oil pressure indicator 4ED, and provides pressure readings in bar (kp/cm2 ).

BO 105 CHAPTER 92 Page 127

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

MAIN BUS PP21

28V-

FU SE SE OIL PRESSURE TRANSMITIER 101ED (201 ED)

r----, I

I

I I I ...J

OIL PRESSURE TRANSMITIER 4 ED

--

900198

Figure 92-45 a.

Oil Pressure Indication

Removal - Remove lockwire, disconnect electrical connector from transmitter and protect with cap. - Unscrew oil pressure transmitter and cap the opening with a sealing plug.

b.

Installation Installation is essentially the reverse of the removal.

BO 105 CHAPTER

Page 128

92

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

VIEwA

900207

1 Oil pressure transmitter lOlED 2 Oil temperature transmitter 102ED Figure 92-46

Location of Components

BO 105 CHAPTER 92

Page 129

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

l--2

VIEWC

VIEwD

900206

1 Oil pressure transmitter 201ED 2 Oil temperature transmitter 202ED Figure 92-47 BO 105 CHAPTER 92 Page 130

Location of Components

- - - - - - - - - - - - - . MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Oil pressure rnonitoring - rnain transrnission (see figures 92-48 and 92-49) The oil pressure warning systern includes the oi1 pressure switch 22EW and 011 pressure transrnitter 301ED at the sarne installation locations as described above. In case of reduction or loss of pressure below 0.5 bar the contact of the oil pressure switch 22EW closes the electric circuit to the warning light ftT OIL ft 3EW, which illurninates. MAIN BUS .PP21

28V:

I

FUSE 5E

~I I

1

&

1

_

01

& ~USE26EW

TRIPLE OIL PRESSURE INDICATOR 4ED 900078

,

Figure 92-48 a.

P c::::¿ +

see Fig. 92-50

-~ v- _ _

EFFECTIVITY

8[jPM

•

CIRCUIT { BREAKER 20 EW

OIL PRESSURE SWITCH 22 EW

~ WARNING LIGHT 3 EW ¡ ~-----~ •

..........

see Fig. 92-50

~

¡-B¡ ~~1 : L _

TOIL

y

-

_1

O

OIL PRESSURE TRANSMITTER 301 ED

up to and including S/N 160 and Series D S/N 161 and subsequent Oil Pressure Warning Systern - rnain transrnission

Rernoval of oil pressure transrnitter 301ED - Rernove lockwire, disconnect electrical connector frorn transrnitter and protect with cap. - Unscrew oil pressure transrnitter and cap the opening with a sealing plug.

b.

Installation Installation is essentially the reverse of the rernoval.

c.

Rernoval and installation of push-button switch 22EW Rernoval and installation is identical to oil pressure transrnitter 301ED.

BO 105 CHAPTER 92 Page 131

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

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Oil temperature transmitter Oil temperature switch Oil temperature transmitter Oil pressure switch 5 Oil pressure transmitter 6 RPM Tachometer-generator 7 Differential pressure switch 8 Chip detector

Figure 92-49 BO 105 CHAPTER 92 Page 132

302ED up to and including S/N 160 21EW 302ED S/N 161 and subsequent 22EW 301ED 3EN llED sEV following implementation of SB 80-41 Main transmission

EUROCOPTER

92 - 59 l.

MAINTENANCE MANUAL BO 105

Temperature monitoring (see figure 92-50)

Oil temperature monitoring - engines and main transmission The oil temperature switch 21EW is installed on the transmission housing below the oil cooler fan assembly (see figures 92-49 and 92-50) . Jf the oil temperature rises above 105 oC, the switch closes and the * "OIL COOL n warning light 3EW comes on. *

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OIL TEMPERATURE TRANSMITTER 302 ED

Oil Temperature Warning System - Schematic Diagram

Removal and installation of the oil temperature switch is described in chapter 11. 2.

Turbine outlet temperature monitoring Refer to chapter 91.

Revision 16

BO 105 CHAPTER 92 Page 133

EUROCOPTER

92 - 60

N 2 G o ver n o r

MAINTENANCE MANUAL 80 105

(see figure 92-51)

The N2 governor consists of: - actuator 103KA for engine 1 and 203KA for engine 2 - four-way switch 8KA (if a dual control system is installed, a second four-way switch is provided for the copilot) - two changeover relays 4KA and 5KA - an interlock relay 6KA (connected only if a dual control system is installed) - diode plate 10KA 1.

General The N2 governor controls output RPM of the engines in relation to load requirements of the helicopter. In order to maintain a constant N2 RPM, the N2 fuel governor controls the fuel flow metering in the N1 gas producer fuel control system.

BO 105 CHAPTER

Page 134

92

- - - - - - - - - - - - - ' M B B HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 By actuating the four-way switch 8KA, torque balance between engines and change in the N2 RPM and Rotor RPM respectively can be achieved. The mechanical comporients of this system and the rigging of the N1 and N2 control linkage are described in chapter 62. a.

Operation Via a mechanical linkage between collective pitch lever and N2 governor the N2 governor control levers (refer to chapter 41) are moved towards "INCR" (max.) when collective blade pitch angle is increased (causing added fuel flow from the N1 fuel control). This prevents a drop in output RPM of the engines and thus a drop in main rotor RPM. EaCh governor lever is equipped with a trim actuator (103KA, ENG. I and 203KA, ENG. I1) built into the mechanical linkage, which allows additional adjustment via four-way switch located on the collective stick grip S/6VE. By actuating the four-way switch 8KA, the following power settings can be achieved:

Switching position INCR DECR L+

=

R+

=

NOTE

=

Function Increase Decrease Increase power of Increase power of

in power of both engines in power ef both engines in power of left engine, decrease in right engine in power of right engine, decrease in left engine

With trim actuator circuitry modified (refer te WDM) .

L+

=

R+

=

Increase in power of left engine, and right engine unchanged. Increase in power of right engine, and left engine unchanged.

With circuit breaker 1KA pushed, and depending upon the position of the four-way switch, relays SKA and 6KA located in the relay box 10VE are energized, and switch to clockwise or counter clockwise rotation of the actuator motors 103KA and 203KA. Extension or retraction motion ef the actuator shaft is transmitted to the N2 gevernor lever, thereby controlling the fuel flow metering in the Nl fuel control. When a dual collective pitch control is installed, the "Filot" foui-way switch has priority, which when actuated, energizes the relay 6KA, thereby disconnecting voltage supply to the "Copilot" four-way switch.

BO 105 CHAPTER 92 Fage 135

----....,..---------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

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BO 105 CHAPTER 92 Page 136

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- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Actuators 103KA and 203KA (see figure 92-52) The two actuators 103KA and 203KA are installed in the N2 control system of the engines. They are DC actuators which can be operated as LH and RH drive. Two rnicroswitches disconnect power supply as soon as their endposition is reached. The extension and retraction speed is approximately lrnm/s. NOTE

3.

Refer to chapter 61 for adjustment, maintenance/inspection, removal and installation.

Relays 4KA to SKA (see figure 92-8) Relays 4KA to SKA are plugged in relay box 10VE (see figure 92-1 to 92-3). Relay box laVE is mounted to the floor shell. NOTE

4.

For work on relay box 10VE, the floor shell must be opened and relay box must be removed if necessary.

Four-way switch 8KA (see figure 92-73) Four-way switch 8KA consists of four microswitches and is installed in the collective stick grip S/6VE. NOTE

5.

Maintenance/inspection as well as removal and installation procedures are described in paragraph 92-95.

Printed circuit board 10KA The printed circuit board 10KA is installed in relay box 10VE (see figure 92-1 to 92-3).

BO 105 CHAPTER 92 Page 137

- - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

VIEwA 4

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8 900~45

Electrical connector 2 Bonding strip 3 Self-locking nut 4 Split pin 5 Bellcrank 6 Trim act uator 7 Screw 8 Rod end

1

Figure 92-52 BO 105 CHAPTER 92 Page 138

Actuator N2 Control

- - - - - - - - - - - - - . MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 61 1.

Troubleshooting - N2 Governor

General Ensure that circuits to be troubleshooted are supplied with power. Prior to changing a system component, check wiring for continuity, insulation faults and loose connection. Subsequently, check if electrical connectors are properly connected to the units. The respective wiring diagrams are contained in the Wiring Diagram Manual. CAUTION

2.

WHEN WORKING ON LlVE COMPONENTS DANGER OF SHORT CIRCUITS!

Troubleshooting - N2 Governor

NO. TROUBLE SYMPTOM 1

2

No engine trirnming possible, i.e. no extension or retraction motion of trim actuator 103KA and 203KA, although four-way switch aKA is correctly actuated.

PROBABLE CAUSE

CORRECTlVE ACTION

Break in wiring, or defective electrical connection 10VEa or 6VEa.

Check wiring for continuity using the applicable wiring diagram. Check electrical connection for good electrical contacto Repair or replace defective components.

Defective printed circuit board 10KA in relay box 10VE.

Check for continuity according to applicable wiring diagram. Replace defective diodes, or printed circuit board.

Left actuator 103KA Defective printed is inoperative, or circuit board 10KA moves in one direc- in relay box 10VE. tion only. Defective switching relay 4KA in relay box 10VE. Defective actuator 103KA.

Table 92-11

Same as above.

Check for continuity using the applicable wiring diagramo Replace defective relay. Replace actuator.

Troubleshooting - N2 Governor (1 of 2)

BO 105 CHAPTER 92 Page 139

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) NO. TROUBLE SYMPTOM 3

Right actuator 203KA is inoperative or moves in one direction only.

PROBABLE CAUSE

CORRECTlVE ACTION

Defective printed circuit board 10KA in relay box 10VE.

Check for continuity using the applicable wiring diagramo Replace defective diode, or printed circuit board.

Defective switching Check for continuity accorrelay SKA in relay ding to applicable wiring box 10VE. diagram. Replace defective relay. Defective actuator 203KA. 4

Switching position: R+ Left actuator 103KA extends, but right actuator 203KA does not retract according to actuator circuitry (refer to WDM). The same happens in switching position L+.

5

Priority four-way switch 8KA npilot n (6VE) fails.

Table 92-11

BO 105 CHAPTER 92 Page 140

Check actuator by temporarily replacing with new actuator. Replace defective actuator. Same corrective action as described for defective printed circuit board or switching relay.

Defective relay 6KA. Check for continuity according to applicable wiring diagram. Replace relay.

Troubleshooting - N2 Governor (2 of 2)

- - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 62 1.

Functional test - N2 governor

Trim actuator 103KA (203KA) a.

Engage and switch on external power and press circuit breaker 1KA.

b.

Four-way switch in position INCR: - both governor control levers move to ftmaxft, i.e. the N2 trim actuators retracto

c.

Four-way switch in position DECR: - both governor control levers move to ftmin ft , i.e. the N2 trim actuators extend.

d.

Four-way switch in position L+: - governor control lever en left engine moves to ftmaxft, governor control lever on right engine moves to ftmin ft , i.e. trim actuator (left engine) retracts, trim actuator (right engine) extends.

e.

Four-way switch in position R+: - governor control lever on right engine moves to ftmaxft and governor control lever on left engine moves to ftmin ft ; i.e. trim actuator (right engine) retracts and trim actuator (left engine) extends. NOTE

f.

When trim actuator circuitry is modified (refer to WDM) .

Four-way switch in positien L+: - governor control lever on left engine moves to ftmaxft, governor control lever on right engine remains unchanged; i.e. trim actuator (right engine) retracts and trim actuator (left engine) remains unchanged.

g.

Four-way switch

~n

position R+:

- governor control lever on right engine moves to ftmaxft, governor control lever on left engine remains unchanged; i.e. trim actuator (right engine) retracts and trim actuator (left engine) remains unchanged. NOTE

Trim actuators must have an extend travel of approx. 30 mm and must automatically switch off in both travel end positions.

BO 105 CHAPTER 92 Page 141

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Priority circuit of four-way switch 8KA "PILOT" when dual collective pitch control system is installed. a.

Move four-way switch 8KA "COPILOT" to all four positions (refer to step l.). Trim actuators must extend and retract according to the selected switch position.

b.

Simultaneously move four-way switch "PILOT" to opposite switch positionsi trim actuator motor must change its rotational direction.

c.

Switching off is made by limit switches installed in trim actuators.

d.

Pull circuit breaker 1KA and switch off external power.

92 - 63

En g i n e a n t i - i c i n g s y s t e m (see figures 92-53 and 92-54)

The engine anti-icing system consists of - one anti-icing valve each for engine 1 and 2 - one actuator (21VE) each for engine 1 and 2 - two relays 5HL (6HL), two toggle switches 2HL (12HL) and indicator light 9HL l.

General When the ambient temperature falls below +4°C, the engine anti-icing system must be switched on to protect the engine compressor air inlet from icing.,

2.

Function The anti-icing system is supplied with electrical power from circuit breakers 1HL, 11HL "ENG. ANTI-ICING 1-2" and is switched on with toggle switches 2HL, 12HL "ENG. ANTI-ICING 1-2". The indicator light 9HL with legend panels EFFECTIVITY

o S/N 7 - 160: o S/N 161 and subsequent:

"L" and "R" "ANTI-ICING 1 and 2"

for the LH and RH engine, indicates operation of the anti-icing system. The circuit with relays 5HL, 6HL ensures that indicator light 9HL remains lit during the closing operation of the anti-icing valve. Actuators are automatically switched off by limit switches "ANTI-ICING ON - OFF" when anti-icing valve has reached its respective end position.

BO 105 CHAPTER 92 Page 142

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

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Engine Anti-Icing Systern BO 105 CHAPTER 92

Page 143/144

- - - - - - - - - - - - - ' M B B HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO lOS Compressor discharge air (approx. 2S0 OC) is routed from the compressor diffuser (see figure 92-S4) scroll through an actuator operated antiicing valve located en the front face of the diffuser scroll and associated anti-icing tubing to the compressor front support. Therefore icing of the engine air inlet is prevented. With toggle switch 2HL (12HL) set in the non-operating position, actuator is supplied with electrical power froro limit switch "ANTI-ICING OFF", with reversed polarity. Actuator extends and closes the anti-icing valve. During the closing operation of the valve, relay SHL (6HL) remains energized through limit switch "ANTI-ICING OFF"and relay contact closes the circuit to the indicator light 9HL, which therefore remains lit during the valve closing operation. When the actuator is switched off in its extend stop position by limit switch "ANTI-ICING OFF", relay SHL (6HL) will de-energize and the indicator light 9HL will extinguish. NOTE

Maintenance/inspection as well as removal and installation procedures are described in chapter 61. 2

7--Hhrli"'\'\i'

Anti-icing tubes 2 Anti-icing valve 3 Actuator 4 Diffusor scroll S Compressor front support 6 Front support radial struts 7 Compressor inlet cone 1

600146

Figure 92-S4

Engine Anti-Icing System BO lOS CHAPTER 92 Page 14S

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 92 - 64

Troubleshooting - engine anti-icing system

NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Defective actuator.

Replace actuator.

Defective circuit breakers 1HL, 11HL.

Replace circuit breakers.

Defective toggle switches 2HL, 12HL.

Replace toggle switches.

Defective wiring.

Check wiring for continuity using the applicable wiring diagram (refer to WDM); replace defective wiring.

Bulbs defective.

Replace bulbs.

Diodes 25WW, 27WW defective.

Check diodes and replace, if necessary.

Wiring defective.

Check wiring for continuity using the applicable wiring diagram (refer to WDM); replace defective wiring.

2

Actuator does not retract or extend.

Indicator light 9HL fails to illuminate a) during operation of the anti-icing systrm

b) during the closing Relays 5HL, 6HL operation of the defective. anti-icing valve, only. Diodes 7HL, 8HL defective.

Table 92-12

92 - 65 l.

Replace relays. Check diodes and replace, if necessary.

Troubleshooting engine anti-icing system

Functional test - engine anti-icing system

General This functional test must be carried out after having changed one or more electrical components, cables, electrical connections, etc. of the engine anti-icing system.

BO 105 CHAPTER 92 Page 146

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Preparations - engines must be shut down - connect and switch on external power supply unit - set BATTERY MASTER switch to EPU ON

3.

Performance of test

NOTE

The test is performed with the engines shut down and is identical for both actuators, LH and RH. a.

Depress circuit breaker ftENGINE ANTI-ICING 1-2 ft 1HL(11HL) and set toggle switch ftENGINE ANTI-ICING 1-2 ft 2HL (12HL) in the ftON ft position. - The actuator retracts and opens the anti-icing valve. - In the retract stop position, actuator is switched off by the limit switch and the indicator light 9HL illurninates.

b.

Set toggle switch "ENGINE ANTI-ICING 1-2" 2HL (12HL) in the "OFF" position. - The actuator extends and closes the anti-icing valve. NOTE

Indicator light 9HL remains lit during the closing operation of the anti-icing valve.

- In the extend stop position, actuator is switched off by the limit switch and the indicator light 9HL extinguishes.

92 - 66

E n 9 i n e f i r e d e t e c t ion (see figures 92-55 to 92-57)

s y s t e m

The engine fire detection system consists of heat sensitive fire detectors 101WG, 102WG for engine 1 and 201WG, 202WG for engine 2 - control unit 24VE - warning lights 104WG and 204WG - test switches 103WG and 203WG l.

General The engine fire detection system monitors potential fire z,ones of the engine compartments and provides a visual warning via 2 warning lights labelled F on the instrument panel 2VE in the event of fire or overheat conditions.

BO 105 CHAPTER 92 Page 147

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Description EFFECTIVITY

S/N 7 - 160

Two heat-sensitive fire detectors 101WG, 102WG and 201WG, 202WG respectively are mounted on each engine (see figure 92-56). When the ambient temperature increases in the engine compartments, the detectors open and thus energize the warning'lights 104WG, 204WG through relays in the control unit 24VE installed in the lower portion of the instrument panel 2VE. To ensure a flicker-free indication, a RC-unit is connected in parallel to the relay coils causing a delay in relay energizing and de-energizing. The engine fire detection system is supplied with electrical power via circuit breaker 1WB and 2WB ftFIRE WARNING I-II ft from the main bus PP21 or, if installed, from the emergency bus PP20. Functional testing of the system is made by push-to-test switch ftTEST FIRE ft 103WG, 203WG. Lamp testing of warning lights is by depressing the warning lights 104WG, 204WG. EFFECTIVITY

S/N 161 and subsequent

The circuit breakers 1WB, 2WB ftFIRE WARNING I-II ft are replaced by fuses lWG, 2WG. The respective control unit is identified 6WG.

BO 105 CHAPTER 92 Page 148

- - - - - - - - - - - - - ' M B B HELICOPTERS'------------MAINTENANCE MANUAL MBB - BO 105

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1 Instrument Panel 2VE Push-to-test switches (103WG, 203WG) Fire warning lights (104WG, 204WG)

EFFECTIVITY

Fire detectors (lOlWG, 102WG (LH); 201WG, 202WG (RH))

S/N 7 - 160

3 Electrical connections (lllVV, 211VV)

Circuit breakers (lWB, 2WB) Control unit (24VE) EFFECTIVITY

S/N 161 and subsequent

Fuses (lWG, 2WG) Control unit (6WG) Figure 92-55

Engine Fire Detection System BO 105 CHAPTER 92 Page 149

_ _ _ _ _ _ _ _ _ _ _ _ _ MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 When the fire detectors 101WG/201WG and 201WG/202WG are closed, both relays in the control unit 24VE are energized and the circuits 104WG/204WG warning light open. Should one of the two detectors on either the left or right engine open due to excessive ambient temperature, the respective relay in the control unit is de-energized and the associated warning light circuit completed. The same effect is obtained by operating the push-to-test switches 103WG/ 203WG, which simulate an opening of the fire detectors.

INSTRUMENT PANEL 2VE

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Figure 92-56 BO 105 CHAPTER 92 Page 150

TEST SWITCH 203 WG

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Engine Fire Warning System

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 67

Troubleshooting - engine fire detection system

NO. TROUBLE SYMPTOM 1

2

Fire warning lights 104WG, 204WG do not illuminate when pressing the pushto-test switches 103WG, 203WG.

Warning light indication at normal temperature in engine compartments.

Table 92-13 92 - 68

PROBABLE CAUSE

CORRECTlVE ACTION

Defective lamps.

Perform an internal lamp test and replace defective lamps, as necessary.

Defective circuit breaker or fuse.

Replace defective circuit breaker or fuse.

Defective wiring.

Check wiring for continuity using the applicable wiring diagram (refer to WDM) . Replace defective wiring, as necessary.

Defective relay in the control unit.

Check control unit and replace, if required.

Defective fire detector.

Check fire detector and replace, if required.

Defective push-totest switch.

Check push-to-test switch and replace, if required.

Defective wiring.

Check wiring for continuity using the applicable wiring diagram (refer to WDM) . Replace defective wiring, as necessary.

Troubleshooting - engine fire detection system

Functional Test - engine fire detection system

NOTE

EFFECTIVITY

Functional testing is performed with engines shut down and is identical for the left and right engine fire detection system.

o S/N 7 - 160: Push circuit breakers 1WB, 2WB. o S/N 161 and subsequent: Insert fuses 1WG, 2WG.

Warning lights 104WG, 204WG shall illuminate briefly (max. 0.5 sec.). BO 105 CHAPTER 92 Page 151

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 a.

Internal lamp testing - Press warning iights 104WG, 204WG. - Warning lights shall illuminate.

b.

Signal circuit testing - Press push-to-test switches 103WG, 203WG. - Warning lights 104WG, 204WG shall illuminate.

92 - 69 1.

Removal and installation - engine fire detection system

Detector switches (figure 92-57) NOTE a.

Removal and installation procedures of the fire detectors are identical for both engines, LH and RH. Removal - Switch off the helicopter electrical power supply. - Loosen hex nuts (5) and remove together with serrated lock washers (3) and electrical wiring (4). - Loosen hex screws (1) and remove together with hex nuts (7), wash~rs (6), and fire detector (2).

b.

Installation Installation is essentially the reverse of the removal. NOTE

2.

Observe identification of electrical wiring when reconnecting the wiring.

Control unit a.

Removal - Remove lower instrument panel fairing according to chapter 7 and battery according to chapter 92-27. - Disconnect the electrical connector 6WGa (24VEa) at the lower side o¡ the control unit 6WG (24VE) - Loosen round head screws with washers and remove together with control unit trom the instrument panel.

BO 105 CHAPTER 92 Page 152

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Installation Installation is essentially the reverse of the removal.

900098

Hex screw 2 Fire detector 3 Serrated lock washer 4 Electrical wiring 5 Hex nut 6 Washer 7 Hex nut

1

Figure 92-57

Fire Detector Switch

BO 105 CHAPTER 92 Page 153/154

- - - - - - - - - - - - - " M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 92 - 70

oi

1 c o O 1 e r f a n f a i 1 u r e s y s t e m (figure 92-58)

wa r n i n g

The oil cooler fan failure warning system consists of - differential pressure switch llED - warning light 10ED 1.

General The oil cooler fan failure warning system monitors the function of the oil cooler fan of the main transmission.

2.

Function The differential pressure switch llED for the oil cooler fan failure warning is located on the ram air duct assembly above the oil cooler (see figure 92-49). If an oil cooler fan failure occurs, the differential pressure switch llED completes the electric circuit of the warning light 10ED to ground and the "OIL COOL" light on the instrument panel 2VE illuminates indicating failure in the oil cooler fan system. • PP20

MAIN BUS

PP21

28V-

,

PRESSURE SWITCH

WARNI~GI L1GHT

fOil COOl 1'0 900079

* NOTE

Figure 92-58

0 EC

1

(11

I

B ~

P

If the emergency bus is installed, connect electrical wiring to PP20.

Oil Cooler Fan Failure Warning System - Schematic Diagram

BO 105 CHAPTER 92 Page 155

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 71

Troubleshooting - oil cooler fan failure warning system

NO.TROUBLE SYMPTOM Warning light 10ED "OIL COOL" does not extinguish when 70% rotor speed is reached.

Table 92-14

92 - 72 1.

PROBABLE CAUSE

CORRECTIVE ACTION

Defective differential pressure switch llED.

Disconnect plug 450VVa. Warning light 10ED "OIL COOL" must extinguish.

Short circuit to ground in wire ED15F22 or ED15E22.

Check w~r~ng for continuity using the applicab1e wiring diagram. Repair or replace defective wiring.

Troubleshooting - oil cooler fan failure warning system

Functional test - oil cooler fan failure warning system

With engines off - Connect an external power unit to the helicopter and switch on power supply to the main bus. Warning light "OIL COOL" 10ED must illumínate.

2.

With engines running at 70% N2 RPM - The warning light "OIL COOL" must extinguish when a rotor speed of 70% is reached.

92 - 73 l.

Removal and installation - oil cooler fan failure warning system

Differential pressure switch llED For removal and installation refer to chapter 63, Lubrication system.

2.

Warning light 10ED (4EV) For removal and installation and for functional tests refer to paragraph 92-133.

BO 105 CHAPTER 92 Page 156

- - - - - - - - - - - - - M B B HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 92 - 74

FUEL SYSTEM

The fuel system consists of: - fuel supply system - fuel shutoff valves - monitoring systems 92 - 75

Locations - fuel system (see figure 92-59)

Component

Location

Fig. or Chapter

Warning lights

See paragraph 92-133

Fig. 92-97

Circuit breakers

See paragraph 92-76

1nstruments

See paragraph 91

Fuel supply system Toggle switches 11QM, 12QM 13QM and14QM

S/N 7-160 1nstrument panel 2VE S/N 161 and subsequent and Series D Overhead panel 12VE

Fig. 92-11 Fig. 92-60

Fuel pumps 5QM and 6QM

Main tank

see chapter 62

Fuel pumps 7QM and BQM

Supply tank

see chapter 62

Toggle switches EMERGENCY FUEL VALVE 1-11 (104WA and 204WA)

1nstrument panel 2VE

Fig. 92-11 to 92-13

Fuel shutoff valve 1 and 2 (102WA)

Fuel supply lines between supply tank and engines

see chapter 62

Fuel quantity transmitter 3EB

Supply tank

see chapter 62

Pressure transmitter 101EA (20lEA)

Engine compartment 1 and 2

see chapter 62

Differential pressure switch l03EA

Engine compartment 1 and 2

see chapter 62

Fuel shutoff valves

Monitoring instruments

Fuel quantity transmitter lEB Main tank

see chapter 62

Fuel quantity transmitter 2EB

see chapter 62

Supply tank

Table 92-15

Location - Fuel system BO 105 CHAPTER 92 Page 157

________________OMBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 76

Protection of circuits of fuel systern

o

The following circuit breakers are installed to protect the fuel systern: CIRCUIT BREAKER Code Protection

PROTECTED CIRCUIT

LOCATION

IDENTIFICATION

1QM 4QM 2QM

5A 5A 5A

Inst rument panel 2VE, see chapter 91

FUEL PUMPS MAIN TANK FUEL PUMPS MAIN TANK FUEL PUMPS SUPPLY TANK

10QM

5A

Fuel Fuel Fuel tank Fuel tank

3E

lA

2E 7E

lA lA

9E

lA

1WA

3A

2WA

3A

pump main tank pump main tank pump supply pump supply

Fuel quantity indicator Low fuel warning Fuel pressure indicator Fuel filter clogging indicator Fuel shutoff valve 102WA Fuel shutoff valve II 102WA

Table 92-16

BO 105 CHAPTER 92 Page 158

FUEL PUMPS SUPPLY TANK

Instrument panel 2VE, RH side see chapter 91 EMERG. FUEL VALVE 1 EMERG. FUEL VALVE 11

Protection - Fue¡ systern

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 Instrument panel (2VE) Circuit breakers (lQM, 4QM; 2QM, 10QM) EFFECTIVITY

2 3 4 5 6

S/N 7 - 160 Toggle Switches (3QM, 9QM)

Fuel pump - supply tank (SQM) Fuel pump - main tank (5QM) Fuel pump - main tank (6QM) Fuel pump - supply tank (7QM) Overhead panel (12VE) EFFECTIVITY

S/N 161 and subsequent Toggle Switches (11QM, 12QM, 13QM, 14QM) Figure 92-59

Fuel Feed System BO 105 CHAPTER 92

Page 159

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Figure 92-60

BO 105 CHAPTER 92 Page 160

B1ank

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - , - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 92 - 77 1.

F u e 1 s u P P 1 Y s Y s t e m (see figure 92-61)

General The fuel supply system consists of two feed systems which, independent of each other, supply fuel to the LH and RH engine. For this purpose, two fuel pumps each are installed in the main tank SQM and 6QM and in the supply tank 7QM and SQM. Fuel pumps SQM and ~QM of main tank are supplied with power from main bus PP 21 via circuit breakers 1QM and 4QM and toggle switches 11QM and 12QM. Fuel pumps 7QM and SQM of supply tank are supplied with power from PP21 via circuit breakers 2QM and 10QM and toggle switches 13QM and 14QM.

EFFECTIVITY 2.

Series D 10QM is connected to emergency bus PP20.

Fuel pumps SQM to SQM NOTE

Maintenance/inspection and removal and installation procedures are described in chapter 62. MAIN BUS PP21 28V-

1I

I

CIRCUIT BREAKER 40M 20M

L

100M

110M

13Q"M"""

120M

--

I

OVERHEAD PANEL 12 VE

AFT

SOM

I

I

aMi

MAIN TANK

Figure 92-61

I

~

RIGHT-'

LEFT

I

I

I

70M

I

L_ 900125

11\

Q

L-

50M

_J

INSTRUMENT PANEL 2 VE

I

1

I

-.l

80M

I I

__ J SUPPLY TANK

Fuel Feed System BO 105 CHAPTER 92 Page 161

MAINTENANCE MANUAL BO 105

92 - 78 NO

Troubleshootlng - fuel supply system TROUBLE SYMPTOM

Fuel pump (SOM, 60M, 70M, SOM) inoperative

PROBABLE CAUSE

CORRECTIVE ACTION .

Defective circuit breaker (10M, 40M, 20M, 100M)

Replace circuit breaker.

Defective toggle switch

Replace toggle switch.

EFFECTIVITY SIN 7-160: 30M, 90M SIN 161 and subsequent: 110M, 120M, 130M, 140M Defective electrical wiring

Check electrical wiring for continuity using the applicable wiring diagram (refer to WDM) and replace defective wiring.

Defective fuel pump

Replace fuel pump.

Table 92-17 Troubleshooting - fuel supply system

92 - 79

Functlonal test - fuel supply system

NOTE

The following functional test must be carried out after having changed one or more electrical components, cables, electrical connections, etc. of the fuel supply system.

1. Engines must be shut down. 2. Connect and switch on external power supply unit, see para 92-33. 3. Set BATTERY MASTER switch to BAT OFF/EPU ON.

CHAPTER 92 Page 162

Revision 21

eeurocopter

MAINTENANCE MANUAL BO 105

IN CASE OF EMPTY FUEL TANKS, THE MAXIMUM ORY RUNNING TIME OF FUEL PUMPS MUST NOT EXCEEO 15 MIN.

CAUTION

4. Push circuit breakers (10M, 40M for main tank, 20M, 100M for supply tank) 5. Set toggle switches for fuel pumps in position "ON". EFFECTIVITY

From SIN 7 • 160 Installed in Instrument panel 2VE Main tank LH/RH 30M Supply tank LHlRH 90M SIN 161 and subsequent; installed in overhead panel 12VE Main tank 110M LH, 120M RH Supply tank 130M LH, 140M RH

6. Operation of the respective fuel pump must be audible. EFFECTIVITY

Fuel pump in the supply tank Dual fuel pressure indicator reading for the respective fuel pump must be within the . specified limits (refer to FLM). Fuel pump In the main tank Dual fuel quantity indicator reading must increase on the supply side.

7. Set toggle switches 1n position ''OFP and pull circuit breakers.

92 - SO

Fuel shutoff system (see figure 92-62)

The electrical system for fuel shutoff consists of: -

two emergency fuel valves, 102WA and 202WA for engine 1 and engine 2 respectively

-

two toggle switches 104WA and 204WA and

-

two circuit breakers 1WA and 2WA for protection

The emergency fuel valves are motor-operated valves, installed in the two fuel feed lines between supply tank and engines in the LH and RH fuselage side shell respectively (see figure 92-63). In an emergency (e.g. tire), the fuel supply to the engines can thus be interrupted. The motors are of the dual field winding configuration, with one winding each for opening and closing operation. They are activated by toggle switches 104WA, 204WA "EMERG. FUEL VALVE 1-11". Toggle switches are installed in the instrument panel 2VE and protected by safety-covers.The motors are automatically switched off by limit switches. The system is supplied with electrical power via circuit breakers 1WA, 2WA "EMERG. FUEL VALVE 1-11" from main bus PP 21 or emergency bus PP 20 respectively. EFFECTIVITY

Series O Electrical power is supplied from connection 1 of fuse 25P at the instrument panel 2VE. Circuit breakers 1WA, 2WA "EMERG. FUEL VALVE 1-11".

NOTE

For removal, instaUation and leakage test procedures refer to chapter 62.

With circuit breakers pushed and toggle switches in the "CLOSEO" position, the motors will close the valves in the fuel feed lines and thus shut off the fuel supply to the engines. Revision 21

CHAPTER 92 Page 163

I

e

eurocopter

MAINTENANCE MANUAL 80 105

MAINBUS PP21 28V-

CIRCUITBREAKER 1WA

\

ro-- CLOSED

--~\r

¡ - CLOSED

---V

OPEN

TOGGLE SWITCH 104WA

1

EMERG.FUELVALVE ___ ~02WA

I

o

o

CHAPTER 92 Page 164

OPEN

TOGGLE SWITCH 204WA

EMERG. FUEL VALVE 102WA

•

CIRCUITBREAKER 2WA

Figure 92-62

Fuel shutoff system

Revision 21

eeurocopter

MAINTENANCE MANUAL BO 10S

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1 Circuit breakers (1 WA, 2WA) Toggle switches (104WA, 204WA) Instrument panel (2VE) 2 Emergency fuel valve (202WA) RH engine 3 Emergency fuel valve (102WA) LH engine

Figure 92-63

Revision 21

•

Locations - Fuel shutoff system

CHAPTER 92 Page 165

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 92

Page 166

Revision 21

e 92 - 81

MAINTENANCE MANUAL 80 105

•

Troubleshooting - fuel shutoff system TROUBLE SYMPTOM

NO.

1.

eurocopter

PROBABLE CAUSE

CORRECTIVE ACTION

Emergency fuel valve 102WA or Defective fuel valve Replace fuel valve. 202WA neither opens nor closes. Defective circuit breaker 1WA or Replace circuit breaker. 2WA Defective toggle switch 104WA or204WA

Replace toggle switch.

Defective electrical wiring

Check wiring for continuity using the applicable wiring diagram (refer to WDM) and replace defective wiring.

Table 92-18 Troubleshooting - fuel shutoff system

92 - 82

Functlonal test - fuel shutoff system The following test must be carried out after replacement of one or both fuel shutoff valves.

NOTE

1. Engines must be shut down. 2. Connect and switch on external power supply unit, see para 92-33. 3. Set BATTERY MASTER switch to BAT OFF/EPU ON. 4. Push circuit breaker 1WA, 2WA"EMERG. FUEL VALVE 1-11". 5. Close emergency fuel valve. a. Remove safety coveroftoggle switch 104WA, 204WA "EMERG. FUEL VALVE 1-11" and settoggle switch to the "GLOSED" pasition. b. Closing of emergencyfuel valve mustbe audible. Emergency fuel valve mustswitch offwhen fullyclosed. EFFECTIVITY

SIN 7-350 Pointer in sight glass of emergency fuel valve must point at "P. SIN 351 and subsequent Position of mechanical see-feel indicator at emergency fuel valve:

Revision 21

CHAPTER 92 Page 167

I

eeurocopter

MAINTENANCE MANUAL BO 10S

6. Opan emergency fuel valve. a. Set toggle switch 104WA, 204WA "EMERG. FUEL VALVE 1-11" to the "DPEN" pasition and reinstall the safety caver. b. Opening of emergencyfuel valve mustbe audible. Emergency fuel valve must switch offwhenfully open. EFFECTIVITY

SIN 7~50 Pointer in sight glass of emergency fuel valve must point at "0". SIN 351 and subsequent Position ot mechanical see-feel indicator at emergency fuel valve:

7. Pull circuit breaker 1WA, 2WA "EMERG. FUEL VALVE 1-11".

1

92 - 83

Leakage test - fuel shutoff system

1. Close emergency fuel valves as described in para 92-82. 2. Switch on fuel pumps in the supply tank. There must be no pressure indication on the dual fuel pressure indicator. 3. Open emergency fuel valves as described in para 92-82. A minimum pump pressure of 0.7 bar must be shown on the dual fuel pressure indicator. 4. Switch off fuel pumps.

CHAPTER 92 Page 168

Revision 21

- - - - - - - - - - - - - M B B HELlCOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 84

MO n i t

O

r i n g -

f

U

e 1

s

U

P P 1 Y s Ys t e m

The following monitoring systems are installed fer continuous monitoring of the fuel system: -

fuel quantity monitoring, see chapter 91 low fuel warning, see paragraph 92-85 fuel pressure monitoring, see chapter 91 fuel filter bypass warning, see paragraph 92-86

92 - 85 1.

Low fuel warning system (see figure 92-64 and 92-65)

General The low fuel warning system provides warning light indication when a certain fuel level limit is reached in the supply tank. The low fuel warning transmitter 3EB censists of a float interconnected with a switch contact and is located in the supply tank. EFFECTIVITY

o S/N 7 - 120 Warning indication is via warning light 7EB "LOW FUEL" on the instrument panel and via additienal red warning light located in the lower portion of the dual fuel quantity indicator 5EB. o S/N 121 and subsequent Warning indication is via warning light 7EB "LOW FUEL".

The system is supplied with electrical power via fuse 2E from the main bus PP21 or emergency bus PP20. Lamp testing is made by depressing the test switch 6EB "TEST WARN. LIGHTS".

BO 105 CHAPTER 92 Page 169

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2.

Function If the fuel level in the supply tank falls below the permissible limit, the float closes the switch contact in the low fuel warning transmitter and thus the warning light circuito MAIN BUS

PP21

¡

28VDUAL FUEL aUANTITY INDICATOR 5EB

!

TEST SWITCH 6EB

2E

~ i

----.

! , -=r- I

I

I I

iO

'O

¡

~ 9EB

16WW

II~ -C>-I"~"""'--'

'---'~

J\~ '

~

3E

FUSE

~"-ooÓo--+----'

rI I

-~-¡-l LOWíI\ FUELJj)

I

1

;/~,:

'

I

¡_'"::=..--7= J'_- -_

I L

LOW FUEL WARNING TRANSMITTER 3EB

'*'

1 I,HY. BLOCK )1 ,_.J1

~j

... -' WARNING LIGHT 7EB

900123

Figure 92-64

BO 105 CHAPTER 92 Page 170

Low Fuel Warning System

------'

- - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1

Instrument panel (2VE) Fuse 2E Dual fuel quantity indicator SEB Warning light 7EB Test switch 6EB

2 Supply tank Low fuel warning transmitter 3EB Figure 92-65

Locations, Low Fuel Warning System BO 105 CHAPTER 92 Page 171

------.....;....------MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 3.

Troubleshooting - Low Fuel Warning System

NO. TROUBLE SYMPTOM 1

Warning light "LOW FUEL" 7EB inoperative.

2

EFFECTIVITY

CORRECTlVE ACTION

Defective fuse 2E.

Replace fuse.

Defective diode 9EB.

Check diode¡ replace if necessary.

Defective bulbs.

Replace bulbs.

Defective electrical wiring between main bus and warning light.

Check wiring for centinuity using the applicable wiring diagram and replace defective wiring.

S/N 7 - 120

Warning light located in dual fuel quantity indicator SEB inoperative

3

PROBABLE CAUSE

Defective fuse 3E. Defective bulbo

Replace fuse. Replace bulbo

Defective electrical wiring between main bus and dual fuel quantity indicator.

Check wiring for centinuity using the applicable wiring diagram (refer to WDM) and replace defective wiring.

Defective electrical wiring between warning light 7EB and dual fuel quantity indicator.

Check wiring for continuity using the applicable wiring diagram (refer te WDM) and replace defective wiring, as required.

Both warning lights Defective transinoperative. mitter 3EB. Defective electrical wiring between transmitter and warning light 7EB.

Table 92-19 NOTE

BO 105 CHAPTER 92 Page 172

Replace transmitter. Check w~r~ng for continuity using the applicable wiring diagram (refer te WDM) and replace defective wiring, as required.

Troubleshooting - Low fuel warning system

.Maintenance/inspectien, removal and installation refer te chapter 62.

_ _ _ _ _ _ _ _ _ _ _ _ _ oMBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 86 l.

Differential fuel pressure (BYPASS) warning system (see figures 92-66 and 92-67)

General The system provides warning light indication on the instrument panel 2VE when fuel filters in the engine assembly fuel pumps are contaminated. Differential pressure switches 103EA, 203EA, installed in the bypass lines of the fuel filters are used as signal transmitters. They consist of diaphragm-operated switches, which close when fuel pressure increases. Indication is provided by warning light lEA with legends ftFILT 1 ft for the LH engine and ftFILT 2ft for the RH engine. The system is supplied with electrical power via fuse 9E from the main bus PP21 and emergency bus PP20 respectively. Lamp testing is by depressing test switch 6EB ftTEST WARN. LIGHTS ft .

2.

Function Heavy contamination of the fuel filter, causes a pressure increase in the bypass lines. The differential pressure switch will close and thus , complete the warning light circuito

MAIN BUS

PP21 9E

28V-

FUSE

TEST SWITCH 6EB BYPASS

I

I

BYPASS DIFFERENTIAL ~o PRESSURE SWITCH

900121

:>;

91

¡

•

r

' 4WW~ ~o ~I ~6WW O~.I I

~

í..

5WW

:

Ron

o

FILTl

l

l'

DIFFERENTIAL PRESSURE SWITCH 203 EA

I

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\:)

o"""':"""

¡ FILT 2 .~-"".~I4_-"""ol

I! ~ ~ I

L--

Figure 92-66

1"'-/:,

é

BYPASS

•

..:-

1-----~cr

:.1

e:

,WARNING L1G~A

o

103 EA

8E

7WW

----.!

Differential Fuel Pressure Warning System

BO 105 CHAPTER 92 Page 173

HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

------------MBB

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900113

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1 Instrument panel (2VE) Fuse 9E Warning light lEA Test switch 6EB 2 Differential pressure switch l03EA 3 Differential pressure switch 203EA Figure 92-67 105 CHAPTER 92 Page 174

BO

Locations, Differential Fuel Pressure Warning System

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-.-=-_.-._-_.-.:==.0==-·-=;r=--2U.:- ~ /" 1/":-'1 ~ ~. l !! r:f0-r~' \~' .fi!l I 1 \, 1~o --.Jj_o.J~._. -G 7/

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900113

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1 Instrument panel (2VE) Fuse 9E Warning light lEA Test switch 6EB 2 Differential pressure switch 103EA 3 Differential pressure switch 203EA Figure 92-68

Rev. 1

Locations, Differential Fuel Pressure Warning System BO 105 CHAPTER 92 Page 175

eeurocopter 92 - 88

MAINTENANCE MANUAL BO 105

Locations - control systems FIGURE

COMPONENT

LOCATION

Warning Iights

see paragraph 92-133

Circuit breaker

see paragraph 92-89

• •

Hydraulic system

92-97 92-11 to 92-13

• Hydraulic switch-over relay 60B Instrument panel 2VE

•

92-68

Instrument panel 2VE

•

92-68 and 92-11 to 92-13

see chapter 43 Hydraulic unit

•

•

Hydraulic test switch SOB Pressure switch system 1, 20B; Pressure switch system 2, 40B; Microswitch 100B1 to 100B6; Solenoid valve 80B

92-68

Cyclic stick trim Actuators 6CC and 7CC

Nose shell

Fig.92-71

Four-way switch 2CC

Cyclic stick grip 3/4VE

Fig.92-71

Retraction and extension relay 6CCto 11CC

Relay box 10VE

Fig. 92-8 and 92-9

Table 92-21 Locations - control systems

92 - 89

Protectlon of clrcults of control systems

The following circuit breakers are installed to protect the control systems: CIRCUIT COOE

BREAKER PROTECTION

PROTECTEO CIRCUIT

LOCATION

10B

SA

Hydraulic system

Instrument panel2VE

1CC

2A

Cyclic stick trim

Instrument panel2VE

10ENTIFICATION

.1 I

HYORAULlC (SIN 7 -160), HYOR. CONTROL (SIN 161 and subsequent), HYOR. SYSTEM (series O, CB-S, CB5-S and OB5-S) TRIMMING, TRIM ACTUATORS (series O, CB-S, CB5-S and OB5-S)

Table 92-22 Protection of control systems

CHAPTER 92 Page 176

Revision 22

·eeurocopter 92 - 90

Hydraulic system

MAINTENANCE MANUAL· BO 105 (see figures 92-68 thru 92-70)

For description, maintenancelinspection, removal and installation refer to chapter 43.

NOTE

The hydraulic system utilizes a hydraulic pressure monitoring system and an electrically initiated system switch-over. .

1

I

Instrument panel (2VE) Circuit breaker (1 OB) Warning Iight (7EB) Warning Iight (30B) Hydraulic test switch (50B) Test switch (6EB) Relay (60B) Oiode (70B) Printed circuit board (1 WW) Figure 92-68

Revision 22

2

Dual hydraulic booster Pressure switch, system 1 (20B) Pressure switch, system 2 (40B) Solenoid valve (80B) Microswitch system switch-over (1 00B1, 100B2, 10083, 10084, 100B5, 100B6)

Locations - Hydraulic system CHAPTER 92 Page ln

I

eeurooopter 92 - 91

MAINTENANCE MANUAL BO 105

Hydraulic pressure monitoring system (see figure 92-69)

1. Descnption Each system (1 and 2) is equipped with a pressure switch 2DB, 4DB. The pressure switch is hydraulically operated and closes when hydraulic pressure falls below 72-6S bar. Warning indication is via warning Iight 3DB, with legends "HYDR. 1" and "HYDR. 2", located on the instrument panel2VE. The system is supplied with electrical power from main bus PP21 or emergency bus PP20 via circuit breaker 1DB "HYDRAULlC" (SIN 7-160), "HYDR. CONTROL" (SIN 161 and subsequent) or "HYDR. SYSTEM" (series D, CB5-S and DB5-S). Lamp testing of warning Iights is carried-out by means of test switch 6EB ''TEST WARN. L1GHTS".

CIRCUIT BREAKER lDB WARNING L1GHT 3DB 17WW TEST SWITCH 6EB

.A.

~ o

11'

lSWW

;1 i:tI

l

PRESSURE SWITCH SYSTEM 2 4BD

PRESSURE SWITCH SYSTEM 1 2DB

:g

g Figure 92-69

CHAPTER 92 Page 178

Hydraulic pressure monitoring system

Revision ·22

MAINTENANCE MANUAL BO 105 2. Troubleshooting - hydraulic pressure monitoring system NO. TROUBLE SYMPTOM 1.

2.

No indication from warning Iight 3DB "HYDR. 1" or "HYDR. 2" although system is unpressurized

PROBABLE CAUSE

CORRECTIVE ACTION

Pressure switch 2DB or 4DB not closed

Check pressure switch and replace as required

Defective circuit breaker 1DB

Check circuit breaker and replace as required

Defective diode 7DB

Check diode and replace as required

Both lamps of either warning Iight defective

Check both lamps and replace as required

Defective wiring

Check wiring for continuity using the applicable wiring diagram (refer to WDM). Repair or replace, as necessary

Warning Iight 3DB "HYDR. 1" or Pressure switch 2DB or 4DB "HYDR. 2" iIIuminates, a1though does not opan systern is pressurized Short circuit to ground

Check pressure switch and replace as required Check wiring for continuity using the applicable wiring diagram (refer to WDM). Repair or replace, as necessary

I

Table 92-23 Troubleshooting - hydraulic pressure rnonitoring system

Revision 22

•

CHAPTER 92 Page 179

_eurooopter 92 - 92

MAINTENANCE MANUAL BO 105

Electrically inltiated system swltch-over - hydraulic system (refer to Figure 92-70)

1. Oescription Each of the three actuators of hydraulic system 1 is equipped with two microswitch assys 100B1/100B2, 100B3/1 00B4, 100B5/1 00B6. Each microswitch assy consists of two microswitches connected in parallel. If a control spool jamming occurs in an actuator of system 1, the override mechanism actuates one of the microswitches, energizing the relay 60B (even afier a very short period of actuation), which then closes the solenoid valve 80B. The relay 60B is self-Iocking in a holding circuit via one of its contacts and the hydraulic test switch 50B. Oue to the relays 60B holding circuit, the solenoid valve 80B remains energized and thus closed. The solenoid valve 80B closes the pressure supply line of system 1 to the shuttle valve and connects the system-1-line of the shuttle valve to the low pressure return line. This situation for the shuttle valve now looks Iike a loss of pressure in system 1, and as a reaction it cloSes the selector valve of system 1 and opens the selector valve of system 2: the actuators of system 2 are pressurized, the actuators of system 1 are on idle. Now the control spools of the actuators of system 2 control the helicopter instead of the jammed control spools of system 1. The second contact of the relay 60B closes the circuit of warning light 7EB "HY BLOCK" on the instrument panel 2VE, which iIIuminates, indicating the switch-over to system 2. EFFECTIVITY

Dual hydraulic boosters with P/N 105-83001, 105-83011, 105-45028 with CAA-Retrofitkit 105-45018, 105-45039 and 105-450390 In addition to "HY BLOCK" warning, pressure switch 20B will close and warning Iight 30B "HYOR. 1" will iIIuminate.

Functional testing of the system is carried--out by means of hydraulic test switch 50B "HYORAUL" (SIN 7-160) or "HYOR. TEST" (SIN 161 and subsequent) on the instrument panel 2VE. The switch is spring loaded to position "TEST" ("HYOR JI") and "RESET". In position "TEST" rHYOR Jlj it simulates a control spool jamming in an actuator of system 1 by energizing the relay 60B. In position "RESET" it deenergizes the self-Iocking relay 60B by opening the holding circuito The original situation (system1 active) is thus restored. The system is supplied with electrical power from main bus PP21 or emergency bus PP20 via circuit breaker 10B "HYORAULlC" (SIN 7-160), "HYOR. CONTROL" (SIN 161 and subsequent) or "HYOR. SYSTEM" (series O, CBS-5 and OBS-5). Lamp testing of warning Iights is carried--out by means of test switch 6EB "TEST WARN. L1GHTS".

CHAPTER 92 Page 180

Revision 22

e

eurocopter

MAINTENANCE MANUAL BO 105

MAIN BUS

LOW FUEL WARNING SYSTEM 9EB

PP21 28VCIRCUIT BREAKER 1DB

-------,1M-.....

7DB WARNING L1GHT 7EB

TEST

r-#-~---'

LOW FUEL WARNING SYSTEM

t

NORMAL

+

RESET I

Dk:J HYDRAULlC TEST SWITCH

RELAY 60B

~DB_~~

SOLENOIO VALVE 80B

\

o------.......2....1WW~

TEST SWITCH 6EB

o----fll

T MICROSWITCH ASSY 10081.10082 LATERAL CONTROL

Figure 92-70

Revision 22

--+SL.L2

MICROSWITCH ASSY 10083. 100B4 COLLECTIVE CONTROL

MICROSWITCH ASSY 10085. 10086 LONGIT. CONTROL

•

Electrically initiated system switch-over

CHAPTER 92 Page 181

eeurocopter •

MAINTENANCE MANUAL BO 105

2. Troubleshooting - electrically initiated system switch-over- hydraulic system NO. TROUBLE SYMPTOM 1.

No indication from warning light 7EB "HY BLOCK" during override or testing

PROBABLE CAUSE

CORRECTIVE ACTION

Defective relay 6DB

Check. coi! and contacts and replace relay as required

Defective diode 7DB

Check diode and replace as required

Defective circuit breaker 1DB

Check circuit breaker and replace. as required

Microswitch assy does not close

Check microswitch and replace as required

Defective hydraulic test switch 5DB

Check hydraulic test switch and replace as required

Both lamps of warning light defective

Check lamps and replace as required

. Defective electrical wiring

2.

Warning Iight 7EB "HY BLOCK" does not extinguish

Contact of relay 6DB does not open

Cneck wiring for continuity using the applicable wiring diagram (refer to WDM). Repair or replace as necessary Check relay contact and replace relay as required

Microswitch assy does not open Check microswitch and replace as required Defective hydraulic test switch 5DB

3.

Solenoid valve 8DB closes for a Defective relay 6DB short time only Defective electrical wiring

•

Check hydraulic test switch and replace as required Check coi! and contacts and replace relay as required Check wiring for continuity using the applicable wiring diagram (refer to WDM). Repair or replace as necessary

Table 92-24 Troubleshooting - electrically initiated system switch-over - hydraulic system (1 of 2)

CHAPTER 92 Page 182

Revision 22

e

eurocopter

NO. TROUBLE SYMPTOM

4.

PROBABLE CAUSE

CORRECTIVE ACTION

Defective solenoid valve

Check solenoid valve and replace as required

Defective circuit breaker 1DB

Check circuit breaker and replace as required

Defective electrical wiring

Check wiring for continuity using the applicable wiring diagram (refer to WDM). Repair or replace as necessary

Defective micro-switch assy

Check microswitch and replace as required

Defective electrical wiring

Check wiring as described above

Defective hydraulic test switch 5DB

Check hydraulic test switch and replace as required

Defective electrical wiring

Check wiring as described above

Contact of relay 6DB does not open

Check relay contaet and replace relay as required

Solenoid valve 8DB does not close: a. at override and hydraulic test

b. at override only

c. at hydraulic test only

5.

MAINTENANCE MANUAL 80 105

Solenoid valve does not opan

Microswitch assy does not open Check microswitch and replace as required Defective hydraulic test switch 5DB

Check hydraulic test switch and replace as required

Short circuit to ground

Check wiring for continuity using the applicable wiring diagram (refer to WDM). Repair or replace as necessary

Table 92-24 Troubleshooting - electrically initiated system switch-over - hydraulic system (2 of 2)

Revision 22

•

CHAPTER 92 Page 183

_eurooopter

MAINTENANCE MANUAL BO 105

BLANK PAGE

CHAPTER 92 Page 184

Revision 22

eeurocopter 92 - 93

MAINTENANCE MANUAL BO 105

Cyclic stick trim (see figures 92-71 to 92-79)

The cyclic stick trim consists of: -

trim actuator 6CC (longitudinal) and trim actuator 7CC (lateral)

-

retraction relays 8CC and 10CC

-

extension re!ays 9CC and 11 CC

-

one each four-way switch 2CC for pilot and copilot

1. General The hydraulic system installed in the helicopter allows for a transmission of cyclic blade pitch changes with reduced effort required for control inputs at the cyclic stick. To give the pilot nevertheless an artificial control feel when moving the cyclic stick, provisions are made that a counteracting force of a preloaded spring (compression spring) must be overcome. In order to facilitate control of the helicopter in certain flight attitudes (hovering, cruise), it is possible for the pilot (copilot) to trim off the cyclic stick pressure holding the cyclic stick 3/4VE (dual control) in the particular position. This is achieved by moving the four-way switch 2CC on the cyclic stick grip in the same direction as that in which the cyclic stick is being held. A trim actuator for the longitudinal and for the lateral direction respectively is installed parallel to the corresponding trim spring and connected to the spring tube via a lever. Depending on the position of the four-way switch, the trim actuators extend or retract, relieving the load on the trim spring. The pressure on the cyclic stick is thus reduced. The trim actuators are lacated in the nose shell between the trim spring tube and the cyclic stick (refer to figure 92-72). Electrical power is supplied from the main bus PP21 via circuit breaker 1CC.

Revision 22

CHAPTER 92 Page 185

I I

- - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

3

3 --\-T--+-a

5

1 2 3 4

Trirn actuator, lateral Circuit breaker Four-way switch Trirn actuator, longitudinal 5 Relay box

Figure 92-71 BO 105 CHAPTER

Page 186

92

7CC 1CC 2CC 6CC 10VE

Locations - Trirnrning

- - - - - - - - - - - - - " M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3

-5

2

Figure 92-72

2.

4

1 Compression spring (lateral) 2 Trim actuator 7CC 3 Compression spring (longit udinal) 4 Relay box 10VE 5 Trim actuator 6CC

Locations - Trirnming

Function (see figure 92-73) a.

Four-way switch 2CC in position ftLeft ft actuator 7CC will extend.

= Lateral trirnming, trim

The voltage applied at center contact of four-way switch 2CC energizes the coil of the extend relay llCC. The energized relay switches the power supply to the trim actuator 7CC via second nor.mally-closed contact of the retract relay 10CC. Circuit to ground is provided via switching contact of the de-energized retract relay and via limit switch, which is closed until the extend motion is completed. b.

Four-way switch 2CC in position ftRight ft actuator 7CC will retracto

= Lateral trirnming, trim

BO 105 CHAPTER 92 Page 187

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

_____r-. MAIN BUS

~PP2'

28V- • •

1CC CIRCUIT BREAKER

~!

~

__ I

: :

~

8

1

'

:

___

I

I

I L

I

:

-+--1--'"

::'-----..;..' RETRACT

'

-€' O~ ·

t

M

;---------1

I

'

1I

EXTEND

l

~~'_...J

"-- ¡ ! i

TRIM ACTUATOR (LONGITUDINAL) 6CC

o

!

i

EXTEND

.

M

"-0t:)-' i ~

BO 105 CHAPTER 92

Page 188

I :

RETRACT I

i

I --~

:I I I t

i I

J

TRIM ACTUATOR (LATERAL) 7CC

900213

Figure 92-73

,.;

:

~-4-0,

o

Cyclic stick trim

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 The voltage is directed froro the four-way switch 2CC to the coil of the retract relay 10CC. The trim actuator 7CC is supplied with electrical power via closed limit switch (until retract motion is completed) and via switching contact of the retract relay 10CC. The circuit to ground is again provided via switching tontact of the energized retract relay. c.

Four-way switch 2CC in position "Forward" = Longitudinal Trirnming, trim actuator 6CC will extend. The voltage applied at center contact of four-way switch 2CC energizes the coil of the extend relay 9CC. , The energized relay switches the power supply to the trim actuator 6CC via switching contact of the retract relay BCC. The circuit to ground is provided via second switching contact of the deenergized retract relay and via limit switch, which remains closed until extend rootion is coropleted.

d.

Four-way switch 2CC in position "Aft" actuator 6CC will retracto

=

Longitudinal trirnming, trim

The voltage is directed froro the four-way switch 2CC to the coil of the retract relay BCC. The trim actuator 6CC is supplied with electrical power via closed limit switch (until retract motion is completed) and via switching contact of the retract relay BCC. The circuit to ground is again provided via switching contact of the energized retract relay. e.

Priority four-way switch 2CC "Pilot" (dual control) In case the four-way switch 2CC "Copilot" is actuated in one of the positions described under 2 a. to d., the pilot may interrupt the trirnming at any time and even trim in the opposite direction by actuating his four-way switch 2CC (refer to figure 92-73).

92 - 94 1.

Troubleshooting - cyclic stick trim

General Troubleshooting is performed with an external power source connected to the helicopter and with circuit breaker 1CC depressed. Open nose shell for testing the operation of the trim actuators.

BO 105 CHAPTER 92 Page 1B9

- - - - - - - ' - - - - - - - - . MBB HELICOPTERS------------MAINTENANCE MANUAL MBB - BO 105 For troubleshooting the systems use the appropriate w~r~ng diagrams incorporated in the Wiring Diagram Manual (WDM). Troubleshooting and corrective action of'the system related mechanical components are described in chapter 41. For functional testing refer to 92-95. CAUTION

BEWARE OF DANGER OF SHORT-CIRCUITING WHEN MEASURING LlVE COMPONENTS!

Check electrical wiring, connections and circuit breakers of the system for secure installation and damage. NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Defective extend relay llCC.

Check relay at connections 10VEA and 10VEB for continuity using the wiring diagram, or check by temporarily replacing with a new relay. Replace defective relay.

Defective trim actuator 7CC.

Check trim actuator for correct power supply. Replace d~fective trim actuator.

Trim actuator 7CC (lateral) does not extend.

2

Trim actuator 7CC (lateral) does not retract.

Defective retract relay 10CC.

Check relay at connections 10VEA, 10VEB for continuity using the wiring diagram or check by temporarily replacing with a new relay. Replace defective relay.

3

Trim actuator 6CC (longitudinal) does not extend.

Defective extend relay 9CC.

Check relay at connections 10VEA, 10VEB for continuity using the wiring diagram or check by temporarily replacing with a new relay. Replace defective relay.

Defective trim actuator 6CC.

Check power supply to trim actuator. Replace defective trim actuator.

~able

BO 105 CHAPTER 92 Page 190

92-25

Troubleshooting - Cyclic stick trim (1 of 2)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 TROUBLESHOOTING (continued) NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

4

Trim actuator 6CC (longitudinal) does not retracto

Defective retract relay BCC.·

Check relay at connections 10VEA, 10VEB for continuity using the wiring diagram or check by temporarily replacing with a new relay. Replace defective relay.

5

Priority four-way switch2CC "Pilot" inoperative.

Defective relay relative to fourway switch position.

Check by temporarily replacing with a new relay. Replace defective relay.

Table 92-25

92 - 95 l.

Troubleshooting - Cyclic stick trim (2 of 2)

Functional test - cyclic stick trim

General This functional test must be carried out after having changed one or more electrical components, cables, electrical connection of the cyclic stick trim system.

2.

Test equipment - hydraulic ground service cart

3.

Preparations - both engines must be shut down - connect and switch on external power supply unit - push circuit breaker Ice "TRIM", for Series D "TRIM ACTUATORS" connect the hydraulic ground service cart - set BATTERY MASTER switch to ON or EPU to ON. NOTE

When actuating the four-way switch to the following switch positions, the cyclic stick must become forcefree in whatever stationary position. In case a force-free condition of the cyclic stick can not be obtained, travel direction of trim actuators must be checked.

BO 105 CHAPTER 92 Page 191

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

4.

Performance of test a.

b.

Lateral trirnming (trim actuator 7CC) 1)

Move cyclic stick within the actuator travel range to the nleft n and hold in this position.

2)

Push four-way switch 2CC to the left and hold until cyclic stick becomes force-free (trim actuator 7CC extends).

3)

Move cyclic stick within the actuator travel range past neutral position to the nright n .

4)

Push four-way switch 2CC to the right and hold until cyclic stick becomes force-free (trim actuator retracts).

5)

Trim lateral control to neutral (neutral position of cyclic stick) .

Longitudinal trirnming (trim actuator 6CC) 1)

Move cyclic stick within the actuator travel range "forward" and hold in this position.

2)

Push four-way switch 2CC forward and hold until cyclic stick becomes force-free (trim actuator 6CC extends) .

3)

Move cyclic stick within the actuator travel range past neutral position in naft n direction.

4)

Push four-way switch 2CC aft and hold until cyclic stick becomes force-free (trim actuator 6CC retracts) .

5)

Trim longitudinal control to neutral (neutral position of cyclic stick) .

c.

Testing of limit switches Consecutively switch four-way switch 2CC to all four positions and hold in each position for several seconds. The trim actuators will retract or extend according to the selected switch position and are automatically switched off by limit switches in each travel direction.

d.

Testing the priority status of the four-way switch 2CC npilot" (only with dual control system). Switch four-way switch 2CC nCopilot n to all four positions in turn, trim actuator 6CC and 7CC must retract or extend according to the switch position. Simultaneously switch four-way switch 2CC "Pilot" to the opposite switch positions. Trim actuator 6CC or 7CC must change its direction of travel. Trim actuators are automatically switched off by limit switches installed in the actuators. NOTE

105 CHAPTER 92 Page 192

BO

Maintenance/inspection, removal and installation procedures are described in chapter 43.

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 96

Cy c 1 i c

s tic k

g r i p

(see figure 92-74)

The grip and cyclic stick are connected via connector 3/4VE and screwed together with an adapter assy. The cyclic stick grip includes three push button switches, a four-way beeper switch and a two-stage push-to-talk button (PTT button). Push button switch 2EW is used for RPM warning suppression and push button switch 7CA for disengaging SAS, if installed. The third push button switch is spare. On stage 1 of the PTT button 14RF, intercommunication is switched on, whereas stage 2 is for transmission (actuating button fully depressed) . The four-way beeper switch 2CC is used for longitudinal and lateral trirnming.

4

5 6

1 Four-way beeper switch 2CC 2 Push button switch (RPM warning suppression) 2EW & spare & 3 Push button switch (RPM warning suppression) 2EW & spare & 4 Push button switch SAS DISENGAGE 7CA 5 Knurled nut (adapter assy) 6 Cyclic stick 7. PTT button 14RF

900149

EFFECTIVITY S/N 7 - 160 S/N 161 and subsequent

Figure 92-74

Cyclic Stick Grip BO 105 CHAPTER 92 Page 193

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 97 l.

Removal a.

2.

Removal and installation - cyclic stick grip (see figure 92-75)

Loosen knurled nut (3) and pull grip (1) from cyclic stick (4). Protect connector (2) with a cap.

Installation a.

Remove cap from connector (2), slip on grip (1) and secure with knurled nut (3) to cyclic stick.

900548

1 2 3 4

Figure 92-75

BO 105 CHAPTER 92 Page 194

Grip Connector Knurled nut Cyclic stick

Removal and installation - cyclic stick grip

- - - - - - - - - - - - - . MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 98

Removal and installation - four-way beeper switch 2CC (see figure 92-76)

NOTE

l.

Screws (9, 10, 19, 20, figure 92-76), threaded pin (7) and pin (18) are potted with sealirrg compound (CM 635), which is to be removed prior to disassembly. Parts have to be potted upon reinstallation. Removal a.

Remove screw (9) together with washer (8).

b.

Lobsen screw by approx. 2 to 3 turns.

NOTE

This work step has to be carried out carefully, as the mounting bracket (21) may drop inside the grip.

c.

Reroove the snap ring (15) froro connector 3/4VEb (14).

d.

Pull out connector 3/4VEb (14) and unsolder respective wiring according to the wiring diagram. Cut open the silicone sleeving located inside the elbow (13), if required.

e.

Solder an extension wire of 150 mm length to each of the unsolder wire leads.

f.

Pull out four-way switch (2) and unsolder wire leads.

NOTE

2.

Pull out four-way switch only to the extent that wire leads inside the elbow can still be withdrawn by pulling the extension wires.

Installation a.

Solder wire leads to terminals of the four-way switch (2) as applicable wiring diagram identified.

b.

Install four-way switch (2) and secure with screws (9, 10) and washer (8).

c.

Withdraw wire leads froro elbow (13) by pulling the extension wires, and solder wire leads to terminals of the connector 3/4VEb as the applicable wiring diagram identified.

d.

Slide insulating sleeving over solder joints and lace insulating sleeving covering the wires.

e.

Install connector 3/4VEb (14) and secure with snap ring (15).

BO 105 CHAPTER 92 Page 195

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

3

4

56J

11------21----'"

-+-----13

14-----:1.....

900147

1

2 3 4 5 6 7

Push button switch Four-way switch Push buttonswitch BaH

Spring Hexagon nut Threaded 8 Washer 9 Screw 10 Screw 11 Threaded cutting screw 12 Push button switch Figure 92-76 BO 105 CHAPTER 92 Page 196

13 Elbow 14 Connector 15 Snap ring 16 Trigger 17 PTT button 18 Pin 19 Screw 20 Screw 21 Mounting bracket 22 Pin 23 Spring 24 Cap nut Cyclic stick grip

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 99

l.

Removal and installation - PTT button 14RT (see figure 92-76, 17)

Removal VARIANT 1 a.

Pull out four-way switch (2).

b.

Drive out pin (18) at the right side of the grip and remove trigger (16).

c.

Loosen hexagon nut (6) and remove together with threaded pin (7), spring (5) and ball (4).

d.

Unscrew cap nut (24) and remove spring (23) together with pin (22).

e.

Unsolder wire leads from connector 3/4VEb as identified and solder an extension wire of 150 mm to each unsoldered wire lead.

f.

Remove screws (19, 20), pull out PTT button (17) from grip and unsolder wiring.

NOTE

Pull out PTT button only to the extent that wire leads inside the elbows can still be pulled out with extension wires.

VARIANT 2 a.

Remove snap ring (15) and pull connector 3/4VEb (14) from elbow (13).

b.

Unsolder respective wiring according to wiring diagram. Cut open silicone sleeving located inside the elbow, if required.

c.

Solder an extension wire of 150 mm length to each unsoldered wire lead.

d.

Drive out pin (figure 92-77, 1) at the right side of the grip.

e.

Pull out PTT button assy (2) from grip and unsolder wiring.

BO 105 CHAPTER 92 Page 197

------......;,...------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 Pin 2 PTT button Figure 92-77 2.

Rernoval PTT button 14RT

Installation VARIANT 1 a.

Solder wiring to PTT button (17) as the w~r~ng diagrarn identified and s1ide insulating sleeving over the solder joints.

b.

Install PTT button (17) in grip by sumultaneously pulling the extension wires downward, until button is properly seated on the grip.

c.

Secure PTT button with screws (19, 20).

d.

Install four-way switch (2) (see figure 92-76).

e.

Solder all wire leads (of four-way switch and PTT button) to terminals of connector 3/4VEb (14) as the wiring diagrarn identified.

BO 105 CHAPTER 92 Page 198

-----....,....--------MBB HELICOPTERS - - - - - - - - - - - - -

MAINTENANCE MANUAL MBB - BO 105 f.

Slide insulating sleeving over solder joints and lace insulating sleeving covering the wires.

g.

Install connector 3/4VEb and secure with snap ring (15).

h.

Secure trigger (16) with pin (18).

NOTE

Install pin from the left side of the grip, so that the knurled end is on the left.

i.

Insert pin (22) and spring (23) of detent mechanism into the grip and protect threaded sleeve with cap nut (24).

j.

Install ball (4), spring (5) and threaded screw (7) together with hexagon nut (6) in the grip.

k.

Adjust threaded pin (7) in grip until it is perceptible that an increased spring load must be overcome when operating the PTT button from stage 1 to stage 2.

l.

When adjustment is made, secure threaded pin (7) with hexagon nut (6) •

VARIANT 2 a.

Solder wiring to PTT button (figure 92-77, 2) as the w~r~ng diagram identified and slide insulating sleeving over solder joints.

b.

Install PTT button i~ grip by simultaneously pulling the extension wires downward, until the button is properly seated on the grip.

c.

Secure PTT button with pin (18).

NOTE

Install pin from the left side of the grip, so that the knurled end is on the left.

d.

Solder wires to ter.minals of connector 3/4VEb as the w~r~ng diagram identified. Slide insulating sleeve over solder joints and lace insulating sleeving covering the wires.

e.

Install connector 3/4VEb in elbow and se cure with snap ringo

BO 105 CHAPTER 92 Page 199

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 100

Removal and installation - push button switch (see figure 92-76, 1, 3, 12)

NOTE

Removal and installation procedures are identical for all three push button switches and therefore described only for one switch.

1.

Removal a.

Remove thread cutting screw (11).

b.

Remove snap ring (15) from connector 3/4VEb (14).

c.

Pull out connector 3/4VEb and unsolder respective wiring according to the wiring diagram.

d.

Solder an extension wire of 150 mm length to each of the unsoldered wire leads.

e.

Pull out push button switch and unsolder the wiring.

NOTE

2.

Pull out push button switch only to an extent that wire leads inside the elbow can still be pulled out with extension wires.

Installation a.

Solder wire leads to push button switch as the wiring diagram identified.

b.

I~stall

NOTE

push button switch and secure with thread cutting screw (11). When installing the push button switch, be sure not to apply pressure on the actuating button. Press switch into grip by applying pressure on the collar around the actuating button.

c.

Withdraw wire leads from elbow by pulling out extension wires and solder wires to terminals of connector 3/4VEb as the wiring diagram identified.

d.

Slide insulating sleeving over solder joints and lace insulating sleeving covering the wires.

e.

Install connector 3/4VEb and secure with snap ring (15).

BO 105 CHAPTER 92 Page 200

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 101

e o n t rol u n i t o n col 1 e c t i v e p i t c h s t i c k (see figure 92-78)

The control unit 6VE is mounted on the forward end of the collective pitch stick. It contains the following switches: - Rocker switch 11MF - Rescue hoist* - Rocker switch 20LA - Landing light* - Four-way switch 8KA - N2 control - Slide switch 24LA - Landing light* - Slide switch 2MD - Load hook* - Trigger switch 13MF - Cable cutter

._------2 .-----3 .---4 5

1 2 3 4 I 6

Switch llMF* Switch 20LA* Four-way switch 8KA Switch 24LA* 5 Switch 2MD* 6 Switch 13MF

* Optional equipment

Figure 92-78

Typical control unit on collective pitch stick BO 105 CHAPTER 92 Page 201/202

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 92 - 102

Removal and installation - components of control unit on collective pitch stick

92 - 103

Removal and installation - four-way switch (SKA) and switches 11MF, 20LA, 24LA and 2MD (see figure 92-7S)

WARNING

DURING ALL MAINTENANCE WORKS ON COLLECTIVE PITCH STICK SWITCH OFF POWER. DANGER OF SHORT CIRCUITS!

NOTE

Removal and installation procedures for rocker and slide switches (3 and lS) are identical.

l.

2.

Removal a.

Switch off electrical power supply.

b.

Remove screws

c.

Withdraw switches (3, lS) together with wiring from opening in metal panel (4).

d.

Unsolder wiring from switch terminals and remove switches.

e.

Lift off the metal panel (4), loosen clamp (10) and withdraw four-way switch together with wiring from opening in the metal panel (4).

f.

Unsolder wires from switch terminals and remove four-way switch SRA.

(16)

and plastic panel

(2) •

Installation a.

Withdraw w~r~ng of four-way switch (1) from opening in metal panel (4) and solder wires to switch terminals according to wiring diagram.

b.

Install four-way switch SKA in metal panel and secure with clamp (10) .

c.

Withdraw wiring of switches (3, 15) from opening in metal panel (4) and solder wires to switch terminals according to wiring diagram.

d.

Position metal panel (4) in its installation position and install switches (3, lS) in openings of metal panel.

e.

Position plastic panel

(2)

on top and secure with screws

(16).

BO lOS CHAPTER 92 Page 203

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

15

3

4

1 2 3 4 5 6 7 8 9

10 11

12 13 14 15 16

Four-way switch Plastic panel Rocker switch Metal panel Trigger switch Safety cap Spring Washer Screw Clamp Washer Nut Washer Rollpin Slide switch Screw

Figure 92-79 Removal and Installation of the Switches in Control Unit on Collective Pitch Stick 92 - 104 l.

Removal and installation - switch 13MF

Removal NOTE

2.

Rollpin (14) is bonded to washer (8) at right side. Remove two-component adhesive (CM 601) prior to removal of rollpin

a.

Remove rollpin (14) together with washers (8, 13), spring (7) and safety cap (6).

b.

Pull out trigger switch (5) and unsolder wires at switch ter.minals.

Installation a.

Solder wires to switch (5) ter.minals according to wiring diagram.

NOTE b.

Bond rollpin (14) to washer at right side (CM 601) . Install trigger switch (5) and secure with safety cap (6), spring (7), washers (8, 13) and rollpin (14).

BO 105 CHAPTER 92 Page 204

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 105

LIGHTING SYSTEMS

The lighting system consists of: -

position lights anti-collision lights internal lighting instrument lighting

92 - 106

Locations - lighting systems Location

Part

Figure Fig. 92-80

Circuit breakers Position light (red) 106LA

Port side (LH) or on end plates of horizontal stabilizer, left

Fig. 92-80

Position light (green)

Starboard side (RH) or on end plates of horizontal stabilizer, right

Fig. 92-80

Tail light (white) 7LA

Center of tail boom

Fig. 92-80

Toggle switch 29LA

Overhead panel l2VE

Fig. 92-80

Anti-collision light (red) 4LA

Top of tail rotor transmission

Fig. 92-85

Anti-collision light (red) 5LA

Nose access door or between frame 4v and 4h

Fig. 92-85

Flasher unit 21LA

lower right side of the instrument panel 2VE

Fig. 92-85

Toggle switch 28LA

Overhead panel l2VE

Fig. 92-85

Cockpit light 6LC

LH side of the cabin ceiling

Fig. 92-89

Hand lamp 4LC

Overhead panel 12VE

Fig. 92-89

Table 92-26

Locations - Lighting system (1 of 2)

BO 105 CHAPTER 92 Page 205

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

Part

Location

Figure

Cargo compartment light 7LC

forward RH side of cargo compartment ceiling

Fig. 92-89

Cargo compartment light 8LC

afterward LH side of cargo compartment ceiling

Fig. 92-89

Toggle switch 40LC

Overhead panel 12VE

Fig. 92-89

Light control unit 9LC

Instrument panel 2VE

Fig. 92-94

Table 92-26 92 - 107

Locations - Lighting systents (2 of 2)

Protection of lighting systems

For protection of lighting systems the following circuit breakers are installed: Circuit breaker

Protected circuit

2LA

4A

Position lighting

1LA

lOA

3LC 1LC

& &

Instrument lighting

Fuse

Instrument lighting

EFFECTIVITY

4A

RPOSITION LIGHT R "ANTICOLL LIGHT" Instrument panel 2VE right side

Internal lighting

S/N 7 - 160 S/N 161 and subsequent

Table 92-27

BO 105 CHAPTER 92 Page 206

Nomenclature

Anti-collision lighting

6,3A

2LC

Location

Protection of lighting systems

"INSTR. LIGHT"

RINTERNAL LIGHT"

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 P o s i t ion 1 i 9 h t s y s t e m (see figures 92-80 and 92-81)

92 - 108

The position lights help to identify position and flight direction of the helicopter. They consists of a red light 106LA on the port side (LH) and a green light 20GLA on the starboard side (RH). The installation location is as follows: EFFECTIVITY

o S/N 7 - 120 on the left and right side of the aft fuselage section. o S/N 121 and subsequent, series D and if rescue hoist is installed (S/N 7 - 120) on the end plates of the horizontal stabilizer.

In addition, a white tail light 7LA is mounted on the tail boom. Power supply of the position lights is from the main bus PP21 via EFFECTIVITY

o S/N 7 - 120 circuit breaker 2LA npOSITION LIGHT n on instrument panel 2VE. o S/N 121 - 160 and series D circuit breaker 2LA on instrument panel 2VE and toggle switch 20LA npOSITION LIGHT n located on overhead panel 12VE. o S/N 161 and subsequent fuse 2LA located on the lower right side of the instrument panel and toggle switch 29LA in the overhead panel 12VE.

92 - 109

Troubleshooting - position lights

NO. TROUBLE SYMPTOM 1

One of the three position lights fails to illuminate

Table 92-28

PROBABLE CAUSE

CORRECTIVE ACTION

Defective lamp

Replace defective lampo

Defective electrical wiring between terminal strip 146VV and position light.

Check wiring for continuity using the wiring diagram (refer to WDM), and repair or replace defective wiring.

Troubleshooting - position light (1 of 2)

BO 105 CHAPTER 92 Page 207

HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

Troubleshooting (continued) NO. TROUBLE SYMPTOM 2

All three position lights fail to illuminate

Table 92 - 28

92 - 110

PROBABLE CAUSE

CORRECTlVE ACTION

Defective fuse or circuit breaker 2LA

Check fu se or circuit breaker and replace, as required.

Defective toggle switch 29LA

Check toggle switch and replace as required.

Defective electrical wiring or connection between instrument panel and terminal strip l46VV.

Check electrical wiring and connection for continuity using the wiring diagram (refer to WDM) . Repair or replace defective wiring, or connection components.

Troubleshooting - Position light (2 of 2)

Inspection and maintenance - position lights

l.

Check lenses of position lights and tail light for damage, contamination ando condensation water. Replace lenses, if required, or clean and make leakproof.

2.

Check lamp base and socket for corrosion. Remove corrosion, if possible, or replace lamp or lamp socket.

3.

Check vibration dampers (if installed) for damage. Replaceas required.

BO 105 CHAPTER 92 Page 208

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3 u. 7 4

5

j

I

i

'-'-'-'-'-1

..

I i

¡

I 6

1 Instrument panel (2VE) Circuit breaker (2LA) Fuse (2LA) ~

~

2 Overhead panel 3

4 5

6 7

Toggle switch Position light Position light Position light Position light Position light

(29LA) (206LA) (206LA) (7LA) (106LA) (106LA) Figure 92-80

EFFECTIVITY S/N 7-120 S/N 7-160 and series D S/N 121 and subsequent, series D or when rescue hoist installed S/N 161 and subsequent

Position Lights BO 105 CHAPTER 92 Page 209

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

MAIN BUS PP21

28V-

t

FUGE 2 LA (CIRCUIT BREAKER)

~

O

OVERHEAD PANEL

s~ITCHI 2. LA ~

, " -:;:QG"GLE

--o-~

!-:

. . . . .: . . .

L"

I

IL o-

_

POSITION L1GHT 106 LA RED 900167

O

.~.~

POSITION L1GHT 206 LA GREEN

11 TAIL LIGHT 7 LA WHITE

EFFECTIVITY

&

S/N 7-160 and series D

&

S/N 121 and subsequent, series D

&

S/N 161 and subsequent Figure 92-81

BO 105 CHAPTER 92 Page 210

Position Lights

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 111

NOTE -----l.

Removal and installation - position lights

Removal and installation procedures for the left and right position light are identical.

Removal (see figure 92-82) a.

Switch off electrical power supply.

b.

Loosen screw (8) and remove together with lens retainer (7), lens (6) and lens seal (9).

NOTE

2.

Do not touch lamp with fingers.

c.

Remove lamp (10).

d.

Remove screws (5) and pull lamp holder (4) from housing (1).

e.

Pull protective cap backward, disconnect electrical wiring (11) and remove lamp holder (4) together with gasket (3) and protective cap (2).

Installation a.

Slide protective cap (2) and gasket (3) over electrical w~r~ng (11) and reconnect wiring to lamp holder (4) according to wiring diagram.

b.

Slide protective cap (2) over wiring connection at the lamp holder (4).

c.

Install lamp holder (4) together with gasket (3) in housing (1) and secure with screws (5).

NOTE

Do not touch lamp with fingers.

d.

Install lamp (10).

e.

Place lens (6) and 1ens seal (9) over lamp and secure in position with lens retainer (7) and screw (8).

f.

Perform a functional test (refer to paragraph 92-113).

BO 105 CHAPTER 92 Page 211

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

900164

8

1 Housing 2 Protective cap 3 Gasket 4 La.llp holder 5 Screw 6 Lens Figure 92-82

92 - 112

Position Light

Removal and installation - tail light

EFFECTIVITY l.

7 Lens retainer 8 Screw 9 Lens seal 10 Lamp 11 Electrical wiring

Without vibration damper

Removal (see figure 92-83) a.

Remove screws (5) with washers (4) and pull tail light assy from vertical tail fairing (1).

b.

Remove protective cap (2) and disconnect electrical wiring (10).

NOTE C.

Do not touch lamp with fingers. Push retainer clip (9) down and remove lens (8) with lens seal (7) and lamp (6).

BO 105 CHAPTER 92 Page 212

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

3

1 2 3

4 5 6

7 8 9

10

Vertical fin fairing Protective cap Lamp holder Washer Screw Lamp Lens seal Lens Retainer clip Electrical wiring Figure 92-83

2.

8

10

Tail light (without vibration damper)

Installation a.

Pull protective cap (2) over electrical w~r~ng (10) and connect wires to lamp holder (3) according to the applicable wiring diagram.

b.

Slide protective cap over wiring connections at lamp holder.

c.

Install lamp holder in vertical tail fairing (1) and secure with screws (5) and washers (4).

NOTE

Do not touch lamp with fingers.

d.

Install lamp (6).

e.

Place lens (8) with lens seal (7) over lamp and secure with retainer clip (9).

f.

Perfor.m a functional test (see paragraph 92-113).

EFFECTIVITY

With vibration damper (S/N 451 and subsequent and when SB 90-27 incorporated).

BO 105 CHAPTER 92 Page 213

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 1.

Removal (figure 92-84) 1 2

5 6

1

7

Vertical tail fairing

2 Mounting flange 3 Hex screw 4 Protective cap

S Electrical wiring 6 Vibration damper Tail light

7

900170

Figure 92-84

2.

Tail Light (with vibrationdamper)

a.

Switch off electrical power supply.

b.

Remove lockwire from hex screws (3) and loosen hex screws.

c.

Pull tail light (7) together with vibration damper (6) from mounting flange (2).

d.

Pull protective cap (4) backward and disconnect electrical wiring (S).

e.

Remove tail light (7) from vibration damper (6).

f.

For removal of lamp refer to procedures described for tail light without vibration damper.

Installation a.

Pull vibration damper (6) over tail light (7) collar.

b.

Place protective cap (4) over electrical wiring (5) and connect wiring to tail light in accordance with the wiring diagram. Slide protective cap over wiring connections on the tail light (7).

c.

Install tail light (7) with vibration damper in mounting flange (2) and align threaded bushings in vibration damper with assembly holes in mounting flange.

d.

Secure tail light lockwire.

BO lOS CHAPTER 92 Page 214

~ith

hex screws (3) and safety hex screw with

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 e. For installation of lamp refer to procedure described for tail light without vibration damper. f. Perform a functional test (refer to paragraph 92-113) 92 - 113

Functional test - position lights system

1.

EFFECTIVITY

o S/N 7 - 120 Switch on electrical power supply and push circuit breaker 2LA npOSITION LIGHT n . o S/N 121 - 160 and series D Switch on electrical power supply; push circuit breaker 2LA and switch toggle switch 29LA npOSITION LIGHT n to ON position. o S/N 161 and subsequent Insert fuse 2LA. Switch on electrical power supply and set toggle switch 29LA in ON position.

2.

All three position lights 106LA (red), 206LA (green) and 7LA (white) shall illuminate.

3.

Pull circuit breaker and set toggle switch 29LA to OFF position and switch off electrical power supply.

92 - 114

A n t i - e o 1 1 i s ion 1 i g h t (see figures 92-85 and 92-86)

s y s

t

e m

The system consists of two red anti-collision lights, which are alternately controlled by the flasher unit 21LA. The pulse frequency of the flasher unit is between 42 and 50 pulses per minute. The anti-collision light 5LA is installed: EFFECTIVITY

o S/N 7 - 100, on the removable nose access door o S/N 101 and subsequent, between frame 4v and 5h

Anti-collision light 4LA is installed on top of the tail rotor transmission and the flasher unit 21LA is installed on the lower right side of instrument panel 2VE. Both anti-collision lights have iodine-quartz lamps. Power supply to the anti-collision lights is from the main busPP21 via: EFFECTIVITY

o S/N 7 - 120, circuit breaker 1LA nANTICOLL LIGHT n on instr. panel 2VE o S/N 121 - 160 and series D circuit breaker 1LA on instrument panel 2VE and toggle toggle switch 28LA nANTICOLL LIGHT n on overhead panel 12VE BO 105 CHAPTER 92 Page 215

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 o S/N 161 and subsequent fuse 1LA on the lower right side of instrument panel 2VE and toggle switch 28LA on overhead panel 12VE

4

,

=

1 Instrument panel (2VE) Circuit breaker (lLA)~ Fuse (lLA) & Flasher unit (21LA) 2 Anti-collision light (SLA)

Toggle switch (28LA)~

.

~ 2

S/N 7-160 and series D S/N 121 and subsequent, series D S/N 161 and subsequent

4 Anti-collision light (4LA) Figure 92-85 BO 105 CHAPTER 92 Page 216

:;

EFFECTIVITY

3

3 Overhead panel

--

~-.,

Anti-Collision Light System

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 MAIN BUS PP21

28V-

& \

FUSE 1LA (CIRCUIT BREAKER)

OVERHEAD PANEL :- -

-:;O~G~ ;W;C;!

I

28 LA

:----.:..1-<1""I I

I

I

I

I

I L-_

~

- - __

Lb

--J

I I

""'-- - - - - - 11

FLASHER UNIT 21 LA

ANTI-COLLlSION L1GHT (FUSELAGE) 5 LA

ANTI-COLLlSION L1GHT (TAIL) 4 LA

900171

EFFECTIVITY

& & &

S/N 7 - 160 and series D S/N 121 and subsequent and series D S/N 161 and subsequent Figure 92-86

Anti-collision Light System

BO 105 CHAPTER 92 Page 217/218

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

92 - 115

Troubleshooting - anti-collision light system

NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTIVE ACTION

1

Defective iodine quartz lampo

Replace.

Defective electrical wiring between flasher unit and anti-col1ision light.

Check wiring for continuity using,the wiring diagram (refer to WDM), and repair or replace defective wiring.

Defective flasher unit 21LA.

Check flasher unit for signal outputs at connection points 3 and 5 of the terminal strip 39VV. Replace flasher unit, if required.

Defective fuse or circuit breaker 1LA.

Check fuse or circuit breaker and replace, as necessary.

Defective toggle switch 28LA.

Check toggle switch and replace, as required.

Defective flasher 2lLA.

Check flasher unit for signal input (connection point 1), signa1 output (connection point 3 and 5) and ground connection (connection point 2 and 4) at terminal strip 39VV. Replace flasher unit, if required.

Defective electrical wiring or connection between main bus and flasher unit.

Check wiring and connection for continuity using the wiring diagram (refer to WDM). Repair or replace defective wiring or connection components.

Defective flasher unit 2lLA.

Check flasher unit for signal outputs. Replace flasher, if required.

2

3

Anti-collision light 4LA or 5LA fails to flash.

Both anti-collision lights fail to flash.

Incorrect flashing rate.

Table 92-29

Troubleshooting - anti-collision light system

BO 105 CHAPTER 92 Page 219

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

92 - 116

Inspection for condition - anti-collision lights 4LA, 5LA

1.

Check glass domes (2, figure 92-87) for damage, contamination and condensation water. Replace glass domes, if necessary, clean and make leakproof, if necessary.

2.

Check lamp socket (4) and contacts of iodine quartz lamp (3) for corrosion. Remove corrosion, if present, or replace lamp and socket respectively.

3.

Check vibration dampers (4) for damage or porosity, and replace, if necessary.

4.

Check pr6tective cap (6) or shrink-on sleeve (6) for damage or porosity, and replace if necessary.

5.

Check clamp (1) for corrosion damage and deformation. Inspect spot welds for cracks.

BO 105 CHAPTER 92

Page 220

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 92 - 117

Removal

92 - 118

Removal and installation - anti-collision light 4LA (see figure 92-87)

1.

and

installation -

anti-collision light system

Removal a.

Switch off electrical power supply.

b.

Remove clamp (1) and detach the glass dome (2).

NOTE

Donot touch iodine-quartz lamp (3) with fingers.

c.

Remove iodine-quartz lamp.

d.

Withdraw lamp socket with vibration damper (4) from mounting bracket (7) to the extent that protective cap (6) may be pulled from electrical wiring connections or that the shrink-on sleeve can be removed.

e.

Disconnect electrical wiring (5) and remove lamp socket with vibration damper.

f.

Remove screws (11) with washers (10) and pull mounting bracket (7) with shim (8) from tail rotor transmission (9).

/e=m~

~

•.

-1

~/-~ 1-

1

"--2 )

1

"

/J

\~...;::S;';

.~

i

3

~.

~.,-,

~ ~

11~U rt __ i1

10

5

6

~,\~

/"/.r

'I"""",\,-

~ ;

7

.'!

Ir-::~~

~8 f',

,.r.t\

le.~e..i 1~!--9 • , 300298.1

Clamp 2 Glass dome 3 Iodine-quartz lamp 4 Lamp socket with vibration damper 5 Electrical wiring 6 Protective cap or shrink-on sleeve 7 Mounting bracket 8 Shim 9 Tail rotor transm. 10 Washer 11 Screw 1

Figure 92-87 Anti-Collision Light 4LA (on the tail rotor transmission)

BO 105 CHAPTER 92 Page 221

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Installation a.

Push shim (8) and mounting bracket (7) over electrical wiring (5) and position on tail rotor transmission (9). Secure with screws (11) and washers (10).

b.

Pull protective cap (6) or shrink-on sleeve over electrical w~r~ng (5) and connect wires to terminals of lamp socket (4) according to the wiring diagram and slide protective cap over wiring connections or shrink on the sleeve.

NOTE

Do not touch iodine-quartz lamp (3) with fingers.

c.

Install iodine-quartz lampo

d.

Position lamp socket with vibration damper (4) and glass dome (2) on mounting bracket (7) and secure with clamp (1).

e.

Perform a functional test (refer to paragraph 92-121) .

92 - 119 l.

Removal and installation - anti-collision light SLA (see figure 92-88)

Removal a.

Refer to removal procedures of anti-collision light 4LA, steps a. to e.

b.

Remove nose access door by loosening quick-release fasteners

EFFECTIVITY

o S/N 7-100 and disconnect plug - receptacle connection 37VV (2).

o S/N 101 and subsequent Access to anti-collision light SLA is via access hole in frame 4V. NOTE C.

The following components are sealed with sealing compound (CM 635), and therefore may stick together. Remove screws (1) with washers (5) and nuts (6) and

EFFECTIVITY

o S/N 7-100 detach angle bracket with receptacle (2).

o S/N 101 and subsequent Pull shrink sleeve (10) backward and remove insulating sleeving (9). BO 105 CHAPTER 92 Page 222

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Remove mounting bracket (8) and shims (3) and remove residual sealing component.

d.

10--._

9

L.

2 3

3 j

er- s

B

19--s

1 Screw 2 Angle bracket with receptacle 37VV & 3 Shim 4 Nose access door, fuselage 5 Washer 6 Nut 7 Electrical w~r~ng 8 Mounting bracket 9 Insulating sleeving ~ & 10 Shrink sleeve

EFFECTIVITY

7-----'7!':

900178

Figure 92-88 2.

&

S/N 7-100

&

S/N 101 and subsequent

Anti-Collision Light SLA

Installation a.

Install mounting bracket (8), shims (3) and

EFFECTIVITY

o S/N 7-100 angle bracket with receptacle (2)

o S/N 101 and subsequent shrink sleeve (10) in nose access door (4) respectively and secure with screws (1), washers (3) and nuts (6). Apply sealing compound (item 635) to shims (3) and mounting bracket (8) prior to installation. b.

Install nose access door.

c.

Refer to installation procedures of anti-collision light 4LA, step b. to e. BO 105 CHAPTER 92 Page 223

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 120 1.

Removal and installation - flasher unit 21LA

Removal a.

Switch off electrical power supply and remove instrument panel fairing.

b.

EFFECTIVITY

o S/N 7-160 Remove splices from electrical wiring and discard.

o S/N 161 and subsequent Remove protective cover froro terminal strip 39VV and disconnect electrical wiring. c. 2.

Loosen screws at the rear of the flasher unit and remove together with flasher unit.

Installation a.

Install flasher unit in instrument panel and secure with screws.

b.

Cut wires to required length,

EFFECTIVITY

o S/N 7-160 and re-connect using new splices in accordance with the wiring diagram. o S/N 161 and subsequent, series D and provide with terminal lugs. Connect wire terminals strip 39VV in accordance with the wiring diagram (re-install the protective cover!).

c.

Perform a functional test (refer to paragraph 92-121) .

92 - 121 1.

Functional test - anti-Collision Lighting

Switch on electrical power supply and

EFFECTIVITY

o S/N 7-120 push circuit breaker 1LA nANTICOLL LIGHT n . o S/N 121-160

push circuit breaker 1LA and set toggle switch 28LA nANTICOLL. LIGHT n to ON position. o S/N 161 and subsequent insert fuse 1LA and set toggle switch 28LA to ON position. BO 105 CHAPTER 92 Page 224

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Anti-collision lights 4LA and 5LA must flash alternate at arate of 42-50 flashes per minute.

3.

Set toggle switch to OFF position, pull circuit breaker and switch off electrical power supply.

92 - 122

1 n ter n a 1

1 i g h t i n g (see figure 92-89 and 92-91)

s y s t e m

The internal lighting system includes cockpit and cargo compartment lighting. The cockpit lighting consists of the cockpit light 6LC mounted on the LH side of the cabin ceiling above the copilot seat and the hand lamp secured to the LH side of the overhead panel. The hand lamp is designed for portable cockpit utility use and is connected to the helicopter power supply via an extension cord. A rheostat control for ON/OFF and DIM/BRIGHT is incorporated in the hand lampo The cargo compartment lighting consists of two lights 7LC and 8LC installed in the cargo compartment ceiling on the forward RH side and aft LH side. Power supply of the internal lighting is from the main bus PP21 via EFFECTIVITY

o S/N 7-120 circuit breaker 2LC "INTERNAL LIGHT" on the instrument panel, o S/N 121-160 and series D circuit breaker 2LC on the instrument panel and toggle switch 40LC "INTERNAL LIGHT" located in the overhead panel, o S/N 161 fuse 2LC located on the lower right side of the instrument panel and toggle switch 40LC in the overhead panel.

Power supply of the hand lamp is only via circuit breaker 2LC or fuse 2LC.

BO 105 CHAPTER 92 Page 225

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

900173

2

3

4

5

1 Instrument panel (2VE) Circuit breaker (2LC)~ Fuse (2lLC) & 2 Toggle switch (40LC) ~ 3 Hand lamp (4LC) 4 Cockpit light (6LC) 5 Cargo compartment light (7LC) 6 Cargo compartment light (8LC)

Figure 92-89

BO 105 CHAPTER 92 Page 226

EFFECTIVITY

~ 2

3

S/N 7-160 and series D S/N 121 and subsequent, series D S/N 161 and subsequent

Internal Lighting

- - - - - - ' - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 MAIN BUS PP21

28V-

o

FUSE2LC~ &

(CIRCUIT BREAKER) HANDLAMP 4 LC

r - - -- - - - - I

I

L

1/

~

"1

OVERHEAD PANEL

Ir--:;:OGGLES-;ITCH~

I

~~I-+-....-~ I I? ~

~-T----~

I

L_ _ _ _

L~2:..C

r---,

l' I I

I

r--- -"l

I II

CARGO COMPARTMENT

I

COCKPIT

I

II

40 LC

' , 7 LC

I

I I o t - ; I - - - - -..........;I~I

l' I L __ 8..!:,C.J

__ ..J

900m

EFFECTIVITY

Lb & &

S/N 7-160 and series D S/N 121 and subsequent, series D S/N 161 and subsequent Figure 92-90

Internal Lighting

"""""",,,--2

4

---/?h-.(¡mTII

Hand lamp Rheostat control/ ON/OFF - DIM/BRIGHT 3 Extension cord 4 Mounting bracket 1 2

900176

Figure 92-91

Hand Lamp BO 105 CHAPTER 92 Page 227

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 123

Troubleshooting - internal lighting

NO. TROUBLE SYMPTOM 1

2

3

4

All lights including the hand lamp are inoperative.

PROBABLE CAUSE

CORRECTlVE ACTION

Defective fuse or circuit breaker 2LC.

Check fuse or circuit breaker, and repIace, as necessary.

Defective w~r~ng or electrical connection between main bus and terminal strip 31VV.

Check w~r~ng and connection for continuity using the wiring diagram (refer to WDM) . Repair or replace defective wiring or connection components.

Only the hand lamp Defective bulbo fails to illuminate. Defective rheostat control ON/OFF BRIGHT/DIM.

Cockpit and cargo compartment lights fail to illuminate, whereas hand lamp is operative.

Replace.

Defective extension cord between hand lamp and terminal strip 31VV.

Check cord for electrical continuity using the wiring diagram (refer to WDM). Replace, as required.

Defective wiring or connection between terminal strip 31VV and cockpit light GLC.

Check wiring and connection for continuity using the wiring diagram (refer to WDM). Repair or replace defective wiring, or connection components.

Defective toggle switch 40LC.

Check toggle switch and replace, as necessary.

Only one light Defective lampo fails to illuminate.

TabIe 92-30

BO 105 CHAPTER 92 Page 228

Replace.

RepIace defective lampo

Troubleshooting - Internal lighting

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Inspection and maintenance - internal lighting

92 - 124 l.

Check glass domes for damage, contamination and condensation water. Replace defective glass domes. Clean and make leakproof, as required.

2.

Check lamp socket and contacts of lamp for corrosion. Rernove corrosion, if present, or replace lamp and socket respectively.

92 - 125

Removal and installation - internal lighting (see figure 92-92)

NOTE l.

2.

Removal and installation procedures of both types are identical. Rernoval a.

Switch off electrical power supply.

b.

Remove screws (6) and detach lens (5), together with seal.

c.

Remove lamp (7).

d.

Remove screws (8) and pull light assy (4) downward from mounting bracket (1).

e.

Pull protective cap (2) backward over electrical wiring (3) and disconnect wiring. Rernove light assy.

Installation The installation of the cockpit and cargo compartment light is essentially the reverse of the removal. Perforrn a functional test subsequent to installation (refer to paragraph 92-126).

BO 105 CHAPTER 92 Page 229

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

;,..c---4

5

Figure 92-92 92 - 126 l.

1 Mounting bracket 2 Protective cap 3 Electrical wiring 4 Light assy 5 Lens 6 Screw 7 Lamp 8 Screw 9 Rivet nut

Cockpit and Cargo Compartment Lights

Functional test - internal lighting

Test

EFFECTIVITY

o S/N 7-120 Switch on electrica1 power supply and push circuit breake+ 2LC wINTERNAL LIGHT w. o S/N 121-160 and series D Switch on electrical power supply; push circuit breaker 2LC and set toggle switch 40LC wINTERNAL LIGHT w to ON position. o S/N 161 and subsequent Insert fuse 2LC switch on electrical power supply and set toggle switch 40LC to ON position.

Cockpit light 6LC and both cargo compartment lights 7LC and 8LC must illuminate. BO 105 CHAPTER 92 Page 230

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

2.

Pull hand lamp out of the base and turn rheostat control fully to the right. Hand lamp must illuminate. Turn rheostat control slowly to the left until it indents in the "OFF" position. The hand lamp must slowly dim and finally extinguish.

3.

Set toggle switch 40LC to OFF position and pull circuit breaker 2LC.

92 - 127

1 n s t r u me n t

1

~

g h t i n g

(see figure 92-93 to 92-9S)

The instrument lighting includes post and eyebrow lights which facilitate reading the instruments during darkness. The magnetic compass utilizes an internal light 2LD and the outside air temp. indicator is illuminated by light 20LC attached to cabin structure. In addition, a reading light SLC is secured to LH side of the horizontal instrument panel section, which is adjustable through a flexible connection. Power supply of the instrument panel is from the main bus PP21 or, if installed, from the emergency bus PP20 via EFFECTIVITY

o S/N 7-160 and series D circuit breaker 3LC "INSTR. LIGHT" on the instrument panel, o S/N 161 and subsequent fuse 1LC and toggle switch 3LC "INSTR. LIGHT" on the instrument panel.

Light intensity regulation of the instrument lights is via potentiometer 10LC "INSTR. LIGHT" and light control unit 9LC in the instrument panel.

BO 105 CHAPTER 92 Page 231/232

- - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1 Instrument panel (2VE) Post and eyebrow lights Reading light (SLC) Circuit breaker (3LC)~ Fuse (lLC) ~ Toggle switch (3LC) ~ 2 Magnetic compass light (2LD) 3 Outside air temp. indo light (20LC)

Figure 92-93

EFFECTIVITY ~

S/N 7-160 and series D

~

S/N 161 and subsequent

Instrument Lighting

BO 105 CHAPTER 92 Page 233

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - ' - - - - - - MAINTENANCE MANUAL MBB - BO lOS The following indicating instruments utilize eyebrow lights: Instrument

Light

Airspeed indicato¡ Altimeter Vertical speed indicator Triple oil temperature indicator SED Triple oil pressure indicator 4ED

13LC 17LC 21LC '33LC 35LC

The following indicating instruments utilize a dual post light or two individual post lights: Instrument

Light

Triple RPM indicator 7EN Shaft moment indicator 2WM N1 RPM indicator ENG 1, lOSEN

upper lower upper lower

N1 RPM indicator ENG 2, 20SEN

left right left right

llLC 19LC 24LC 30LC 26LC 31LC

The following indicating instruments utilize a post light which is located on the LH side above the instrument: Instrument

Light

Dual torque indicator TOT indicator ENG 1, 10SEL TOT indicator ENG 2, 20SEL Clock Dual fuel quantity indicator SEB Dual fuel pressure indicator 2EA

Table 92-31

BO lOS CHAPTER 92 Page 234

Instrument lighting

23LC 2SLC 27LC 2SLC 29LC 32LC

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 128

Troubleshooting - instrument lighting

NO. TROUBLE SYMPTOM

PROBABLE CAUSE

CORRECTlVE ACTION

1

Entire instrument lighting including reading light inoperative.

Defective circuit breaker 3LC, fuse lLC or toggle switch 3LC.

Check circuit breaker, fuse or toggle switch and replace, as necessary.

2

Entire instrument lighting fails to illuminate, but reading light is operative.

Defective potentiorneter 10LC.

Check potentiorneter and replace, as required.

Defective light control unit 9LC.

Replace defective light control unit.

Reading light fails to illuminate.

Defective lampo

Replace defective lampo

Defective electrical wiring.

Check wiring for continuity using the wiring diagrarn (refer to WDM). Repair or replace, as necessary.

Defective lamps or electrical wiring.

Replace lamp or repair wiring, as necessary.

3

4

Only individual lights fail to illuminate.

Table 92-32

92 - 129

Troubleshooting - instrument lighting

Rernoval and installation - eyebrow lights and post lights

Rernoval and installation procedures of lights are described in the Maintenance Instruction of the respective systern to which the indicating instrument belongs.

BO 105 CHAPTER 92 Page 235

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 130

l.

Removal and installation - light control unit 9LC (see figure 92-94)

Removal a.

Switch off electrical power supply and remove instrument panel fairing.

b.

Disconnect electrical connection at light control unit 9LC and protect plug 9LCa with a cap.

c.

Remove screws (2) with washers (3) and detach light control unit.

~i I

I

3

2

1 2 3

900174

Figure 92-94

2.

Light control unit Screw Washer

Light Control Unit 9LC

Installation The installation oí the light control unit is essentially the reverse of the removal. Perform a functional test subsequent to installation (refer to paragraph 92-132).

BO 105 CHAPTER 92 Page 236

- - - - - - - - - - - - - . MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 131

1.

Removal and installation - potentiometer 10LC (see figure 92-95)

Removal a.

Switch off electrical power supply and remove instrument panel fairing.

b.

Remove control knob (1).

c.

Loosen hex nut (2) and pull potentiometer (5) backward from instrument panel (4) •

d.

Unsolder electrical wiring (6) and remove potentiometer.

~i

I

r~~

ul

.Q9

4f I

I

~~I~f

.~'

11 I

1 Control knob 2 Hex nut 3 Name plate 4 Instrument panel 5 Potentiometer 6 Electrical wiring

900179

Figure 92-95 2.

I

I

Potentiometer

Installation The installation is essentially the reverse of the removal. When resoldering the electrical wiring, observe the applicable w~r~ng diagram. Perform a functional test subsequent to the installation.

BO 105 CHAPTER 92 Page 237

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 132

Functional test - instrument lighting

1.

EFFECTIVITY

o S/N 7 - 160 and series D Switch on electrical power supply and push circuit breaker 3LC ftINSTR. LIGHT ft . o S/N 161 and subsequent Insert fuse 1LC, switch on electrical power supply and set toggle switch 3LC ftINSTR. LIGHT ft to ON position.

- With the potentiometer 10LC ftINSTR. LIGHT ft turned to the right, all post and eyebrow lights on the indicating instruments and the reading light 5LC (S/N 161 and subsequent, switch on additionally) must illuminate. 2.

Turn potentioroeter 10LC to the left. - The instrument lighting (not the reading light) must dim.

3.

Pull circuit breakers and set toggle switches to OFF position respectively and switch off the electrical power supply ..

92 - 133

Wa r n i n g 1 i g h t

s e g ro e n t s

(see figure 92-97)

The top section of the instrument panel 2VE and the vertical section contains the warning light segments. These warning lights indicate malfunctions and failure of major systems. Functional test of all warning lights is performed by pressing the test switch ftTEST WARN. LIGHTS ft 6EB on instrument panel 2VE. 1.

Rerooval and installation warning lights lamps (see figure 92-96). a.

Removal 1)

Switch off electrical power supply.

2)

Press latch (22) to the right. - Lamp board assembly (3) will slip out and then can be pulled froro the housing (1).

3)

Pull out lamps (4) froro lamp board assembly.

4)

Disassemble lamp board assembly as shown in figure 92-96.

BO 105 CHAPTER 92 Page 238

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

4

1 2 3 4

Housing Latch Lamp board assembly Lamp

Figure 92-96

b.

1 2 3 4 5 6

Lamp board assembly Push button housing Colour filter Legend plate Legend mask/diffuser Face plate

Warning lights

Installation Installation is essentially the reverse of the removal.

BO 105 CHAPTER 92 Page 239

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

S/N 7-60

EFFECTIVITY

J

OIL LOW ,.. .fº-Ol....,_lU~t.HYD I BLOCK 10ED

EFFECTIVITY

LOW

!

FILT,

T OIL

GEN 2

FILT 2

HYD 2

3EW

23P

1EA

3DB

HYD 1

----

MAG ,...5-~..1

3EV

S/N 61 and subsequent

__A~M_

~

T OIL

..,

... HY BLOCKI

GEN 1

---- ---- ----

7EB

ffi ~ .f~~ l

APM

~ ~~E~ ~¡~I~~ ~

I

GEN 2

FILT 2

!

MAG HYDR 1 I PLUG 1

~

>

. , -;D-;-;r~~C~~ I

I - - - -1

~

OIL COOL o

BAT 60 BAT 70

@ S!

1---.....,.1_ _-;..1__ OA -I----+~~...¡

! BAT 60

. . ---t'--,I

BAT 70

... HY BLOCK!

w

1 .., f -GEN ---

I

~

N

GEN 2

T OIL FILT 1

--FILT 2

~

..,w~

START 2

r <

<

~

N

MAG

_

~D~':" ~ ~~G.2 I MAG

HYDR 2 I PLUG 2 : ENG START 1! Oll1

.., ----1----

-,

START 21

< O

N

~LG2

~~ :'::'H~~~6~ GEN 2 OHI BAT 70

~

EFFECTIVITY

r ID

~

Series D

EFFECTIVITY LOW i .... .f~~~ __R~~

OIL fO.QL_

~

~

> w

..,

GE~'_OH _C~~l. ~ GEN 2 OH

ENG OIL

~

r,aJ~ ~~

~ IGENZ! ~ FlLT2

1/')

N

o

~

I----+--::::::-OIL--; ~

~ S~~ ~

w

"

S! OA

~

~

Ir

O

~

BAT 70

START 2

COOl

eÑG OIL

o

N

w~

1/')

N

~--+-...::;::::...-;

< GEN' OH BAT 60

------

GEN 2 OH

BAT 70

BO 105 DBS

~

~

¡,:",:¡¡:~_

1~~zl 02

~~ ~1Xl ~~

900156

Figure 92-97 BO 105 CHAPTER 92 Page 240

Warning Light Segments

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 92 - 133A

M 1 S C E L L A N E O U S E LEC TRI CAL

92 - 134

P i t o t

t u b e

h e a t i n g

S Y S T E MS

(see figure 92-98)

The pitot tube supplies the airspeed indicator with dynamic pressure, see chapter 91. The pitot tube can be heated to prevent the formation of ice. The pitot heating 3HG is supplied with electrical power from the main bus PP21. EFFECTIVITY

o S/N 7 - 160 via circuit breaker 1HG in the control panel 2VE. o Series D via fuse 5HG and toggle switch 4HG in the control panel 2VE. o S/N 161 and subsequent via fuse 1HG and toggle switch 4HG in the control panel 2VE.

The indicator 2HG in the instrument panel indicates the operation of pitot tube heating 3HG. To drain condensation water and to connect test equipment, a T-piece with cap assembly is installed in the pipe/hose line system.

MAIN BUS

~PP21

28V-~

FUSEl"G TOGGLE SWITCH 4 HG

~ o

l

IND'CATOR 2 HG

~

PITOT

TUB~ -

~ PITOT TUBE ;::J

HEATING 3 HG

1

900117

Figure 92-98

Pitot tube heating 3HG BO 105 CHAPTER 92 Page 241

- - - - - - - - - - - ' - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB ~ BO 105 92 - 135

Troubleshooting - pitot tube heating

NO. TROUBLE SYMPTOM 1

Pitot tube does not heat

PROBABLE CAUSE

CORRECTIVE ACTION

EFFECTIVITY S/N 7-160 Circuit breaker "PITOT TUBE HEATING" defective.

Check circuit breaker and replace, if necessary.

EFFECTIVITY S/N 161 and subsequent Fuse 1HG defective Toggle switch "Pitot tube heating" defective

Check toggle switch and replace, if necessary.

Heating element in pitot tube defective

Check heating element between contact pins on pitot tube for continuity and replace, if necessary.

Cabling between circuit breaker fuse and connection to pitot tube defective

Check cabling for contuinity and replace or repair, if necessary.

EFFECTIVITY Series D Fuse 5HG defective

Table 92 - 136

Check fuse and replace, if necessary.

Check fuse or replace, if necessary.

Toggle switch "PITOT HEATING" defective

Check toggle switch or replace, if necessary.

Heating element defective

Check continuity and replace, if necessary.

92~33

Troubleshooting - Pitot tube heating

Functional test - pitot tube heating

1.

Connect external power unit and remove pitot tube protection. On indicator 2HG "PITOT TUBE HEATING" the white sectors must be visible on the black background.

2.

Switch on pitot tube heating.

NOTE

The pitot tube heating should be switched on only briefly when the Helicopter is on the ground.

BO 105 CHAPTER 92 Page 242

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

EFFECTIVITY

o S/N 7 - 160 Depress circuit breaker 1HG "PITOT TUBE HEATING" .

o Series D Insert fuse sHG and switch on toggle switch 4HG "PITOT HEATING". o S/N 161 and subsequent Insert fuse 1HG and switch on toggle switch 4HG "PITOT HEATING". - The white sectors on indicator 2HG "PITOT HEATING" must no longer be visible. CAUTION

PITOT TUBE MAY OVERHEAT.

3.

Find out whether the pitot tube is being heated by carefully moving hand towards it.

4.

Switch off pitot heating and external power unit.

5.

Put on pitot tube protection when the tube has cooled down.

92 - 137

o ver h e a d pan e

1

12VE

(see figure 92-99 and 92-100)

The overhead panel 12VE is located above the pilot seats in the center of the cabin roof. The overhead panel consists of an upper section, solidly riveted to the cabin ceiling, and a lower section, bolted to the upper section. The overhead panel contains - depending upon series number and configuration - control units required for the operation of various electrical systems (e.g. optional equipment) . A hand lamp is mounted to left side of upper overhead panel section.

BO 105 CHAPTER 92 Page 243/244

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

~--2

",

"'.>0---"::"'_--=- 3

------5

900166

"

1 Overhead panel - upper section

2 Headset jack, VHF - radio como 10RF* 3 Microphone jack, VHF - radio como 11RF* 4 Overhead panel - lower section 5 Hand lamp 6 Headset jack, VHF - radio como 8RF* 7 Microphone jack, VHF - radio como 9RF* 8 Microphone jack, VHF - radio como 7RF* 9 Headset jack, VHF - radio como 6RF*

EFFECTIVITY

&

S/N 7 - 160

* Optional equipment Figure 92-99

Overhead panel 12VE

BO 105 CHAPTER 92 Page 245

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

....... \ ,...-/

(

~-"'----T- 2

4 -j----..:"-_~-~-'"'

::==:':';::::"::~::=.::======:"'---+-3 1- ..... ,

1 ' __ "

I

,,-,

I

\

,.;.,

\_",1

'-' ~.:r.r=:;¡

1I ,1 il

11

'1 1I

~c.=~

/ - ...

.,

I

\

'--

"\

I ./

900180

1 2 3 4

Pushbutton, VHF radio cornm. 12RF* Pushbutton 104P, 204P Toggle switch 28LA, 29LA, 40LA Toggle switch 11QM, 12QM, 13QM, 14QM * Optional equipment

Figure 92-100

BO 105 CHAPTER

Page 246

92

Typical overhead panel 12VE with operating switch

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

92 - 138

pan e 1

Center

(see figure 92-101)

The center panel is located between the pilot seats and extends from the horizontal section of the instrument panel 2VE. The center panel contains the controls of the optional epuipment (refer to MOM, chapter 801 or to Avionic Manual) . \l•...,.,

V"2

"'

~ ~ ~ C\lO~

filWlWl

O~

-

_,

~~NO Wllct

....

IUIIJ

~

~

~ ~ ~

C'''

el:

_,........

","

!lO

_,

@

8

~~8 8

8 0 0)

(2)

¡~000000~

iíil

O O O

QP\¡.07

PIL.OT

¡OOO i

/,O-~

1

\

'11

I

-.:_;1'

.

O ,""x

0--"":-.

1

(

~

~_'"

'1

PIlESS TO T'-:'I(

900155

Figure 92-101

Typical center panel

BO 105 CHAPTER 92

Page 247/248

EUROCOPTER

MAINTENANCE MANUAL BO 105

101 INSPECTIONS AND AIRWORTHINESS LIMITATIONS Table of Contents

Section

Title

Page

101 -1

GENERAL - INSPECTIONS ANO AIRWORTHINESS L1MITATIONS

3

101 -2

INSPECTIONS - TIME L1MITS

5

101 -3

LUBRICATION CHART

7

101 - 3.1

Lubricatíon Chart Basic-Helicopter

7

101 -4

PREFLIGHT CHECK

11

101 - 4.1 101 -4.2

Preflight Check Basic-Helicopter Preflight Check Optional Equipment

11 23

101 - 5

SUPPLEMENTARV CHECK 25/50 FH

33

101 - 5.1 101 - 5.1.1 101":' 5.1.2

Supplementary Check 25/50 Fh Basic-Helicopter Supplementary Check 25 Fh Basic-Helicopter Supplementary Check 50 Fh Basic-Helicopter

33 33

34

101 -6

SUPPLEMENTARV CHECK 100 FH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

101-6.1 101 - 6.2

Supplementary Check 100 Fh Basic-Helicopter Supplementary Check 100 Fh Optional Equipment

35 37

101 -7

12-MONTH INSPECTION

39

101 -7.1 101 -7.2

12-Month Inspection Basic-Helicopter 12-Month Inspection Optional Equipment

39 43

101- 8

PERIODICAL INSPECTION

45

101 - 8.1 101 - 8.2

Periodical Inspection Basic Helicopter Periodicallnspection Optional Equipment

45 51

101 - 9

EXTENDED PERIODICAL INSPECTION

53

101 - 9.1 101 - 9.2

Extended Periodical Inspection Extended Periodical Inspection Optional Equipment

53 59

101 -10

SUPPLEMENTARV INSPECTION ACCORDING TO OPERATING TIME IN FH AND/OR CALENDAR TIME

61

101 -10.1 101 - 10.2

Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Basic Helicopter Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment

61 69

101 - 11

SPECIAL INSPECTIONS AFTER MAINTENANCE ACTIVITV .............•......

79

101 -11.1 101 -11.2

Special Inspections after Maintenance Activity Basic Helicopter Speciallnspections after Maintenance Activity Optional Equipment

79 81

101 -12

INSPECTIONS AFTER OPERATION UNDER SPECIAL ENVIRONMENTAL CONDITIONS

101 -12.1 101

-1~.2

Inspections after Operation under Special Environmental Conditions . Basic Helicopter Inspections after Operation under Special Environmental Conditions Optional Equipment

......

83 83 85

101 -13

SPECIAL INSPECTIONS AFTER OPERATIONAL INCIDENTS

87

101 -13.1

Special Inspections after Operational Incidents Basic Helicopter

87

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MAINTENANCE MANUAL BO 105

101 -13.2

Speciallnspeetions after Operationallncidents Optional Equipment

111

101 -14

TIME BETWEEN OVERHAUL OF COMPONENTS (TBO)

113

101 -14.1 101 - 14.2

Time Between Overhaul of Components Basic Helicopter Time Between Overhaul of Components Optional Equipment

113 115

101 -15

AIRWORTHINESS L1MITATIONS

117

101 -15.1 101 -15.2 101 -15.2.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service TImes ot Lite-Limited Parts .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Times of Lite-Limited Parts Basic-Helicopter Helicopter series A, C, D, S, except tor B0105 CB-5, B0105 CBS-5 and B0105 DBS-5 Service Times of Lite-Limited Parts Basic-Helicopter Helicopter series B0105 CS-5, B0105 CBS-5 and B0105 DBS-5 Basic-Helicopter .. Service TImes ot Lite-Limited Parts Optional Equipment Al! Series

117 119

101 -15.2.2 101 -15.3

CHAPTER 101 Page2

119 123 125

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EUROCOPTER

101-1

MAINTENANCE MANUAL BO 105

GENERAL - INSPECTIONS AND AIRWORTHINESS LlMITATIONS

1. General a. The inspections/measures specified in Chapter 101 must be accomplished by the latest on reaching those time limits as determined in Section 101-2 to ensure continued airworthiness of helicopter. b.

Inspections of Basic-Helicopter are described in Sections Equipment are described in Sections 101-X.2.

101-X.1, inspeetions of Optional

c.

Fig. 101-1 represents Chapter 101 ulnspections and Airworthiness Limitations". The contents of Sections 101-5 thru 101-9 are compiled in such a way, that on reaching the corresponding time Iimits only the required inspeetions have to be performed.lnspeetions with shorter intervals are fully incorporated. This means, that the Extended Periodicallnspection 101-9 contains the Periodicallnspeetion 101-8, which in tum contains the Supplementary Check 100 Fh 101-6 and the 12 Month Inspection 101-7. The Supplementary Check 25/50 Fh 101·5 is incorporated in the Supplementary Check 100 Fh 101-6.

d. The inspections/measures are to be performed in compliance with specified sections. The column Reference of the inspection schedules denotes according to which detailed instruction the inspection and maintenance work is to be performed. The column Initial is ¡ntended forverification of performance of inspection. A signature in this column verifies that the respective checkslinspections and the removal of any discrepancies have been performed correetly and in consequence the helicopter can be retumed to flight operations. e.

Inspeetions of vendor components and systems are to be performed in accordance with applicable vendor documentation. Aefer to List of Applicable Publications (lOAP).

f.

Supplementary checks may also be performed by trained pilots.

2. Scheduled Checks/lnspections a. The scheduled checks/ inspections listed in Seetion 101-3thru 101-9are to be performed bythe latest on reaching corresponding operating time of helicopter. In case the operating times of components do not coincide with those of the helicopter, regard the operating times of components as applicable. b. The supplementary inspections listed inspections/rneasures 101-5 thru 101·8. c.

3.

in

Seetion

101-10

supplement

the

periodical

Inspeetion resp. maintenance points of scheduled checks/inspections may be performed earlier. Forthis make sure that the specified time limits are not exceeded for those measures perforrned in advance.

Further Scheduled Measures a. Time Between Overhaul-components are contained in Section 101-14. These components are to be overhauled by the respective manufacturer or an authorized service station according to applicable documentation. b. Seetion 101-15 contains a Iisting of all time change items, their related time Iimits as well as special regulations determining the use ofthese items. The operating times ofthese items must not be exceeded.

4.

Unscheduled Inspections a. Section 101-11 contains special inspections to be performed after specific maintenance aetivities. b. Seetion 101-12 contains special inspeetions to be performed after lengthy operation under special environmental conditions. Special environmental conditions could be: saline atmosphere, high share of sand particles in air or polluted atmosphere. It is the responsibility of the helicopter operator to judge the necessity of these special inspections. .

Aevision 18

CHAPTEA 101 Page3

EUROCOPTER

c.

MAINTENANCE MANUAL 80105

Section 101·13 contains special inspections to be performed immediately afierthe occurrence of specific operational incidents. These inspections ensure the upholding respectively re-establishment of airworthiness.

5. Inspection Scheme 101-3 Lubrication Chart 101-4 Preflight Check

I

101-5 Supplementary Check 25/50 Fh

I

101-6 Supplementary Check 100 Fh

I I

101-7 12 Month Inspection

101-8 Periodicallnspection 101-9 Extended Periodicallnspection 101-10 Supplementary Inspection according to Operating Time in Flight Hours and/or Calendar Time 101-11 Special Inspection afier Maintenance Activity 101-12 Inspection afier Operation under Special Environmental Conditions 101-13 Conditional Inspection afier Operational Incident 101-14 Time Between overhaull 101-15 Airworthiness Limitationsl Fig. 101-1 - Inspection Scheme 6. Abbreviations IPC EPU Fh FLM LOAP NHA OAT OMM PF REM TBO TCI TSI TSN TSO CHAPTER 101 Page4

lIIustrated Parts Catalog External power unit Flight hours Flight Manual List of Applicable Publications Next Higher Assembly Outside Air Temperature Operation and Maintenance Manual (Allison) Preflight Check Repair Manual Time Between Overhaul Time Change Item Time Since Inspection Time Since New Time Since Overhaul Revision 18

eeurocopter 101 - 2

MAINTENANCE MANUAL 80 105

INSPECTIONS - TIME LIMITS

1. Notes regarding Time Limits a. The time Iimits and allowable over-the-Iimit times for the inspectionsJmeasures are specified under step2. b. When unusuallocal conditions dictate, it is the responsibility of the helicopter operator to increase the frequency and scope of inspectionsJmeasures to guarantee safe flight operation. c.

It is permissible to exceed Intervals up to specifiad Iimits. These over-the-Iimit times are to be disregarded when determining time of next inspection or measure.

d. The time of inspection is specified by the following expresslons: 1) Flight hours (Fh) are the intervals between takeoff and landing of the helicopter. If time Iimits are expressed in flight hours, they generally apply to the f1ight hours of the helicopter, unless the Iisted flight hours are directly relatad to a specific component (Nomenclature, Part Number). 2) Calendar TIme in months or years are the intervals of Time Since New (TSN) or Time Since Inspection (TSI). If time limits are expressed in calendar time, they generally apply to the helicopter, unless the Iisted calendar time is directly relatad to a specific component (Nomenclature, Part Number). Storage times following operation must be taken into account. These inspection requirements do not apply to new or overhauled equipment that has been stored according to manufacturer's directives and that has not been operated, unless they are additionally required. • 3) Number of FlIghts is the number of landings (ground contacts). 4) Retlrement TIme is the permissible ope~ating time for Time Change Items (TCI) in flight hours, calendar time or number of flights since new. It is always related to a component identified by nomenclature and part number. 5) Time Between Overhaul (TBO) is the operating time of a component (Nomenclature, Part Number), afterwhich the component is to be overhauled. The interval begins with Time Since New (TSN) or Time Since Overhaul (TSO).

Revision 21

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MAINTENANCE MANUAL BO 10S

2. Time Limits a. The 011-1 Lubricant Change is to be performed according to Saetion 101-3.The Iistedtjme jntervals are applicable. It is perrnissible to exceed the respective intervals by 10%. b. The Preflight Check is to be performed according to Seetion 101-4 by the latest prjorto the fjrst flight of the day. Items marked with a symbol haye to be checked each f1ight befare takeoff. c. The Supplementary Check 25/50 Fh is to be performed according to Seetion 101-5 eyery 25 raspo 50 flight hours. It is perrnissible to exceed these time limits by 5 f1ight hours. This does not apply if the Supplementary Check 100 Fh, the Periodical Inspection or the Extended Periodicallnspection is performed on reaching scheduled time. d. The Supplementary Check 100 Fh is to be performed accordingto Seetion 101-6 eveIY 100 fligbt hours. It is perrnissible to exceed this time limit by 10 f1ight hours. The Supplementary Check 100 Fh does not apply if the Periodical Inspection or the Extended Periodical Inspection is performed on reaching scheduled time. e. The 12-Month Inspectlon isto be performed accordingto Seetion 101-7 every 12 months. It is perrnissible to exceed this time limit by 3 months. The 12-Month Inspection does not apply if the Periodical Inspeetion or the Extended PeriodicaJ Inspection is performed on reaching scheduled time.

I

1.

The Periodical Inspection is to be performed according to Seetion 101-8 every 600 fligbt hours or 4 ~, depending on which time Iimit is reached first. It is permissible to exceed these time limits by 60 f1ight hours resp. 6 months. The Periodicallnspeetion does not apply if the Extended Periodicallnspection is performed on reaching scheduled time.

g. The Extended Periodicallnspection is to be performed according to Saetion 101-9 forthe firsttime on reaching 6000 flight hours or 12 years, depending on which time Iimit is reached first. It is permissible to exceed these time limits by 600 f1ight hours resp. 12 months. The subsequent Extended Periodicallnspections are to be performed according to Saetion 101-9 eyery 6000 flight hours or 8 years, depending on which time Iimit is reached first. It is permissible to exceed these time limits by 600 f1ight hours resp. 6 months.

I

h. The Supplementary Inspections are to be performed according to Saetion 101-10. The Usted time jntervals are applicable. It is perrnissible to exceed the respective intervals by 10%. i.

The Speciallnspections after Maintenance Activity areto be performed according to Section 101-11. The listed time jntervals are applicable. It is perrnissible to exceed the respective intervals by 10%.

j.

The Inspectlons after Operation under Special Environmental Conditlons are to be performed according to Seetion 101-12. The listed time intervals are applicable. It is perrnissible to exceed the respective intervals by 10%.

k. The Speclal Inspections after Operational Incidents are to be performed according to Section 101-13. The listed time intervals are applicable. Intervals must not be exceeded.

1.

Time Between Overhaul components are to be replacecl according to Saetion 101-14. The IistedDme Between Overhaul (IBO) is applicable. It is perrnissible to exceed this time limit by 3%.

m. Life-Iimited components are to be replaced according to Seetion 101-15. The Iisted Iimits are applicable. These must not be exceeded. CHAPTER 101 Page6

Revision 21

e

eurocopter

101 -3

_MAINTENANCE MANUAL BO 105

LUBRICATION CHART

101 - 3.1

Lubrication Chart Basic-Helicopter

NOTE

Specifications and quantities of lubrication items are contained in Fig. 101-3.1. For intervals of oil change or regrease, refer to table 101-3.1.

Registration No.:

H/C Serial

No.:

Inspection or Malntenance Work

_

Total Hours:

Fh

Inltial

Relerence

Interval 11 - MAIN TRANSMISSION

(1)

Change oil, inspect and clean filter element

SOFh TSN/TSO, 600Fh or 12 months TSN/TSO, then 600Fh or 12 months, whichever occurs first

11-4 and 11-13

32 - TAIL ROTOR ORIVE (1)

Change oil of intermediate gearbox and tail rotor gearbox

SOFhTSNITSO, 600Fh or 12 months TSN/TSO, then 600Fh or 12 months, whichever occurs first

32-9

33 - TAlL ROTOR (1)

Grease ball bearing of sliding sleeve

600Fh or 12 months, whichever occurs first

(2)

Grease splines of tail rotor shaft for sliding sleeve

600Fh or 12 months, whichever occurs first

33-27 step 13

41 - FLlGHT CONTROLS MAIN ROTOR (1)

Grease swashplate bearing

600Fh or 12 months, whichever occurs first

41-74

43 - HYORAULlC SYSTEM -'(.....;1)_C_h_a_n..:::;.ge __ hY:-d_ra_u_li_c_f1u_i_d

I

'--_2_y:....e_a_rs_ _ L4_3-_6

---I

_

TabeI101-3.1 - Lubrlcatlon Chart Basie-Hellcopter (1 012) Revision 22

CHAPTER 101 Page7

EUROCOPTER

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Interval

Reference

Initial

43 - HVDRAULlC SVSTEM (2)

Grease splines of hydraulie pump drive shaft

600Fh or 2 years, whichever oeeurs first

43-27, 43-29

61-ENGINE (1)

EFFECTIVITV Grease

lubrieated

starter-

200Fh

61-21, 61-23

generator Remove starter-generators, elean splines 01 stub shaft and engine driveshaft and then lubricate with grease

TabeI101-3.1 - Lubrication Chart Basic-Helicopter (2 of 2)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page8

Revision 18

_eurocopter lIIl EA05

MAINTENANCE MANUAL 80105

Cbmpeny

MAIN ROTOR HEAD MIL-L-23699 approx. 1.91

~I _

POWER PLANTS REFER

ro

ALLlSON OMM 10W2

MI I

~

.nI

5W2

approx. 41 each power plants

o

O al

WARNING

I

MAIN TRANSMISSION FS72A MIL-L-23699 FS72B MIL-L-23699 FS72E old EXXON T0.25 new BP TURBO OIL 25 10,31

GREASE MIL-G-23827 IS NOT COMPATIBLE WITH GREASE MIL-G-81322. OBSERVE GREASE IDENTIFICATION PLATE.

Figure 101-3.1: Lubrication Chart Basic-Helicopter

Revision 25

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MAINTENANCE MANUAL BO 105

EUROCOPTER

BLANK PAGE

CHAPTER 101 Paga 10

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

101 - 4

PREFLlGHT CHECK

101 - 4.1

Preflight Check Basic-Helicopter

1. General The preflight check shall be accomplished not later than the first flight of the day, and according to Flight Manual (Section 4) or the Pilot's Checklist. The preflight check is not a detailed mechanical inspection, but essentially a visual check of the helicopter for correct condition. Items marked with a star (*) need to be checked each flight before takeoff. When unusuallocal conditions dictate, the extent and/or frequency of this check shall be increased as neo cessary to promote safe operation.

NOTE

• The following list contains only check items for the basic helicopter in standard configuration. • In addition to these items, check antennas. In addition make certain that the necessary inspections have been performedaccording to the Maintenance Manual. • For optional equipment check items refer to the respective Flight Manual Supplements or Maintenance Manual, Chapter 101 • 4.2.

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2. Exterior Check The exterior check is laid out as a walk-around check, starting forward right at the pilot's door, proceeding' clockwise to the tail boom, to the left-hand side (including the upper and lower areas of the helicopter) and being completed at the helicopter nose area.

100473

1. Fuselage - right side

4. Cabin roof

2. Tail boom

5. Nose area

3. Fuselage - left side Figure 101-2

Exterior Check Sequence

• If possible, ensure that the helicopter is headed into the wind before starting the engines.

NOTE

• The area around the helicopter should be clear of all foreign objects. • To avoid excessive drain on the helicopter battery, particularly during cold weather, all ground operations should be conducted using an external power unít (EPU). • When the battery is used, the operation of electrical equipment should be kept to a minimum.

*

Helicopter forms and documents

-

Check, complete

Fuselage underside

-

Condition, no fuelleaks

Each fuel tank (3)

-

Drain sample

Fuel temperature

-

Measure; Determine fuel type to be used andlor Iimit the operation altitude in accordance with FLM Section 2.

Covers and tie-downs

-

Removed

Ice and snow (if any)

-

Removed

Ground handling wheels

-

Removed

If OAT ~+40°C or S-32°C:

*

* *

*

To be checked before each flight

CHAPTER 101 Page 12

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MAINTENANCE MANUAL BO 105

Cockpit AII switches

-

OFF

Power levers

-

OFF

Rotor brake handle (if installed)

-

In lowest position

Circuit breakers/fuses

-

As required

Battery switch

-

ON

Voltmeter indication

-

24 VDC nominal

-

OFF

-

Function

Position lights

-

Function

Anti collision lights

-

Function

Landing light(s)

-

Fl,Inction

Dome and instrument lights

-

Function

Utility lamp

-

Function

Hand lamp

-

Function

Battery switch

-

OFF

Hand-held fire extinguisher

-

On board, check pressure

Flashlight

-

On board, Function

First aid kit (if installed here)

-

On board

Cockpit overhead window

-

Condition

OAT indicator probe

-

Condition

Cockpit door

-

Condition, function, jettison handle secured

Pilot seat and safety belts

-

Condition

If EPU is available: Battery switch Pitot tube heating Lighting:

Before Night Flights:

Fuselage - Right Side

* * *

Static port

-

Clean, unobstructed

Pitot tube(s)

-

Condition, clean, unobstructed

*

To be checked before each flight

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CHAPTER 101 Page 13

EUROCOPTER

MAINTENANCE MANUAL 80105

Fuselage - Right Side (Cant.) Landing gear and step

-

Condition

Cabin door

-

Condition, function

Baggage, cargo, loose items

-

Stowed, secured

Passenger seats and safety belts

-

Condition

Transmission compartment

-

No foreign objects, no leakage, free of icel snow

Oil cooler

-

No leakage

Engine oillevel

-

Above "ADD OIL" mark

Engine oil tanks

-

Security of mounting, no leakage, filler caps secured

Scavenge oil filter (if installed) filter clogging indicator pin (2x)

-

Check in

Main transmission oillevel

-

Oil level above "MIN" mark

Main transmission

-

Condition, security of mounting, no leakage, filler cap closed

Rotor brake (if installed)

-

Condition

Rotor brake

-

Oil level, filler cap secured

Engine air intake

-

Condition, no dirt, no foreign objects, free of ice/snow

Compressor

-

Rotate by hand, check for smooth ratation

Transmission access door

-

Closed, secured

Engine compartment

-

No foreign objects, no fuel/oilleakage

Engine compartment ventilation air intake

-

Clear

Engine

-

General condition

Wiring, linkages and lines

-

Condition, no leakage, no chafing

Engine mounts

-

Condition, security

N1-governor and connections

-

Security of mounting

Starter-generator

-

Security of mounting

*

Engine access door

-

Closed, secured

*

To be checked before each flight

*

* *

*

*

* *

*

CHAPTER 101 Page 14

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

Fuselage - Right Side (Cont.)

* *

* *

Orain and vent ports

-

Clear

Battery (if installed here)

-

Condition, no electrolyte spillage, security of mounting

Battery connectors (2)

-

Connected

Battery vents

-

Clear

Battery compartment door

-

Closed, secured

Engine cowling

-

Secured

Engine exhaust pipe

-

Condition, security

Fuselage exterior

-

General condition

Clam shell doors and latches

-

Condition, function

First aid kit (if installed here)

-

On board

Avionics (in avionic equipment bay)

-

Security of mounting

Baggage, cargo, loose items

-

Stowed,secured

Avionic bay door

-

Closed

Clam shell doors

-

Closed, secured

Spoiler

-

Condition

Tail Boom

* *

Tail boom - AH

-

Condition

Tail rotor driveshaft fairing

-

Secured

Orain ports

-

Clear

*

AH horizontal and vertical stabilizer, position light (green)

-

Condition

Vertical fin, position light (white), anti-collision Iight

-

Condition

Vertical fin cowling

-

Secured

*

Tail rotor

-

Condition

PU-Erosion protective film (if fitted)

-

Condit'ion, no separation

* *

Intermediate gearbox

-

Oil level, no leakage

To be checked before each flight

Revision 18

CHAPTER 101 Page 15

EUROCOPTER

MAINTENANCE MANUAL BO 105

Tail Boom (Cont.) NOTE

* * * *

*

More reliable oillevel readings may be obtained by first shaking the tail boom by means of the tail skid. -

Condition, oillevel, no leakage

-

Closed, secured

Tail skid

-

Condition

lH horizontal and vertical stabilizer, position light (red)

-

Condition

Tail boom - lH

-

Condition

Tail rotor driveshaft fairing

-

Secured

Drain ports

-

Clear

Fuel filler cap

-

Closed, secured

Fuselage exterior

-

Condition

Engine exhaust pipe

-

Condition, security

Engine cowling

-

Secured

Engine compartment

-

No foreign objects, no fuel/oilleakage

Engine compartment ventilation air intake

-

Clear

Engine

-

General condition

Wiring, Iinkages and lines

-

Condition, no leakage, no chafing

Engine mounts

-

Condition, security

N2-governor and control linkage

-

Condition, security

Starter-generator

-

Security of mounting

Engine access door

-

Closed, secured

Hydraulic compartment

-

No foreign objects, no leakage, free of icel snow

Hydraulic system

-

No leakage

Under icing conditions: Area between hydraulic unit and XMSN floor, especially control rod bellows

-

Free of ice/snow

Tail rotor gearbox Intermediate installed)

gearbox

access

door

(if

Fuselage - Left Side

* * * *

* * * *

*

To be checked before each flight

CHAPTER 101 Page 16

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

Fuselage - Left Side (Cont.)

* * * *

* * * * *

*

*

*

Water drain ports

-

Clear

Hydraulic filter clogging indicator pins (4x)

-

Check in

Hydraulic reservoir oil level (2x)

-

Above "FILL" mark

Service fitting caps

-

Installed, secured

Transmission

-

Condition, security of mounting, no leakage

Engine air intake

-

Condition, no dírt, no foreign objects, free of ice/snow

Compressor

-

Rotate by hand, check for smooth rotation

Hydraulic compartment access door

-

Closed, secured

Main rotor

-

Rotate by hand in direction of rotation, check for smooth rotatíon

Rotor hub oil level

-

Between "MIN" and "MAX" marks

Rotor blades

-

Condition

Rotor blade attachment bolts

-

Secured

Polyurethane erosion protection tape (PUR tape), if fitted

-

Condition, no separation

Oriving link assy, mixing lever assy

-

Condition, secured

Rotating control rods

-

Condition, free movement, secured

Rotating control rod spherical bearings

Smooth operation

Swashplate and boot

-

Condition, secured

Pendulum absorbers (if installed)

-

Condition, free movement

Air intake

-

Condition, no foreign objects, free of icel snow

Engine inlet deflector shield (if installed)

-

Condition, no foreign objects

Cockpit overhead window

-

Condition

Cabin door

-

Condition, function

Baggage, cargo, loose items

-

Stowed, secured

Passenger seats and seat belts

-

Condition

Fuel vent

-

Clear

Landing gear and step

-

Condition

To be checked before each flight

Revision 18

CHAPTER 101 Page 17

EUROCOPTER

MAINTENANCE MANUAL BO 105

Fuselage - Left Side (Cont.)

*

*

Static port

-

Clean, unobstructed

Cockpit door

-

Condition, funetion, jettison handle secured

Copilot cyclic stick (if installed)

-

Secured, safety-wired

Copilot collective lever (if installed)

-

Secured

Copilot seat and safety belts

-

Condition

-

Closed, taut

Windshields

-

Condition

Battery (if installed here)

-

Condition, no electrolyte spillage, security of mounting

Battery connectors (2)

-

Connected

Battery vents

-

Clear

Nose compartment

-

No foreign objects

Nose compartment door

-

Closed, secured

Cockpit air intake screens

-

Clear

Drain ports

-

Clear

Lower cockpit windows

-

Condition

Fuselage bottom

-

Condition

Anti-eollision Iight

-

Condition

Landing Iight(s)

-

Condition

For single pilot flights: Copilot safety belts

Nose Area

*

3. Interior Check

* * * * *

Seat and pedals

-

Adjust

Safety belts

-

Fasten, adjust

Shoulder harness locks

-

Function

-

Check and set

Instrument panel: AII instruments

To be checked befare each flight

CHAPTER 101 Page 18

Revision 18

EUROCOPTER

MAINTENANCE MANUAL 80 105

Interior Check (Cont.)

*

*

*

Switch panel: Emergency fuel shutoff switches

-

Guarded

Circuit breakers

-

As required

Al! switches

-

OFF

COMM/NAV equipment

-

OFF

Overhead panel: OFF

Power levers AII switches

-

OFF

Circuit breakers

-

As required

-

OFF

-

ON

Battery switch

-

OFF

EPU

-

Con,nected

EPU caution light

-

ON

Battery

-

Minimum 24 V

EPU

-

24/28 V

Warning/caution Iights

-

Test

Mast moment indicator

-

Test

Fuel quantity indicator

-

Check readings

Fuel pumps (4)

-

Function

Cyclic stick lock (if fitted)

-

Removed, secured

Collective lever lock

-

Removed

Flight controls (cyclic stick, collective lever, pedals)

-

Check for ease and freedom of movement through entire control range

Collective lever switch panel Al! switches

Pre-start Check Battery switch For EPU starts:

* * *

*

*

* * * *

Voltmeter indication

To be checked before each flight

Revision 18

CHAPTER101 Page 19

EUROCOPTER

MAINTENANCE MANUAL BO 105

Pre-start Check (Cant.) Hydraulic override (HY BLOCK)

Collective lever

-

Raise slightly

Hydraulic test switch

-

RESET and release

HY BLOCK warning light

-

Check off

Collective lever

-

Raise until HY BLOCK warning Iight comes on, then lower slowly and release

Hydraulic test switch

-

RESET and release

HY BLOCK warning light

-

Check off

Collective lever

-

Lower until HY BLOCK warning Iight comes on, then raise slowly and release

Hydraulic test switch

-

RESET and release

HY BLOCK warning light

-

Check off

Cyclic stick

-

Move forward until HY BLOCK warning light comes on and release

Hydraulic test switch

-

RESET and release

HY BLOCK warning light

-

Check off

Each remaining cyclic control direction

-

Check as aboye

Collective lever

-

Fulldown

Collective lever lock

-

Engage

HY BLOCK warning light

-

Check on

Trim actuator I¡mit switches

-

Check function as follows

This check is performed to ensUre that the cyclic stick retains its full range of travel when the trim actuators are switched off.

NOTE

*

Check function

To get accurate results, the cyclic stick must be moved exactly along the roll and longitudinal axes of the helicopter.

NOTE

* *

-

Cyclic stick trim switch

-

Trim full forward until aetuator is heard to switch off

Cyclic stick

-

Check for full fore/aft travel, ease of move· ment

Each remaining cyclic control axis

-

Check as aboye

To be checked before each flight

CHAPTER 101 Page 20

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

Pre-start Check (Cant.)

* *

Cyclic stick

-

Trim neutral

Cyclic stick lock (if fitted)

-

Engage

*

Rotor brake lever (if installed)

-

FuI! down

*

To be checked before each flight

Revision 18

CHAPTER 101 Page 21

MAINTENANCE MANUAL 80 10S

EUROCOPTER

BLANK PAGE

CHAPTER 101 Page 22

Revision 18

MAINTENANCE MANUAL 80 105

EUROCOPTER

101 - 4.2 Preflight Check Optional EJlpment 801 Shoulder Hamess wlth Automatlc Inertla Real

Shoulder harness

-

Condition

Automatic inertia reel

-

Function

802 Electrical Heating and Ventilation System 4 kW/3+1 kW

Four-Iight annunciator

-

Check for function by pressing plastic cover

Functional check of the heating system is only possible with EPU engaged or generators operating

NOTE

Heating system

-

Function

803 Windshield Wiper System CAUTION

OPERATE WINDSHIELD WIPER ONLY ON WET WINDSHIELDS OR L1FT WIPERARMS

Windshield wiper system

-

Condition

Windshield wiper system

-

Function

804 Dual Windshield Wlper System CAUTION

OPERATE WINDSHIELD WIPER ONLY ON WET WINDSHIELDS OR L1FT WIPER ARMS

Dual windshield wiper system

-

Condition

Dual windshield wiper system

-

Function

Reservoir

-

Fluid level

Cover

-

Security

Windshield wiper and washer system

-

Functíon

Windshield wiper

-

Condition

Split bench seat

-

Condition, correct installation

Lap-safety belts

-

Condition

Bench seat

-

Condition, secured

Lap-safety belts

-

Condition

805 Wlndshield Wiper and Washer System

*

806 Split Bench Seat

807 Bench Seat

*

To be checked before each flight

Revision 18

CHAPTER 101 Page 23

MAINTENANCE MANUAL BO 105

EUROCOPTER

808 Bench 5eat

Bench seat

-

Condition, correct installation

Lap-safety belts or lap-safety belts with shoulder harnesses

-

Condition

4-seat back-to-back bench

-

Condition, correct installation

Safety belts

-

Condition

-

Condition

809 4-Seat Back-To-Back Bench

810 Retractable Landing Ljght System

Landing light system

Pertorm preflight functional test of landing Iight using external power unit (EPU) or generators

NOTE

Landing light system

-

Function

-

Condition

811 Retractable Landing Light System

Landing light system

Pertorm preflight functional test of landing light using external power unít (EPU) or generators

NOTE

Landing light system

-

Function

-

Condition, Function

812 Search and Landing Light

Search and landing light 813 Searchlight WARNING

AllOW SEARCHLJGHT TO COOl DOWN BEFORE TOUCHING IT

Searchlight, mounting

-

Condition, correct installation

Searchlight lens

-

Clean

-

Condition

-

Condition

-

Condition

814 Medical Equipment Mounting Plate

Medical equipment mounting plate 815 Wall Cabinet Assembly

Wall cabinet assembly 816 Suction Bottle Holder

Suction bottle holder

*

To be checked befare each flight

CHAPTER 101 Page24

Revision 18

MAINTENANCE MANUAL 80105

EUROCOPTER

817 Oxygen Bottle Holder

-

Condition

-

Condition

-

Condition

-

Condition

Litter rails

-

Cleanliness and security of installation

Litter mounting

-

Secured

Safety utilities

-

Condition, Function

Litter(s)

-

Condition, secured

Safety belts for patients

-

Adjusted, secured

Cargo hook system

-

Condition, secured

Mechanical and electrical release mechanism

-

Functíon

LOAD HOOK-Switch

-

CLOSED

Mechanical release lever

-

CLOSED

-

Condition, correct installation

-

Condition, correct installation

Oxygen bottle holder 818 Infusion Bottle Suspension Hook

Infusion bottle suspension hook 819 Medical Attendant's Seat

Medical attendant's seat 820 Converted Copilot Seat

Copilot seat 821 Litter Retention System

822 Cargo Hook System

823 Antisettling Shoes

Antisettling shoes 824 Snow Skids

Snow skids 825 Emergency Flotation System NOTE

The following check should be performed prior to each flight over water.

Float covers and attaching lines NOTE

Condition

For flights over waterthe rubber ropes must be attached to the spoiler. For other flights the ropes can be stowed in clamps attached to the skids.

Rubber ropes

*

-

-

Attached to spoiler

To be checked before each flight

Revision 18

CHAPTER 101 Page25

MAINTENANCE MANUAL 80 10S

EUROCOPTER

Pressure pipes

-

Condition, correct installation

Pressure bottles

-

Condition, correct installation

Pressure of bottles

-

Check

EMERGENCY FLOTATION TEST Switch

-

Press

-

lIIuminated

-

Closed, lead wire sealed

Microfilter

-

Drain

Warning segments FILT 1/FILT 2

-

Functionally test by pressing contamination indicator pin on top of the respective filter

Vent and drain pipes

-

Condition, conneeted, no leakage

Long range fuel tank(s)

-

Secure installation, no leakage, no damage

Long range fuel tank(s)

-

Drain

-

Installed

Fuel pipe(s)

-

Condition, connected, no leakage

Mechanical tank valve indicator

-

"CLOSED"-indication

Electrical connections

-

Conneeted

Fuel level, each tank

-

Open lid and check

Tank Iid(s)

-

Secured

-

Condition, correct installation

Signallamps Cover of EMERGENCY FLOTATION switch 828 Fuel Microfilter System

831 Long Range Fue! Tank

Only one long range fuel tank installed: Tank protect wall

833 Externa! Loudspeaker System

Loudspeaker system NOTE

Following check is possible only with engines operating

Externalloudspeaker

-

Speech test

-

Condition, correct installation

834 External Loudspeaker System 80105 S

Loudspeaker system NOTE

Following check is possible only with engines operating

Externalloudspeaker

*

-

Speech test

To be checked befare each flight

CHAPTER 101 Page 26

Revision 18

MAINTENANCE MANUAL 80 105

EUROCOPTER

835 Safety Harness Safety harness

-

Condition

836 Rescue Hoist Assembly NOTE

•

During winch operation with battery power, the cable will not retraet completely. Complete retraetion of the cable is possible after start of the generators. For cable inspeetion, it is recommended to use the EPU.

•

Placement and function of the winch switch depends on the SIN of the helicopter. Up to SIN 160, a rocker-type switch is installed on the pitch control stick. For SIN 161 and subsq., a 4-way switch is installed (referto Figures 836-2 and 836-3). For operation, refer to the OPM 104.

CAUTION

FOR BOOMS OPERATED WITH A SERVO MOTOR DC2040 M4C, THE DIRECTION OF ACTUATOR MOVEMENT MUST NOT BE CHANGED BEFaRE THE MOTOR HAS COME TO A STANDSTILL (RUN-DOWN TIME IS APPROXIMATELY 5 SEC.). A DIRECTIONAL CHANGE CAN BE PERFORMED IMMEDIATELY IF THE BOOM IS OPERATED BY A SERVO MOTOR 13.1-0100.

WARNING

THE RESCUE HOIST MUST ALWAYS BE OPERATED BY ONE PERSON ONLY. SIMULTANEOUS CONTROL INPUTS TO COLLECTIVE LEVER AND WINCH CONTROL LEVER ARE NOT ALLOWED.

Prior to the first flight of the day Winch boom

-

Condition, secure installation on fuselage

Electrical connections (2)

-

Tight, secured

Circuit breaker WINCH Circuit breaker CABLE CUTTER

-

Pulled

Eleetrical connections (2)

-

Tight, secured

Copilot seat

-

Reversed as necessary

Dual controls (cyclic stick and collective lever)

-

Removed

Retaining belt and safety belt

-

Condition, secure installation, fasten belt

Winch control grip

-

Connected

Circuit breaker WINCH Circuit breaker CABLE CUTTER, Circuit breaker HEATING (if installed)

-

Push

Temperature control for electrical heating

-

Turn to maximum

Prior to the first rescue hoist operation of the day

*

To be checked before each flight

Revision 18

CHAPTER 101 Page 27

MAINTENANCE MANUAL BO 105

EUROCOPTER

Prior to the first rescue hoist operation of the day (Cont.) Main switch HEATING (if installed)

-

Set to position HEATING, the four indicator Iights HEATING must iIIuminate

Main switch WINCH

-

Set to ON, indicator Iight WINCH must iIIuminate, the four indicator Iights HEATING must extinguish and the heating must be inoperative

Eleetrical heating (if installed)

-

Switch OFF

Switch CABLE CUTTER TEST

-

Push, indicator Iight CABLE CUTTER TEST must iIIuminate

Press annunciator

-

Lamp test

Winch control grip (winch operator)

-

Extend winch boom, reel out approx. 1m of cable

Winch boom

-

Condition, secure installation on fuselage

B06t on hooklbumper assy

-

Detach at the bottom, fold up

Indicator pins

-

Check for damage. If damaged and length is more then 2mm shorter, replace indieator pins and inspect cable.

Cable in vicinity of bumper

-

Condition

Boot

-

Fold down and reattach to hooklbumper assy

Wineh control grip (winch operator)

-

Reel in cable until automatie switch-off occurs, retract winch boom

Collective lever (pilot)

-

Extend winch boom, reel out cable approximately 1m, reel in cable until automatic switch-off oecurs, fully retract winch boom

Main switch WINCH

-

Set to OFF

Skid guard assembly

-

Installed

Eleetrical connections (2)

-

Tight, secured

Retaining belt and safety belt

-

Condition, secure installation, fasten belt

Wineh control grip (winch operator)

-

Connected

Check of indicator pins and cable inspection:

Prior to every rescue hoist Qperation

*

To be checked before each f1ight

CHAPTER 101 Page28

Revision 18

MAINTENANCE MANUAL BO 105

EUROCOPTER

Circuit breaker WINCH Circuit breaker CABLE CUTTER

-

Push

Main switch WINCH

-

Setto ON, indicator Iight WINCH must iIIuminate

Winch control grip (winch operator)

-

Extend winch boom, reel out approx. 1m of cable

Winch boom

-

Condition, secure installation on fuselage, winch unit and hooklbumper assy for signs of impact

Prior to every rescue hoist operation

Check of indicator pins inside hooklbumper assy and cable inspection: Boot on hooklbumper assy

-

Detach at the bottom, fold up

Indicator pins

-

Check for damage. If damaged and length is more then 2mm shorter, replace indicator pins and inspect cable.

Cable in vicinity of bumper

-

Condition

Boot

-

Fold down and reattach to hooklbumper assy

Winch control grip (winch operator)

-

Reel in cable until automatic switch-off occurs, retract winch boom

Switch CABLE CUTTER TEST

-

Push, indicator Iight CABLE CUTTER TEST must iIIuminate

Main switch WINCH

-

Setto OFF

Mirror

-

Secure fit

Mirror glass

-

Condition

Cover (night flights only)

-

Attached

High landing gear

-

Proper installation

Cross tubes

-

Deformation

-

Condition

837 External Rearview Mirror

838 High Landing Gear

840 Lightning Protector

Lightning protector

*

To be checked before each flight

Revision 18

CHAPTER 101 Page29

EUROCOPTER

MAINTENANCE MANUAL 80 105

841 Engine Air Cleaner

Air c1eaner panels

-

Condition, unclogged

Bypass doors (by operating Bowden cable or actuator)

-

Freedom of movement

Air cleaner panels

-

Condition, unclogged

Bypass doors using actuator

-

Unrestricted movement

-

Condition, unclogged

Pendulum absorbers

-

Proper installation

Shaft seals

-

Leakage

-

Press, warning light must iIIuminate

-

Functional check per para. 846-5

Bleed air system

-

Function

Air selector lever

-

Easy operation

Air inlets and nozzles/jets

-

No foreign objects

Search and landing Iight

-

Condition

Search and landing light

-

Function

-

Tight connection

Fire extinguishing system

-

Condition

Charge pressure on pressure gauge

-

Check charge pressure on pressure gauge against permissible limits in table 853-2

Light bulbs

-

Functional check per para. 853-5

842 Engine Air Cleaner (with Bleed Air Shutoff)

843 Engine Inlet Screen

Engine inlet screen 844 Pendulum Absorbers

845 Chip Warning Indication

T PLUG warning light 846 Stability Augmentation System (SAS)

SAS system 850 Bleed Air Heating

851 Search and Landing Light 450 W

852 Compressor Rinsing Equipment

Compressor rinsing equipment 853 Fire Extinguishing System

*

To be checked before each flight

CHAPTER 101 Page 30

Revision 18

CDeurocopter

MAINTENANCE MANUAL 80105

en EAD6 D:lmpany

854 Main Rotor Blade Folding System Locking lever

-

Correct installation

Locking lever and pip pin

-

Function and safetying

-

Condition

Particle separator

-

Condition, integrity

Housing

-

Secure

Bypass door

-

Clean, clear of foreign objects

859 Wire Strike Protection System (WSPS) WSPS

860 Engine Air Cleaner Exterior Check

*

When conditions permit, open bypass door and check particle separator interior for cleanliness.

NOTE

Swirl tube panels

-

Clean, c1ear of foreign objects

Damage swirl tubes must be replaced or sealed closed.

NOTE

Scavenge blower ducts

-

Secure, clear of foreign objects

Scavenge blower electrical connector (each side)

-

Secure

Seals (mast, control rods and particle separator)

-

CondWon,secure

Mast and control rods

-

Check for chafing

Oil cooler air intake scoop and screen

-

Secure, c1ear of foreign objects Clean, clear of foreign objects

Oil cooler air outlet Interior Check

NOTE

*

Under sand/dust conditions, make certain that SANDFILTER switch is ON before switching battery on so that bypass door remains closed.

Engine air cleaner system

-

Check function

SANDFILTER switch

-

ON; check that SANDF. caution light comes on for approx. 2 seconds (if bypass door was open), that bypass door closes, and that both blowers come on.

SANDFILTER switch

-

OFF (as required); check that SANDF. caution light comes on for approx. 2 seconds, that bypass door opens, and that both blowers go off.

To be checked before each flight

Revision 18

CHAPTER 101 Page 31

eeurocopter

, . 8Il

MAINTENANCE MANUAL 80105

EAOO Compeny

-,

Interior Check NOTE

If use of the particle separator is necessary during engine starting, pull the two SANDF. BLWR circuit breakers so that the bypass door remains c10sed and the blowers are off.

868 IR Search- and landing Iight 400/200 W

*

IR Search- and landing light unit

-

Condition, stowed

Before night flights: IR Search- and landing light

-

Function

Annunciator Iight LDG L1GHT

-

Function

-

To be checked before each flight

CHAPTER 101 Page 32

Revision 25

O~~er 101 - 5

MAINTENANCE MANUAL SO 105

SUPPLEMENTARY CHECK 25/50 FH

101 - 5.1

Supplementary Check 25/50 Fh Basic-Helicopter

101 - 5.1.1 Supplementary Check 25 Fh Basic-Helicopter

Registration No.:

_

H/C Serial No.:

_

Total Hours:

------ Fh

Reference

Inspection or Maintenance Work

Initial

GENERAL (1 )

Review aircraft log book and ensure all recorded discrepancies have been corrected

(2)

Ensure compliance with all applicable airworthiness directives and manufacturer's (ECO) directives

(3)

Ensure compliance with all supplementary inspections and special inspections

(4)

Ensure life-limited parts do not exceed service life

(5)

Ensure TBO-components do not exceed TBO

(6)

Ensure all required inspections of engines, equipment and components have been performed according to respective manufacturer's documentation

(7)

Record compliance with these inspections in Historical Record 11 - MAIN TRANSMISSION

(1)

EFFECTIVITY

No electrical chip detector installed:

11-18

Inspect magnetic plug of main transmission for deposits and clean magnetic plug 41 - MAIN ROTOR CONTROLS

(1)

~

Deleted

.L..-

_

63 - LUBRICATION SYSTEM (1)

EFFECTIVITY

Ram air ventilation not installed:

Visually inspect baffle plate, located between oil cooler and fan, and attaching clamps for cracks. Table 101-5.1 - Supplementary Check 25 Fh Basic-Helicopter (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 23

CHAPTER 101 Page 33

I

MAINTENANCE MANUAL 80 10S

101 - 5.1.2 Supplementary Check 50 Fh Basic-Helicopter

Registration No.:

_

_ Total Hours:

H/C Serial No.:

Inspection or Maintenance Work

Reference

Fh

Initial

GENERAL

(1 )

Review aircraft lag book and ensure all recorded discrepancies have been corrected

(2)

Ensure compliance with all applicable airworthiness directives and manufacturer's (ECO) directives

(3)

Ensure compliance with all supplementary inspections and special inspections

(4)

Ensure lite-Iimited parts do not exceed service lite

(5)

Ensure TBO-components do not exceed TBO

(6)

Ensure all required inspections of engines, equipment and components have been performed according to respective manufacturer's documentation

(7)

Record compliance with these inspections in Historical Record 11 - MAIN TRANSMISSION

(1)

EFFECTIVITY

No electrical chip detector installed:

11-18

Inspect magnetic plug of main transmission for deposits and clean magnetic plug . 32 - TAIL ROTOR DRIVE (1)

Inspect magnetic plugs of tail rotor gearbox and intermediate gearbox 32-56 for deposits and clean magnetic plugs 41 - MAIN ROTOR CONTROLS

I

(1)

Deleted 63 - LUBRICATION SYSTEM

(1)

EFFECTIVITY

Ram air ventilation not installed:

Visually inspect baffle plate, located between oil cooler and fan, and attaching clamps for cracks Table 101-5.2 - Supplementary Check 50 Fh Basic-Helicopter (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 34

Revision 23

.eurocopter

, . lIfl

MAINTENANCE MANUAL SO 105

EAOS Compony

101 - 6

SUPPLEMENTARY CHECK 100 FH

101 - 6.1

Supplementary Check 100 Fh Basic-Helicopter

Registration No.:

_

H/C Serial No.:

_

Total Hours:

Inspection or Maintenance Work

Fh

Reference

Initial

GENERAL (1 )

Review aircraft log book and ensure all recorded discrepancies have been corrected

(2)

Ensure compliance with all applicable airworthiness directives and manufacturer's (ECD) directives

(3)

Ensure compliance with all supplementary inspections and special inspections

(4)

Ensure life-Iimited parts do not exceed service life

(5)

Ensure TSO-components do not exceed TSO

(6)

Ensure all required inspections of engines, equipment and components have been performed according to respective manufacturer's documentation

(7)

Record compliance with these inspections in Historical Record 11 - MAIN TRANSMISSION

(1 )

Inspect magnetic plug of main transmission for deposits and clean magnetic plug

11-18

(2)

Visually inspect area of support tube f1ange for cracks

11-3, step 12.

14 - MAIN ROTOR BLADE (1 )

EFFECTIVITY

Main rotor blade type 2

14-3, step 13.

First time at 1000 Fh TSN of main rotor blade: Inspect main rotor blade for bulging in the vicinity of balance weight 1

31 - TAIL BOOM ASSEMBLY (1)

EFFECTIVITY

Tail boom assemblies up to SIN 350, if AS 15 not accomplished:

Remove tail rotor shaft fairing and visually inspect in the vicinity of the three bearing brackets (P/N 105-30251.17/.181.19) for cracks. Refer to AS 15 for further limitations (2)

Inspect tail rotor gearbox attach fitting in vertical fin for loose rivets and cracks

31-2, step 5.

Table 101-6.1 - Supplementary Check 100 Fh Sasic-Helicopter (1 of 2)

Revision 24

CHAPTER 101 Page 35

---------------_._._-.-- _--_._-------...

tDeurocopter 8ft EAOS

MAINTENANCE MANUAL BO 105

Company

Inspection or Maintenance Work

Reference

-

Initial

32 - TAIL ROTOR DRIVE (1)

Inspect magnetic plugs of tail rotor gearbox and intermediate gearbox 32-56 for deposits and clean magnetic plugs

(2)

EFFECTIVITY

"Single webbed" type of gearbox housing (see Fig. 32-23): Visually inspect flange to housing transition area for cracks and conditions indicating presence of cracks, such as oil leakage and accumulation of dirt 33 - TAIL ROTOR

(1)

Without disassembly, inspect spherical bearings in fork end of tail rotor shaft for play

33-21, step 1.c.

(2)

EFFECTIVITY

33-16, step 2.

Tail rotor blade mounting forks made from aluminum alloy P/N 105-31711, 105-31722:

Inspect blade mounting forks for cracks NOTE

Remove tail rotor blade prior to inspection

34-4, 34-5

34 - TAIL ROTOR BLADE (1)

EFFECTIVITY

Pre S8 80 105-30-112: all tail rotor blades except P/N: 105-31791,105-317915, 105-31793, 105-31970, 105-31980 Post S8 80 105-30-112: all tail rotor blades except 80 105 C8S-5KLH and 80 105 C8-3

34-2, steps 2., 4., 6. thru 9., 12., 13.

Inspect tail rotor blade for impact damage and cracks in surface protection. The cover tape in the nose area must not be removed for this purpose. 41 - MAIN ROTOR CONTROLS (1)

EFFECTIVITY

Lock washer not installed:

41-3, step 4.c.

-

Inspect bolts connecting rotating control rods to controllevers of main rotor head for tightness 61 - ENGINE (1)

Visually inspect exhaust clamps for cracks, particularly near latches

1_6_1-_3

_

63 - LUBRICATION SYSTEM (1)

EFFECTIVITY

Ram air ventilation not installed:

Visually inspect baffle plate, located between oil cooler and fan, and attaching clamps for cracks Table 101-6.1 - Supplementary Check 100 Fh 8asic-Helicopter (2 of 2)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 36

Revision 25

EUROCOPTER

101 - 6.2

MAINTENANCE MANUAL 80105

Supplementary Check 100 Fh Optional Equipment

Registration No.:

H/C Serial No.:

_

_

Total Hours:

Inspection or Maintenance Work

------ Fh

Reference

Initial

GENERAL (1 )

Review aircraft log book and ensure all recorded discrepancies have been corrected

(2)

Ensure compliance with all applicable airworlhiness directives and manufacturer's (ECO) directives

(3) (4)

Ensure compliance with all supplementary inspections and special inspections Ensure life-limited parls do not exceed service Iife

(5)

Ensure TBO-Components do not exceed TBO

(6)

Record compliance with these inspections in Historical Record 831 - LONG RANGE FUEL TANK

....:(---:1)~_C_he_c_k_lo_n....::g::....r_a_n.:::..ge_fu_e_1 t_a_nk_fo_r_c_on_d_it_io_n---:(:-..it_ta_n_k_re_m_ai_ns_in_st_a_lIe_d....:..)_ _1_8_31_~_4

_

845 - CHIP WARNING INDICATION

(1)

Inspect electrical chip detector on main transmission tor deposits. then clean and functionally check chip detector

845-5

857 - CONTINUOUS IGNITION SYSTEM (1)

Check spark igniters for condition

'-8-57---4------.-----

Table 101-6.2 - Supplementary Check 100 Fh Optional Equipment

(1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 37

MAINTENANCE MANUAL BO 105

EUROCOPTER

BLANK PAGE

CHAPTER 101 Page 38

Revision 18

EUROCOPTER

MAINTENANCE MANUAL 80 105

101 - 7

12-MONTH INSPECTION

101 - 7.1

12-Month Inspection Basic-Helicopter

Registration No.:

_

H/C Serial No.:

_

Total Hours:

Inspection or Maintenance Work

Fh

Reference

Initial

GENERAL (1 )

Review aircraft log book and ensure all recorded discrepancies have been corrected

(2)

Ensure compliance with all applicable airworthiness directives and manufacturer's (ECO) directives

(3)

Ensure compliance with all supplementary inspections and special inspections

(4)

Ensure Iife-Iimited parts do not exceed service lite

(5)

Ensure TBO-Components do not exceed TBO

(6)

Ensure all required inspections of engines, equipment and components have been performed according to respective manufacturer's documentation

(7)

Record compliance with these inspections in Historical Record 11 - MAIN TRANSMISSION

(1)

Remove magnetic plug and test magnetic retaining force

11-17,11-19, 11-18,02-14

(2)

EFFECTIVITV Transmission mounting struts P/N 105-10161 and 11-3, step 10. 105-10162: Inspect transmission mounting struts for condition

,21 - FUSELAGE (1)

Inspect landing gear mounting brackets and surrounding fuselage area for condition

21-3, step 10.

(2)

Clean, grease and functionally check jettison device of cockpit doors. Renew lead wire seal

21-4

32 - TAIL ROTOR ORIVE (1)

Remove magnetic plugs of intermediate gearbox and tail rotor gearbox and test their magnetic retaining force

32-9,02-14

41 - MAlN ROTOR CONTROLS (1)

Visually inspect seals on upper rod ends of control rods for damage

41-3

The following control rods are affected:

(2)

-

Vertical control rods below hydraulic unit (3 off)

-

control rods between hydraulic unit and mixing lever assy (3 off)

-

rotating control rods (4 off)

Check rigging of collective control torces

102-16, step 9.

Table 101-7.1 -12-Month Inspection Basic-Helicopter (1 of 3) Revision 18

CHAPTER 101 Page 39

EUROCOPTER

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

41 - MAlN ROTOR CONTROLS (3)

EFFECTIVITY Aotating control rods P/N 105-13121: Distinguishing feature of control rod:

0.0. of tube is 20 mm . Visually inspect reinforcement sleeves on control rod ends for cracks. Aeplace cracked control rods (4)

Clean swash plate sliding surface on support tube. Move swash plate to upperrnost position to expose sliding surface. Use cleaning solvent (CM 201, 202 or 217) 42 - TAIL ROTOR CONTROLS

(1)

Visually inspect seals on rod end and clevis for damage

42-3

Following rods are affected:

(2)

-

control rod in the tail boom

-

control rod in vertical fin (upper c1evis)

Control rod in vertical fin: Visual inspect sealing of blind hole in fork end for damage 43 - HYDRAULlC SYSTEM 43-11

(1 )

Inspect hydraulic system for condition

(2)

Spray-coat N2-lever (droop-compensation) with corrosion preventive compound (CM 508)

(3)

Check filter contamination indicator (lateral indicator pin configuration) 43-14

(4)

Functionally test hydraulic system

43-15

(5)

Perform ground run check of selector valve setting

43-16 or 43-16A

(6)

Inspect system 1 selector valve for corrosion

43-13

Table 101-7.1 -12-Month Inspection Basic-Helicopter (2 of 3)

CHAPTEA 101 Page40

Aevision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

700 - STANDARD EQUIPMENT (2)

Inspect cabin ventilation for condition, check for function

(3)

Inspect identification and other markings for legibility, and adhesive-backed decals for damage and proper adhesion

(4)

Inspect harnesses, buckles and inertia reels for condition

704-2

701-2 step 5, 6 and 7

91 - INSTRUMENT SYSTEM (1 )

Ventilate dual torque indication system

91-57

(2)

Inspect instruments for condition

91-4

(3)

Clean and drain pitot-static system, inspect for condition and check for function

91-9 thru 91-12

(4)

Inspect magnetic compass for condition and function and compensate magnetic compass

91-24 thru 91-26

(5)

Calibrate TOT indication system

91-45

(6)

Inspect instrument panel, center panel and overhead panel for presence, legibility and security of labels and placards NOTE Replace missing placards and rebond separated placards 92 - ELECTRICAL SYSTEMS

--.:(,--1):.-_In_s..:....p_ec_t_s_o_ck_e_t_o_f_a_nt_i-_co_I_lis_io_n-----.:lig::....h_t_fo_r_c_o_n_di_ti_on

1_9_2-_1_16

_

Table 101-7.1 -12-Month Inspection Basic-Helicopter (3 of 3)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 41

MAINTENANCE MANUAL BO 105

EUROCOPTER

BLANK PAGE

CHAPTER 101 Page 42

Revision 18

MAINTENANCE MANUAL 80105

101 -7.2

12-Month Inspection Optional Equipment

Registration No.:

_

H/C Serial No.: - - - - - - Total Hours:

Inspection or Maintenance Work

- - - - - - Fh

Reference

Initial

GENERAL (1)

Review aircraft log book and ensure all recorded discrepancies have been corrected

(2)

Ensure compliance with all applicable airworthiness directives and manufacturer's (ECO) directives

(3)

Ensure compliance with all supplementary inspections and special inspections

(4)

Ensure life-limited parts do not exceed service life

(5)

Ensure TBO-eomponents do not exceed TBO

(6)

Record compliance with these inspections in Historical Record 836 - RESCUE HOIST ASSEMBLY

(1)

Lubricate winch unit

836-22

(2)

Inspect relay box for condition

836-3B

I

845 - CHIP WARNING INDICATION (1)

Remove chip detector and test magnetic retaining force

845-4, 845-6, 02-14

Table 101-7.2 - 12-Month Inspection Optional Equipment

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 25

CHAPTER 101 Page 43

Aeurocopter ~

MAINTENANCE MANUAL 80105

811 EAOO CDmpnny

-

-BLANK PAGE

-

CHAPTER 101 Page 44

MAINTENANCE MANUAL 80105

101 - 8

PERIODICAL INSPECTION

101 - 8.1

Periodical Inspection Basic Helicopter

Registration No.:

_

H/C Serial No.:

_ Total Hours:

Inspection or Maintenance Work

Fh

Reference

Initial

GENERAL (1 ) Review aircraft log book and ensure all recorded discrepancies have been corrected (2) Ensure compliance with all applicable airworthiness directives and manufacturer's (ECD) directives (3) Ensure compliance with all supplementary inspections and special inspections (4) Ensure life-limited parts do not exceed service life (5) Ensure TBO-components do not exceed TBO (6) Ensure all required inspections of engines, equipment and components have been performed according to respective manufacturer's documentation (7) Record compliance with these inspections in Historical Record 11 - MAIN TRANSMISSION (1 ) Inspect main transmission and attached parts for condition

11-3 step 1. thru 16.

(2) Remove magnetic plug and inspect for deposits, clean and test for magnetic retaining force

11-17,11-18, 11-19,02-14

(3) EFFECTIVITV

H/C up to S/N 690 if not installed with washers P/N 105-13104.17:

Inspect underside of rotor mast flange in the area of bores, including webs between the bores, for cracks, using a magnitying glass 12 - ROTOR BRAKE SYSTEM (1) Inspect rotor brake system for condition

112-3

13 - MAlN ROTOR SYSTEM (1) Inspect main rotor system for condition

13-3

(2) Remove primary bolts and secondary bolts, clean and inspect fer condition; crack inspection not necessary

13-10, -11, -14, -16, -17, -18

Table 101-8.1 - Periodical Inspection Basic-Helicopter (1 of 6)

Revision 23

CHAPTER 101 Page45

I

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

14 - MAIN ROTOR BLADE (1) Inspect main rotor blade tor condition

NOTE

14-2 or 14-3

Note tollowing when inspecting erosion protective shells tor debonding: When tirst-time debonds are tound, or existing debonds have increased in area, the inspection shall be repeated after 50Fh. Only when an inspeetion has revealed no further debonding do the periodic inspeetion intervals re-apply

21 - FUSELAGE (1 ) Inspect tollowing trames tor cracks:

-

upper corners offrames 7,8, 9, torward and aft, and diagonal trame and trame 10

-

lower trame segments 7 and 8

NOTE

Stop-drill cracks. Repair any cracks in the upper area ot trames 7 and 9 and diagonal trame within the next 50Fh. Repair any cracks in the upper area ot frames 8 and 10 and in the lower area of frames 7 and 8 within the next 600Fh. Check for crack propagation every 200Fh. Repair cracks which show propagation within the next 50Fh.

(2) Inspect landing gear mounting brackets and surrounding tuselage area tor condition

21-3, step 10.

(3) Inspect transmission strut attach fittings and engine mount attach fittings tor condition and inspect fuselage area adjacent to attach tittings for loose rivets and cracks

21-3, step 5 and 7

(4) Clean, grease and functionally check jettison device of cockpit doors. Renew lead wire seal

21-4

(5) Ensure drain holes are not obstrueted

21-3, step 4.

31 - TAlL BOOM (1) EFFECTIVlTV

Tail boom assemblies up to S/N 350 if AB 15 not accomplished:

Remove tail rotor shaft fairing and visually inspect in the vicinity of the three bearing brackets P/N 105-30251.17/.18/.19 for cracks. Reter to AB 15 for further Iimitations (2) Inspect tail boom assembly far condition

31-2

32 - TAIL ROTOR DRIVE (1) Inspeet tail rotor drive tor condition

32-3

(2) Remove magnetic plugs of intermediate gearbox and tail rotor gearbox and test their magnetic retaining force

32-9, 02-14

Table 101-8.1 - Periodical Inspection Basic-Helicopter (2 of 6) CHAPTER 101 Page 46

Revision 24

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

32 - TAlL ROTOR DRIVE (3) EFFECTIVITV

"Single webbed" type of gearbox housing (see Fig.32-23):

Visually inspect flange to housing transition area for cracks and conditions indicating presence of cracks, such as oil leakage and accumulation of dirt 33 - TAIL ROTOR (1 ) Inspect tail rotor for condition

33-4, step 1 - 7

(2) Without disassembly, inspect spherical bearings in fork end of tail rotor shaft

33-21, step 1.c

(3) EFFECTIVITV

Tail rotor blade mounting forks made from aluminum alloy P/N 105-31711, 105-31722:

33-14 thru 33-18

Remove and inspect blade mounting forks for condition (4) Remove bellcrank assy and inspect for condition

33-9 thru 33-12

(5) Check ball bearings of sliding sleeve for proper running and absence of 33-27, step 14. play (6) Remove bolt connecting tail rotor shaft to tail rotor head, and clean and 33-21, step 1.e. inspect bolt for condition 34 - TAIL ROTOR BLADE _(_1)_ln_s-,-p_e_ct_t_a_il_ro_to_r_b_la_d_e_s_f_or_c_o_n_d_iti_0_n

I_34_-_2

_

41 - MAIN ROTOR CONTROLS (1 ) Inspect flight control components (boosted section of flight controls) located above hydraulic system including swash plate for condition

41-3

(2) Check swash plate bearing for proper running

41-73

(3) Check rigging of collective control forces

102-16, step 9.

(4) Clean swash plate sliding surface on support tube. Move swash plate to uppermost position to expose sliding surface. Use cleaning solvent (CM 201, 202 or 217) (5) Visually inspect seals on upper rod ends of control rods for condition

41-3

The following control rods are affected:

-

Vertical control rods below hydraulic unit (3 off) control rods between hydraulic unit and mixing rever assy (3 off) rotating control rods (4 off)

(6) EFFECTIVITV

Rotating control rods P/N 105-13121: Distinguishing feature of control rod:

0.0. of tube is 20 mm Visually inspect reinforcement sleeves on control rod ends for cracks. Replace cracked control rods Table 101-8.1 - Periodical Inspection Basic-Helicopter (3 of 6)

Revision 22

CHAPTER 101 Page 47

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

42 - TAIL ROTOR CONTROLS (1 ) EFFECTIVITV

H/C up to SIN 310 if S8-801 05-30-17 not accomplished:

42-33, step 4.

Remove control rod in the tail boom and inspect chafe protection for condition and grease sliding areas (2) Visually inspect seals on rod end and clevis for damage

42-3

Following rods are affected:

-

control rod in the tail boom

-

control rod in vertical fin (upper clevis)

(3) Control rod in vertical fin: Visual inspect sealing of blind hole in fork end for damage

43 - HYDRAULlC SYSTEM (1 ) Inspect switchover control Iinkage for play

43-17 or 43-17A

(2) Inspect hydraulic system for condition

43-11

(3) Spray-coat N2-lever (droop-compensation) with corrosion preventive compound (CM 508) (4) Check filter contamination indicator (lateral indicator pin configuration)

43-14

(5) Functionally test hydraulic system

43-15

(6) Perform ground run check of selector valve setting

43-16 or 43-16A

(7) Inspect system 1 selector valve for corrosion

43-13

51 - LANDING GEAR ...;(...;1)_ln_s-,-p_ect_la_n_d_in...;g;;...g;:..e_a_r_fo_r_c_o_n_dit_i_on

1_5_1-_2

_

61 - ENGINE

I

(1 ) Inspect exhaust clamps for corrosion and cracks

61-34

(2) Inspect engine accessories and mounting struts fer condition

61-3

(3) Remove anti-icing valve actuators and inspect mounting brackets for condition

61-37 thru 61-39

(4) Remove chip detectors and test their magnetic retaining force

02-14

NOTE

For removal and installation procedures, see Allison OMM 10W2 or 5W2 as applicable

62 - FUEL SYSTEM (1 ) Inspect fuellines in the engine compartment for condition

62-3

(2) Check fuel differential pressure switch for function

62-39

(3) Perform functional test and leakage test of fuel shutoff valves

92-82, 92-83

Table 101-8.1 - Periodical Inspection 8asic-Helicopter (4 of 6)

CHAPTER 101 Page48

Revision 24

eeurocopter

MAINTENANCE MANUAL BO 10S

Initial

Reference

Inspection or Maintenance Work 63 - LUBRICATION SYSTEM (1) EFFECTIVITY

Ram air ventilation not installed:

Visually inspect baffle plate, located between oil cooler and fan, and attaching clamps for cracks (2) Inspect lubrication system for condition

63-3

(3) Remove oil drain plugs of oil tank and test the magnetic retaining force of their respective magnetic plugs

63-4, step 1.b, 02-14

64 - FIREWALLS (1) Inspect fire walls for condition

1_6_4-_2

i...-

_

65 - ENGINE OPERATION AND CONTROL (1) Inspect engine operation and controllinkages for condition

165-3

700 - STANDARD EQUIPMENT (1) Inspect pilot and copilot seats for condition

701-2

(2) Inspect cabin equipment for condition

702-2

(3)

704-2

Inspect cabin ventilation for condition, check for function

(4) Inspect identification and other markings for legibility, and adhesive-backed decals for damage and proper adhesion (5) Inspect hamesses, buckles and inertia reels for condition

701-2 step 5., 6. and 7.

91 - INSTRUMENT SYSTEM (1) Ventilate dual torque indication system

91-57

(2) Inspect instruments for condition

91-4

(3) Clean and drain pitot-static system, inspect for condition and check for function

91-9 thru 91-12

(4) Inspect magnetic compass for condition and function and compensate magnetic compass

91-24 thru 91-26

(5) Calibrate TOT indication system

91-45

(6) Inspect instrument panel, center panel and overhead panel for presence, legibility amd security of labels and placards

NOTE

Replace missing placards and rebond separated placards

92 - ELECTRICAL SYSTEMS (1) Inspect battery bonding jumper for tight installation and unimpaired surface protection (2) Check voltage regulator setting

92-17

Table 101-8.1 - Perlodlcallnspectlon Baslc-Hellcopter (5 of 6)

Revision 22

CHAPTER 101 Page49

I

eeurocopter

MAINTENANCE MANUAL 80 105

Inspection or Maintenance Work

Reference

Inltial

92 - ELECTRICAL SYSTEMS (3) Inspect socket ot anti-eollision Iight tor condition

92-116

(4) Remove starter-generator and inspect carbon brushes

92-20, 92-20A

Table 101-8.1 - Periodicallnspection Basic-Helicopter (6 of 6)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 PageSO

Revision 22

eeurocopter

MAINTENANCE MANUAL 80105

101 - 8.2 Periodical Inspection Optional Equipment

Registration No.:

_

H/C Serial No.:

_ Total Hours:

Fh Inltlal

Reference

Inspectlon or Malntenance Work GENERAL

(1 ) Review aircraft log book and ensure all recorded discrepancies have been corrected (2) Ensure compliance with all applicable airworthiness directives and manufacturer's (ECO) directives (3) Ensure compliance with all supplementary inspections and special inspections (4) Ensure Iife-Iimited parts do not exceed service Iife (5) Ensure TBO-COmponents do not exceed TBO (6) Record compliance with these inspections in Historical Record 831 - LONG RANGE FUEL TANK

~(1-:)_C_h_ec_k_l_on...;g:...-r_a_n=-ge_fu_e_1t_a_nk_fo_r_c_on_d_it_io_n-e(:.-if_ta_n_k_r_em_ai_n_s_in_s_ta_"_ed...,:)_ _1_8_31_-4

l..-

_

836 - RESCUE HOIST ASSEMBLY

~(1-:)_L_'_ub_r_ica_t_e_w_in_c_h_U_n_it

1_8_36_-_22

.......L..

845 - CHIP WARNING INDICATION

(1) Remove chip detector, check, clean, test for function and test magnetic 845-4,845-5, retaining force 845-6,02-14 854 - MAIN ROTOR BLADE FOLDING SYSTEM

(1) Remove locking lever assembly, clean and inspect for condition (crack inspection not required)

854-3, step 1

(2) Remove locking lever assembly -

Clean and inspect nickel-plated bolts for condition, and provide with 854-3, step 1.a corrosion protection (crack inspection not required) and 854-4, step 2.f

-

Clean and inspect solid film lubricant-coated bolts for condition (crack 854-3, step 1.b inspection not required). Coat boltwith lubricant (CM146) and 854-4, step 2.g Table 101-8.2 - Periodicallnspectlon Optional Equlpment (1 of 2)

Revision 22

CHAPTER 101 Page 51

_

EUROCOPTER

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

857 - CONTINUOUS IGNITION SYSTEM (1) Check spark igniters tor condition

857-4

(2) Visually inspect noise suppressor and accessible parts ot wiring tor condition

857-4

Table 101-8.2 - Periodicallnspection Optional Equipment (2 of 2)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 52

Revision 18

O~~er 101 - 9 101 - 9.1

MAINTENANCE MANUAL 80 105

EXTENDED PERIODICAL INSPECTION Extended Periodical Inspection Basic Helicopter

Registration No.:

_

H/C serial No.:

_

Total Hours:

Inspection or Maintenance Work

Fh

Reference

Initial

GENERAL

(1) Review aircraft log book and ensure all recorded discrepancies have been corrected (2) Ensure compliance with all applicable airworthiness directives and manufacturer's (ECO) directives

(3) Ensure compliance with all supplementary inspections and special inspections

.

(4) Ensure life-limited parts do not exceed service life (5) Ensure TBO-components do not exceed TBO (6) Ensure all required inspections of engines, equipment and components have been pertormed according to respective manufacturer's documentation

(7) Record compliance with these inspections in Historical Record

11 - MAIN TRANSMISSION (1) Inspect main transmission and attached parts for condition

11-3, step 1 thru 16

(2) Remove magnetic plug and inspect for deposits, clean and test for magnetic retaining force

11-17,11-18, 11-19,02-14

(3) EFFECTIVITV

H/C up to S/N 690 if not installed with washers P/N 105-13104.17:

Inspect underside of rotor mast tlange in the area of bores, including webs between the bores, for cracks, using a magnifying glass

12 - ROTOR BRAKE SYSTEM (1) Inspect rotor brake system tor condition

13 - MAIN ROTOR SYSTEM (1) Inspect main rotor system fer condition

13-3

(2) Remove primary bolts and secondary bolts, clean and inspect tor condition; crack inspection not necessary

13-10, -11, -14, -16, -17, -18

Table 101-9.1 - Extended Periodical Inspection Basic-Helicopter (1 of 5)

Revision 23

CHAPTER 101 Page 53

I

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

14 - MAlN ROTOR BLADE (1) Inspect main rotor blade for condition

NOTE

_

14-2 or 14-3

Note following when inspeeting erosion protective shells for debonding: When first-time debonds are found, or existing debonds have increased in area, the inspection shall be repeated after 50Fh. Only when an inspection has revealed no further debonding do the periodic inspeetion intervals re-apply

21 - FUSELAGE (1 ) Inspect fuselage forcondition

21-3

(2) Inspect following frames for cracks:

-

uppercorners offrames 7, 8, 9, forward and aft, and diagonal frame and frame 10

-

lower frame segments 7 and 8

NOTE

Stop-drill cracks. Repair any cracks in the upper area of frames 7 and 9 and diagonal frame within the next 50Fh. Repair any cracks in the upper area of frames 8 and 10 and in the lower area of frames 7 and 8 within the next SOOFh. Check for crack propagation every 200Fh. Repair cracks which show propagation within the next 50Fh.

(3) Clean, grease and funetionally check jettison device of cockpit doors. Renew lead wire seal

21-4

31 - TAIL BOOM (1) EFFECTIVITV

Tail boom assemblies up to S/N 350 if AS 15 not accomplished:

Remove tail rotor shaft fairing and visually inspeet in the vicinity of the three bearing brackets P/N 105-30251.17/.18/.19 for cracks. Refer to AB 15 for further Iimitations (2) Inspeet tail boom assembly for condition

31-2

32- TAIL ROTOR DRIVE (1) Inspect tail rotor drive for condition (2) EFFECTIVITY

32-3

"Single webbed" type of gearbox housing (see Fig.32-23):

Visually inspect flange to housing transition area for cracks and conditions indicating presence of cracks, such as oil leakage and accumulation of dirt

33 - TAIL ROTOR (1) Inspeet tail rotor for condition

133-4, step 1 -

7

Table 101-9.1 - Extended Periodical Inspeetion Basic-Helicopter (2 of 5) CHAPTER 101 Page 54

Revision 23

MAINTENANCE MANUAL 80105

Inspection or Maintenance Work

Initial

Reference

33 - TAIL ROTOR (2) Without disassembly, inspect spherical bearings in fork end of tail rotor shaft for play (3) EFFECTIVITV

Tail rotor blade mounting forks made from aluminum alloy P/N 105-31711, 105-31722:

33-21, step 1.c 33-14 thru 33-18

Remove and inspect blade mounting forks for condition (4) Remove bellcrank assy and inspect for condition

33-9 thru 33-12

(5) Check ball bearings of sliding sleeve for proper running and absence of 33-27, step 14 play (6) Remove bolt connecting tail rotor shaft to tail rotor head, and clean and 33-21, step 1.e inspect bolt for condition

34 - TAIL ROTOR BLADE ...;(....:1)_ln_s..:..p_ect_t_ai_1_ro_to_r_b_la_d_e_s_fo_r_c_O_n_d_iti_O_n

I_3_4-_2

...1.-

41 - MAIN ROTOR CONTROLS (1) Inspect all flight control components for condition

41-3

(2) Check swash plate bearing for proper running

41-73

(3) Check rigging of collective control forces

102-16, step 9

(4) Clean swash plate sliding surface on support tube. Move swash plate to uppermost position to expose sliding surface. Use cleaning solvent (CM 201, 202 or 217) 42 - TAIL ROTOR CONTROLS (1 ) EFFECTIVITV

H/C up to S/N 310 if SB-B0105-30-17 not accomplished:

42-33, step 4

Remove control rod in the tail boom and inspect chafe protection for condition and grease sliding surface (2) Visually inspect seals on rod end and clevis for damage

42-3

Following rods are atfected:

-

control rod in the tail boom

-

control rod in vertical fin (upper clevis)

(3) Control rod in vertical fin: Visually inspect sealing of blind hole in fork end for damage 43 - HYDRAULIC SYSTEM (1 ) Inspect switchover control linkage for play

43-17 or 43-17A

(2) Inspect hydraulic system for condition

43-11

(3) Spray-coat N2-lever (droop-compensation) with corrosion preventive compound (CM 508) (4) Check filter contamination indicator (lateral indicator pin configuration)

43-14

Table 101-9.1 - Extended Periodical Inspection Basic-Helicopter (3 of 5)

Revision 21

CHAPTER 101 Page 55

_

O~er

MAINTENANCE MANUAL 80 105

Reference

Inspection or Maintenance Work

Initial

43 - HYDRAULlC SYSTEM

(5) Functionally test hydraulic system

43-15

(6) Perform ground run check of selector valve setting

43-16 or 43-16A

(7) Inspect system 1 selector valve for corrosion

43-13

51 - LANDING GEAR

-.;.(1-.;.)_ln_s.;..p_ect_la_n_d_in.....;g;.,.g;:..e_a_r_fo_r_c_o_n_dit_io_n

1_5_1-_2

_

61 - ENGINE

I

(1 ) Inspect exhaust clamps for corrosion and cracks

61-34

(2) Inspect engine accessories and mounting struts for condition

61-3

(3) Remove anti-icing valve actuators and inspect mounting brackets for condition

61-37,61-38, 61-39

(4) Remove chip detectors and test their magnetic retaining force

02-14

For removal and installation procedures, see Allison OMM 10W2 or 5W2 as applicable

NOTE

62 - FUEL SYSTEM

(1 ) Inspect fuel lines in the engine compartment for condition

62-3

(2) Check fuel differential pressure switch for function

62-39

(3) Perform functional test and leakage test of fuel shutoff valves

92-82, 92-83

63 - LUBRICATION SYSTEM

(1 ) EFFECTIVITY

Ram air ventilation not installed:

Visually inspect baffle plate, located between oil cooler and fan, and attaching clamps for cracks (2) Inspect lubrication system for condition

63-3

(3) Remove oil drain plugs of oil tank and test the magnetic retaining force of their respective magnetic plugs

63-4, step 1.b, 02-14

64 - FIREWALLS

....;.(1....;.)_ln_s..;..p_ect_f_ire_w_a_lIs_f_o_r_co_n_d_it_io_n

1_64_-_2

_

65 - ENGINE OPERATION AND CONTROL

(1) Inspect engine operation and control linkages for condition

1_6_5-_3

_

700 - STANDARD EQUIPMENT

(1 ) Inspect pilot and copilot seats for condition

701-2

(2) Inspect cabin equipment for condition

702-2

(3) Inspect cabin ventilation for condition, check for function

704-2

(4) Inspect identification and other markings for legibility, and adhesive-backed decals for damage and proper adhesion Table 101-9.1 - Extended Periodicallnspection Basic-Helicopter (4 of 5) CHAPTER 101 Page 56

Revision 24

EUROCOPTER

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

91 - INSTRUMENT SYSTEM (1 ) Ventilate dual torque indication system

91-57

(2) Inspect instruments tor condition

91-4

(3) Clean and drain pitot-static system, inspect tor condition and check tor tunction

91-9 thru 91-12

(4) Inspect magnetic compass tor condition and tunction and compensate magnetic compass

91-24 thru 91-26

(5) Calibrate TOT indication system

91-45

(6) Inspect instrument panel, center panel and overhead panel tor presence, legibility amd security ot labels and placards

NOTE Replace missing placards and rebond separated placards 92 - ELECTRICAL SYSTEMS (1 ) Inspect battery bonding jumper tor tight installation and unimpaired surtace protection (2) Check voltage regulator setting

92-17

(3) Inspect socket ot anti-collision light tor condition

92-116

(4) Remove starter-generator and inspect carbon brushes

92-20, 92-20A

Table 101-9.1 - Extended Periodicallnspection Basic-Helicopter (5 of 5)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 57

MAINTENANCE MANUAL 80105

EUROCOPTER

BLANK PAGE

CHAPTER 101 Page58

Revision 18

e

eurocapter

MAINTENANCE MANUAL BO 10S

101 - 9.2 Extended Periodical Inspection Optional Equipment

Registration No.:

_

H/C Serial No.:

_

Total Hours:

Fh

Reference

Inspectlon or Malntenance Work

Inltlal

GENERAL

(1) Review aircraft log book and ensure all recorded discrepancies have been corrected (2) Ensure compliance with all applicable airworthiness directives and manufacturer's (ECO) directives (3) Ensure compliance with all supplementary lnspections and special inspections (4) Ensurelife-limited parts do not exceed service Iife (5) Ensure TBO-Components do not exceed TBO (6) Record compliance with these inspections in Historical Record 831 - LONG RANGE FUEL TANK

...:.(1...;.)_C_he_c_k_lo_n....:g~r_a_ng=-e_fu_e_1ta_nk_fo_r_co_n_d_it_io_n....;(,-if_ta_n_k_re_m_a_i_ns_in_s_ta_lIed----'-)_ _1_8_3_1-4

'-

_

836 - RESCUE HOIST ASSEMBLY o

...:.(1...;.)_·_Lu_b_n_ca_t_e_w_in_c_h_u_n_it

1_8_36-_22

--'-

845 - CHIP WARNING INDICATION

(1) Remove chip detector, check, clean, test for function and test magnetic 845-4, 845-5, retaining force 845-6,02-14 854 - MAlN ROTOR BLADE FOLDING SYSTEM

(1)· Remove locking lever assembly, clean and inspect for condition (crack inspection not required)

854-3, step 10

(2) Remove locking lever assembly -

Clean and inspect nickel-plated bolts for condition, and provide with 854-3, step 1.a corrosion protection (crack inspection not required) and 854-4, step 2.f

-

Clean and inspect solid film lubricant-coated bolts for condition (crack 854-3, step 1.b inspection not required). Coat boltwith lubricant (CM146)and 854-4, step 2.g Table 101-9.2 - Extended Perlodlcallnspectlon Optlonal Equlpment (1 of 2)

Revision 22·

CHAPTER 101 Page59

_

EUROCOPTER

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

857 - CONTINUOUS IGNITION SYSTEM (1) Check spark igniters for condition

857-4

(2) Visually inspect noise suppressor and accessible parts of wiring for condition

857~4

Table 101-9.2 - Extended Periodical Inspection Optional Equipment (2 of 2)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 60

Revision 18

Oeurocopter lIfl

MAINTENANCE MANUAL BO 105

EADS Compeny

101 -10 SUPPLEMENTARY INSPECTION ACCORDlNG TO OPERATING TIME IN FH ANDIOR CALENDAR TIME

101 - 10.1 Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Basic Helicopter

Registration No.:

_

H/C Serial No.:

Inspection or Maintenance Work

_

Interval

Total Hours:

Fh

Initial

Reference

11 - MAIN TRANSMISSION (1 )

EFFECTIVITY

Bolts with P/N 105-60701.15/.16:

150Fh

11-54, 11-55, part A, step 10 or part B, step 5

300Fh

11-59, step 1 and 2, 11-60, step 11

Remove bolts and inspect for condition (2)

EFFECTIVITY

Drive f1ange P/N 4619 302 037 on main transmission:

Check torque of screw on drive f1ange. If torque is too low, remove drive f1ange and inspect for damage (3)

Remove input drive shafts and inspect for condition

(4)

Remove transmission mounting struts and inspect for condition

(5)

EFFECTIVITY

Borg Warner free wheel unit P/N 4638202007:

Remove freewheel unit and inspect for condition (6)

EFFECTIVITY

Kaflex shafts made by Kamatics Company:

Remove drive shafts and send to manufacturer for assessment

4800Fh or 6 years, whichever occurs first

11-54 thru 11-56

3000Fh

11-50 thru 11-52

1200Fh TSN, then every 600Fh 6000Fh or 9 years, whichever occurs firs

11-60, 11-64, 11-67 11-54

I

13 - MAIN ROTOR SYSTEM (1 )

EFFECTIVITY

Quadruple nuts P/N 105-14101.54/.55:

1200Fh

REM106

1200Fh

REM106

Remove quadruple nuts and inspect for cracks (2)

EFFECTIVITY

Bolts P/N 105-14101.76/.77:

Remove bolts and inspect for cracks Table 101-10.1 - Supplementary Inspection according to Operating TIme in Fh and/or Calendar Time Basic Helicopter (1 of 7) Revision 25

I

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MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Interval

Reference

Initial

13 - MAIN ROTOR SYSTEM (3)

EFFECTIVITY

Quadruple nuts P/N 105-14101.19/.20:

Remove upper and lower quadruple nuts and inspect for cracks

1200Fh TSN, then every 300Fh

REM 106

1200Fh TSN, then every 300Fh

REM 106

NOTE Quadruple nuts with serial numbers listed below do not require periodic inspections during their service life. For these quadruple nuts it is also not necessary to install quadruple nuts with the same serial number (also refer to S8 10-18). Serial numbers: Quadruple nuts, upper 105-14101.19 SIN 63, 145 thru 151, 153 thru 172, 197, 198,212 thru 221,247,249 thru 251,269,270,272 thru 281, 283, 290 thru 293 Quadruple nuts, lower 105-14101.20 SIN 63,145 thru 151, 153 thru 171,197,213 thru 221,247,249 thru 251, 269 thru 283,290,292 (4)

EFFECTIVITY

80lts P/N 105-14101.22/.23:

Remove bolts and inspect for cracks (5)

EFFECTIVITY

Main rotor head P/N 105-14101:

Remove main rotor head and inspect for condition per REM 106 (6)

EFFECTIVITY

Main rotor head P/N 105-14104:

Remove main rotor head and inspect for condition per REM 106 (7)

EFFECTIVITY

Quadruple nuts P/N 1121-14102.191.20:

1800Fh or 3 years, whichever occurs first

13-6, REM106

2400Fh or 4 years, whichever occurs first

13-6, REM106

2400Fh

REM106

2400Fh

REM106

Remove, clean and inspect primary and secondary bolts for cracks and condition

2400Fh

13-10, 13-11, 13-14 and 13-16 thru 13-18

(10) Remove, disassemble and inspect driving link assembly for condition

3000Fh

13-20 thru 13-24

-

Remove quadruple nuts and inspect for cracks (8)

EFFECTIVITY

80lts P/N 1121-14102.22/.23:

Remove bolts and inspect for cracks (9)

Table 101-10.1 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time 8asic Helicopter (2 of 7)

CHAPTER 101 Page 62

Revision 25

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MAINTENANCE MANUAL 80 105

un EA06 Compllny

Inspection or Maintenance Work

Interval

Reference

Initial

13 - MAIN ROTOR SYSTEM

(11) EFFECTIVITY

Main rotor head : P/N 105-141081 (PRE ASS-SO 105-10-113); P/N 105-141091 (POST ASS-SO 105-10-113):

Remove main rotor head and inspect for condition per REM 106

4800Fh or 8 years TSN, whichever occurs first, then every 4800Fh or 6 years, whichever occurs first

13-6, REM106

14 - MAIN ROTOR BLADE

(1)

Remove main rotor blade and inspect for condition

1200Fh

14-4,14-5

NOTE Note following when inspecting erosion protective shells for debonding: When first-time debonds are found, or existing debonds have increased in area, the inspection shall be repeated after 50Fh. Only when an inspection has revealed no further debonding do the periodic inspection intervals re-apply. 21 - FUSELAGE

3000Fh or 21-3 when engine(s) is removed, whichever occurs first

(1 )

Inspect bores in the engine mounting fittings for wear

(2)

Inspect doors, windows, structure and tailboom connecting flange for condition

2400Fh

(3)

Visually inspect frame 2L of tail boom (fuselage side) for cracks

2400Fh or 6 years TSN, whichever occurs first, then every 1800Fh or 3 years, whichever occurs first

21-3

2400Fh or 6 years TSN, whichever occurs first, then every 1800Fh or 3 years, whichever occurs first

21-3

NOTE Depending on the operational spectrum of the helicopter and on the existing environmental conditions, different inspection intervals may be established upon consultation with ECD.

(4)

Visually inspect connecting flange of tail boom (fuselage side) and adjacent fuselage areas for condition and cracks, using a magnifying glass NOTE Depending on the operational spectrum of the helicopter and on the existing environmental conditions, different inspection intervals may be established upon consultation with ECD.

21-3, step 1, 2, 3 and 9

Table 101-10.1 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Sasic Helicopter (3 of 7)

Revision 25

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CHAPTER 101 Page 63

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~ en EADS Compeny

Inspection or Maintenance Work

Interval

Reference

Initial

21 - FUSELAGE (5)

Inspect spherical bearings and c1aw bushings in main transmission fittings for condition and play

3000Fh

21-3

22 - COWLlNGS (1)

Remove cowlings and inspect for condition

2400Fh

122-2 thru 22-5

_ _ _ _ _-----.J'-----

...L-

_

31 - TAIL BOOM ASSEMBLY (1)

Remove tail boom and inspect interior and exterior for condition NOTE Depending on the operational spectrum of the helicopter and on the existing environmental conditions, different inspection intervals may be established upon consultation with ECD.

2400Fh or 6 years TSN, whichever occurs first, then every 1800Fh or 3 years, whichever occurs first

31-2,31-5,31-6

32 - TAIL ROTOR ORIVE (1 )

EFFECTIVITY

Tail rotor drive with Bendix shafts and coupling:

Remove shafts and coupling and inspect their exterior and interior surfaces for condition (2)

EFFECTIVITY

Tail rotor drive with laminated disk coupling:

Remove, disassemble and inspect forward short driveshaft, couplings, long driveshaft and aft short driveshaft in vertical fin for condition (3)

Remove intermediate gearbox and tail rotor gearbox and inspect for condition

2400Fh or 4 years, whichever occurs first

32-36, 32-46, 32-40, 32-50

3600Fh or 6 years, whichever occurs first

32-11 thru 32-34

3600Fh or 6 years, whichever occurs first

32-55 thru 32-57 and 32-59 thru 32-61

-

33 - TAIL ROTOR (1 )

Measure play between blade mounting fork and inner sleeve

1200Fh

33-16, step 1.

(2)

Remove bolts connecting laminated strap pack to blade mounting forks, and inspect for condition

1200Fh or 6 years, whichever occurs first

33-16, step 5.

(3)

Remove, disassemble and inspect tail rotor head for condition

2400Fh or 6 years, whichever occurs first

33-14 thru 33-17

(4)

Inspect tail rotor shaft for play

2400Fh

33-4, step 8

Table 101-10.1 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Basic Helicopter (4 of 7)

CHAPTER 101 Page 64

Revision 25

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MAINTENANCE MANUAL BO 105

un EAr:5 Compcny

Inspection or Maintenance Work

Interval

Reference

Initial

34 - TAIL ROTOR BLADE (1)

Inspect tail rotor blade for impact damage and cracks, and inspect installed parts for separation

300Fh

34-2, steps 2., 4. thru 9.,12.,13.

(2)

Remove tail rotor blade and inspect for condition

2400Fh

34-2, 34-4, 34-5

41 - MAIN ROTOR CONTROLS (1 )

EFFECTIVITY

Pitch shaft without bonded brake pads:

1200Fh

41-55

Inspect pitch shaft for condition (2)

Remove, disassemble control rods and inspect for condition. The following control rods are affected:

-

control rods between hydraulic unit and mixing lever assy (3 off)

-

rotating control rods (4 off)

3000Fh or 4 years, whichever occurs first

41-76 thru 41-83

41-27 thru 41-34

(3)

Remove compression springs of longitudinal and lateral trimmers, c1ean and inspect for condition. Lubricate spring case

4 years

(4)

Remove all bolts from the boosted section of the main rotor controls (i.e. above hydraulic unit) and inspect for condition and cracks

3000Fh or 4 years, whichever occurs first

NOTE

Crack inspection per dye penetrant method ASTM-E-1417 or magnetic particle method ASTM-E-1444. The following bolts are affected:

-

lower and upper bolts of the 3 control rods between tandem hydraulic unit and mixing lever assy

-

lower and upper bolts of the 2 control rods between mixing lever assy and swash plate

-

lower and upper bolts of the 4 rotating control rods

NOTE

Perform inspections (5), (6) and (7) on the occasion of main transmission overhaul, if possible

(5)

Remove, disassemble mixing lever assembly and inspect for condition

3000Fh

41-65 thru 41-70

(6)

Inspect swash plate for condition

3000Fh

REM 403

(7)

Remove control rods between mixing lever assy and swash plate and inspect for condition

3000Fh

41-78,41-80, 41-83

42 - TAIL ROTOR CONTROLS (1)

Inspect tail rotor controls for condition

1200Fh

Table 101-10.1 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Basic Helicopter (5 of 7) Revision 25

CHAPTER 101 Page 65

I

·eurocopter •

8l\

MAINTENANCE MANUAL BO 105

EAOS ComplIny

Inspection or Maintenance Work

Interval

Reference

-

Initial

43 - HYDRAULlC SYSTEM

ot hydraulic system

(1 )

Inspect tlat springs correct tunctioning

11 tor

(2)

Remove, disassemble and inspect control rods tor condition

(3)

Change filter elements

1200Fh TSN, then every 300Fh

43-19

3000Fh or 4 years, whichever occurs first

43-36,43-37, 41-79,41-80

2 years

43-31, 43-32

NOTE It the hydraulic unit was not returned to service after filter replacement, the filter need not be replaced again until 2 years after return to service (4)

EFFECTIVITY

Bushings P/N 105-45511:

Distinguishing feature: These bushings can be rotated in installed position.

2400Fh TSN, then every 600Fh

43-11, step 14.

Remove hydraulic unit and inspect guide bushings

ot couplings tor play 51 - LANDING GEAR Inspect the internal cross tubes tor corros ion

600Fh

1

51 - 2

61 - ENGINE (1)

Inspect exhaust clamps tor corrosion and cracks

300Fh

61-34

(1)

Remove engine mounts and inspect tor condition

2400Fh

61-8 thru 61-19

NOTE It the associated engine is to be removed within 600Fh after the inspection is due, the inspection can be performed concurrently with engine removal. (2)

Remove engine stub shaft and inspect tor condition

3000Fh or 6 years, whichever occurs first

-

61-40

63 - LUBRICATION SYSTEM (1)

EFFECTIVITY

H/C with scavenge oil filters:

Remove and replace ti/ter elements oil filters

ot scavenge

200Fh or 6 months, whichever occurs first

63-30

700 - STANDARD EQUIPMENT (1)

Inspect interior paneling and f100r covering tor condition

2 years

703-2

Table 101-10.1 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Basic Helicopter (6 ot 7)

CHAPTER 101 Page 66

Revision 25

-

_eurocopter 10 EAOO

MAINTENANCE MANUAL 80 105

Company

Inspection or Maintenance Work

Interval

Reference

Initial

92 - ELECTRICAL SYSTEMS (1 )

Remove battery and inspect for condition in accordance with manufacturer's instructions

(2)

Inspect components of electrical system for condition

(3)

Inspect battery-temparature warning

Time and 92-27 scope of inspection in accordance with manufacturer's instructions 2400Fh 1 year

92-4

I

92-34E

Table 101-10.1 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Basic Helicopter (7 of 7)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 25

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MAINTENANCE MANUAL BO 105

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BLANK PAGE

-

CHAPTER 101 Page 68

-eurocopter _

MAINTENANCE MANUAL BO 105

en EAOO Compeny

101 -10.2 Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment H/C Serial No.:

Registration No.:

Inspection or Maintenance Work

Total Hours: Interval

Fh

Reference

Initial

801 - SHOULDER HARNESS WITH AUTOMATIC INERTIA REEL (1 )

Inspect shoulder harness with automatic inertia reel for condition

300Fh

801-4

(2)

Check shoulder harness with automatic inertia reel for function

300Fh

801-5

NOTE

For permissible shelf life and service life of shoulder harness and reel, refer to Autoflug Component Maintenance Manual 802 - ELECTRICAL HEATING AND VENTILATION SYSTEM 4kW/3+1kW

(1 )

Inspect system for condition

300Fh

802-4

(2)

Check system for function

300Fh

802-5

NOTE

Functional check of the heating system is only possible with EPU engaged or generators operating 803 - WINDSHIELD WIPER SYSTEM

-

(1 )

Inspect windshield wiper system for condition

300Fh

803-4

(2)

Perform electrical functional test

300Fh

803-5

804 - DUAL WINDSHIELD WIPER SYSTEM (1 )

Inspect dual windshield wiper system for condition

300Fh

804-4

(2)

Perform electrical functional test

300Fh

804-5

805 - WINDSHIELD WIPER AND WASHER SYSTEM (1)

Inspect windshield wiper and washer system for condition, and check for function

300Fh

805-3, 805-4

806 - SPLlT BENCH SEAT (1)

Inspect lap-safety belts for condition

Refer to Autoflug GmbH manufacturer's Maintenance instructions for Manual time intervals and scope of inspection for belts

Table 101-10.2 - Supplementary Inspection according to Operating lime in Fh and/or Calendar Time Optional Equipment (1 of 10) Revision 25

I

CHAPTER 101 Page 69

Aeuroc.opter 'W" an EAOO

MAINTENANCE MANUAL BO 105

Compnny

Inspectíon or Maíntenance Work

Interval

Reference

Initíal

S06 - SPLlT BENCH SEAT _(_2)_ _ ln_s_pe_c_t_s_p_lit_b_e_n_c_h_s_ea_t_f_or_c_o_n_d_it_io_n

3_0_0F_h_ _1_8_06_-_3

_

S07 - BENCH SEAT (1 )

Inspect lap-safety belts for condition

(2)

Inspect bench seat for condition

Refer to Autoflug GmbH manufacturer's Maintenance instructions for Manual time intervals and scope of inspection for belts 300Fh

sos (1 )

-

BENCH SEAT

Inspect lap-safety belts or lap-safety belts with shoulder harnesses for condition

NOTE

(2)

807-3

Autoflug GmbH Maintenance Manual

Refer to Autoflug GmbH Maintenance Manual for permissible storage and usage time limits of lap-safety belts or lap-safety belts with shoulder harnesses

Inspect bench seat for condition

300Fh

808-3

S09 - 4-SEAT BACK-TO-BACK BENCH (1)

Inspect 4-seat back-to-back bench for condition

80 9-3 300Fh -----1

S10 - RETRACTABLE LANDING L1GHT SYSTEM

(1 )

Inspect landing light system for condition

300Fh

810-4

(2)

Perform functional test

300Fh

810-5

NOTE

-

Perform functional test of landing light using external power unit (EPU) or generators S11 - RETRACTABLE LANDING L1GHT SYSTEM

(1 )

Inspect landing light system for condition

300Fh

811-4

(2)

Perform functional test

300Fh

811-5

NOTE

I

Perform functional test of landing light using external power unit (EPU) or generators

Table 101-10.2 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment (2 of 10)

CHAPTER 101 Page 70

Revision 25

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MAINTENANCE MANUAL SO 105

EAD5 DImpany

Inspection or Maintenance Work

Interval

Reference

Initial

812 - SEARCH ANO LANDING L1GHT

(1 )

Inspect search and landing light for condition

300Fh

812-4

(2)

Check search and landing Iight for function

300Fh

812-5

813 - SEARCHLlGHT

(1)

Inspect searchlight for condition

300Fh

813-4

(2)

Test searchlight for function

300Fh

813-5

NOTE

Functionally test searchlight using either external power (EPU) or generator power

(3)

Cleaning of foam filter element

300Fh

813-18

(4)

Cleaning of IR filter

300Fh

813-20

814 - MEDICAL EQUIPMENT MOUNTING PLATE

(1)

Inspect medical equipment mounting plate for condition

814-3

300Fh

815 - WALL CABINET ASSEMBLY

-,(_1)'---_ln_s-'---pe_c_t_w_a_lI_c_a_b_in_e_t_as_s_e_m_b---,IY_f_o_r_c_on_d_it_io_n

3_00_F_h_ _1_8_15_-_3

-----'--

_

816 - SUCTION BOTTLE HOLDER

(1)

Inspect suction bottle holder for condition

300Fh

1816-3

------

817 - OXYGEN BOTTLE HOLDER

-,(_1)'---_1n_s-,---pe_c_t_o_x..:.-yg=-e_n_b_o_tt_le_h_ol_d_e_rf_o_r_co_n_d_it_io_n

3_00_F_h_ _1_8_17_-_3

_

818 - INFUSION BOTTLE SUSPENSION HOOK

(1)

Inspect infusion bottle suspension hook for condition

300Fh

818-3

819 - MEDICAL ATTENDANT'S SEAT

-,(_1)_ _ ln_s-,---p_ec_t_m_e_d_ic_a_l_a_tt_en_d_a_n_t'_s_s_ea_t_f_o_rc_o_n_d_it_io_n

3_00_F_h_ _1_8_19_-_3

_

820 - CONVERTED COPILOT SEAT

_(_1)_ _ In_s_pe_c_t_c_o_p_ilo_t_s_e_at_f_o_r_co_n_d_it_io_n

3_00_F_h_ _1_8_20_-_3

_

821 - L1TTER RETENTION SYSTEM

--,(_1):.--_1n_s-=---p_ec_t_li_tt_er_r_e_te_n_ti_o_n_s-=-y_st_e_m_f_o_r_co_n_d_it_io_n

3_00_F_h_ _1_8_2_1-_3

---"-

Table 101-10.2 - Supplementary Inspection according to Operating lime in Fh and/or Calendar Time Optional Equipment (3of 10)

_

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Revision 25

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~---.-

_

_----------

Aeurocopter

MAINTENANCE MANUAL BO 105

. . . , . en EAOS Com¡loIoy

Inspection or Maintenance Work

Reference

Interval

Initial

822 - CARGO HOOK SYSTEM

(1 )

Inspect cargo hook for condition NOTE

One load cycle = 1x opening and c10sing of hook

After 1000 load cycles or 3 years in service, whichever occurs first

Perform maintenance in accordance with SIREN Component Maintenance Manual

(2)

Inspect cargo hook system for condition

300Fh

822-4

(3)

Inspect cross tube fittings for cracks

600Fh

822-4

-

823 - ANTISETTLlNG SHOES

(1)

Inspect antisettling shoes for condition

Always prior to 823-3 installation and every 50Fh if antisettling shoes remain installed

824 - SNOW SKIDS

(1)

Inspect snow skids for condition

Always prior to 824-3 installation and every 50Fh if snow skids remain installed

825 - EMERGENCY FLOTATION SYSTEM

(1 )

Inspect emergency flotation system for condition

300Fh

825-4

(2)

Check emergency flotation system for function

300Fh

825-5

NOTE

-

Refer to manufacturer's documentation for time intervals and extent of inspection for pressure cylinders and floats 826 - FUEL JETTISON SYSTEM

(1 )

Check fuel jettison system for correct function NOTE

(2)

300Fh

826-4

Or when helicopter is defueled

Visually inspect fuel jettison system for leakage

300Fh

If fuel leakage is evident, check threaded connections for prescribed torque load. If necessary, replace respective sealing element

I

Table 101-10.2 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment (4 of 10)

CHAPTER 101 Page 72

Revision 25

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eeurocopter

, . 1111 EADS

MAINTENANCE MANUAL BO 105

Compony

Interval

Inspection or Maintenance Work

Reference

Initial

827 - FUEL JETTISON SYSTEM (76 mm dia.) (1 )

Check fuel jettison system for correct function NOTE

(2)

300Fh

827-4

Or when helicopter is defueled 300Fh

Visually inspect fuel jettison system for leakage If fuel leakage is evident, check threaded connections for prescribed torque load. If necessary, replace respective sealing element

828 - FUEL MICROFILTER SYSTEM (1 )

Inspect fuel microfilter system for condition

300Fh

828-4

(2)

Check fuel microfilter system for function

300Fh

828-5

(3)

replace filter element

Every 1200Fh or when c10gged (not when caused by ice crystals) 829 - CROSSFEED UNES

---,(---,1)'-----_C_h_ec_k_c_r_o_ss_fe_e_d_lin_e_s_f_or_f_u_n_ct_io_n

3_00_F_h_ _1_8_29_-_4

_

830 - SELF SEAUNG FUEL TANKS ---,(---,1)'-----_ln_s-'-pe_c_t_in_s_ta_I_le_d_f_ue_l_ta_n_k_s_f_o_rc_o_n_d_it_io_n

"-----_3_0_0_F_h_ _1_8_30_-_4

-----"-

_

831 - LONG RANGE FUEL TANK (1)

Inspect long range fuel tank for condition

Every 50Fh if tank remains installed

831-4

832 - FUEL SYSTEM WITH DIVIDED SUPPLY TANK (1 )

Inspect fuel system for condition

300Fh

832-4

(2)

Check fuel system for function

300Fh

832-5

833 - EXTERNAL LOUDSPEAKER SYSTEM (1 )

Inspect system for condition

300Fh

833-4

(2)

Check system for function

300Fh

833-5

(3)

Check final amplifier 4TD for function

Take action Wandel and according to Goltermann manufacturer's Maintenance instructions Manual

Table 101-10.2 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment (5 of 10)

CHAPTER 101 Page 73

Revision 25

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MAINTENANCE MANUAL BO 105

en EAOO Compeny

Inspection or Maintenance Work

Interval

Reference

Initial

833 - EXTERNAL LOUDSPEAKER SYSTEM

(4)

Check preamplifier VV450 for function

Wandel and Goltermann Maintenance Manual

Take action according to manufacturer's instructions

834 - EXTERNAL LOUDSPEAKER SYSTEM BO 105 S

(1)

Inspect system for condition

300Fh

834-4

(2)

Check system for function

300Fh

834-5

(3)

Check final amplifier 4TD for function

Take action according to manufacturer's instructions

Wandeland Goltermann Maintenance Manual

(4)

Check preamplifier VV450 for function

Take action according to manufacturer's instructions

Wandeland Goltermann Maintenance Manual

_.

835 - SAFETY HARNESS

(1)

Inspect safety harness for condition

300Fh

------

1

835 -3

836 - RESCUE HOIST ASSEMBLY

• For service life of life-limited parts, refer to 101-15. • One cable operating cycle comprises: Reel out of cable (full or partial) in flight and subsequent reel in until automatic switch-off occurs.

NOTE

I

deleted (1 )

Inspect rescue hoist for condition

20 cable operating cycles

836-3

(2)

Check rescue hoist for function

20 cable operating cycles

836-4

(3)

Inspect cable

20 cable operating cycles

836-5

(4)

Lubricate winch unit

Each time cable is replaced or 1x annually, whichever occurs first

836-22

I

-

Table 101-10.2 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment (6 of 10)

CHAPTER 101 Page 74

Revision 25

-

_eurocopter llIl

MAINTENANCE MANUAL BO 105

EAD6 Compeny

Inspection or Maintenance Work

Interval

Reference

Initial

836 - RESCUE HOIST ASSEMBLY

(5)

Disassemble and inspect winch boom assy

600Fh or 4 years (installation and storage time)

836-10,836-11

(6)

Disassemble and inspect hook/bumper assy

200 cable operating cycles or 4 years (installation and storage time), whichever occurs first

836-17,836-18

(7)

Remove and inspect mounting fittings

600Fh or 4 years (installation and storage time), whichever occurs first

836-38,836-39

(8)

Inspection of winch unit

First accomplished after 4 years, then every 2 years TSNfTBO

836-3A

(9)

Replace seal of relay box by new one

after 4 years, TSN

836-3B

I

837 - EXTERNAL REARVIEW MIRROR

-:.(-:.1)_ _ In_s,---pe_c_t_m_i_rr_or_f_o_r_co_n_d_it_io_n

3_00_F_h_ _1_8_37_-_3

_

838 - HIGH LANDING GEAR

---,-(-.:1)c--_ln_s,---pe_c_t_h---.::ig=--h_l_an_d_i-.:ng=-=.ge_a_r_f_or_c_o_n_d_it_io_n

3_00_F_h_ _1_8_38_-_3

--'-

_

840 - L1GHTNING PROTECTOR

--,(-.:1)_ _ ln_s,---pe_c_t_li.=..9h_t_n_in-=.g...:.p_ro_t_e_ct_o_r_fo_r_c_o_nd_it_io_n

3_00_F_h_ _1_8_40_-_3

_

841 - ENGINE AIR CLEANER

(1 )

Inspect engine air cleaner for condition

300Fh

841-4

(2)

Check engine air c1eaner for function

300Fh

841-5

Table 101-10.2 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment (70f 10)

I

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Revision 25

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_eurocopter 8ft EAI:E

MAINTENANCE MANUAL 80 105

CornplIny

Inspection or Maintenance Work

Interval

-

Initial

Reference

842 - ENGINE AIR CLEANER (WITH BLEED AIR SHUTOFF) (1 )

Inspect engine air cleaner for condition

300Fh

842-4

(2)

Check engine air cleaner for function

300Fh

842-5

843 - ENGINE INLET SCREEN (1)

Inspect engine inlet screen for condition

300Fh

1843 -3

844 - PENDULUM ABSORBERS (1 )

Inspect pendulum absorbers for condition

(2)

Inspect split line of upper and lower pendulum brackets for cracks and corros ion (not fer P/N 105-81022.01/.02)

300Fh

844-4, steps 1. thru 7.

300Fh or 1x annually, whichever occurs first

844-4, step 8.

-

846 - STABILlTY AUGMENTATION SVSTEM (SAS) (1 )

Inspect actuator and control rod assemblies and base plate with gyro amplifiers fer condition

300Fh

846-4

(2)

Check actuator and control rod assemblies and base plate with gyro amplifiers fer function

300Fh

846-5

(3)

Remove actuator and control rod assembly and disassemble control rod and inspect fer condition

2400Fh or 6 years (if boots are unimpaired) , whichever occurs first

846-6, 846-7

847 - FOLLOW-UP TRIM (1 )

Inspect follow-up trim for condition

300Fh

847-4

(2)

Check follow-up trim fer function

300Fh

847-5

-

848 - SPERRV HELlPILOT ....;(....;1)_ _ ln_s-,-pe_c_t_S....:..p_e_rr-,,-y_H_e_li-,-p_i10_t_fo_r_c_o_n_d_iti_on

-'--__3_0_0_F_h_ _1_8_48_-_4

----'-

_

850 - BLEED AIR/AUXILlARV HEATING SVSTEM (1)

Inspect bleed air/auxiliary heating system for condition

300Fh

850-4

851 - SEARCH AND LANDING L1GHT 450 W (1 )

Inspect search and landing light for condition

300Fh

851-4

(2)

Check electrical components of the search and landing light fer function

300Fh

851-5

I

Table 101-10.2 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment (8 of 10)

CHAPTER 101 Page 76

Revision 25

Oeurocopter

MAINTENANCE MANUAL BO 105

en EAOS Cclrnpeny

Interval

Inspection or Maintenance Work

Reference

Initial

852 - COMPRESSOR RINSING EQUIPMENT (1)

Inspect compressor rinsing equipment for condition

300Fh

852-3

853 - FIRE EXTINGUISHING SYSTEM (1 )

Inspect fire extinguishing system for condition NOTE

300Fh

853-4

300Fh

853-5

Observe special local safety regulations

(2)

Perform functional test

(3)

Remove and dispose of explosive cartridge

(4)

Weigh fire extinguisher bottle

Accomplish when cartridge Iife (combined storage and in-situ time) has expired Before initial installation, then every 5 years

853-8, 853-10

853-9

854 - MAIN ROTOR BLADE FOLDING SYSTEM (1 )

Inspect rotor blade folding cradles, strut, handling bar and clip assemblies for condition

(2)

Remove locking lever assembly, c1ean and inspect for condition and cracks

Prior to installation

854-3, step 2.

2400Fh

854-3, step 1.

856 - ATTACH FITTINGS-MULTIPURPOSE PYLON (1 )

Visually inspect attach fittings-multipurpose pylon - as far as accessible - for damage

(2)

Inspect attach fittings-multipurpose pylon for condition (multipurpose pylon removed)

After each removal of the multipurpose pylon 300Fh

856-3

859 - WIRE STRIKE PROTECTION SYSTEM (WSPS) (1)

Inspect WSPS for condition

300Fh

[_8_59_-_3

_

860 - ENGINE AIR CLEANER (1 )

Inspect engine air c1eaner for condition

300Fh

860-4

(2)

Perform functional test

300Fh

860-5

Table 101-10.2 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment (9 of 10)

CHAPTER 101 Page 77

Revision 25

-------------_.-

I

•... "

"

..

_-------_.

CDeurocopter

MAINTENANCE MANUAL 80105

en EAOO Cornpany

Inspection or Maintenance Work

Interval

Reference

-

Initial

867 - CARTIOGE-TYPE FUEL PUMP

_(_1)_ _ In_s_pe_c_t_fu_e_'_p_u_m_p_f_o_rc_o_n_d_it_ío_n

6_0_0F_h_ _1_8_67_-_3

_

868 - IR SEARCH ANO LANOING L1GHT 400/200 W

(1 )

Inspect IR search and landing Iight for condition

300Fh

868-4

(2)

Check electrical components of the IR search and landing light for function

300Fh

868-5

I

Table 101-10.2 - Supplementary Inspection according to Operating Time in Fh and/or Calendar Time Optional Equipment (10 of 10)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

-

CHAPTER 101 Page 78

Revision 25

EUROCOPTER

101 -11

MAINTENANCE MANUAL 80105

SPECIAL INSPECTIONS AFTER MAINTENANCE ACTIVITV

101 - 11.1 Special Inspections after Maintenance Activity Basic Helicopter

Registration No.:

Incident

_

H/C Serial No.:

Inspection or Maintenance Work

_

Fh

Total Hours:

Interval

Reference

Initial

11 - MAIN TRANSMISSION (1 )

EFFECTIVITY Transmission mountíng struts P/N 105-10155, 105-10156,105-10161 und 105-10162:

Inspect transmission mounting struts for missing or damaged sealant on rivet heads

High-pressure cleaner used in transmission compartment

Always before and after the transmission compartment is high-pressure cleaned

14 - MAIN ROTOR BLADE (1 )

Inspect erosion Installation of new main rotor blade or replacement protective shells for peeling of erosion protective shell NOTE If peeling occurs after between 5Fh to 10Fh, inform ECO product support before next flight

(2)

If debonding was found in the warning area of the blade, pertorm special tappingtest to determine whether debonding has increased

Inspect erosion protective shells for increase in debonding

5Fh - 10Fh after 14-2, incident and step 12. once or after 200Fh 14-3, step 10.

Every 25 Fh after incident, but have erosion protective shell replaced by manufacturer before more than 100Fh have elapsed

14-2, step 12. or 14-3, step 10.

I

I

32 - TAIL ROTOR DRIVE (1 )

Installatíon of tail rotor gearbox NOTE Not applicable if spring washers were used in the attachment of the tail rotor gearbox

Inspect attachment bolts and nuts of tail rotor gearbox for required torque and tighten as necessary

5Fh -1 OFh after installation

Figure 32-23

Table 101-11.1 - Speciallnspections after Maintenance Activity Basic Helicopter (1 of 2)

Revision 19

CHAPTER 101 Page 79

_eurocopter Ineldent

MAINTENANCE MANUAL BO 10S

Inspectlon or Malntenance Work

Interval

Reference

Inltlal

34 - TAIL ROTOR BLADE (1 )

Installation of new tail rotor Inspect installed parts blade or replacement of for peeling erosion protective shell NOTE If peeling occurs after between 5Fh to 10Fh, inform ECO product support bafore next flight

5Fh - 10Fh after 34-2, steps 7. incident and thru 9.,12. once after100Fh

91 -INSTRUMENTS (1)

After major structural modification of helicopter

Compensate compasses

after completion of maintenance activity

91-26

Table 101-11.1 - Speclallnspections after Maintenance Aetlvlty Basle Hellcopter (2 of 2)

Teehnielan

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 80

Revision 21

EUROCOPTER

MAINTENANCE MANUAL 80105

101 - 11.2 Special Inspections after Maintenance Activity Optional Equipment

Registration No.:

_

H/C Serial No.:

_

Inspection or Maintenance Work

Incident

Total Hours:

Interval

------ Fh

Reference

Initial

857 - CONTINUOUS IGNITION SYSTEM (1)

Check continuous ignition system for function

After replacement of system parts

857-5

Table 101-11.2 - Special Inspections after Maintenance Activity Optional Equipment (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 81

EUROCOPTER

MAINTENANCE MANUAL 80 105

BLANK PAGE

CHAPTER 101 Page 82

Revision 18

EUROCOPTER

101 -12

MAINTENANCE MANUAL 80 105

INSPECTIONS AFTER OPERATION UNDER SPECIAL ENVIRONMENTAL CONDITIONS

101 - 12.1 Inspections after Operation under Special Environmental Conditions Basic Helicopter Registration No.:

H/C Serial No.:

Total Hours:

Inspection or Maintenance Work

Interval

Fh

Reference

Initial

11 - MAIN TRANSMISSION (1)

Inspect housing of main transmission for condition

I

12 months

1_1_1-_3

---l~

_

13 - MAIN ROTOR SYSTEM (1)

Remove primary and secondary bolts, clean and inspect for condition; crack inspection not necessary

1S0Fh

13-10, -11, -14, -16, -17, -18

33-4, step 1.

33 - TAIL ROTOR (1 )

Inspect pitch Iinks

SOFh

(2)

Remove, clean and inspect following bolts for condition:

300Fh

- Bolt between tail rotor shaft and tail rotor head

33-21, step 1.

- Bolts between tail rotor head and tail rotor blade

33-16, step 6.

- Bolts between laminated strap pack and blade mounting fork

33-16, step S.

NOTE Protect nickel-plated bolts against corrosion by brush-coating them with grease (CM 101, 102, 120, 146) or with corrosion preventive compound (CM SOS) prior to installation. Do not lubricate new bolts coated with solid film lubricant. Apply lubricant (CM 146) to previously installed bolts coated with solid film lubricant. Table 101-12.1 -

Revision 18

Inspections after Operation under Special Environmental Conditions Basic Helicopter (1 of 2)

CHAPTER 101 Page 83

EUROCOPTER

MAINTENANCE MANUAL 80 105

Inspection or Maintenance Work

Interval

Reference

Initial

61-ENGINE (1 )

Wash eompressor of both engines

After the last AIIison OMM Pub. f1ight of the day No. 5W2 or 10W2

(2)

Inspeet air inlet of eompressor for eondition

After the last AIIison OMM Pub. flight of the day No. 5W2 or 10W2 in snow

Table 101-12.1 -

Inspections after Operation under Special Environmental Conditions Basic Helicopter (2 of 2)

Technician

Date:

Inspector

Date:

Name

Signatura

Stamp

Signature

CHAPTER 101 Page 84

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

101 - 12.2 Inspections after Operation under Special Environmental Conditions Optional Equipment Registration No.:

H/C Serial No.:

Total Hours:

Inspection or Maintenance Work

Interval

Reference

Fh Initial

854 - MAlN ROTOR BLADE FOLDING SYSTEM (1)

150Fh

Remove locking lever assembly -

Clean and inspect nickel-plated bolts for condition, and provide with corrosion protection (crack inspection not required)

854-3, step 1.a and 854-4, step 2.1

-

Clean and inspect solid film lubricant-coated bolts forcondition (crack inspection not required). Coat bolt with lubricant (CM146)

854-3, step 1.b and 854-4, step 2.g

Table 101-12.2 -

Inspections after Operation under Special Environmental Conditions Optional Equipment (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 85

EUROCOPTER

MAINTENANCE MANUAL 80 105

BLANK PAGE

CHAPTER 101 Page 86

Revision 18

_~JooI~er

MAINTENANCE MANUAL 80105

101 -13 SPECIAL INSPECTIONS AFTER OPERATIONAL INCIDENTS 101 - 13.1 Special Inspections after Operational Incidents Basic Helicopter 1.

Measures to be taken after exceeding rotor speed of 110%

.

88

2.

Special inspection after contact of main rotor with an obstacle

.

89

3.

Special inspection after contact of tail rotor with an obstacle. .

.

91

4.

Special inspection after a hard landing

.

93

5.

Measures to be taken if mast moment Iimits are exceeded (MM-Limit warning light remains on)

97

6.

Special inspection after excessive main rotor blade bending

98

7.

Special inspection of main transmission and when mast moment indicating sys. defective/removed 100 •

.

Presence of deposits 8.

Defective or removed mast moment indicating system

Measures to be taken with regard to main transmission FS 72 A after reaching max. torque ranges or exceeding max. permissible torque limits

.

101

Measures to be taken with regard to main transmission FS 72 B after reaching max. torque ranges or exceeding max. permissible torque limits

.

102

10. Measures to be taken with regard to main transmission FS 72 E after reaching max. torque ranges or exceeding max. permissible torque Iimits

.

104

11. Special inspection of the hydraulic system

.

105

12. Measures to be taken following freewheel clutch slippage due to engine rpm N2 exceeding rotor rpm NRo

.

106

13. Special inspection of instruments

.

107

14. Measures to be taken after flights in falling snow

.

108

15. Measures to be taken after flights in sandy environment

.

108

16. Measures to be taken when operating at extremely low temperatures

.

109

9.

Filter contamination indicator pin has popped out Indicator ring changes position

-

After flight in thunderstorm

-

After parking the helicopter for a longer period of time (3 months) in one direction

Revision 24

CHAPTER 101 Page 87

O~~er

MAINTENANCE MANUAL BO 105

1. Measures to be taken after exceeding rotor speed 01 110% 1. The service lite ofthe parts listed below is adversely affected if rotor speed exceeds 110%. a.

During their service lite, these parts may be subjected 60times to tail rotorspeeds aboye 110% but not exceeding 115%. Each time a rotor speed of 11 0% is exceeded, an entry must be made in the related historical record.

b.

Discard the following parts ifthey have been subjected 60 times to a rotor speed aboye 11 0% or once to a rotor speed aboye 115%.

Registration No.:

_

H/C Serial No.:

_

Inspection or Maintenance Work (1 )

Re1erence

Fh

Initial

Main rotor head:

-

Bendix tie bar/tension torsion strap

(4 off)

-

Ouadruple nut, upper

(1 off)

-

Ouadruple nut, lower

(1 off)

Bolts for quadruple nuts - bendix tie bar/tension torsion strap

(4 off)

Bolts for bendix tie bar/tension torsion strap - nut (outside)

(4 off)

(2)

Total Hours:

Tail rotor head:

-

Laminated strap pack assembly

(1 off)

Blade mounting fork

(2 off)

-

Fitted bolt (blade mounting fork - laminated strap pack)

(2 off)

-

Fitted bolt (blade mounting fork - tail rotor blade)

(4 off)

Table 101-13.1.1 - Measures to be taken after exceeding rotor speed 01110% (1 011)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 88

Revision 18

O~er

MAINTENANCE MANUAL BO 105

•

2. Special inspection after contact of main rotor with an obstacle.

WARNING

IF SEVERE VIBRATIONS, OUT-OF-TRACK PROBLEMS OR BALANCE PROBLEMS OCCUR FOLLOWING KNOWN OR SUSPECTEO ROTOR CONTACT WITH AN OBSTACLE, CONTACT THE ECO CUSTOMER SERVICE FOR ADVICE ON HOW TO PROCEEO.

NOTE

If the allowable damage limits on any component have been exceeded as a result of contact with an obstacle, contact the ECO Customer Service for advice on how to proceed.

Registration No.:

_

H/C Serial No.:

_

Total Hours:

Fh

a. Special inspection after contact of main rotor with an obstacle without a change in main rotor

rpm. This inspection shall be performed if contact with an obstacle did not cause a change in the rotor rpm or sudden stoppage of the main rotor. Reference

Inspection or Maintenance Work

Initial

14 - MAIN ROTOR BLADE (1)

Remove main rotor blade and inspect for condition

b. Special inspection after contaet of main rotor with an obstacle with a change in main rotor rpm. The sudden stoppage of the main rotor, or change in main rotor rpm, is caused by contact of the main rotor blades with the ground, water, snow, dense vegetation, or other objects of sufficient mass. The following types of main rotor blade damage may be regarded as evidence of a blade strike: • Skin damage, such as deformation, delaminations or cracks. • Oeformation of erosion protection and end cap. • Trailing edge damage, such as bulging, delaminations and chipping. • Out-of-track and imbalance conditions that cannot be rectified. Reference

Inspection or Maintenance Work

Initial·

11 - MAIN ROTOR TRANSMISSION (1)

Inspect main rotor transmission for condition

11-3, step 1. thru step 7

(2)

Inspect drive shafts for condition

11-3, step 8

(3)

Inspect transmission V-mounting struts for condition, also for correct installed position of main transmission relative to fuselage

11-3, step 10

(4)

NOTE

If drive shaft is damaged, inspect OMM engines per "Sudden Stoppage Inspection" in the A1lison Operation and Maintenance Manual No. 5W2 or 10W2, as applicable 13 - MAlN ROTOR SVSTEM

(1)

Inspect main rotor system for condition, in particular the main rotor head (including visible area of inner sleeves) and driving links (including fitted bolts and other attaching hardware) Table 101-13.1.2 -

Revision 23

13-3

Special inspection after contact of main rotor with an obstacle (1 of 2) CHAPTER 101 Page 89

-eurocopter

, . 8Il EA[S

MAINTENANCE MANUAL 80105

c:amp..y

Table 101-13.1.2 - Special inspection after contact of main rotor with an obstacle (2 of 2)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 90

Revision 19

MAINTENANCE MANUAL BO 105 3. Speciallnspection after contact of tall rotor with an obstacle.

WARNING

IF SEVERE VIBRATIONS OR BALANCE PROBLEMS OCCUR FOLLOWING KNOWN OR SUSPECTEO ROTOR CONTACT WITH AN OBSTACLE, CONTACT THE ECO CUSTOMER SERVICE FOR AOVICE ON HOW TO PROCEEO.

NOTE

lf the allowable damage Iimits on any component have been exceeded as a result of contact with an obstacle, contact the ECO Customer Service for advice on how to proceed.

This inspection shall be performed if there has been contact with e.g. the ground, snow, cables or dense vegetation. Tail rotor blade contact with an obstacle might not necessarily be noticed by the pilot. Registration No.:

_

H/C Serial No.:

_

Total Hours: Reference

Inspection or Maintenance Work

Fh Inltlal

31 - TAIL BOOM (1)

Visually inspect tail boom for cracks, loose rivets and other damage (e.g. deformation of vertical fin)

31-2

(2)

Remove tail rotor gearbox and visually inspect tail rotor gearbox attachment fitting on vertical fin for cracks

31-2, step 5

32 - TAIL ROTOR DRIVE (1)

Visually inspect tail rotor drive and couplings for condition, especially the rivets connecting the shaft to the flange

32-4 or 32-5

(2)

Visually inspect intermediate gearbox and tail rotor gearbox for cracks

32-4or32-5

33 - TAIL ROTOR (1)

Inspect tail rotor for condition. If pitch Iink(s) are damagedlbroken, or severe imbalance is presentlsuspected, perform following inspections: - Remove, disassemble and inspect tail rotor head per REM

Remove following bolts and inspect for cracks (using visible dye method): - Laminated strap pack to blade mounting fork connecting bolts Blade mounting fork to tail rotor blade connecting bolts Close-tolerance bolt between tail rotor head and tail rotor shaft Bolts between tail rotor head and pitch Iinks Bolts between sliding sleeve and pitch Iinks Bolts between sliding sleeve and bellcrank Bolts between bellcrank and tail rotor gearbox

33-4

REM 301 or REM308

33-16, step 5 33-16, step 6 33-21

34 - TAIL ROTOR BLADE -,(-,1)_R_e_m_o_v_e_t_ai_'r_o_to_r_b_la_d_e_a_n_d_in_s~p_ect_fo_r_c_o_n_di_tio_n Table 101-13.1.3 Revision 21

1_34-_2.;...,34--4_--..:...,_34-_5_L-1

Speciallnspection after contact of tall rotor wlth an obstacle (1 of 2) CHAPTER 101 Page 91

I

EUROCOPTER

MAINTENANCE MANUAL 80105

Inspection or Maintenance Work

Reference

Initial

42 - TAIL ROTOR CONTROLS (1)

Inspect tail rotor controls for condition. Visually inspect pivot pin for bellcrank on tail rotor gearbox for cracks, using magnifying glass Table 101-13.1.3 -

42-3

Special inspection alter contact of tail rotor with an obstacle (2 of 2)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 92

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

4. Special inspection after a hard landing A hard landing is one which results not only in deformation of one or both cross tubes but also in one or more of the following damage conditions: Oamage to the lower part of frame 9 -

Oamage to the upper part of the canted frame (in the area of the rear door)

-

Oamage to underside of fuselage as a result of ground contact

-

visible permanent deformation of the tail boom

The entire helicopter must be subjected to a thorough visual inspection. For this purpose, remove all engine cowlings, tail rotor fairings, interior panels and other panels and fairings, including all firewalls and covers. A 1o-power magnifying glass is required for some inspection areas. Registration No.:

_

H/C Serial No.:

_

Inspection or Maintenance Work

Total Hours:

Reference

Fh

Initial

GENERAL (1)

Remove all panels and fairings, firewalls and the tail boom

11 - MAlN TRANSMISSION (1)

Inspect bolts of transmission struts for cracks by penetrant method per MIL-STO-6866, type 11, visible dye

(2)

Inspect main transmission struts for deformation and inspect for cracks, using magnifying glass. If deformation is evident, replace affected V-strut only. If one of the V-struts is cracked, it must be removed together with the opposite V-strut

21 - FUSELAGE (1 )

Inspect engine and transmission attachment fittings for damage and proper riveting, and ball bearings of transmission attachment fittings for damage and excessive play

(2)

Inspect engine and transmission attachment areas on fuselage for deformation and damage. lf damage is suspected, pertorm dye penetrant crack inspection per MIL-STO-6866, type 11, visible dye

(3)

Inspect frame 7, frame 9, canted frame and frame 2L for local buckling. For inspection of frame 2L, remove tail boom

(4)

Inspect aft cross tube attachment areas on fuselage, outer skin, tail boom and tail cone for deformation and damage

(5)

Inspect landing gear fittings and the rivets connecting them to the fuselage for damage

(6)

Inspect doors and panels for flush fit. Improper fit is an indication of structural deformation of the fuselage

(7)

If deformation of the fuselage is suspected, pertorm leveling of the fuselage and compare values with original data in the leveling table. lf deformation is verified, contact ECO or a service facility authorized by ECO for advice on how to proceed

Table 101-13.1.4 - Special inspection after a hard landing (1 of 4)

Revision 18

CHAPTER 101 Page 93

EUROCOPTER

MAINTENANCE MANUAL 80105

Inspection or Maintenance Work

Reference

Initial

31 - TAIL BOOM (1 )

Inspect necked-down bolts in the tail boom to fuselage flange connection for the specified torque load (7.5 Nm). Replace bolts having less than the required torque

(2)

Visually inspect tail boom for damage

(3)

Visually inspect attachment fitting of intermediate gearbox and tail rotor gearbox for cracks and proper riveting to vertical fin. If damage is suspected, rer'nove intermediate gearbox or tail rotor gearbox, as applicable, and pertorm a penetrant crack inspection of attaching areas and bolts per MIL-STD-6866, type 11, visible dye

32 - TAIL ROTOR ORIVE (1 )

Inspect tail rotor drive shafts for correct alignment

(2)

Inspect intermediate gearbox and tail rotor gearbox for secure mounting, and inspect housing for cracks, using a magnifying glass

(3)

Check tail rotor gearbox and intermediate gearbox with alignment device for correct installed position

32-60

33 - TAIL ROTOR (1)

Visually inspect tail rotor for damage. If there is evidence of a blade strike, pertorm "Special inspection after contact of tail rotor with an obstacle"

41 - MAIN ROTOR CONTROLS (1)

Visually inspect all control rods between hydraulic unit and main rotor head and between mixing lever assembly and swashplate for damage, and bearings for free movement without play

43 - HYORAULlC SYSTEM (1)

Visually inspect hydraulic unit for damage and check for secure mounting on fuselage

(2)

Apply hydraulic pressure to the hydraulic unít, using a ground hydraulic cart or a portable unit, and visually inspect hydraulic system for leaks

51 - LANOING GEAR (1)

Inspect cross tubes for deformation

(2)

Inspect landing gear for condition

61-ENGINE NOTE (1)

When the fuselage hits the ground during a hard landing, it must be assumed that the engines have suftered an impact load of 10 9 or more.

For inspections pertaining to engines and engine accessories, refer to manufacturer's documentation. After loading in excess of 10 g, return engine for overhaul

Table 101-13.1.4 - Special inspection after a hard landing (2 of 4)

CHAPTER 101 Page 94

Revision 18

EUROCOPTER

MAINTENANCE MANUAL 80 105

Inspection or Maintenance Work

Reference

Initial

61-ENGINE (2)

Inspect engine mounts for deformation and cracks. Use a magnifying glass for crack inspection

(3)

Inspect rubber bushings of mounting supports for damage by rocking the engine. The resulting movement within the rubber bushings must not be so great as to cause the washers on each end of the rubber bushings to contact the outer metal part of the rubber bushings (metal contact is audible)

(4)

Inspect exhaust ducts for firm attachment 62 - FUEL SYSTEM

(1 )

Inspect fuel tanks for evidence of leakage

(2)

Visually inspect fuel lines for damage, loose connections and security of attachment

(3)

Inspect fuel system for evidence of leakage at operating pressure 63 - LUBRICATION SYSTEM

(1)

Visually inspect lubrication system for damage, loose connections and security of attachment

(2)

Inspect lubrication system for evidence of leakage at operating pressure 64 - FIREWALLS

(1)

Visually inspect firewalls for damage 700 - STANDARD EQUIPMENT

(1)

Visually inspect interior panels for damage

(2)

Inspect seat fittings and safety belts for security of attachment 800 - OPTIONAL EQUIPMENT

(1)

Inspect optional equipment for condition and correct functioning. If in doubt, contact ECO or a service facility authorized by ECO 91 - INSTRUMENTS

(1)

Inspect instruments for security of attachment and correct function 92 - ELECTRICAL SYSTEMS

(1)

Inspect battery for condition (refer to manufacturer's instructions) Table 101-13.1.4 - Special inspection after a hard landing (3 of 4)

Revision 18

CHAPTER 101 Page 95

EUROCOPTER

MAINTENANCE MANUAL BO 105

Inspection or Maintenance Work

Reference

Initial

92 - ELECTRICAL SVSTEMS (2)

Visually inspect battery mounting support tor damage

(3)

Compensate compasses Table 101-13.1.4 - Special inspection after a hard landing (4 of 4)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 96

Revision 18

EUROCOPTER

MAINTENANCE MANUAL 80 105

5. Measures to be taken if mast moment Iimits are exceeded (MM-Limit warning Iight remains on) After exceeding the max. permissible mast moment, which is indicated by continuous iIIumination 01 the MM-Limit warning light, proceed according to Table 101-13.1.5 below:

Registration No.:

_

H/C Serial No.:

_

Reference

Inspection or Maintenance Work

(1 )

Enter the incident in the historical record

(2)

Check torque on special nuts securing the rotor mast to the studs 01 the main rotor head. If the tightening torque on all nuts is at least 140 Nm, 11ight operations may be continued

(3)

If the tightening torque on ane or more nuts is below 140 Nm, stop 11ight operations and give ECO a detailed repart 01 the incident

Table 101-13.1.5 -

Total Hours:

Initial

Measures to be taken after mast moment Iimits have been exceeded (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

Fh

CHAPTER 101 Page 97

EUROCOPTER

MAINTENANCE MANUAL BO 105

6. Special inspection after excessive main rotor blade bending

WARNING

Registration No.:

THE DESIGN OF THE MAIN ROTOR BLADE IS SUCH THAT DAMAGE NOT IMMEDIATELY DETECTABLE ON THE BLADE EXTERIOR WILL BECOME EVIDENT THROUGH DISTINCT CHANGES IN THE BALANCE AND TRACK BEHAVIOR OF THE BLADE.

_

H/C Serial No.:

_

Total Hours:

Inspection or Maintenance Work (1)

The main rotor blades shall be removed and inspected if it is suspected that they have been bent beyond an acceptable degree, e.g" by gusts of wind when not or inadequately tied down.

Reference

Fh

Initial

Chapter 14

Acceptable / Unacceptable bending (see figure 101-13.1.6): Acceptable: Upward and downward blade bending of up to 1.4 m from the rotor plane and/or a once-only downward blade bend of 1.4 to 1.6 m. A bend of 1.6 m corresponds to a ground clearance of approx. 1.4 m. These measurements shall be taken at the blade tipo Unacceptable:More than the once-on1y allowable bend of between 1.4 m and 1.6 m. Bending in excess of 1.4 m upwards and in excess of 1.6 m downwards. The latter corresponds to a ground clearance of less than 1.4 m. These measurements shall be taken at the blade tipo (2)

Check balance and track behavior during next flight

Table 101-13.1.6 -

CHAPTER 101 Page 98

Chapter 106

Special inspection after excessive bending of the main rotor blades (1 of 1)

Revision 18

MAINTENANCE MANUAL 80105

eo>-

, c

C1>o o-

c'"

olil 'OQ;

.s¡ o E o:: ... al

~o

Q> ...

a.cn Figure 101-13.1.6 Main Rotor Blade Bending Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 99

MAINTENANCE MANUAL BO 105

Special inspection of main transmission and when mast moment indicating system defective/removed

Registration No.:

_

Incident

H/C Serial No.:

_ Total Hours:

Inspection or Maintenance Work

Interval

Reference

Fh Initial

11 - MAIN TRANSMISSION (1 )

Presence of deposits

Remove oil filter element from main transmission and inspect for deposits

(2)

Defective or removed mast moment indicating system

Check torque on special nuts securing the rotor mast to the studs of the main rotor head. If the torque on any of the special nuts is less than 140 Nm, stop flight operations and consult ECD

5Fh to 15Fh after incident

11-12 thru 11-14

Within the next 150Fh after failure of the mast moment indicating system, then every 150Fh until it is returned to service

Table 101-13.1.7 - Special inspection of main transmission (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 100

Revision 24

EUROCOPTER

MAINTENANCE MANUAL BO 105

8. Measures to be taken with regard to main transmission FS 72 A after reachlng max. torque ranges, or exceeding max. permissible torque limits Registration No.:

_

H/C Serial No.:

------

Total Hours:

Fh

A. Overtoad ranges and overload limits The following overload ranges and overload Iimits (torque/duration) apply to the main transmission FS 72 A within the overhaul interval (TBO) (for measures to be taken after reaching or exceeding these ranges/limits. refer to step B): (1)

(2)

Twin-engine operation: Torgue range (%)

Max. duration

2x94-100% or

55

2 x 80 - 93% or

15 s

a total torque of 158% on both engines with one engine allowed to reach 80% to max. 93%

15 min

Single-engine operation (one engine inoperative): Torgue range (%)

Max. duration

1 x 101 - 110% or

55

1 x 94-100%

15 s

B. Measures to be taken after reaching overload ranges or exceeding overload limits

Inspection or Maintenance Work (1)

Reference

Initial

Whenever the overload ranges specified under point A (torque values/duration) are reached or their respective limits exceeded. notice to this effect must be entered into the historical record of the main transmission. It is necessary to have the main transmission inspected by the manufacturer ZF in the following cases: -

If ~ of the values for torque range/duration specified in (1) or (2) was reached more than twice within the overhaul interval (TBO).

-

If ~ of the values for torque Iimits/duration specified in (1) or (2) was exceeded within the overhaul interval (TBO).

Table 101-13.1.8 -

Measures to be taken after reaching overload ranges or exceeding overload Iimits (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 101

EUROCOPTER

MAINTENANCE MANUAL BO 105

9. Measures to be taken with regard to main transmission FS 72 B after reaching max. torque ranges or exceeding max. permissible torque Iimits .

Registration No.:

_

H/C Serial No.:

_

Total Hours:

Fh

A. Overload ranges and overload limits

The following overload ranges and overload limits (torque/duration) apply to the operation of the main transmission FS 72 B for the time interval between overhauls (TBO): (Refer to step B. for measures to be taken after reaching or exceeding these ranges/limits): EFFECTIVITY

(1 )

Twin-engine operation: Torgue range (%)

Max. duration

2 x 96-105% or

5s

2 x 87 - 95% or

15 s

a total torque of 172% on both engines with one engine allowed to reach 87% to max. 95% torque.

15 min

Singl~ngine

(2)

operation (one engine inoperative):

Torgue range (%)

Max. duration

1 x 101 - 110% or

5s

1 x 96-100%

15 s

EFFECTIVITY

(3)

The torque ranges and their respective duration Iisted below under points (1) and (2) apply to BO 105 C23, CS, C-2, CS-2, O and OS helicopter series, provided that they have been modified by SB 60-44 or SB 60-47. The overload ranges and limits listed below do not apply to BO 105 A helicopters.

The torque ranges and their respective puration listed below under items (3) and (4) apply to BO 105 C23, CS, C-2, C8-2, O and OS helicopter series, provided that they have not been modified by either SB 60-44 or SS 60-47. If they have been modified by these bulletins, the values specified under points (1) and (2) apply to them.

Twin-engine operation: Torgue range (%)

max. duration

2 x 94 - 105% or

5s

2 x 80 - 93% or

15 s

a total torque of 158% on both engines with one engine allowed to reach 80% to max. 93% torque.

15 min

CHAPTER 101 Page 102

Revision 18

EUROCOPTER

(4)

MAINTENANCE MANUAL BO 105

Single-engine operation (one engine inoperative): Iorgue range (%)

Max. dUration

1 x 101 - 110%

55

or

1 x 94-100%

15 s

B. Measures to be taken after reaching overload ranges or exceeding overload Iimits

Inspection or Maintenance Work (1)

Reference

Initial

Whenever the overload ranges specified under point A (torque values/duration) are reached or their respective limits exceeded, notice to this eftect must be entered into the historical record of the main transmission. It is necessary to have the main transmission inspected by the manufacturer ZF in the following cases: -

If one of the values for torque range/duration specified in (1) or (2) or in (3) and (4) was reached more than twice within the overhaul ¡nterval (IBO).

-

If ~ of the values for torque limits/duration specified in (1) or (2) or in (3) or (4) was exceeded within the overhaul interval (IBO).

Table 101-13.1.9 -

Measures to be taken after reaching overload ranges or exceeding overload Iimits (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPIER 101 Page 103

EUROCOPTER

MAINTENANCE MANUAL BO 105

10. Measures to be taken with regard to main transmission FS 72 E after reaching max. torque ranges or exceeding max. permissible torque Iimits A. Overload ranges and overload limits

The following overload ranges and overload limits (torque/duration) apply to the main transmission FS 72 E within the overhaul interval (TBO): (for measures to be taken after reaching or exceeding these ranges/limits. refer to step B.): EFFECTIVITV

(1 )

The following torque ranges and respective duration in steps (1) and (2) apply to helicopters which have been modified for VTOL mode.

Twin-engine operation: Torgue range (%)

Max. durat;on

2x 96-105% or

5s

2 x 87 - 95%

15 s

or a total torque of 172% on both engines with one engine allowed to reach 87% to max. 95% torque (2)

15 min

Single-engine operation (one engine inoperative): Torgue range (%)

Max. duration

1 x 111 - 123%

16 s

B. Measures to be taken after reaching overload ranges or exceeding overload limits Reference

Inspection or Maintenance Work (1)

Initial

Whenever the overload ranges specified under point A. (torque values/duration) are reached or their respective limits exceeded, enter notice to this effect in the historical record of the main transmission. An inspection of the main transmission by the manufacturer ZF is required: -

If one of the values for torque range/duration specified in (1) or (2) was reached more than ten times within the overhaul interval (TBO).

-

If one of the values for torque limits/duration specified in (1) or (2) was exceeded within the overhaul interval (TBO).

Table 101-13.1.10 -

Measures to be taken after reaching overload ranges or exceeding overload Iimits (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 104

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

11. Special inspection 01 the hydraulic system

Registration No.:

_

H/C Serial No.:

_

Inspection or Maintenance Work

Incident

Interval

Total Hours:

Relerence

Fh

Initial

43 - HYORAULIC SYSTEM (2)

Filter contamination indicator pin has popped out

Inspect for deposits in filter element

(3)

EFFECTIVITY Hydraulic reservoir with trapped air indicator (ring)

Bleed hydraulic system

10Fh after occurrence

43-30

Within 10Fh after 43-5 initial occurrence

Indicator ring changes position

Table 101-13.1.11 - Special inspection 01 the hydraulic system (1 01 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 105

EUROCOPTER

MAINTENANCE MANUAL 80105

12. Measures to be taken following freewheel clutch slippage due to engine rpm N2 exceeding rotor rpm NRo In the event of freewheel clutch slippage, Le., when N2 speed of one of the engines has exceeded rotor speed NRo. the rpm difference between N2 and NRo may result in a sudden hard clutch engagement, thus causing damage to the drive shafts between engine and transmission. Perform corrective measures listed below in Table 101-13.1 .12 .

Registration No.:

_

H/C Serial No.:

_

Total Hours:

Inspection or Maintenance Work

Reference

(1 )

Remove and discard appropriate drive shaft between main transmission and engine. Install new drive shaft.

Chapter 11

(2)

Remove and discard freewheel clutch. Install new freewheel clutch.

Chapter 11

(3)

Inspect and, if necessary, replace drive units of transmission input stage

REM 103

(4)

NOTE

The inspection referred to below shall be performed if the above-mentioned incident occurs more than once. A once-only occurrence does not require inspection of the engine. However, the incident shall be recorded in the engine log, together with the date of occurrence and the accumulated flight hours at the time. Eg. Clutch slippage occurred for the first time on ........... after .......... flight hours.

Fh

Initial

Special Inspections in AIIison OMM 5W2 or 10W2

Inspect engine as described under "Slippage and/or sudden engagement of freewheel clutch unít" in Allison OMM Table 101-13.1.12 -

Measures to be taken in the event of freewheel clutch slippage (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 106

Revision 18

EUROCOPTER

MAINTENANCE MANUAL 80105

13. Special inspection of instruments

Registration No.:

_

H/C Serial No.:

------

Inspection or Maintenance Work

Incident

Interval

Total Hours: Reference

Fh Initial

91 - INSTRUMENTS (1 )

After flight in thunderstorm

Compensate compasses

After occurrence

(2)

After parking the helicopter for a longer period of time (3 months) in one direction

Compensate compasses

After occurrence

Table 101-13.1.13 - Special inspection of instruments (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

Revision 18

CHAPTER 101 Page 107

EUROCOPTER

MAINTENANCE MANUAL BO 105

14. Measures to be taken after flights in falling snow

Registration No.:

_

H/C Serial No.:

------

Total Hours:

Fh

After flights in falling snow, inspect engines according to documentation of engine manufacturero Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

15. Measures to be taken after flights in sandy environment

Registration No.:

_

H/C Serial No.:

------

Total Hours:

Fh

After flights in sandy environment, inspect engines according to documentation of engine manufacturero Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 108

Revision 18

EUROCOPTER

MAINTENANCE MANUAL 80105

16. Measures to be taken when operating at extremely low temperatures

The following measures only apply when the helicopter is continuously operated at temperatures below -30 oC.

NOTE

Inspection or Maintenance Work

Reference

Initial

LIFTING SYSTEM Do not operate rotor brake at temperatures below -30 oC (1 )

Preheat oil in main transmission to a temperature of at least -25 oC

PF, refer to FLM

(2)

Inspect boot on 5washplate for condition

PF FUSELAGE

(1)

At ambient temperatures of -30 oC and below, heat the cabin interior PF until the cabin thermometer indicates a temperature of -10°C for at least 15 mino TAILBOOM

(1 )

Chapter32

Tail rotor drive shaft (Bendix): Axial play necessary for operation at extremely low temperatures must have been adjusted

(2)

Inspect boots on tail rotor sliding sleeves for condition

PF

FLIGHT CONTROLS (1 )

Inspect neoprene edge protectors for condition at locations where control rods of tandem hydraulic unit pass through fuselage

PF

POWERPLANT (1 )

Preheat engine oil to at least -25 oC

PF, refer to FLM

(2)

Preheat engine fuel controls

PF, refer to Allison OMM und FLM OPTIONAL EQUIPMENT

(1 )

(2)

-

Do not switch on SAS when outside temperatures are below -35°C

-

Observe operating limits laid down by manufacturers of optional equipment

If installed, visually inspect rescue hoist for signs of leakage. Leakage of lubricant indicates a deteriorated sea!. Replace such seals.

PF

INSTRUMENTS AND ELECTRICAL SYSTEMS (1)

Preheat battery with electric blanket or store battery in heated room

Revision 18

IPF

CHAPTER 101 Page 109

MAINTENANCE MANUAL 80105

EUROCOPTER

BLANK PAGE

CHAPTER 101 Page 110

Revision 18

EUROCOPTER

MAINTENANCE MANUAL BO 105

101 - 13.2 Special Inspections after Operational Incidents Optional Equipment 1.

Measures to be taken when Reflector of Searchlight is contaminated . . . . . . . . . . . . . . . . . . . . . . .

Revision 18

112

CHAPTER 101 Page 111

EUROCOPTER

MAINTENANCE MANUAL BO 105

1. Measures to be taken when Reflector of Searchlight is contaminated If contaminants form a film on rhodium plating of the searchlight reflector, proceed according to Table 101-13.2.1 below:

Registration No.:

_

H/C Serial No.:

------

Inspection or Maintenance Work (1)

Total Hours: Reference

Cleaning of reflector

Initial

813-19

Table 101-13.2.1 -

Measures to be taken whenReflector is contaminated (1 of 1)

Technician

Date:

Inspector

Date:

Name

Signature

Stamp

Signature

CHAPTER 101 Page 112

Fh

Revision 18

O~~er

MAINTENANCE MANUAL 80 105

101 - 14 TIME BETWEEN OVERHAUL Of COMPONENTS (TBO) 101 - 14.1 Time Between Overhaul of Components Basic Helicopter The fellewing tables are arranged in ehapter sequenee and list the everhaul intervals (TBO) ef individual assemblies. When everhaul is due, the unit eoneerned must be removed and overhauled er replaeed by a new er overhauled unit. If a part has been assigned different overhaul intervals, the interval expiring first shall apply. Periodie inspeetiens do not affect overhaul intervals.

_C_O_M_P_O_N_E_NT

I_p_AR_T_N_O_.

I_T_B_O

_

11 - LlFTING SYSTEM Main Transmission (built-up)

4619 001 003 (FS 72 A)

1200Fh

Main Transmission (built-up)

4638 001 001 (FS 72 B)

3OO0Fh

Main Transmission (built-up)

4638 001 003 (FS 72 B)

3000Fh

Main Transmission (built-up)

4638 001 004 (FS 72 B)

3000Fh

Main Transmissien (built-up)

4638 001 011 (FS 72 B)

3000Fh

Main Transmission (built-up)

4638 001 007 (FS 72 E)

3000Fh

Main Transmission (built-up)

4638 001 008 (FS 72 E)

3000Fh

Main Transmission (built-up)

4638 001 009 (FS 72 E)

3000Fh

Main Transmission (built-up)

4638 001 010 (FS 72 E)

3000Fh

32 - TAlL ROTOR DRIVE Intermediate Gearbox (built-up)

4619002005

3600Fh

Intermediate Gearbox (built-up)

4619002003

3600Fh

Tail Rotor Transmission (built-up)

4619003003

3600Fh

I

43 - FLIGHT CONTROL SYSTEM Hydraulie Pump

IAP05VC-032

I1800Fh

61 - POWER PLANT Allisen Engine

250-C18

Refer te 250-C18 CSL 8

Allisen Engine

250-C20

Refer to Allison 250-C20 Operatien and Maintenanee Manual

Allisen Engine

250-C20B

Refer te Allison 250-C20 Operation and Maintenanee Manual

Starter/Generator

1000Fh

Table 101-14.1 - Time Between Overhaul of components Basic Helicopter (1 of 1)

Revision 23

CHAPTER 101 Page 113

-eurocopter •

MAINTENANCE MANUAL 80 10S

en EAOO CIlnIpMy

BLANK PAGE

CHAPTER 101 Page 114

-eurocopter . . 811

MAINTENANCE MANUAL BO 105

EADS 0Jmpcmy

101 - 14.2 Time Between Overhaul of Components Optional Equipment The following tables are arranged in chapter sequence and list the overhaul intervals (TBO) of individual assemblies of Optional Equipment. When overhaul is due, the unit concerned must be removed and overhauled or replaced by a new or overhauled unít. If a part has been assigned different overhaul intervals, the interval expiring first shall apply. Periodic ínspections do not affect overhaul intervals.

J

CO_M_P_O_N_E_N_T

PART NO.

I TBO

822 - CARGO HOOK SYSTEM

Load hook

S1609.2.105

I 1500 release operations* or 5 years,

Load hook

S1609.2.106

1500 release operations* or 5 years,

&

Load hook

S1609.2.105A

Load hook

S1609.2.106A

& 1500 reJease operations* or 5 years, &

1500 release operations* or 5 years,

&

Load hook

S1609.1.118A

1500 rele&operations* or 5 years, 1

* One release operation is defined as one times opening and closening.

NOTE

836 - RESCUE HOIST ASSEMBLY

Winch unit

105-81215 105-81216

300 cable operating cycles or 8 years,

WE-3821-3 WE-3821-4

300 cable operating cycles or 8 years,

Servo motor

DL 2050 M4D

8 years

Servo motor

13.1-0100

8 years

Servo motor

13.1-0110

8 years

Winch unit

&

&

Table 101-14.2 - Time Between Overhaul of components Optional Equipment (1 of 1)

&

whichever occurs first.

Revision 25

CHAPTER 101 Page 115

Aeurocopter ~

Dll

MAINTENANCE MANUAL BO 105

EAOS Compeny

BLANK PAGE

CHAPTER 101 Page 116

_~r

MAINTENANCE MANUAL BO 105

101 - 15 AIRWORTHINESS L1MITATIONS 101 - 15,1 General 1. List of Revisions

Revision

Date

LBA approval

Secondlssue

Dec.1,1990

signed by Schonemann

Revision 1

not applicable, chapter 101-15 (former 101-9) not affected

Revision 2

May 15,1991

Revision 3

not applicable, chapter 101-15 (former 101-9) not affected

Revision 4

not applicable, chapter 101-15 (former 101-9) not affected

Revision 5

not applicable, chapter 101-15 (former 101-9)· not affected

Revision 6

not applicable, chapter 101-15 (former 101-9) not affected

Revision 7

not applicable, chapter 101-15 (former 101-9) not affected

Revision 8

March 23,1993

Revision 9

not applicable, chapter 101-15 (former 101-9) not affected

Revision 10

Feb. 1, 1994

Revision 11

not applicable, chapter 101-15 (former 101-9) not affected

Revision 12

not applicable, chapter 101-15 (former 101-9) not affected

Revision 13

not applicable, chapter 101-15 (former 101-9) not affected

Revision 14

Sept. 21, 1995

signed by Schonemann

Revision 15

Dec.8,1995

signed by Kayser-Herold

Revision 16

July 26, 1996

signed by Kayser-Herold

Revision 17

not applicable, chapter 101-15 (former 101-9) not affected

Revision 18

June 30,1997

Revision 19

not applicable. chapter 101-15 (former 101-9) not affected

Revision 20

not applicabJe, chapter 101-15 (former 101-9) not affected

Revision 21

not applicable, chapter 101-15 (former 101-9) not affected

Revision 22

not applicable, chapter 101-15 (former 101-9) not affected

Revision 23

Aug. 23, 2002

signed by Kayser-Herold

Revisoin of Chapter 101-15

Issue date

EASA approval number and date

Revision 24

May 2,2005

2005-1339 dated 09.02.2005

Revision 24

signed by Schonemann

signed by Schonemann

signed by Schonemann

signed by Schonemann

CHAPTER 101 Page 117

MAINTENANCE MANUAL 80 105

2. General The tables in this section contain retirement times of parts whose failure would adversely affect the airworthiness of the helicopter. Retirement times must not be exceeded. In addition, it is necessary to observe the Intermediate Inspections, Periodic Inspections and Speciallnspections outlined in paras 101-S thru 101-13, and the Overhaullntervals outlined in para 101-14. The life-limited parts listed in this paragraph must be retired from service as soon as their service times are completed. They must be removed and replaced by new parts or serviceable used parts which still have a number of usefullife hours. It must also be noted that as a consequence of exceeding the operationallimits of a part (refer to para 101-13), the retirement life of the part may have to be reduced. In paragraph 1S.2 are listed the life-limited parts for the Basic Helicopter, in paragraph 1S.3 are listed the life-limited parts for Optional Equipment.

WARNING L1FE-L1MITED COMPONENTS MUST NOT BE INTERCHANGED BETWEEN B010S AND B010S LS HELICOPTERS OR BETWEEN B010S AND BK117 HELlCOPTERS.

WARNING IF PARTS WHICH HAVE ALIFE L1MITATION ARE INTERCHANGED BETWEEN DIFFERENT B010S SERIES HELlCOPTERS, THE PARTS MUST BE RESTRICTED TO THE LOWEST RETIREMENT TIME.

WARNING

I

NOTE

CHAPTER 101 Page 118

WHEN L1FE-L1MITED PARTS ARE REPLACED, THEIR ATTACHING HARDWARE MUST BE REPLACED AT THE SAME TIME. AFTER REMOVAL, THIS ATTACHING HARDWARE SHALL BE RENDERED UNSERVICEABLE AND NEW (UNUSED) ATTACHING HARDWARE INSTALLED IN ITS PLACE. THIS DOES NOT APPLY TO L1FE-L1MITED ATTACHING HARDWARE. SUCH ATTACHING HARDWARE SHALL BE REPLACED WHEN IT REACHES ITS OWN L1FE L1MIT. Certain part numbers have been changed by ASB- BO 1OS-1 0-113. Both the new and old part numbers ofthe affected pars are shown in the following list 101-1S.2.2 "Service Times of Life-Umited Parts Basic-Helicopter Helicopter series B010S CB-5, B010S CBS-S and B010S DBS-S Basic-Helicopter". The old part numbers are shown in brackets.

Revision 23

_~pter

MAINTENANCE MANUAL 80 10S

101 - 15.2 service Times of Life-Limited Parts 101 - 15.2.1 service Times of Life-Limited Parts Basic-Helicopter Helicopter series A, C, D, 5, except for BOlOS CB-S, BOlOS CBs-S and BOlOS DBs-5 _P_A_R_T

I_p_A_R_T_N_O_.

IRETIREMENTTIME

LIFTING SYSTEM Rotor Mast

4619305032

9000 Fh 6800 Fh

I

Transmission Support Struts, LH

~

105-10161

Transmission Support Struts, RH

~

105-10162

6800 Fh

Free Wheel Unit

~

CL-42071-1 or 4619302063

300 Fh

Free Wheel Unit

~ ~ ~ ~ ~

4619302048

1500 Fh

4619302059

1500 Fh

4638202006

1500 Fh

105-15103

&& 10000 Fh && 10 years or 2400 Fh or 15600 &

Free Wheel Unit Free Wheel Unit Main Rotor Blade Main Rotor Blade Tension-Torsion-Strap

105-87214 2602559

10000 Fh

flights Tension-Torsion-Strap

2606576

10 years or 2400 Fh or 15600 & flights

Tension-Torsion-Strap

2604067

10 years or 40000 flights

&

Tension-Torsion-Strap

J17322-1

10 years or 40000 flights

105-14101.19

2400 Fh or 15600 flights

& &

105-14101.54

2400 Fh or 15600 flights

&

1121-14102.19

30000 flights

&.

105-14101.20

2400 Fh or 15600 flights

&

Quadruple Nut, upper Quadruple Nut, upper Quadruple Nut, upper Quadruple Nut, lower

~ ~ ~ ~

Table 101-1S.2.1 - Service Times of Life-Limited Parts Basic-Helicopter Helicopter series A, C, D, S, except for B010S CB-S, B010S CBS-S and B010S DBS-S (1 of 4)

WARNING FOR WARNINGS, REFER TO CHAPTER 101, PAGE 118 Service life is unlimited when blade is modified by a cuff in the blade fitting area, using retrofit kit P/N 105-87218. Refer also to the historical records.

&

&.

If the number of flights cannot be determined: 4800 Fh In this connection the number of flights is to be considered equal to the number of landings (ground contacts).

&

Concurrent replacement of attaching hardware is not required.

&

Whichever occurs first.

~ For alternative part without life Iimit, refer to IPC. Revision 24

CHAPTER 101 Page 119

MAINTENANCE MANUAL BO 105

_P_'A._R_T

I_PA_RT_N_O_.

1 RETIREMENT

TIME

UFTING SYSTEM Ouadruple Nut, lower

~

105-14101.55

2400 Fh or 15600 flights

&,

Ouadruple Nut, lower

~

1121-14102.20

30000 flights

&

Nut

105-142241.01

122850 fligths

MM

Solt

105-141041.22

109200 fligths

MM

Solt

105-141041.23

109200 fligths

I

MM

Solt

~

105-14101.22g and up

2400 Fh or 15600 flights

~

Solt

~

105-14101.76

2400 Fh or 15600 flights

~

Solt

~

105-14101.23g and up

2400 Fh or 15600 flights

~

Solt

~

105-14101.77

2400 Fh or 15600 flights

&,

Solt

~

1121-14102.22

20000 flights

&,

Solt

~

1121-14102.23

20000 flights

&,

Secondary Slade Mounting Solt

~

105-14101.35 thru e

2400 Fh

TAlL UNIT Slade Mounting Fork

~

105-31711

2400 Fh

Slade Mounting Fork

~

105-31722

1200 Fh

Table 101-1S.2.1 - Service Times 01 Li1e-Limited Parts Basic-Helicopter Helicopter series A, C, D, S, except 10r B010S CB-S, B010S CBS-5 and B010S DBS-S (2014)

WARNING

FOR WARNINGS, REFER TO CHAPTER 101, PAGE 118

&

If the number of flights cannot be determined: 4800 Fh In this connection the number of flights is to be considered equal to the number of landings (ground contacts) .

.&.

If the number of flights cannot be determined: 3600 Fh In this connection the number of flights is to be considered equal to the number of landings (ground contacts).

~

Whichever occurs first.

~ For alternative part without life limit, refer to IPC.

&

I ' fthe total installation time is not known, the total operating time of the main rotor head can be assumed instead.

MI 'The f the number of flights cannot be determined: 18900 Fh. number of flights is to be considered equal to the number of landings (ground contacts). 12

~ I l f the number of flights cannot be determined: 16800 Fh.

The number of flights is to be considered equal to the number of landings (ground contacts). CHAPTER 101 Page 120

Revision 24

_~er _P_A_R_T

MAINTENANCE MANUAL 80105

I_p_A_R_T_N_O_.

--l.I_R_E_T_IR_E_M_E_N_T_T_IM_E

_

TAlL UNIT Laminated Strap Pack Assy.

105-31727

25350 flights

.&

Laminated Strap Pack Assy.

105-317261

25350 flights

.&

105-31725.12/.14/.16

600 Fh

Close Tolerance Boft

1121-31712.10

25350 flights

.&

Close Tolerance Boft

105-317391 .12

25350 flights

.&

105-31742

4800 Fh

105-87161

4800 Fh

105-31743/44/45/46

6000 Fh

19E144-1

1800 Fh

19E145-1

1800 Fh

19E144-3

1800 Fh

Close Tolerance Boft

hh

Lihhh hh hh hh hh hh hh hh

19E145-3

1800 Fh

105-31503 (19E144-3, mod.)

3600 Fh

&.

Bendix Shaft

hh

105-31504 (19E145-3, mod.)

3600 Fh

&..

Bendix Shaft

hh

105-31505 (19E144-1, mod.)

2400 Fh

&.

Bendix Shaft

hh

105-31506 (19E145-1, mod.)

2400 Fh

&.

Bendix Shaft

hh hh hh

19E144-2/2A

6000 Fh

19E145-2/2A

6000 Fh

19E143-1/1A

6000 Fh

Tail Rotor Blade Tail Rotor Blade Tail Rotor Blade Bendix Shaft Bendix Shaft Bendix Shaft Bendix Shaft Bendix Shaft

Bendix Shaft Bendix Coupling

Table 101-1S.2.1 - Service Times 01 Li1e-Limited Parts Basic-Helicopter Helicopter series A, C, D, S, except 10r B010S CB-S, B010S CBS-S and B0105 DBS-S (3014) WARNING

.& &.

hh &

FOR WARNINGS, REFER TO CHAPTER 101, PAGE 118

I l f the number of flights cannot be determined: 3900 Fh The number of flights is to be considered equal to the number of landings (ground contacts). Service life after modification. For afternative part without life limit, refer to IPC. Cannot be used unmodified. See SB 30-32.

Revision 24

CHAPTER 101 Page 121

I I

O~er _P_'A_R_T

MAINTENANCE MANUAL BO 105

I_PA_R_T_N_O_.

....LI_R_ET_I_R_E_M_E_N_T_T_IM_E

_

HYDRAULIC UNIT

&

Piston Rod

0133-750.08E

1800 Fh

Flat Spring

EE-4-2054

2400 Fh

Flat Spring

0133-741.11 E

2400 Fh

Flat Spring

105-457211.14

2400 Fh

&.

POWERPLANT Rubber Bushing (Freudenberg)

&

0118530

300 Fh

Rubber Bushing (Lord)

& & & & & &

J 14403-2

300 Fh

J 14326-2

300 Fh

0133-867

300 Fh

105-60376

300 Fh

105-60377

300 Fh

105-60378

300 Fh

V-Struts

0133-373

10000 Fh

V-Strut, LH

105-60371

10000 Fh

V-Strut, RH

105-60372

10000 Fh

Lower Strut

0133-597

10000 Fh

Lower Strut

105-60361

10000 Fh

Lower Strut

105-60363

10000 Fh

0133-592

10000 Fh

Rubber Bushing (Lord) Teflon Bushing Rubber Bushing Rubber Bushing Rubber Bushing

Flange

&

ENGINE Allison

250-C18

Refer to 250-C18 CSL 10

Allison

250-C20

Refer to Allison 250-C20 Operation and Maintenance Manual

Allison

250-C20B

Refer to Allison 250-C20 Operation and Maintenance Manual

Table 101-1S.2.1 - Service Times of Life-Limited Parts Basic-Helicopter Helicopter series A, C, O, S, except for B010S CB-S, B010S CBS-S and B010S DBS-S (4 of 4)

WARNING

&.

&

FOR WARNINGS, REFER TO CHAPTER 101, PAGE 118

This service lite applies only to piston rods with S/N 101 to 440, manufactured by Teledyne Hydra-Power (THP). For alternative part without lite limit, refer to IPC.

CHAPTER 101 Page 122

Revision 24

MAINTENANCE MANUAL 80105

101 - 15.2.2 Service Times of Life-Limited Parts Basic-Helicopter Helicopter series B010S CB-5, B010S CBS-S and B010S DBS-S BasicHelicopter _P_'A_R_T

I_p_'A_R_T_N_O_.

IRETIREMENTTIME

L1FTING SYSTEM Bearing Block

117-132031.11

6000 Fh

Hexagon Bolt

117-132031.13

6000 Fh

Hexagon Bolt

105-13104.13

4500 Fh

Aotor Mast

4619305032

9000 Fh

Tension-Torsion-Strap

2604067

10 years or 25000 flights

~

Tension-Torsion-Strap

J17322-1

10 years or 25000 flights

~

Nut

105-142241.01

122850 fligths

MM

Bolt

105-141041.22

109200 fligths

MM

Bolt

105-141041.23

109200 fligths

CL-42071-10r 4619302063

300 Fh

4619302048

1500 Fh

4619302059

1500 Fh

4638202006

1500 Fh

A1 A1 A1 A1

Free Wheel Unit Free Wheel Unit Free Wheel Unit Free Wheel Unit

I MM

TAIL UNIT Laminatecl Strap Pack Assy.

105-31727

25350 flights

Laminated Strap Pack Assy.

105-317261

25350 flights

Close Tolerance Bolt

1121-31712.10

25350 flights

Close Tolerance Bolt

105-317391.12

25350 flights

& & & &

Table 101-1S.2.2 - Service Times of Life-Limited Parts Basic-Helicopter Helicopter series B010S CB-S, B010S CBS-S and B0105 DBS-5 Basic-Helicopter (1 of 2)

WARNING

& ~

FDA WAANINGS, AEFEA TD CHAPTEA 101, PAGE 118

I l f the number of flights cannot be determined: 3900 Fh The number of f1ights is to be considered equal to the number of landings (ground contacts). Whichever occurs first.

A1 For alternative part without life ¡imit, refer to IPC. M I l fthe total installation time is not known, the total operating time of the main rotor head can be assumed instead.

M I l f the number of flights cannot be determined: 18900 Fh. 12

The number of flights is to be considered equal to the number of landings (ground contacts).

M I l f the number of flights cannot be determined: 16800 Fh. The number of flights is to be considered equal to the number of landings (ground contacts). Aevision 24

CHAPTEA 101 Page 123

I

O~er

MAINTENANCE MANUAL BO 105

IPART NO.

PART

IRETIREMENT TIME

FLIGHT CONTROL SYSTEM Control Ring

105-41953

10800 Fh

Control Rod

1120-13281

6600 Fh

Control Rod

1120-13282

6600 Fh

HYDRAULIC UNIT

I

Piston Rod

D133-750.08E

1800 Fh

Flat Spring

EE-4-20S4

2400 Fh

Flat Spring

D133-741.11 E

2400 Fh

Flat Spring

105-457211.14

2400 Fh

Hex. Bolt (installed in forkend assy P/N 105-45613, 105-456311 )

105-45016.26 (LN9485-8x22)

7000 Fh

&.

POWER PLANT V-Strut, LH

105-60371

10000 Fh

V-Strut, RH

105-60372

10000 Fh

Lower Strut

105-60363

10000 Fh ENGINE

Allison

250-C20B

Refer to Allison 250-C20 Operation and Maintenance Manual

Table 101-15.2.2 - Service Times of Life-Limited Parts Basic-Helicopter Helicopter series B0105 CB-5, B0105 CBS-5 and B0105 DBS-5 Basic-Helicopter (2 of 2) WARNING

&

FOR WARNINGS, REFER TO CHAPTER 101, PAGE 118

This service lite applies only to piston rods with S/N 101 to 440, manufactured by Teledyne Hydra-Power (THP).

CHAPTER 101 Page 124

Revision 24

MAINTENANCE MANUAL BO 105

101 - 15.3 Service Times of Life-Limited Parts Optional Equipment Al! Series _P_'A_R_T

--'I_p_'A_R_T_N_O_.

1 RETIREMENT

TIME

RESCUE WINCH Cable

WA-2485

300 cable operating cycles

Roller, driving

WA-4354

10-year period of installation and storage

Roller, driving

WA-2479

10-year period of installation and storage

Explosive Cartridge

TA 97155

5-year period of installation and storage

Explosive Cartridge

Mark 23 Mod. O

5-year period of installation and storage

~

NOTE Oriving rollers may only be replaced by ECO.

1

FIRE EXTINGUISHING SYSTEM _E_x_p_IO_s_iv_e_C_a_rt_ri_dg_e Explosive Catridge

+A_E_13_0_8_3_-5 13083-5

--1f-8_y_e_a_rs_&_o 4 years

&.

EMERGENCY FLOTATION SYSTEM Pressure Sottle

16017194-12

24-year period of installation and storage

Table 101-15.3 - Service Times of Life-Limited Parts Optional Equipment all Series (1 of 1)

WARNING

FOR WARNINGS, REFER TO CHAPTER 101, PAGE 118

~

For definition of cable operating cycles, refer to paragraph 10.2: Supplementary Inspection according to Operating Time in Fh and/or Calender Time, Optional Equipment, Point 836 - Rescue Winch

&

If cartridges are stored in the original factory packaging, the total life of the cartridge will be 10 years (storage time and service life), in which case service life may not exceed 8 years.

&.

If cartridges are stored in the original factory packaging, the total life of the cartridge will be 6 years (storage time and service life), in which case service life may not exceed 4 years.

Revision 24

I I

CHAPTER 101 Page 125

MAINTENANCE MANUAL 80 10S

BLANK PAGE

CHAPTER 101 Page 126

MAINTENANCE MANUAL

EUROCOPTER

eo 105

102 B A SIC R 1 G G 1 N G O F T H E M A 1 N R O T O R A N D TAl L R O T O R C O N T ROL S

Table of Contents

Page

Paragraph

Title

102 - 1

BASIC RIGGING OF THE MAIN ROTOR CONTROLS

3

102 - 2

Preparatory work

5

102 - 3

Installation of the rigging fixture - tandern hydraulic unit . . . . . . . .. .

.5

Installation and adjustrnent of the rigging fixture rnixing lever assembly . . . . . . . .

6

Adjustrnent - tandern hydraulic unit rigging fixture and control rods between tandern hydraulic unit and rnixing lever assembly . . . . .

7

102 - 4 102 - 5

102 - 6

Zero setting - rotating pitch links

11

102 - 7

Rigging - collective controls

11

102 - 8

Rigging - longitudinal controls

12

102 - 9

Rigging - longitudinal controls incorporating Ferranti FAS-2 (Stability Augrnentation Systern)

13

102 - 10

Rigging - lateral controls

15

102 - 11

Rigging - lateral controls incorporating Ferranti FAS-2 (Stability Augrnentation Systern)

16

102 - 12

Adjustrnent - cyclic stick lock

19

102 - 13

Adjustment - longitudinal ánd lateral trirnrners

2J

102 - 14

Check - end position of actuators

20

BO 105 CHAPTER 102 Page 1

EUROCOPTER

Paragraph

Title

102 - 15

Check and adjustment - cyclic control forces

21

102 - 16

Adjustment - collective control forces

27

102 - 17

Check - main rotor controls for freedom of movement

30

102 - 18

Final work .

30

102 - 19

CHECK - RIGGING OF THE MAIN ROTOR CONTROLS

31

102 - 20

Check - rigging of the longitudinal controls

31

102 - 21

Check - rigging of the lateral controls

33

102 - 22

Check - rigging of the collective controls

34

102 - 23

RIGGING OF TAIL ROTOR CONTROLS

39

102 - 24

Rigging - tail rotor controls (tail rotor hub with titanium blade grips) .

102 - 25

* * * * * * * * * * *

MAINTENANCE MANUAL 80 105

102 - 26 102 - 27

.

39

Rigging - tail rotor controls (tail rotor hub with aluminum blade grips and symmetrical-chord blades)

41

Check and adjustment of control forces of tail rotors with 00 coning angle blades . . . . . . . . . . . . .

45

Check and adjustment of control forces of tail rotors with 10 coning angle blades . . . . . . . . . . . . .

48

102 - 28

Del e t e d

102 - 29

Del e t e d

BO 105 CHAPTER 102 Page2

Page

Revision 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 102 - 1

BASIC RIGGING OF THE MAIN ROTOR CONTROLS

Required Equipment: External electrical power unit (28VDC) External hydraulic power unit Hydraulic servo tester E20000 or Hydraulic cart . 10SW10 10SW26 or Hydraulic cart or as a makeshift Portable hydraulic unit 10SW11 or equivalent equipment Spring scale, range 0-30 N Measuring tape, approx. 2 m Special tools: Adjusting device Adjusting device

10S-13101 W3 10S-42110 W1

Additional1y - for helicopters, Group 1~ : Adjustment device 105-42110 W2 - for helicopters, Group 2~ : Adjustment device 10S-42110 W3 - for helicopters, Group 3~ : Segment 10S-42110 W11 in combination with either adjustment device 10S-42110 W2 or adjustment device 105-42110 W3. - for helicopters incorporating the Ferranti Stability Augmentation Systern: Two standard control rods 10S-41488

~

For grouping, refer to figure 102-3 or table 102-2

BO lOS CHAPTER 102 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

"

-

, . - " ...

-

,.

, ,. , '

,.

" l'

16

400001.2

1 2 3 4 5

Control rod, lateral Pitch link Control rod, longitudinal Control rod, collective

through Control rods

10

Figure 102-1 BO 105 CHAPTER 102

Page 4

11

12 13 14 15 16 17 18

Tandem hydraulic unit Collective stick Trim actuator, longitudinal Trirnmer, longitudinal Trirnmer, lateral Trim actuator, lateral Cyclic stick Four-way switch, 2 CC

Main rotor controls

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 102 - 2

Preparatory work

l.

Remove LH lining from baggage compartment.

2.

Remove nose door.

3.

Remove the engine cowling.

4.

Remove LH side panel from floor.

5.

Remove LH front seat according to chapter 701.

6.

Remove pilot's collective stick (12, fig. 102-1) according to chapter 41.

7.

Disconnect the longitudinal and the lateral trimmers (14, 15) from the pilot's cyclic stick (17) according to chapter 41.

8.

Remove locking devices from the rod ends of the control rods (8, 9, 10).

9.

Check the cyclic stick for freedom of movement.

10.

Remove guard plate from RH side wall of the tandem hydraulic unit and drain line from between engine deck and angle bracket on the RH side wall of the tandem hydraulic unit according to chapter 43. Remove protective caps from hydraulic system outboard couplings PAI and PAII.

11.

Disconnect Teleflex cables of the N2 droop compensator from the tandem hydraulic unit. Refer to chapter 65.

102 - 3

Installation of the rigging fixture - tandem hydraulic unit

l.

Remove rigging pins (6, fig. 102-2) and loosen pivot lever bolt (7).

2.

Remove knurled bolts (4, 5) and fit rigging fixture from left to right on the tandem hydraulic unit so that the shaft of the pivot lever bolt (7) engages with the corresponding bore in the LH sidewall of the tandem hydraulic unit.

3.

First insert knurled bolt (4), then knurled bolt (5). Tighten both knurled bolts and the pivot lever bolt.

BO 105 CHAPTER 102 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

i\':,-:

I '" \\ I \" !

\'~

8 6

1 2 3 4 5

Rigging Rigging Rigging Knurled Knurled

segment A segment B segment C,D or E bolt bolt

5

Rigging pin Pivot lever bolt 8 Setscrews

6 7

Figure 102-2 Rigging fixture for the main rotor controls

102 - 4

Installation and adjustment of the rigging fixture - mixing lever assembly

l. Prior to installing rigging fixture (11, fig. 102-4), verify that all three locking levers (1) can be pulled from their respective supports by hand without having to apply force. If necessary, reduce spring tension via setscrews (6). 2. Install rigging fixture (11) as follows: a.

Remove split pin (12), castellated nut (13) and washer (14) from the bolt which connects the main transmission to the V-struts.

b.

Loosen knurled bolt (4) and pull spindle (5) outward.

BO 105 CHAPTER

Page 6

102

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 c.

Attach rigging fixture (11) so that retaining pins (2, 7) engage with the bores in the heads of the bolts which connect the main transmission to the V-struts. If necessary, adjust position of retaining pin (2) to obtain fit.

d.

Swivel up locking levers (1).

e.

Push nut (3) with spindle (5) inward and screw nut (3) on the bolt connecting the main transmission to the. V-strut. Lock spindle (5) with knurled bolt (4).

102 - 5

NOTE ------

Adjustment - tandem hydraulic unit rigging fixture and control rods between tandem hydraulic unit and mixing lever assembly In the following procedure use only the three same-type rigging pins. The fourth one with the red code and the unsymmetrical tip must not be used.

1. Connect an external hydraulic power unit to system 1 of the tandem hydraulic unit and apply a pressure of 40 bar. 2. Adjust rigging fixture for the tandem hydraulic unit.

a.

Loosen setscrews (8, fig. 102-2) on all three rigging segments so that the segments can be moved.

b.

Operate longitudinal controls to obtain servo actuator piston rod extension length ·x ft (see fig. 102-3) for the particular BO 105 helicopter variant (see rigging data in fig. 102-3). Use vernier caliper to take the measurement. Position rigging segment (3, fig. 102-2) so that rigging pin (6) can be fully inserted through the 00 bore (7, fig. 102-3) without displacing the actuator input lever. Fix the rigging segment in this position by tightening the corresponding setscrew (8, fig. 102-2).

c.

Set the rigging segment (1) for the lateral control in the same way as described in step b. for the longitudinal control.

d.

Move the collective servo actuator piston to its lower.most position. Insert the rigging pin (6) through the -0.2 0 bore (6, fig. 102-3). Maintain a slight axial force on the pin to keep its wedge-shaped tip in tight contact with the two centering rod ends in the actuator input lever. In this condition move the rigging pin together with the input lever and the rigging segment up just enough to extend the'actuator piston by 0.5 mm to 1.0 mm from its lower.most position. Fix the rigging segment in this position by tightening the setscrew (8, fig. 102-2) .

BO 105 CHAPTER 102 Page 7

- - - - - - - - - - - - - ' - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO lOS

*

3.

Leave rigging pins for longitudinal and lateral control inserted in their respective rigging positions as described in step 2. Remove rigging pin for collective control from the -0.2°,bore (6, fig. 102-3) and insert into the 7.8° bore (8).

4.

Swing down collective locking lever (1, fig. 102-4) of mlxlng lever rigging fixture to engage the collective control rod connecting bolt. If full engagement is obtained, the relative position of the collective mixing lever to the collective servo actuator is correcto

S.

If the locking lever slot does not easily engage, adjust length of control rod (9) until full engagement is obtained. In doing so, take care not to expose the red portion of the rod end threads on any of the control rods. After adjustment is completed, tighten retaining nuts and safety with lockwire.

6.

Check longitudinal control rod (8) for proper length in the same way as described in step 4. for the collective control rod. If necessary, adjust as described in step S.

7.

Check lateral control rod (10) for proper length in the same way as described in step 4. for the collective control rod. If necessary, adjust as described in step S.

8.

Remove rigging pins from the rigging fixture on the tandem hydraulic unit.

9.

Remove rigging fixture from the mixing lever assembly.

* * *

10.

Reinstall castellated nut (13) together with washer (14) to the bolt which connects the main transmission to the V-strut. Tighten nut to the torque specified in fig. 102-4 and secure with split pin (12).

BO lOS CHAPTER 102 Page 8

Revision 2

- - - - - - - - - - - - - M a B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MaB - BO 105

0

0 - - t i• • • •1-1-_ Oo

8

I --;--4

400563-01

Longitudinal Control Helicopter Variant

Dlmens. 'X'lnel. thiekness of lab washer (2) ¡n mm

Rigg. Segm.

Group 1

39.4-40.4

C

Group 2

42.1-43.1

D

Group 3

39.4-40.4

E

Group 1: Group 2: Group 3:

1 Piston rod Tab washer 3 Control rod 4 Servo actuator 5 0° rigging bore, lateral control 6 -0.2° rigging bore, collective control 7 0° rigging bore, longitudinal control 8 7.8° rigging bore, collective control

2

Lateral Control

Rfgg. pin in bore

Dimens. 'X' ¡nel. lhiekness of lab washer (2) ¡n mm

Col1ective Control

Rigg. Segm.

Rigg. pin in bore

A

O·

Rigg. pin in bore

Rigg. Segm.

31.4-32.4

O·

31.4-32.4

I

-0.2·

B

31. 4-32. 4

BO lOSA All BO 105 helicopters not belonging to groups 1 and 3 All helicopters certified for 2500 kg max. takeoff mass and all helicopters with an extended C.G. range

Figure 102-3

Revision 3

Required rigging data and rigging segrnents

BO 105 CHAPTER 102 Page 9.

- - - - - - - - - - - - M a B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MaB - BO 105 2

_,¿;.-----3 10-----1 "("O~._---4

9------==---l

~0J.LV_----5

8-----------~ 7

DETAlL

12 13 -115 - 20 Nm

B

I

1 2 3 4 5 6 7

14

DETAlL

A

8 9

400737

10 11 12 13 14

Locking lever Retaining pin, adjustable Nut Knurled bolt Spindle Setscrew, spring preload Retaining pin Control rod, longitudinal Control rod, collective Control rod, lateral Rigging fixture, mixing lever assy Split pin Castellated nut Washer

6--.J

Figure 102-4 BO 105 CHAPTER 102 Page 10

Installation - Rigging fixture for mixing lever assy

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 102 - 6

Zero setting - rotating pitch links

l.

Disconnect pitch links (2, fig. 102-1) from swash plate and pitch horno

2.

Set pitch links to a length of 286.9 mm to 287.3 mm if they are to be installed into a helicopter without blade folding system or to a length of 289.8 mm to 290.2 mm if they are to be installed into a helicopter with blade folding system. For details of length adjustment and for positioning of the rod ends, refer to chapter 41.

3.

Reinstall the pitch links. For details refer to chapter 41.

102 - 7

Rigging - collective controls

l.

Reinstall pilot's collective stick (1, fig. 102-6).

2.

Move collective stick slowly downward against stop (4). Hold in this position. NOTE

Position of stop (4) must not be changed.

3.

Check that rigging pin of segment B (9, fig. 102-6) can be fully inserted through the -0.2° bore without using force.

4.

If the rigging pin cannot be fully inserted, adjust control rod (12) of the servo actuator input lever, until it can be fully inserted. Insert pin to full extent and fit input lever in installed position. Adjust length oi' control rod (12) to fit. Tighten rod end jaro nuts after adjusting the length of the control rods. Connect control rod (12) to the servo actuator input lever. Secure castellated nut with a split pin and secure rod end jaro nuts with lockwire.

5.

Remove rigging pin from segment B.

6.

Pull collective stick slowly against stop (3). Check that rigging pin of segment B can be fully inserted through the +15.8° bore without using force.

7.

If the rigging pin cannot be fully inserted, loosen stop (3) and move collective stick until the rigging pin can be fully inserted. Shift stop (3) until it abuts the collective stick, then secure in this position.

BO 105 CHAPTER 102 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - . MAINTENANCE MANUAL MBB - BO 105 8. Rernove rigging pin frorn segment B. 9. Check collective controls for unrestricted rnovernent.

102 - 8 NOTE

Rigging - longitudinal controls Be sure to use the rigging segment appropriate to the helicopter variant. See table in fig 102-3.

1. Pull cyclic stick (5, fig. 102-6) slowly against stop (19). Hold in this position.

2. Insert rigging pin in either segment C, O (i.e. in + 4.7 0 bore) or E (i.e. in + 5.5 0 bore), depending on the helicopter variant. Check that rigging pin can be fully inserted without using force. 3. If the rigging pin cannot be fully inserted, adjust length of control rod (11) in the sarne way as described for control rod (12) in chapter 102-7, step 4. 4. Rernove rigging pin frorn the rigging segmento

5. Back off stop nut (20) to its outerrnost position. Move cyclic stick slowly forward until rigging pin of segment C (10) can be fully inserted through the -9.3 0 bore or the rigging pin of segments O or E can be fully inserted through the -10.5 0 bore. Turn stop nut (20) clockwise until it abuts the cyclic stick support (16). Secure stop nut using with splít pino 6. Rernove rigging pin frorn segment C, O or E, as applicable. 7. Check longitudinal controls for unrestricted rnovernent.

BO 105 CHAPTER 102 Page 12

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BQ 105 102 - 9

Rigging - longitudinal controls incorporating Ferranti FAS-2 (StabilityAugmentation Systern)

1.

Remove control rod with integrated electromechanical actuator (refer to chapter 846) and install the standard control rod p/N 105-41488 (1, fig. 102-5) in its place.

2.

Rig longitudinal controls according to chapter 102-8, steps 1. through 5.

3.

Remove standard control rod without changing its assembly length.

4.

Measure assembly length "L" of the standard control rGd (refer to figure 102-5) .

5.

Connect plug 29 VEb (2) of control rod with integrated actuator (3) to socket 29VEB (red code) .

6.

Connect an external electrical power unit to the helicopter and switch on (refer to chapter 92).

7.

Press circuit breaker 1CA of the Stability Augmentation System. Set toggle switch 2CA in the control panel 28VE to the STDBY position (refer to chapter 846), then wait approximately five minutes to allow the actuator to reach its end position (electrical zero position) .

8.

Check that dimension 27.15 mm to 27.85 mm on the control rod (3) has been obtained. If not, readjust the electrical zero position according to chapter 846.

9.

Disconnect plug 29VEb (2) from socket 29VEB.

10. Remove lockwire (6) and loosen retaining nut (5) on the control rod end. Disengage tabs of lockwasher (4) and rotate rod end (7) until the length of the control rod is equal to assembly length "L" measured in step 4. and the rod ends are offset 90° to each other. After the length is set, installlockwasher (4) and hand-tighten retaining nut (5). 11. Tighten retaining nut (5) and secure with lockwire. 12. Reinstall control rod with integrated actuator. The actuator must be at the lower end. 13. Check longitudinal rigging according to chapter 102-8, steps l. through 5. 14. Connect the red color-coded plug 29VEb (2) to socket 29VEB of same color. 15. Check longitudinal controls for unrestricted movement. 16. Switch off and disconnect the external electrical power supply.

BO 105 CHAPTER 102 Page 13

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

---------....,......---MBB

I

L

~2

54

I

-J

==utL!Lv

3

Ilo--

27.15 to 27.85 L 400022

1 Standard control rod 105-41488 2 Plug 29VEb for longitudinal actuator, plug 29VEc for lateral actuator 3 Control rod with integrated electromechanical actuator

Figure 102-5 BO 105 CHAPTER 102 Page 14

4 5 6 7

Lockwashe'r Retaining nut Lockwire Rod end

Adjustment - assembly length of control rods with integrated actuator

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 102 - 10

Rigging - lateral controls

1. Check setting of stop screw (18, fig. 102-6) with cyclic stick positioned to extreme left. If the dimension measures 28.5 mm (see fig. 102-6, Detail C), the stop screw setting is correcto Otherwise, readjust stop screw. NOTE

No further adjustment of step screw (18) is permitted.

2. Provisionally adjust stop screw (14) to obtain dimension 75 mm (See

figure 102-6). 3. Move cyclic stick slowly to the left until it abuts stop (18). Hold in

this position. 4. Check that rigging pin of segment A (8) can befully inserted through

the -5.65° bore without using force. 5. If the rigging pin cannot be fully inserted, adjust control rod (13) in the same way as described for control rod (12) in chapter 102-7, step 4. 6. Remove rigging pin from the rigging segmento 7. Move cyclic stick slowly to the right until it abuts stop (14).

8. Check that rigging pin of segment A can be fully inserted through the +4.23° bore without using force. 9. If the rigging pin cannot be inserted, adjust stop screw (14) until the rigging pin can be inserted. Hold the cyclic stick against the stop while doing so. 10. Secure stop (14) in this position by tightening jam nut (15). 11. Remove rigging pin from segment A.

12. Check lateral controls for unrestricted movement.

BO 105 CHAPTER 102 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - . MAINTENANCE MANUAL MBB - BO 105 102 - 11

Rigging - lateral controls incorporating Ferranti FAS-2 (Stability Augmentation System)

l. Remove control rod with integrated electromechanical actuator (refer to chapter 846) and install the standard control rod p/N 105-41488 (l,fig. 102-5) in its place. 2. Rig lateral controls according to chapter 102-10, steps l. through 10. 3. Remove standard control rod without changing its assembled length. 4. Measure assembly length "L" of the standard control rod (refer to figure 102-5) . 5. Connect blue color-coded plug 29VEc (2) to socket 29VEC of same color. 6. Connect and switch on an external electrical power supply (refer to chapter 92). 7. Press circuit breaker 1CA of the Stability Augmentation System. Set togg1e switch 2CA in the control panel 28VE to the STDBY position (refer to chapter 846), then wait approximately five minutes to allow the actuator to reach its end position (electrical zero position) . 8. Check that dimension 27.15 mm to 27.85 mm on the control rod (3) has been obtained. If not, readjust the electrical zero position according to Chapter 846. 9. Disconnect plug 29VEc (2)from socket 29 VEC. 10. Remove lockwire (6) and loosen retaining nut ·(5) on the control rod end. Disengage lockwasher (4) and rotate rod end (7) so that the assembly length of the control rod equals that measured in step ~. and the rod ends are offset 90° to each other. 11. Tighten retaining nut (5) and secure with lockwire. 12. Reinstall control rod with integrated actuator. The actuator must be at the lower end. 13. Check lateral rigging according to chapter 102-10, steps 3. through 10. 14. Connect the blue color-coded plug 29 VEc (2) to socket 29VEC of same color (refer to chapter 846). 15. Check lateral controls for unrestricted movement. 16. Switch off and disconnect the external electrical power supp1y.

BO 105 CHAPTER 102 Page 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

_---9 DETAlL

8---;.........~.

A -+---3

.-.......-10 ~-----4

5

-;""--11

Collective stick Nut Stop, upper 4 Stop, lower 5 Cyclic stick 6 Dual hydraulic booster 7 Riqqinq fixture, dual hydraulic booster 8 Riqqinq seqment B (lateral controls) 9 Rigqinq seqment B (collective controls) 10 Riqqinq seqment e, o or E 11 Control rod, lonqitudinal 12 Control rod, collective 13 Control rod, lateral 14 Riqht travel stop, cyclic stick 15 Jam nut 16 Cyclic stick support (lateral control link) 17 Jaro nut 18 Left travel stop, cyclic stick &i9 Aft travel stop, cyclic stick 20 Forward travel stop, cyclic stick 21 Spindle for lonqitudinal stop 1 2 3

DETAlL 400690

DETAlL

B

21-..... 20

18

~ Clevis pin 105-40126.07 (refer to IPC) shall be used

17

16 15

75--t

for helicopters in Group 3 (see fiq. 102-3)

18

19

~

Figure 102-6

e

Rigqing - collective, longitudinal, and lateral controls 105 102 Page 17/18

BO CHAPTER

14

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 102 - 12

Adjustment - cyclic stick lock

l. Move the cyclic stick into a position in which both the rigging pin of the lateral rigging segment A and the rigging pin of the longitudinal rigging segment C, D or E, depending on helicopter variant, can be fully inserted through the respective 0° bores. With the rigging pins thus installed, the cyclic stick is in its neutral position. 2. Loosen nuts (6, fig. 102-7) and adjust position of plate (4) on the cyclic stick lock so that the bore in the plate engages the centering pin (8) on the cyclic stick when the cyclic stick lock is lowered. Tighten nuts (6).

--:;~~----------5

.------6

o·

o·

1 2 3 4

0° rigging bore, lateral 0° rigging bore, longitudinal

Rigging fixture, tandem hydraulic unit Plate Figure 102-7

5 6 7 8

Cyclic stick lock Nut Cyclic stick Centering pin

Adjustment - cyclic stick lock

BO 105 CHAPTER 102 Page 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 102 - 13

Adjustment - longitudinal and lateral trimmers

l. Lock cyclic stick in neutral position using either the cyclic stick lock or the rigging fixture (refer to para 102-12, step l.). 2. Make sure that longitudinal and lateral trimmers are disconnected from the cyclic stick. 3. Set lateral and longitudinal trim actuators to their respective neutral positions (refer to fig. 102-8), using the four-way switch on the cyclic stick grip. 4. Check whether the longitudinal and the lateral trimmers can be reconnected to the cyclic stick without having to adjust their length. If not, rotate rod end of affected trimmer(s) until the required length is obtained, then finger-tighten jam nut. If the rigging procedure is not yet completed, connect trirnmers provisionally to the cyclic stick. Otherwise tighten castellated nuts on the connecting bolts and secure with split pins, and tighten rod end jam nuts and secure with lockwire.

5. Disengage cyclic stick lock or remove rigging fixture from tandem hydraulic unit, as applicable. The cyclic stick must retain its neutral position. 6. Reinstall drain line and guard plate to the RH side wall of the tandem hydraulic unit according to chapter 43. Blank off the hydraulic system outboard couplings with their protective caps. 102 - 14

Check - end position of actuators

l. Connect and switch on an external electrical power supply (refer to chapter 92).

2. Extend longitudinal and lateral trim actuators to their respective fully eA~ended positions by actuating the four-way switch in the cyclic stick grip, then measure dimension "B" (refer to figure 102-8). 3. Retractlongitudinal and lateral trim actuators to their respective fully retracted positions, then measure dimension "A" (refer to figure 102-8). 4. Replace trim actuator if actual dimensions "A" or "B" deviate from those specified. 5. Switch off and disconnect external electrical power supply (refer to chapter 92). 6. If the rigging procedure is not yet completed, leave trirnmers connected provisionally to the cyclic stick. Otherwise tighten castellated nuts on the connecting bolts and secure with split pins, and tighten rod end jam nuts and secure with lockwire.

BO 105 CHAPTER 102 Page 20

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1

•

I

~

l

-

í(

bl A

..

-

O

-

B

400565

Dimension

Actuator, longitudinal

Actuator, lateral

A (retracted)

257.5 - 258.1 mm

268.8 - 269.4 mm

O

263.6 - 264.2 mm

273.7 - 274.3 mm

287.9 - 288.5 mm

281.6 - 282.2 mm

(neutral) B (extended)

Figure 102-8

102 - 15 NOTE

End positions and neutral position - trim actuators

Check and adjustment - cyclic stick control forces Check and adjust control forces at an ambient temperature of between 10 oC and 30 oC.

1. Connect and switch on external electrical power supply.

2. Connect an external hydraulic power unit to the hydraulic system and apply 103 bar.

BO 105 CHAPTER 102 Page 21

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

Attach adhesive tape around the middle section of the cyclic stick grip and mark it with a "X" on the right side (refer to figure 102-9).

4.

Move the cyclic stick longitudinally and laterally through entire operational ranges several times to reduce the initial stiffness of rubber boots and friction in control linkage.

5.

Pull the cyclic stick against its stop. The position of the "X" marked on the cyclic stick grip is the reference point for the following measurements.

6.

Release the cyclic stick and by means of the longitudinal actuator move it to a position where the "X" is 145 mm to 155 mm in front of the reference point established in step 5.

7.

Maintaining position in longitudinal direction, move cyclic stick into lateral zero-position by means of the lateral actuator. Obtain zero-position by alignment to the cyclic stick lock.

8.

Disconnect longitudinal and lateral trirnmers from the cyclic stick.

9.

Adjust tension of the rubber cords (1 and 5, fig. 102-10) so that the cyclic stick position established in steps 6. and 7. is maintained.

10. Using a spring scale, check that the cyclic stick breakout forces in fore, aft, right and left directions do not differ by more than 0.5 N.

=-í

----...

145-155 mm

1 i

2 ---:;::==~

e e

r-------3

---------4

'" '" ,.., '" '" ~

I

400686

Adhesive tape 2 "X" mark

3 4

1

Figure 102-9 BO 105 CHAPTER

Page 22

102

Cyclic stick

Cyclic stick grip Cyclic stick

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

11. Connect longitudinal and lateral trimmers to the cyclic stick. 12. Check cyclic stick breakout forces in fore, aft, right and left control directions. a.

Attach spring scale to cyclic stick grip so that its point of attachment is level with the "X" mark on the grip. Then pul! spring scale in each of the four control directions in turn until the cyclic stick has moved 9-11 mm from its neutral position. Record force required to produce this travel in each control direction.

b.

Determine the difference between the fore and aft control forces and between the left and right control forces. In neither case must the difference exceed 1 N.

c.

Readjust affected rubber cord if the above limit of 1 N is exceeded.

d.

Calculate the mean value of the opposing longitudinal breakout forces and of the opposing lateral breakout forces.

e.

If the mean values are between 7.5 N and 8.5 N and the difference between the opposing breakout force s does not exceed 1 N, no further adjustment is necessary. Tighten and secure connecting hardware. Make sure that rod end retaining nuts. on the trimmers are tightened and secured with lockwire.

13. Adjust affected trimmer if the mean value of the breakout force is smaller than 7.5 N or greater than 8.5 N. a.

Remove trimmer from aircraft. Proceed with step b. through step f. when adjusting trimmers of variant 1 (adjustment by use of shims) and with step g. through step k. when adjusting trimmers of variant 11 (Adjustment by means of a setscrew~ .

b.

Remove split pin (5, fig. 102-11) and unscrew nut (4) from trim rod (14) •

c.

Remove lockwire (6) and retaining rings (13) from both ends of the spring case (15). Remove trimmer rod and spring from spring case. Breakout force too high: reduce number of installed washers by removing them equally from both ends of the spring until the required breakout force is obtained. Breakout force too low: install the appropriate number of washers on both ends of the spring until the required breakout force is obtained. A change in spring length of 0.7 mm changes the breakout force by 1 Nm.

d.

Reassemble trimmer. For details refer to chapter 41. Tighten nut (4) just enough to remove the axial play between trim rod and spring.

e.

Reinstall trimmer and recheck cyclic stick breakout force by repeating steps 12a through 12e.

BO 105 CHAPTER 102 Page 23

- - - - - - - - - - - - - . MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 f.

Secure retaining rings (13) with lockwire and safety nut (4) with a split pino

g.

Remove split pin (9). Straighten tangs of lockwasher (12) and remove jam nut (11). Reinstall jam nut (11) together with a new lockwasher (12). Do not tighten jam nut (11) at this time.

h.

If the breakout force is too low, tighten setscrew (8) until the required breakout force is attained. Turning setscrew (8) by half a turn increases the breakout force of the"cyclic stick by 1 N measured at nX n marked on stick grip. On the standard trim system tighten nut (10) just enough to remove the axial play between trim rod and spring.The follow-up trim system (refer to chapter 847) requires an axial play of 0.5 mm.

i.

If the breakout force is too high, back off nut (10) several turns and back off setscrew (8) until the required breakout force is obtained. Turning setscrew (8) by half a turn decreases the breakout force of the cyclic stick by 1 N measured at the nX n marked on the stick grip. On the standard trim system tighten nut (10) just enough to remove the axial play between trim rod and spring. The follow up trim system requires an axial play of 0.5 mm.

j.

Reinstall trirnmer and recheck cyclic stick breakout force in accordance with steps 12a. thru 12e.

k.

Tighten jam nut (11) and secure with lock washer (12). Secure nut (10) with a split pino

14. Remove adhesive tape from the cyclic stick grip. 15. Switch off and disconnect external hydraulic power unit. 16. Switch off and disconnect external electric power unit.

BO 105 CHAPTER 102 Page 24

- - - - - - - - - - - - - M E B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

DETAlL

A 1

~ Installed as follows:

~-2

DETAlL

B

3

H:t--7

1 DETAlL

~

D

4------'"T 400691

Figure 102-10

Rubber cord, for weight compensation of lateral controls 2 Rubber cord, for weight compensation of collective controls 3 Clamp 4 Fuselage bracket 5 Rubber cord, for weight compensation of. longitudinal controls 6 Bolt 7 Washer 8 Split pin .

Weight compensation - flight controls BO 105 CHAPTER 102 Page 25

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Variant 1 14

2

1 16

DETAlL

13

A

-~'17~~--

6

A,_

()

-

9

-e:::

-- V

-

-

-

-

"'

/

r

400033.2

12

1 Laminium washer 2 Compressión spring 3 Laminium washer 4 Castellated nut 5 Split pin 6 Safety wire 7 Sleeve 8 Setscrew

Figure 102-11

/ ""

,"''l

R:=IL

'--

BO 105 CHAPTER 102 Page 26

8

7

15

Variant II

(

5

4

16 3

9

10 11

12 13

14 15 16

10

1\ T

11

Ir

10

Split pin Castellated nut Jam nut Leck washer Retaining ring Trim red Spring case Washer

Trirnmer - cyclic stick force

14

MAINTENANCE MANUAL 80 105

EUROCOPTER

102 - 16

Adjustment - co¡lective control forces

*

* * *

NOTE

o Adjust collective friction at an ambient temperature of between 10 oC and 30 oC. 1. Using an external hydraulic power unit, apply a pressure of 103 bar to the helicopter hydraulic system. 2. Only for configuration with rubber cord (installed on S/N 351 and subsq. or after incorporation of SB 40-27):

* *

Adjust collective controls weight compensation as follows. a.

Connect rubber cord (2, fig. 102-10) to the uppermost holes of the fuselage bracket (4), but do not secure at this time.

b.

Pull collective stick full up and hold in this position.

c.

Loosen and position clamp (3) so that the cord is taut but not stretched. Ensure that the fastening lug of the clamp points in the prescribed direction (refer to figure 102-12) and tighten clamp.

3. Adjust pressure exerted by friction clamp (4) by turning collective friction adjustingknob (2) so that the operating forces measured at the

*

center of the collective stick grip correspond to the values specified in Table 102-1. Collective stick starting position Mid-travel position Mid-travel position

Direction of - Operating forces collective stick displacement up down

25 N max. 8 ~ 12 N

* * * *

Table 102-1 Control forces - collective stick

*

*

4. Retain collective friction adjusting knob (2) in its present position. Rembve split pin from castellated nut (3) and screw it against the fric-

tion clamp. Secure the castellated nut in this position. If the split pin cannot be inserted in this position, back off nut to next split pin hole and secure with split pino

Revision 13

* * * * *

BO 105 CHAPTER 102 Page 27

MAINTENANCE MANUAL BO 105

EUROCOPTER

NOTE

*

The collective pitch stick must not move from its mid-travel position when the friction clamp is fully released.

* ** 5. Turn friction adjusting knob ccw to full extent (friction clamp released * to friction force adjustment), then measure stick operating force and * check whether the collective pitch stick moves from its mid-travel * position. Readjust friction clamp in the following cases: * * - the collective pitch stick does not remain in the mid-travel position. *

* *

-

the stick operating forces do not correspond with the values specified in Table 102-1.

* * 6. Secure attaching bolt (6, figure 102-10) of rubber cord, using washer (7)

* and split pin (8). * * 7. Check rubber cord attaching clamp for clearance to adjacent parts through * the full travel range of the collective pitch stick.

*

* 8. Switch off hydraulic power supply.

*

* NOTE o The following check can be performed using hydraulic power (e.g. * from hydraulic test stand) or when ground running the helicopter. * * o Refer to Chapter 101, Periodical Inspections for frequency of this * check. * * * 9. Check stick operating force. * a. Connect hydraulic power to hydraulic unit of helicopter and apply * 103 bar or ground run the helicopter with engines. If stick operating * force is checked during ground run, ground run the helicopter with both engines simultaneously: put one engine power lever to position IDLE and the other engine power lever to position FLIGHT.

*

* * *

b.

Turn friction adjusting knob (2, figure 102-12) of friction clamp ccw to full extent (friction clamp released to minimum friction force adjastment) .

*

c.

* * * *

Check that the force required to operate collective pitch stick (1) is within the values specified in Table 102-1 and that the collective pitch stick does not move on its own from the mid-travel position.

d.

If necessary, readjust stick operating force via friction adjusting knob (2). Remove split pin from castellated nut (3), then screw castellated nut against the friction clamp and reinstall split pino

*

e.

If·the split pin cannot be installed, back off castellated nut to next split pin hole and install split pino

f.

Check stick operating force again.

g.

Switch off hydraulic pressure supply or stop ground run, as applicable.

* *

* *

*

* * *

*

* *

* *

*

BO 105 CHAPTER 102 Page 28

Revision 13

MAINTENANCE MANUAL 80 105

EUROCOPTER

*

*

* * '------2 :.4.·....~--3

* *

* *

* *

* *

* * 4 - - - - - - - - - - - - . : : :..............¡~

,.,............10

O

1 2 3 4

Collective stick Friction adjustipg knob Castellated nut Friction clamp 5 Clamp

r>

5--++--"'"

Figure 102-12 Adjustment-collective friction

Revision 13

BO 105 CHAPTER 102 Page 29

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

102 -

Check -

17

main rotor controls for freedom of movement

AII parts of the control system must be checked for freedom of movement after the basic rigging procedure.

NOTE

1.

Connect and switch an external electrical power supply.

2.

Using an external hydraulic power unit, apply a pressure of 103 bar to the hydraulic system.

3.

Move the cyclic stick longitudinally and laterally through the entire operational ranges. Simultaneously, check that all control rods can be rotated, especially the longitudinal control rod between the cyclic stick and the bellcrank in front of frame 4 (or both longitudinal control rods if dual controls are installed).

4.

Check the main rotor system and the mixing lever assembly for freedom of movement as -follows: a.

Turn main rotor through 360 0 by hand and simultaneously perform the following control inputs via the collective and cyclic sticks. - Pull collective pitch stick full up. - Push cyclic stick forward to full extent. - Push cyclic stick left to full extent.

b.

Visually inspect rod ends for correct installed position. They must not seat against the pitch horn nor in the fork of the swash plateo

5.

Switch off and disconnect external hydraulic power unit.

6.

Switch off and disconnect external electric power supply.

102 - 18

Final work

1.

Seal control rods (refer to chapter 41).

2.

Check for foreign objects and for proper safetying of all attaching hardware.

3.

Reinstall LH cover sheet.

BO 105 CHAPTER

Page 30

102

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4. Reinstall LH front seat according to chapter 701. 5. Connect the Teleflex cables of the N2 droop compensator to the tandem hydraulic unit and check the N2 droop compensator for proper adjustment. Refer to chapter 65. 6. Reinstall drain line and guard plate to the RH side wall of the tandem hydraulic unit according to chapter 43. Plug the hydraulic system outboard couplings with their protective caps. 7. Reinstall the engine cowling. 8. Reinstall LH lining in cargo compartment. 9. Reinstall nose door.

102 - 19

CHECK - RIGGING OF THE MAIN ROTOR CONTROLS

Required Equipment: External electrical power unit (28VDC) External hydraulic power unit Hydraulic servo tester E20000 10SW10 or Hydraulic cart 10SW26 or Hydraulic cart or as a makeshift Portable hydraulic unit 10SW11 or equivalent equipment Special tool: Rigging fixture 105-42110 W1 102 - 20

Check - rigging of the longitudinal controls

l. Remove engine cowling as required. 2. Fasten rigging fixture (8, fig. 102-13) to the mixing lever assembly (12) as described in chapter 102-4. 3. Turn the main rotor by hand until the yellow color-coded rotating pitch link (4) is positioned straight above the rear non-rotating pitch link (3) •

4. Using an external hydraulic power unit, apply 103 bar to the hydraulic system.

BO 105 CHAPTER 102 Page 31

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 5.

Check that locking levers (9, 10, 11) disengage easily when pulled out of their supports by hand. If necessary, reduce spring tension by turning the setscrew.

6.

Move the collective stick full down and place the cyclic stick in the longitudinal neutral position (no particular lateral position is required). Swing down locking lever (9) to engage the head of the rear (longitudinal) mixing lever connecting bolt. Using a clinometer, measure and record the blade angle of the yellow color-coded rotor blade (measure at the blade grip upper surface). Do not change rotor position.

7.

Swing locking lever (9) upward and move cyclic stick against its forward stop. Measure and record the rotor blade angle as described in step 6. Do not change rotor position.

8.

Pull cyclic stick against its rear stop and measure and record blade angle as described in step 6.

9.

Calculate blade angles. a.

Subtract angle determined in step 6. from angle determined in step 7. to obtain the blade angle for the cyclic stick full forward position.

b.

Subtract angle determined in step 6. from angle determined in step 8. to obtain the blade angle for the cyclic stick full aft position.

10. Check that measured angles are within the limits specified in table 102-2. Readjust rigging if necessary. 11. Switch off the external hydraulic power unit.

Cyclic stick longitudinal position

Helicopters Group 1

Helicopters Group 2

full forward

- 9.3 0 ± 20'

- 10.5 0 ± 20'

- 10.5 0 ± 20'

4.7 0 ± 20'

4.7 0 ± 20'

5.5 0 ± 20'

full aft

Helicopters Group 3

Group 1:

BO lOSA

Group 2:

AlI BO 105 helicopters n6t belonging groups 1 and 3

Group 3:

All helicopters certified for 2.St max. takeoff mass or all helicopters with an extended C.G. range. Table 102-2

BO 105 CHAPTER 102 Page 32

Blade angles - longitudinal control

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

102 - 21

Check - rigging of the lateral controls

1.

Turn themain rotor by hand until the yellow color-coded rotating pitch link (4, fig. 102-13) is positioned straight above the forward non-rotating pitch link (1).

2.

Switch on the external hydraulic power unit and apply 103 bar to the helicopter hydraulic system.

3.

Move collective stick full down, and place cyclic stick in the lateral neutral position (no particular longitudinal position is required). Swing down locking lever (11) to engage the head of the forward (lateral) mixing lever connecting bolt. Using a clinometer, measure and record the blade angle of the yellow color-coded main rotor blade (measure at the blade grip upper surface). Do not change rotor position.

4.

Disengage locking lever (11) and move cyclic stick to the extreme left position and hold there. Measure and record the blade angle as described in step 3. Do not change the rotor position.

5.

Move cyclic stick to the extreme right position and hold there. Measure and record the blade angle as described in step 3.

6.

Calculate blade angles. d.

Subtract angle determined in step 3. from angle determined in step 4. to obtain the blade angle for the cyclic stick extreme left position.

b.

Subtract angle determined in step 3. from angle determined in step 5. to obtain the blade angle for the cyclic stick extreme right position.

7.

Check that measured angles are within the limits specified in table 102-3. Readjust rigging if necessary.

8.

Switch off the external hydraulic power unit.

Cyclic stick lateral control

All variants

full left

- 5.65° ± 20'

full right

4.23° ± 20'

Table 102-3 Blade angles - lateral control

BO 105 CHAPTER 102 Page 33

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - . MAINTENANCE MANUAL MBB - BO 105 102 - 22

Check - rigging of the collective controls

1.

Choose any one of the main rotor blades as reference blade. Turn the main rotor by hand until the pitch link belonging to the reference blade is positioned straight above one of the two non-rotating pitch links (1 or 3, fig. 102-13) .

2.

Connect an external hydraulic power unit to the helicopter hydraulic system and apply 103 bar.

3.

Move the collective stick full down and place the cyclic stick at neutral. Swing down the locking levers (9, 11) to engage the bolts which connect the mixing levers to the control rods (5, 7). Using a clinometer, -measure and record the blade angle of the reference blade (measure at the blade gtip upper surface) .

4.

Rotate the main rotor by half a revolution, then again measure and record the blade angle as described in step 3. Do not change the rotor head position.

5.

Pull collective stick full up, then measure and record the blade angle as described in step 3.

6.

Calculate the change in the minimum and maximum collective pitch angles. a.

The minimum collective pitch angle is the mean value of the angles determined in step 3. and step 4.

b.

The maximum pitch change angle is the difference between the angles determined in step 4. and step 5. NOTE

The minimum collective pitch angles specified in table 102-4 are based on a theoretical pitch link length (zero setting) for helicopters with and without a blade folding system (optional equipment) . Basic rigging is performed with the rotating pitch links set to zero. Any alteration in the length of the pitch links arter basic r.Lgging is performed wil1 change the minimum pitch anqle of the associated blades. Thereforc, if a helicopter has alr0.é1dy 1Jndergonc blade tracking 01 autorotational speed adjustrnent (both procedures normally necessitating pitch link length corrections) the minimum collective pitch angle obtained in step 6a. must be reduced to the theoretical value for the pitch link in zero setting.

BO 105 CHAPTER 102 Page 34

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

blade angle with collective stick full down pitch change for full up collective stick displacement

helicopters without blade folding system

helicopters with blade folding system

5°48' ± 20'

4°48' ± 20'

16° ± 40'

16° ± 40'

Table 102-4 Minimurn collective pitch angle/maximum pitch angle change

105 102 Page 35

BO CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

7.

Applies only to helicopters with pitch links no longer in zero setting. Deterrnination of the theoretical minimum collective pitch angle. a.

If the number and the direction of pitch link turns made for blade track and autorotation speed adjustment are known, calculate the correction angle according to the following: Assuming correct installation (coarse thread above, fine thread below), one complete clockwise turn (viewed from above) of the pitch link tube will increase the length of the' pitch link by 0.5 mm and reduce the blade angle by ID' provided rod end angularity remains unchanged. Correspondingly, one complete counter-clockwise turn of the pitch link tube will shorten the link by 0.5 mm and increase the blade pitch by 10'.

b.

If the number and direction of pitch link turns is not known, remove the reference blade pitch link froro the helicopter.

c.

Measure the actual assembly length of the pitch link (center-tocenter of the rod ends) .

d.

Calculate the difference between the actual assembly length and the pitch link zero setting.

e.

Calculate the correction angle according to the following: Increasing the pitch link length by 1 mm will decrease the blade pitch by 20'. Correspondingly, decreasing the pitch link length by 1 mm will increase the blade pitch by 20' .

f.

Calculate the theoretical minimum collective pitch angle froro the actual minimum pitch angle determined in step 6a. and the correction angle obtained in step 7a. or 7e. as applicable. If the reference blade pitch link had been shortened for track and autorotation speed adjustroent, the amount of pitch correction must be subtracted froro the actual angle. If it has been lengthened, the correction angle must be added.

8.

Check that minimum collective pitch angle and maximum collective pitch angle change are within the specified range (refer to table 102-4). Readjust rigging if necessary.

9.

Reinstall and safety pitch link if previously removed.

10. Switch off and disconnect external hydraulic power unit.

11. Remove rigging fixture from helicopter. 12. Reinstall cowling.

BO 105 CHAPTER 102

Page 36

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2

+------5

+------6

A

1-+------7

12

400692

11

1 Non-rotating pitch link, lateral 2 Rotating pitch link 3 Non-rotating pitch link, longitudinal (not shown) 4 Rotating pitch link 5 Control rod, longitudinal 6 Control rod, collective Figure 102-13

Check -

10

7

9

8

Control rod, lateral

8 Rigging fixture, rnixing lever

assembly Locking lever, longitudinal 10 Locking lever, collective 11 Locking lever, lateral 12 Mixing lever assembly 9

rnain rotor rigging 105 102 Page 37/38

BO CHAPTER

MAINTENANCE MANUAL

EUROCOPTER

102 - 23

RIGGING OF TAIL ROTOR CONTROLS

102 - 24

Rigging - tail rotor controls (Tail rotor head with titanium blade grips)

eo 105

Special tools: Rigging device 117-43001 W1 or W3 Pedal clamp assembly 105-31702 W20

* *

*

1. Remove nose door and vertical fin fairing. WARNING

DO NOT ALLOW THE CONTROL ROD TO HANG DOWN FREELY FROM THE BELLCRANK ON THE INTERMEDIATE GEARBOX AS DAMAGE TO THE CLEVIS ON THE UPPER END OF THE CONTROL ROD MAY RESULT.

2. Disconnect control rod (2, fig. 102-15) from bellcrank (1) on intermediate gearbox and attach it to the vertical fin with adhesive tape, cord or similar material, so that it is in the installed attitude. 3. From both blade grips, remove the center screw (3) attaching the control lever to the blade grip. 4. Replace tab washers (4, fig. 102-14) under the jamnuts on the pedal stop screws with new ones. 5. Lock the right (pilot's) pedals in line, using pedal clamp assembly 105-31702 W20, as shown in fig. 102-14. 6. Install rigging device 117-43001 W1 or W3, as shown in fig. 102-15. 7. Set tail rotor blades to the pitch angle specified for the pedals-in-line control position in table 102-5, by adjusting either the bellcrank on the tail rotor gearbox or the sliding sleeve; tighten knurled screw (6) to lock blades at this setting. WARNING

WHEN ADJUSTING THE LENGTH OF THE CONTROL RODS, THE ROn ENDS MUST NOT BE UNSCREWED TO THE EXTENT TriAT THE RED PART OF THE THREAD IS SEEN TO PROTRUDE THROUGH THE JAMNTJT.

NOTE

If the control rod cannot be adjusted in the vertical fin without exposing the red part of a rod end thread, the long control rod in the tailboom must also be adjusted, followed by the control rod in the right side shell of the cargo compartment if adjustment is still not possible.

Revision 11

BO 105 CHAPTER 102 Page 39

* * *

EUROCOPTER

MAINTENANCE MANUAL 80 105

8.

Take care to replace existing tab washer of rod end jamnut with a new one. Adjust the length of control rod (2) by adjusting the amount of rod end thread engagement at its lower end until the control rod can be installed in the bellcrank (1) without use of force. When installing the control rod, tighten the jamnut enough to eliminate rod end play in the control rod and align the rod end with the clevis at the upper end of control rod so that maximum freedom of movement about the longitudinal axis of the control rod is obtained. Then torque-tighten jam nut to 6 - 8 Nm.

9.

Install control rod (2) located in vertical fin to bellcrank (1) on intermediate gearbox, using hex head bolt, washer and castellated nut. Torque castellated nut to 3-5 Nm and safety with cotter pino Remove makeshift control rod attachment installed in step 2.

10. Remove pedal clamp assembly from pedals. 11. Loosen knurled nut (6) of rigging device on tail rotor just enough to

unlock the blades. 12. Adjust pedal stop to obtain max. blade pitch angle as follows: a.

Tighten pedal stop screw (5, fig. 102-14) until the pitch angle specified in table 102-5 under column "left pedal full forward" is obtained when the left pedal is against its travel stop. This requires jamnut (6) to be tightened to the extent that stop screw (5) is seated free of play in lever (8).

b.

Release left pedal. Holding the stop screw (5), torque-tighten jamnut (6) and safety with tab washer (7).

13. Adjust pedal stop to obtain mino blade pitch angle as follows:

a.

Tighten pedal stop screw (2) until the pitch angle specified in table 102-5 under column "right pedal full forward" is obt.ained when the right pedal is against its travel stop. This requires jamnut (3) to be tightened to the extent that stop screw (2) is seated free of play in lever (8).

b.

Release right pedal. Holding the stop screw (2), torque-tighten jamnut (3) and safety with tab washer (4).

14. Remove adjusting device from tail rotor head. 15. Reinstall control lever attaching screws (3, fig. 102-15) removed in step 3., together with washers and nuts. Torque-tighten nuts to 3.5-5 Nm and safety with cotter pins. 16. Inspect all moving parts of the tail rotor controls for freedom of movement. 17. Install nose door and vertical fin fairing.

BO 105 CHAPTER 102 Page 40

MAINTENANCE MANUAL BO 105

HELlCOPTER S/N

S/N 350 and prior

S/N 351 thru S/N 750

S/N 751 and subsq.

.&.

BLADE CHaRO

MAX. ALLOWABLE GROSS MASS

BLADE PITCH ANGLE RELATIVE TO PEDAL POSITION LEFT PEDAL FULL FORWARD

PEDALSIN L1NE

RIGHT PEDAL FULL FORWARD

Symmetric

2,400 kg

+18° ± 30'

+9° ± 20'

_6° ± 30'

Asymmetric

2,400 kg

+16° ± 30'

+7° ± 20'

_8° ± 30'

Asymmetric

2,500 kg

+17°30' - 30'

+6° ± 20'

_8° ± 30'

Symmetric

2,400 kg

+18° ± 30'

+7° ± 20'

_6° ± 30'

Asymmetric

2,400 kg

+16° ± 30'

Asymmetric

2,500 kg

+17°30' - 30'

+6° ± 20'

_8° ± 30'

Asymmetric

2,500 kg

+17°30' - 30'

+6° ± 20'

_8° ± 30'

+20°40' to 21°

+9°10' ± 20'

Asymmetric

&.

&.

+5° ±20'

_8° ± 30'

-4°50' to -5°10'

------=---------------&. If helicopter is equipped with yaw brake, the blade pitch angle with pedal 5 in line is +7° ± 20'. & &..

EFFECTIVITY: all helicopters after modification in accordance with SB B0105-30-112 The max. allowable gross mass regarding the helicopter P/N remains effective.

----=----~=--------:....._--

Table 102-5 Tail rotor blade pitch angles

102 - 25

Rigging - tail rotor controls (tail rotor with aluminum blade grips and symmetrical-chord blades)

Special tools:

Adjusting device Pedal clamp assembly

105-31702 W21 105-31702 W20

Rigging is basically the same as that described in para 102-24, except that rigging device 105-31702 W21 is installed on thetail rotor head as shown in fig. 102-16, (instead of adjusting device 117-43001 W1 or W3). In order to adjust the length ofthe control rod in the vertical fin with the pedal 5 in line, the tail rotor blades are locked by inserting the rigging pin(4) either in the +9° groove (for helicopters S/N 350 and prior) or in the +7° bore (for helicopters S/N 351 and subsq.) of rigging device 105-31702 W21. The pedal stop screws shall be adjusted . 50 that the blade grip can be pinned through the +18° groove of rigging fixture 105-31702 W21 with the left pedal full down, and through the _6° groove with the right pedal full down.

Revision 24

CHAPTER 102 Page 41

I

I

O~~er

a:: 0

MAINTENANCE MANUAL 80 105

1

'"'"0 1

:t:

~ :gl

5

o al

14

1 Pedal clamp assembly 2 Pedal stop screw (right pedal down) 3 Jamnut 4 Tab washer

7

6

-1

Nm

B

I

5 Pedal stop screw (Ieft pedal down) 6 Jamnut 7 Tab washer 8 Lever

Figure 102-14 Locking the rudder pedals in line CHAPTER 102 Page42

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - - - ' MAINTENANCE MANUAL MBB - BO 105

1

2 3 4 5 6

Bellcrank Control rod Attaching hardware Rigging pin Rigging device Knurled screw

6

DETAlL

A

~--3.4

VIEW

3

B

5

400539

Fig. 102-15 Rigging - tail rotor controls (tail rotor head with titanium blade grips) 105 102 Page 43

BO CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - ; . . . - . - - - - - MAINTENANCE MANUAL MBB - BO 105

/

/

/

I

/

/

/

/ DETAlL

A

+ 9 C rigging positi.on + 7 C rigging position

Bellcrank Control rod 3 Connecting hardware

1 2

4 Rigging pins 5 Rigging device

Fig. 102-16 Rigging - tail rotor controls (tail rotor head with aluminum blade grips) BO 105 CHAPTER 102 Page 44

3,4

EUROCOPTER

102 - 26

MAINTENANCE MANUAL 80 105

Check and adjustment of control forces of tail rotors with 0° coning angle blades

*

* *

NOTE

o In the following, pedal breakout force (initial fo~ce) means the minimum force which must be applied to a pedal in the forward direction to move the pedals from the parallel position.

* * *

*

* o The pedal breakout force is measured as pressure force at the center * of the foot area of the pedal and along a line perpendicular to the * pedal lever. * * o It is practical to use a spring scale with a drag indicator for * taking these measurements. * * 1. If yaw brake (Optional Equipment, CHAPTER 858) is installed: * * a. Removal vertical fin fairing. * * b. Ensure yaw brake is exerting no frictional force. Frictional force is * absent if bolt (11, fig. 42~20A) can be rotated by hand. * * c. Reinstall vertical fin fairing. * * 2. Measurement of the pedal breakout forces (initial forces). * * a. Position pedals in lineo *

*

b.

Place spring scale against left pedal.

c.

Slowly increase force on the pedal through the spring scale and observe pedal and spring scale.

d.

The force indicated at the moment the pedal begins to move is the breakout force of the left pedal. Note and record this value.

e.

Position pedals in lineo

*

* * * * * *

* * f. Measure breakout force of right pedal by the same procedure. * * g. The pedctl breakout forces must not exceecl 28 N. Ir this füice is * exceeded, isolate and rectify cause of pedal binding. * * 3. Measurement of the pedal final forces. * * a. Position pedals in lineo * * b. Place spring scale against left pedal. * * c. Slowly increase force on the pedal through the spring scale until the * pedal begins to move from the in-line position. *

Revision 11

BO 105 CHAPTER 102 Page 45

EUROCOPTER

* * * * * * * * * * * * *

MAINTENANCE MANUAL 80 105

d.

Using spring scale, continue to move pedal evenly until it is just short of the pedal stop.

e.

The force indicated just before the pedal reaches the pedal stop is the final force for the left pedal. Note and record this value.

f.

Position pedals in lineo

g.

Measure final force of right pedal by the same procedure.

h.

The final force of the pedal must not exceed 75 N. If this force is exceeded, isolate and rectify cause of pedal binding.

* 4. Measurement of control forces in hover * * * * * * * * * * * * * * * * * 5.

* *

a.

Hover IGE at between 1.800 and 1.900 kg gross mass without turning about the vertical axis.

b.

Release pedals and, using a spring scale on each pedal (left and right), measure the pedal forces required to make the helicopter turn once about the vertical axis.

c.

Determine the mean value of both measurements.

d.

Repeat this procedure two more times and determine the mean value of the three measurements thus obtained.

e.

If the mean value exceeds 45 N, examine control linkage and tail rotor to determine the cause of binding.

Adjustment - tail rotor balance weights a.

Install balance weights on blade grip so that the center of each is 83 to 87 mm away from the blade grip centerline (see fig. 102-17).

b.

Perform hover flight IGE under the following conditions: - gross mass approx. 1.800 - 1.900 kg - pedal forces (breakout forces and final forces) within allowable limits - max. 10 knots wind - 100% rotor rpm When the pedals are released, the helicopter must maintain its heading, with torque on each engine being within the following ranges: 48-54% on engines 1 and 11 for symmetrical-chord blades 53-59% on engines 1 and 11 for asymmetrical-chord blades If engine torque is not within the range specified for the respective blade type, the tail rotor balance weights must be adjusted as follows:

BO 105 CHAPTER 102 Page 46

Revision 11

EUROCOPTER

MAINTENANCE MANUAL BO 105

* *

1) Remove cotter pins from balance weights. 2) Reducing the distance between the balance weight and the blade grip centerline hy 1 mm results in a reduction in torque of approx. 3%. Increasing the distance between them by 1 mm results in an increase in torque of approx. 3%. 3) If engine torque is still too high with the balance weights at their innermost position, an equal amount of material must be removed from all four balance weights. However, the weight of the individual balance weights must not be less than 120 g for syrnrnetrical-chord blades or 105 g for asyrnrnetrical-chord blades. The heaviest balance weight must not be more than 1 g heavier than the lightest balance weight. If the specified torque cannot be obtained with the balance weights at their outermost positions,install oversize balance weights weighing 145 g. 4) Safety the balance weights using identical cotter pins.

c.

Perform the following manoeuvres in hover flight: - rearward flight - left and right sideward flight - left and right turns at maximum 90 degrees per second. The helicopter must exhibit normal flight characteristics during these manoeuvres.

Tungsten

Steel

I.

83-87mm 300347

Figure 102-17

Revision 11

~

I

Balance weight adjustment BO 105 CHAPTER 102 Page 47

*

EUROCOPTER

MAINTENANCE MANUAL BO 105

* 102-27 Check and adjustment of control force s of tail rotors with 1° coning * angle blades

*

*-* NOTE o In the following, pedal breakout force (initial force) means the *-minimum force which must be applied to a pedal in the forward * direction to move the pedals from the in-line position. * o The pedal breakout force is measured as pressure force at the center * of the foot area of the pedal and along a line perpendicular to the * pedal lever. * * o It is practical to use a spring scale with a drag indicator for * taking these measurements. * * * 1. If yaw brake (Optional Equipment, CHAPTER 858) is installed, neutralize * its braking effect. * a. Remove vertical fin fairing. * * b. Remove yaw brake frictional force by unscrewing Nylstop nut (19, fig. * 42-20A) until bolt (11) can be turned by hand. * * * 2. Measurement of pedal breakout forces (initial forces) *-* NOTE *-* a. * * b. * * c. * * * d. * * * e. * * f. * * g. * *

If installed, the yaw brake must not exert frictional force during the measurement of the pedal breakout forces. Position pedals in lineo Place spring scale against left pedal. Slowly increase force on the pedal through the spring scale and observe pedal and spring scale. The force indicated at the moment the pedal begins to move is the breakout force of the left pedal. Note and record this value. Position pedals in lineo Measure breakout force of right pedal by the same procedure. The pedal.breakout forces must not exceed 28 N. If this force is exceeded, isolate and rectify cause of pedal binding.

BO 105 CHAPTER 102 Page 48

Revision 11

EUROCOPTER

3.

MAINTENANCE MANUAL 80 105

Measurement of the pedal final forces.

NOTE

4.

If installed, the yaw brake must not exert frictional force during the measurement of the pedal final forces. a.

Position pedals in lineo

b.

Place spring scale against left pedal.

c.

Slowly increase force on the pedal through the spring scale until the pedal begins to move from the in-line position.

d.

Using spring scale, continue to move pedal evenly until it is just short of the pedal stop.

e.

The force indicated just before the pedal reaches the pedal stop is the final force for the left pedal. Note and record this value.

f.

Position pedals in lineo

g.

Measure final force of right pedal by the same procedure.

h.

The final force of the pedal must not exceed 75 N. If this force is exceeded, isólate and rectify cause of pedal binding.

If yaw brake is installed (Optional Equipment, CHAPTER 858), set yaw brake frictional force.

NOTE

The yaw brake frictional force adjustment described in the following constitutes a basic setting. If yaw instability occurs during forward flight with feet off the pedals, further adjustment may be made to increase the frictional force. However, the resulting force must not exceed a maximum pedal breakout force of 60 N. a.

Remove vertical fin fairing.

b.

Tighten Nylstop nut (19, fig. 42-20A) on bolt (11) so that the breakout force s of the in-line pedals are 15 to 20 N above those measured in step 2.

c.

Secure Nylstop nut (19) with split pin (18).

d.

Reinstall vertical fin fairing.

Revision 11

BO 105 CHAPTER 102 Page 49

EUROCOPTER

5.

MAINTENANCE MANUAL BO 105

Measurement of pedal retaining forces in hover and in cruise flight.

NOTE o In the following, pedal retaining force means the minimum force that must be applied to a pedal in the forward direction in arder to maintain a particular steady flight condition. o The pedal retaining force is measured as pressure force at the center of the foot area of the pedal and along a line perpendicular to the pedal lever. o To obtain accurate retaining force readings, the measurements should not be taken by the pilot himself. Instead, measurements shall be taken on the left pedals by a second, suitably qualified person from the copilot's seat. . o As the values indicated by the spring scale may fluctuate as a result of vibrations, the average reading shall always be taken. o If the yaw brake is installed, measurement of the pedal retaining forces in hover and in cruise flight shall be taken with yaw brake frictional force applied. a.

b.

Preparatory work 1)

Ensure that the 150 g balance weights are screwed on the control levers so that the threaded shank ends of the control lever are flush with the outboard ends of the balance weights, and ensure balance weights are secured with split pins.

2)

To obtain a gross mass of 2,000 to 2,250 kg, fuel or load helicopter accordingly.

3)

Temporarily remove copilot's cyclic stick.

Measurement of pedal retaining force in hover

NOTE The wind speed must not exceed 10 knots for the duration of this - - measurement. 1)

With 60% torque on both engines, go into hover IGE without rotating about the yaw axis.

2)

If conditions are windy, head helicopter into the wind and maintain a steady heading.

3)

Set spring scale on left pedal and push it with a force sufficient to prevent the pedal from moving or the helicopter from beginning to yaw when the foot is removed from the pedal.

4)

Carefully remove foot from pedal.

BO 105 CHAPTER 102 Page 50

Revision 11

EUROCOPTER

c.

MAINTENANCE MANUAL 80 105

5)

Slowly reduce the force on the spring scale while observing the spring scale reading.

6)

Note and record the force indicated at the moment when either the the pedal begins to move or the helicopter begins to yaw. This shall be the first of the force measurements in hovero

7)

Repeat this measurement three times and then calculate the average retaining force in hover flight from the values thus obtained.

Measurement of pedal retaining force in cruise flight 1)

Set torque on both engines at 75% and go into steady straight and level flight.

2)

Carefully release the pedals and determine whether the helicopter begins to yaw.

3)

If the helicopter does not yaw, the pedal retaining force is zero.

4)

If the helicopter yaws, determine the pedal retaining force required to maintain cruise flight without yaw as follows: a) Correct right yaw by applying left pedal or correct left yaw by applying right pedal, whichever is applicable, until the helicopter returns to steady straight and level flight without yawing. b) If there is a tendency to yaw to the left (right), set spring scale on right (left) pedal and apply such force as will prevent the pedal from moving or the helicopter from beginning to yaw when the foot is removed from the pedal. c) Carefully remove foot from pedal. d) Slowly reduce force on spring scale while observing spring scale reading. e) Note and record the force indicated at the moment when either the pedal begins to move or the helicopter begins to yaw. Also note pedal on which force is being measured. This shall be the first of the force measurements in cruise flight.

5) d.

Repeat this measurement three times and then calculate the average retaining force in cruise flight from the values thus obtained.

Final work Reinstall copilot's cyclic stick.

Revision 11

BO 105 CHAPTER 102 Page 51

MAINTENANCE MANUAL BO 105

EUROCOPTER

6.

Adjustment - tail rotor balance weights The pedal retaining forces can be adjusted within a particular range by altering the depth of thread engagement of the balance weights. a.

The permissible pedal retaining force ranges are as follows: Hover flight, left pedal . Cruise flight, right pedal Cruise flight, left pedal

o N to

30 N O N to 15 N O N to 15 N

Pedal retaining force in cruise flight should be kept as low as possible. b.

Determination of the required balance weight adjustment. A change in the depth of engagement of the balance weights does not affect the pedal retaining force in hover and in cruise flight to the same extent, but in accordance with the following table 102-6. Therefore, when determining the required adjustment, which depends on both resultant measurements obtained from steps S.b. and S.c. it is necessary to estimate the effect of the adjustment on the pedal retaining force in hover and in cruise flight (see Example 1). NOTE

From the mid (flush-mounted) position of the balance weights there are ·approx. two full turns available in either direction for adjustment purposes. Should this travel range be insufficient to bring the pedal retaining forces within the permissible limits, the following checks shall be performed: - Pitch link bearings for play. Refer to Chapter 33. - Tail rotor blades for damage. Refer to Chapter 34.

c.

Remove cotter pins and adjust balance weights as required.

d.

Secure balance weights, using same cotter pins.

e.

Recheck pedal retaining forces in hover and in cruise flight per S.b. and S.c.

BO 105 CHAPTER 102 Page 52

Revision 11

EUROCOPTER

One full turn of all

MAINTENANCE MANUAL 80 105

Change in pedal retaining force

four balance weights

Cruise

Hover

in following direction

Right pedal

Left pedal

Left pedal

Clockwise (decreases distance from blade mounting fork)

Approx. 3 N reduction

Approx. 3 N increase

Approx. 5 N increase

Counterclockwise (increases distance from blade mounting fork)

Approx. 3 N increase

Aoprox. 3 N reduction

Approxo 5 N reduction

Table 102-6 Correlation between pedal retaining force and depth of engagement of balance weights: Example 1 Given average values: Pedal retaining force in cruise flight (right pedal) .. +18 N Pedal retaining force in hover flight (left pedal) .... +24 N Find: Necessary adjustment in depth of engagement of balance weightso Solution: To bring the pedal retaining force in cruise flight within the limits (O N to 15 N for the right pedal), it is necessary to reduce the force by at least 3 N. In accordance with Table 102-6, this requires the balance weights to be rotate:d one full turn in cl.ockwise directioIi. Although the adjustment of the balance weights by one full turn in the clockwise direction increases the pedal retaining force in hover by 5 N from 24 N,to 29 N, it still remains below the 30 N limit for hovero Further rotation of the balance weights in the clockwise direction would, of course, reduce the retaining force in cruise fligLt even more, but simultaneously would also increase the retaining force in hover to beyond the permissible limito Therefore, the sought-after amount of balance weight adjustment in this case is one full turn in the clockwise direction.

Revision 11

BO 105 CHAPTER 102 Page 53/54

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

103

ME A S U R 1 N G

T HE

H E L 1 C O P TER

Table oí Contents

Page

Paragraph

Title

103 - 1

INTRODUCTION

3

103 - 2

PRELIMINARY STEPS

S

103 - 3

ESTABLISHING THE DATUM PLANE

7

103 - 4

MEASURING THE HEIGHT OF THE FIXED POINTS

11

103 - S

PLUMBING

13

MEASUREMENT OF MAIN ROTOR ANO TAIL ROTOR ANGLES OF INCLINATION USING CLINOMETER .

18

. 103 - 6

BO 105 CHAPTER 103 Page 1/2'

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 INTRODUCTION

103 - 1 1.

General Measurement of the relative position of certain fixed points on the helicopter provides a means of detecting permanent structural deformation. See fig. 103-4 for the location of the fixed points.

2.

Procedures Measurement of the helicopter comprises the following procedures: a.

Establishing the datum planeo The helicopter is accurately leveled along the longitudinal and lateral axes, then the datum plane is established.

b.

Measuring the height of the fixed points. The vertical distance between the individual fixed points and the datum plane is measured.

c.

Plumbing The distance between the fixed points projected on to the ground is measured.

d.

Angular measurements Using a clinometer, the angles of inclination of the main rotor mast and the tail rotor shaft are measured.

The measurements obtained shall be ente red in the appropriate columns of the measuring data sheet (see figure 103-5) and compared with the nominal values and the permissible tolerances.

BO 105 CHAPTER 103 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Special Too1s and Equiprnent

3.

14 - - - - - - -

.qs"., , " """ " ;"

15 - - - - - - . ~;::::;;:;===:;:::::::;;;:¡i:¡::¡:;::¡;;:::;¡;;:;;;;¡:;:¡;;;¡;;J.J 16

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-7

11

12

10

9

8

200120

Item No.

Descrlptlon

Quantlty

Drawing No.

1121-W1 17103- 00-00

1 2

Weighlng beam Jack assembly

1 3

3 4 5

Cllnometer Trlpod. dumpy level Double prism (approx. 50 mm long) Tape measure Adheslve tape (approx. 50 mm wide) Strlng (approx. 20 m) String (approx. 5 m) Plumb bob IIne Level Splrlt level (approx. 1000 mm long) Dumpy level Stralghtedge (300 mm) Stralghtedge (1000 mm) Straightedge (2000 mm) Protractor (approx. 300 mm long)

1 1 1 1 1 1

Support. tor use with jack assy (weighing beam) Assembly stand BO 105 measuring data sheet (figure 103-5) Use original lor addltlonal copies

1 1

6 7

8 9 10 11 12 13 14 15

16 17

Figure 103-1 BO 105 CHAPTER

Page 4

103

1 1 1 1

1 1

1 1 1

Specia1 too1s and equiprnent

Remarks

Co. Hydro or equivalent

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 PRELIMINARY STEPS

103 - 2

Special Tools and Equipment: Leveling support beam Jacks Spirit level Base for jack under leveling support beam 1.

General The following preliminary steps have to be performed prior to the actual leveling. NOTE

2.

3.

4.

The person performing the measuring requires help from an assistant.

Leveling area preparation a.

The helicopter must be leveled in a closed, draught-free, hangar where constant temperatures prevail.

b.

The ground must be level and clean.

c.

Ensure that adequate working space is available.

d.

Working area has to be roped off in order to prevent disturbance from outside.

Helicopter preparation a.

Remove all external stores and optional equipment (e.g. long range fuel tank, load hook system).

b.

Connect helicopter to ground (see Chapter 06) .

c.

Defuel helicopter (see Chapter 06).

d.

Remove main rotor head together with silver shim and retainer (refer to chapter 13) .

e.

If instrument panel and/or battery are not installed, install ballast.

f.

If tail rotor head is not installed, install ballast with the appropriate lever armo

Jacking and alignment of helicopter (figure 103-2). a.

Install ground handling wheels.

BO 105 CHAPTER 103 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Install leveling support beam to both front jacking points and secure using locking bolt.

c.

Place jack below support beam, tilting tail skid slightly as necessary. The jack base must be aligned so that a cord can be streched as shown in fig. 103-9. CAUTION

d.

SECURE TAIL SKID TO PREVENT TIP OVER.

Place a jack (2) below each of the rear jacking points. WARNING

ALL JACKS MUST BE OPERATED SIMULTANEOUSLY ANO HELICOPTER MUST ONLY BE RAISED TO REQUIRED WORKING HEIGHT.

e.

Simultaneously operate the three jacks until the skids are clear of the ground at their forward ends and approx. 70 mm above the ground at their aftends.

f.

Place a spirit level on the cabin floor and align the helicopter by raising and lowering it at the jacking points.

g.

Hand-tighten jack ram lock nuts.

Fitting

",~",,---2

VIEW

B VIEwA

200119

Figure 103-2 BO 105 CHAPTER 103 Page 6

Jacking the helicopter

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 103 - 3

ESTABLISHING THE DATUM PLANE

Special tools and Equipment: Dumpy level Tripod for dumpy level Graduated bar, 300 mm Circular spirit level

NOTE

The datum plane is established at a height of approx. 250 mm above the cabin floor.

1.

Place tripod-mounted dumpy level in measuring position 1 (see figure 103-3) .

2.

In turn, place graduated bar with attached circular spirit level vertically on each of the fixed points0 ,0, and® on the cabin floor and, in conjunction with the dumpy level, adjust the jacks under the helicopter until all three fixed points are in the same horizontal planeo

3.

Place graduated bar with attached circular spirit level vertically on one of the above fixed points and adjust height of dumpy level until its line of sight (i.e. the datum plane) is approx. 250 mm above the cabin floor.

4.

Hand-tighten jack retaining rings.

<,.1.5. íf\'" ~

Positlon No. 2

'PP"'" ,.5~ 200\22

~

Figure 103-3

Measuring positions BO 105 CHAPTER 103 Page 7

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 a

Figure 103-4 BO 105 CHAPTER

Page 8

103

13

29

14

30

Fixed point locations

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Helicopter Seri.1 No. Registration No.

BO 105 MEASURING DATA SHEET Distlnces Hellcopter levelad 80 that flxed polnts no. 6, no. 7 and no. 11 are Iylng In same horizontal plane.

bItweIn

Check for:

pointno.

Fu""" Deformltion

Clbin Flaor Deforlllltion

rlíl BoOm Bending Ind Tonion

Deviltion of Horizontal Stebiliz.. from Horizontal Plene

Perpendicularity of Horizontal Stabilizer to HelicoDter Centerline Deviation of Tail Boom Centerline from Hellcopter Centerllne

lIId DOint no.

muo m....redin

0 0

® ®

0 0 0

® ®

(z)

0 0

®

direction

PlrmIIIibII deviation DimensioMI Rtehec:k It .... hou,. It ..•. hou,. from orilinll •..•. hou,. . dimenllon IIircrm tIDUI time IIinnft tDbI ti. . lIircnft . . time

.Ohou,. (.ircnft ...t

mm

t 2mm

mm

t 3mm

mm

t 3mm

mm

t 3mm

mm

t 3mm

mm

t 3mm

@

mm

t 3mm

®

mm

tl0mm

®

mm

!10mm

mm

t12mm

mm

t12mm

mm

tl0mm

mm

t 5mm

mm

tl0mm

0

0 0 0 0 ® ®

® ®

0)

®

vertlcII

@ @ in longitudinel (x) direction in lit.... (y) direction

Anlles between

Forward Tilt of Mlin Rotor Axis

lIt...1 TUt of Mlin Rotor Axis

Inclination of Tail Rotor Axis Sweep blck of rlíl Rotor Axis

vertic:ellnd rotor IXis

side vi. . (a)

•

t 5'

vertic:ellnd rotor axis horizontal plene Ind 1Iil rotor Ixis 1It. .1Ixis Ind 1IíI rotor Ixis

front viIW lP)

•

t 10'

true Ingle (y)

111

,

ptln vi. . (<<5)

111

,

Recorded by: Date·

DevÍltions exceeding the mex. permissible Iimits are c:eUI8 for ClOrrective Ictions (repeir/repllcement) 100470

Figure 103-5

meesurecl in

Measuring data sheet 105 103 Page 9/10

BO CHAPTER

! 30'

t30'

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 103 - 4

MEASURING THE HEIGHT OF THE FlXED POINTS

Special tools and Equipment: Dumpy level Tripod for dumpy level Graduated bar, 300 mm Graduated bar, 1000 mm Graduated bar, 2000 mm Circular Spirit Level 1.

Determine fuselage alignment from Measuring Position 1 a.

Establish datum plane according to paragraph 103-3.

b.

To level the fuselage along the lateral axis, position the graduated bar (300 mm) and attached circular spirit level vertically as shown in figure 103-6, and adjust jacks until fixed points® and0 are level with each other.

c.

To level the fuselage along the longitudinal axis adjust jacks until fixed points@ and0 are level with each other.

d.

Recheck lateral plane and correct as necessary.

e.

Hand-tighten jack retaining

f.

Measure the vertical distance between fixed points 0,0,0 and0 on cabín floor and the datum plane, using graduated bar (300 mm long) and attached circular spirit level as shown in fig. 103-6. Perform calculations and enter results in measuring data sheet.

r~ngs.

0(0)

@t@))

FuselaQe reference plane (R8H) Datum plane

---

200123

Figure 103-6

Leveling the cabin floor along the longitudinal and lateral axes BO 105 CHAPTER 103 Page 11

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2.

Determine tail boom alignment from measuring position l. a.

Determine horizontal stabilizer distortion by measuring the vertical distance between fixed points@ and@ and the datiun plane, using graduated bar (1000 mm long) and attached circular spirit level as shown in fig. 103-7. Perform calculations and enter results in the measuring data sheet. The difference between the measured distances isthe extent of distortion.

b.

Measure the vertical distance between fixed points ® and@ and the datum plane, using graduated bar (1000 mm long) and attached circular spirit level as shown in fíg. 103-7. Perform calculations and enter results in measuring data sheet.

c.

Measure the vertical distance between fixed points @ and@ and the datum plane, using graduated bar (1000 mm long) and attached circular spirit level as shown in fig. 103-7. Perform calculations and enter results in measuring data sheet .

...... H~- Graduated bar 1000 mm

1rD---Circular splrlt level

200124

Figure 103-7

d.

BO 105 CHAPTER

Page 12

Alignment checks using fixed points ,@ ,@ ,@ ,@ and@

®

Measure the vertical distance between fixed points ® and@ and the datum plane, using graduated bar (2000 mm long) and circular spirit level as shown in fig. 103-8. Perform calculations and enter results in measuring data sheet.

103

- - - ' - - - - - - - - - - - - MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Graduated bar _ _....... 2000 mm

20012S

Figure 103-8 3.

Measuring the height of fixed points@

and@

Dertermine fuselage alignment from Measuring Position 2 a.

Place tripod-mounteddumpy level (1) in measuring position 2 (see fig. 103-3).

b.

Estab1ish the datum plane according to para 103-3.

c.

Measure vertical distance between fixed points and@ and the datum plane, using graduated bar (300 mm long) and attached circular spirit level as shown in fig. 103-6. Perform calculations and enter results in measuring data sheet.

103 - 5

0

PLUMBING

Special tools and Equipment: Adhesive tape, Tesadur (width approx. 40 mm) Plumb line String Set square Measuring tape (Steel) Template for tail rotor transmission Chalk and cord l.

Measuring the extent of parallelism of the tail boom with fuselage center line a.

Hang the plumb bob from fixed point(2) so that it is suspended approx. 4 mm above the ground.

b.

Attach a piece of approx. 60-rnrn-long adhesive tape to the ground directly beneath the point of the plumb bob and identify it with (2) . BO 105 CHAPTER 103 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

Fuselage center Une

200126

Figure 103-9

Projecting the fuselage center line on to the ground, using plumb bobo

c.

Allow plumb bob to stabilize, then lower it on to the tape. Using a lead pencil, mark the impression left on the tape by the point of the plumb bob with alead pencil and then draw a circle around it.

d.

Plumb fixed points@ , ®

e.

Halve the distance between projected fixed points...69) and@ . This midway point is designated imaginary fixed point@ .

and@

in the same manner.

f.

Stretch a cord on the ground along the entire length of the helicopter so that it passes through projected fixed points (2) and @ and beyond the projected fixed points of the tail boom. Attach the cord firmly to the ground with pieces of adhesive tape approx. 300 - 400 mm long.

g.

Measure distance from cord to point 27 and enter in measuring data sheet (fig. 103-5).

BO 105 CHAPTER

Page 14

103

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 2.

Measuring of horizontal stabilizer angularity (fig. 103-10). a.

Hang plumb bob frorn fixed point~ 4 mm above the ground.

b.

Attach a piece of approx. 60-mm-long adhesive tape to ground directly below the point of plumb bob and identify it with~ .

c.

Lower plumb bob so that its point leaves an impression on the tape.

d.

Using alead pencil, rnark the irnpression and draw a circle around it.

e.

Repeat this plumbing procedure at fixed points@ , @

f.

Measure distances between projected fixed points~ and@ and between@ and@ and enter thern in rneasuring data sheet (figure 103-5) .

so that it is suspended approx.

and@ .

200128

Figure 103-10

Plumbing of fixed points~

,@

,@

and@ BO 105 CHAPTER 103 Page 15

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

3.

Measuring the angle of inclination (6) of tail rotor drive shaft in the horizontal plane a.

Using alead pencil, find the center point on the tail rotor gearbox cover by drawing three connecting lines between opposing screw heads (center to center) .

b.

Perform plumbing froro center of cover and froro tail rotor shaft as shown in fig. 103-11 and according to procedure described in step 2. Stretch cord through points A and B (fig. 103-11).

Cord joining projected polnts

®-®

200129

Figure 103-11

BO 105 CHAPTER

Page 16

103

Projecting the tail rotor shaft axis.

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

c.

Check whether point 27 is on the projected fuselage center lineo If not, stretch a cord between points 12 and 27 as shown in fig. 103-11, so that the tail boom center line is projected on to the ground.

d.

Position the level on the projected tail rotor shaft axis.

e.

Position the protractor against the level and align with fuselage center lineo

f.

Read the angle and enter it in the measuring data sheet (fig. 103-5).

Protractor

----~..s=~~,

~~~~-B

200130

Figure 103-12

Determination of angle

~

105 103 Page 17

BO CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 103 - 6

MEASUREMENT OF MAIN ROTOR MAST ANO TAIL ROTOR SHAFT ANGLES OF INCLINATION USING CLINOMETER

Special tools and Equipment: Clinometer Prism l.

Measuring angle of inclination of the tail rotor shaft ( horizonzal.

y )

from the

a.

Place prism on tail rotor shaft so that it contacts the sleeve (see figure 103-13).

b.

Place clinometer upon prism.

c.

Determine angle and enter it in measuring data sheet (see figure 103-5) .

1 Prism 2 Clinometer 3 Tail rotor shaft

/

Figure 103-13

BO 105 CHAPTER 103 Page 18

Measuring the tail rotor angle of inclination (

y )

- . . . . , . . . . - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2.

Measuring the angle of inclination of the main rotor mast along the longitudinal axis (angle a) and along the lateral axis (angle P) . a.

Place clinometer (1) on clean flange of rotor mast so that it is parallel to helicopter centerline, then read angle and enter it in the measuring data sheet.

b.

Rotate clinometer 90 0 on flange so that it is perpendicular to helicopter centerline, then read angle and enter it in measuring data sheet.

1 2

Figure 103-14

Clinometer Rotor mast

Measuring the angles of inclination along the longitudinal (a angle) and lateral (P angle) axes.

BO 105 CHAPTER 103 Page 19/20

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 104

WE 1 G HIN G

T HE

H E L 1 C O P TER

Table of Contents

Page

Paragraph

Title

104 - 1

INSTRUCTIONS FOR WEIGHING

3

104 - 2

WEIGHING PROCEDURE

3

104 - 3

WEIGHING AND BALANCE REPORT (sample)

4

104 - 4

WEIGHING AND BALANCE REPORT (forro)

5

BO 105 CHAPTER 104 Page 1/2

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 104 - 1

INSTRUCTIONS FOR WEIGHING

Helicopters should be weighed in a draught-free hangar. Prior to weighing, the equipment status of the helicopter shall be checked against the equipment listo The equipment list must be completed if necessary. In addition, the mass must be determined for items which do not belong to the helicopter, but have to be weighed together with the helicopter (fixtures, tools, etc.). The mass of these items must then be subtracted from the recorded total mass of the helicopter. Prior to the weighing, check the oil levels of engines, main transmission, intermediate gear box, tail rotor transmission, hydraulic reservoir¡ if necessary, replenish. The oil levels must be at the ftMax. ft oil level marking.

104 - 2

WEIGHING PROCEDURE

Special tools: -

Jacks Weighing beam 1121 W1 Spirit level or clinometer Weighing device

J-

refer to Chapter 103

l.

Defuel the helicopter (refer to chapter 06), but without draining residual (unusable) fuel.

2.

Install weighing device and raise the helicopter¡ refer to Chapter 103.

3.

Using a spirit level or clinometer, adjust the helicopter to a horizontal position¡ refer to Chapter 103.

4.

Enter the individual masses measured at the weighing points into the Weighing Report (fig. 104-2). Weighing devices for which a proper adjustment to zero position is not possible must be weighed together with the helicopter and entered into the Weighing and Balance Report as gross masses. The mass of the weighing device and weighing beam alone is entered as tare.

5.

When using electronic weighing cells it is recornmended to carry out several weighings. Between the individual weighings the cells must be interchanged (counterclockwise). Enter the mean value of the weighings into the Weighing and Balance Report.

6.

Lower the helicopter carefully and remove the special tools.

BO 105 CHAPTER 104 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 104 - 3

WEIGHING AND BALANCE REPORT (sample) This Weighing and Balance Report is based on the Equipment List dated Dec. 17, 1981

Model:

Serial No. : S-439

BO 105 Year of manufacture: 1980

OC[

~ 3"

-1r-

Registration No.: D-HDl·1M

~I'--,,:j!1r t l :'-'

Date of weighing: Dec. 17, 1981 Approved by:

Weighed by:

I

LP

Level points on frame No. 7, LH and RH side, external fuselage QE Reference datum 3000 mm fwd of LP RBA Rotor reference axis 3295 mm E .aft of reference datum G1 Fwd weighing point, 2055 mm 1 0474 (Xl) aft of QE G2 Aft weighing points, 3755 mm (X2) aft of QE

V

I

I

•

X1 G1

3m

~

X2

~_¡-=-I

G2

/~~

-

~62'-

. - 924 ~

Arm

Moment

(kg)

Net weight (kg)·

(m)

(kgm)

-

-

264.7

2.055

544.0

Weighing points, aft (G2) left ......... right ........

-

-

529.8 538.5

3.755 3.755

1989.4 2022.1

Total

-

(2) : (1) 3.417

(2) 4555.5

Fuel: 10 liters

-

-

3.000

+ 24.0

(4) : (3) 3.415

(4) 4579.5

Scale reading (kg)

Tare

Weighing point, fwd (G1) centre .......

RESULT:

6

Mass empty and. mass empty center of gravity

6

-

-

(1) 1333. O

+ 8.0 (3) 1341.0

Included in the empty mass are all lubricants and hydraulic fluids; not included is the usable fuel. Information on unusable fuel is contained in the FLM. Figure 104-1

BO 105 CHAPTER 104 Page 4

Weighing and Balance Report (sample)

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 104 - 4

WEIGHING AND BALANCE REPORT (form) This Weighing and Balance Report is based on the Equipment List dated Serial No.:

Model:

4:1:

~ 3D

-1¡

Year of manufacture: Registration No. :

Hft~ ti

Date of weighing:

"

Weighed by:

Approved by:

Level points on frame No. 7, LH and RH side, external fuselage QE Reference datum 3000 mm fwd of LP RBA Rotor reference axis 3295 mm P.E aft of reference datum Gl Fwd weighing point, 2055 mm 00474 (Xl) aft of QE G2 Aft weighing points, 3755 mm (X2) aft of QE LP

Scale reading (kg)

RESULT:

Tare (kg)

¡Ií L

~

1--.-

-r

I

. I

I

X1

•

G1

3m

~

X2

~-¡C

G2

/'F-P~

- 'f+ 62L-

-

Net weight (kg)

924

Arm

Moment

(m)

(kgm)

Weighing point, fwd (G1) centre ....... Weighing points, aft (G2) left ......... right ........ (1)

(2) : (1)

(2)

(3)

(4) : (3)

(4)

Total Fuel:

liters

Mass empty 6 and mass empty center of gravity

6

Included in the empty mass are all lubricants and hydraulic fluids; not included is the usable fuel. Information on unusable fuel is contained in the FLM. Figure 104-2

Weighing and Balance Report (form) BO 105 CHAPTER 104 Page 5/6

- - - - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

105

GRO U N D R U N / F U N C T ION A L T E S T F L 1 G H T

Table of Contents

Page

Paragraph

Title

105 - 1

GENERAL

3

105 - 2

EXPLANATION - GROUND RUN/FUNCTIONAL TEST FLIGHT

3

105 - 3

CHECK LISTS - GROUND RUN/FUNCTIONAL TEST FLIGHT

17

105 - 4

MATRIX - GROUND RUN/FUNCTIONAL TEST FLIGHT

23

105 - 5

CHECKING ANO ADJUSTING THE AUTOROTATION ROTOR RPM

29

Revision 2

BO 105 CHAPTER 105 Page 1/2

* * *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 105 - 1 1.

2.

Ground run and/or functional test flight are performed to check the proper functioning and performance of individual systems/components and their interaction: a.

after extended parking periods of helicopter (4 weeks or more)

b.

after assembly following dispatch of helicopters

c.

after installation of optional equipment

d.

after replacement, maintenance, adjustment and/or repair

Ground run and/or functional test flight must always be performed after work on components/systems which are necessary for the helicopters flight readiness and flight safety (refer to checklists 105-3 and matrix for ground run/functional test flight 105-4).

105 - 2

NOTE

GENERAL

EXPLANATION - GROUND RUN/FUNCTIONAL TEST FLIGHT

o The extent of the ground run and/or functional test flight depends on the performed work and has to be determined before the flight. o The arrangement of the following explanation of ground run and/or functional test flight corresponds to the checklists of paragraph 105-3.

BO 105 CHAPTER 105 Page 3

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 1.

Ground run and/or funktional test flight report Helicopter Variant .. (1)., Registration No.: . (2) .. , Date: .. (3)

,

Serial No.:

,

Crew:

(4) (6)

, Airport: , Gross mass:

Center of gravity:

(8)

QNH: .. (10).hPa, QNE: ..

(ll).ft,

Mission:

mm, Fuel:

(5) (7)

kg,

:

(9)

Wind: .. (12) .. o/ .. kts, OAT: .. (14)

kg,

(l3) .. oC

.

Take off:

(15)

.

Landing:

(16)

.

Flight time:

(17)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

·

.

Helicopter Variant, e.g. BO 105 C-2, CB, DBS, CBS, CBS-4, CB-3 etc. Registration No. of the helicopter Listed as follows: day, month, year Data in accordance with label on right hand fuselage Abbreviation of airport (e.g. EDMR for Ottobrunn) Names of crewmembers: pilot, mechanic, inspector Consisting of: Mass empty in accordance with FLM, plus fuel, plus crew (1 person = 80 kg), plus equipment, plus payload Calculate if necessary Indicated quantity M + S = Total in kg Barometric pressure during flight, preset at altimeter in hPa before flight Airport altitude (field elevation) according to altimeter with corresponding barometric pressure Direction and velocity Indicated value on OAT indicator Record, if check flight, leak test run, ground run or which points of functional test flight programme Take-off time Landing time Flight time

BO 105 CHAPTER 105 Page 4

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - -

MAINTENANCE MANUAL MBB - BO 105 A. Ground run:

a.

I:::::~~h~.~~~~~.:~: .(2) (1) Pre-flight check (refer to chapter 101 or FLM) (2)

b.

Battery

00 .. , V,

..•.•..•.....

00 00 00 .. 00

001

Completion must be signed

Values indicated on voltmeter (chargeless) . Minimum values for starting engines: 19 Cell battery = 23.5 V 20 Cell battery = 24 V If voltage is below those values, engine must be started using EPU. During starting engine with 28 V EPU the current flow is limited to maximum 600 A.

Starting engine: with/without EPU (1) O Engine l:Startuptime: (2) ••• s, max. TOT: .. O Eng!ne 2: Startup time: (2) ••• s, max. TOT: .. B =first engine started

(3) •• (3) ••

oC oC

100484

(1) Cancel corresponding with or without EPU. If battery voltage is below minimum, use EPU for starting engines "EPU" - light "ON"

. (2) Starting engine time: Time from pressing the starter button until reaching engine idle RPM. (3) Maximum TOT: Maximum value during starting engine.

NOTE

Identify first engine started by a cross

BO 105 CHAPTER 105 Page 5

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

c.

I~~~.:~~~.~~~~.~~~.~~~~~

(1)

kg

(1) The illumination of the LOW FUEL warning light indicates fuel quantity left in the supply tank. The warning light must illuminate if the fuel quantity is approx. 60 kg. d.

lDLE r rr n Ro n lI nl rr MTr MTrr TOT r TOT rr POil r PoilrI Poi! xm

(1)

(2)

(2)

(3)

(3)

(4)

(4)

(5)

(5 )

r

rr

Pfuel

Pfuel

(7)

(7 )

(6)

100485

Use the upper columns for lDLE values indicated before takeoff Use the lower columns for lDLE values indicated after landing NOTE

Read values after 2 minutes with engines in lDLE

(1) Normal range: 65 - 75%

(2) Normal range: 59 - 65% (3) Normal value: 10% (4) Normal range: 480 - 580 oC, according to OAT (5) Oil pressure > 3.5 kp/cm2 (bar); during starting engine oil pressure erection must be indicated (6) Normal range: 0.5 - 2.0 kp/cm2 (bar) (refer to chapter 91), above 0.5 kp/cm2 (bar); warning light "T OlL" must extinguish (7)

Normal range: 0.6 - 1.7 kp/cm2 (bar)

BO 105 CHAPTER 105 Page 6

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

e.

Oil cooler warning light "OFF" .............••.••..••..•.••.•••• (1)

% n2

(1) Indicated n2 value when the oil cooler warning light "OIL COOL" extinguishes. With n2 > 70%, OIL COOL warning light must extinguish (refer to chapter 91)

f.

Max. RPM (pitch down) nRO nn nnI MTI MTII TOT' 1 TOT II Poil I 100% (4 ) (3) ( 1 ) (2 ) ( 2) (4) (3) (5 ) 100% RPM Range RPM Warning (both engines) nRmin nRmax (7 )

(8)

6

n1

(9 )

n

2max ( 10)

poil

II

(5)

I 11 Poil xm (6 )

MT 11 (11 ) ( 11) 1

100486

NOTE (1) (2) (3) (4) (5)

(6) (7) (8) (9) (10) (11)

Read values after two minutes with engine power levers in position "FLIGHT" Adjust nominal value of approx. 100% with equalized torques Normal range: approx. 75 - 82% Normal value: approx. 20% Normal range: approx. 480 - 630 oc 6.3 - 9.1 kp/cm2 (bar) 0.8 - 2.0 kp/cm2 (bar) < 95% ± 1% 103% RPM warning (refer to step o. "Autorotation") 10 - 12% Normal range: 100 - 101,5% with engine trim full forward. Approx. 20% Torque difference between engine 1 and 2 shall be ~ 10%

BO 105 CHAPTER 105 Page 7

e

eurocopter

MAINTENANCE MANUAL BO 105

Eng 1:

n2

(1)

separately)

Eng2:

n2

(1) ...•......... %

n2

(2)

Both engines:

NOTE

I

%

RPM range (each engine

%

Power lever of engine not being checked must be in "IDLE" position.

(1) Nominal value n2: 98.5 - 99.5% with engine trim full forward. With engine trim full rearward, read indicated RPM and add the determinad value for pitch compensation (refer to step h.). Nominal value is n2: 94.0 - 97.0% (2) Nominal value n2: 100 - 101.5% (engines trim full forward)

Electrical system:

Gen. 1: ••..•..•• (1)

V,

(3) ..........•. A

Gen. 11:

V,

(3)

(2)

A

(1) Set bus bar current indicator switch to position "GEN. 1" (Generator 2 and BAT in position "OFP, .Warning Iight "GEN. 2" must lIuminate). Nominal value 27 - 28V (refer to chapter 91) (2) Set bus bar current indicator switch to position "GEN. 2" (Generator 1 and BAT in position "OFP, Warning Iight "GEN. 1" must iIIuminate). Nominal value 27 - 28V (refer to chapter 91) (3) Current consumption approx. 10 - 50 A (standard equipment)

Engine anti-icing ON(1)/OFF(2): t:.. TOTIo" ..•.• (1) .•.. oC, t:.. TOTu," ••... (1) ..... oC (1) Controllights must iIIuminate, TOT must increase, nominal value t:..TOT: 15 - 25 °C (2) Controllights must extinguish, TOT must decrease to initial value

CHAPTER 105 Page8

Revision 22

EUROCOPTER

MAINTENANCE MANUAL 80 105

* * *

Mast moment indication ..•.... (1) ..._..•rmn, green range at 70 rmn for HC models CB-5, CBS-5 and DBS-5. For all other HC models 75 mm displacernent of cyclic stick.

NOTE

When checking rnast moment indication the windspeed must be < 10 kts.

(1) Push cyclic stick forward taking into account the MM limito 70 mm displacernent of cyclic stick for HC models CB-5, CBS-5 and DBS-5. For all other HC models 75 mm displacement of cyclic stick. Measured from the center of cyclic stick grip. MM indication must be ± 4 rmn at the end of the green arc (indication range).

I~~~~~~~~~ .~~~~~.~.~~~~~~ .~~~~~ (

1) •. ,

.

(1) Break-out force for cyclic control (for nominal values refer to chapter 102) Track check: .•.................. (1) (2) Balance check: .:

. .

~

(1) For track check and nominal track values refer to chapter 106 (2) For balance check and nominal balance values refer to chapter 106 g.

Hydraulic systern (Switch reaction) .......•.....•......... (1)

rmn

(1) Position change of the selector switch. For switch reaction check refer to chapter 43 h.

Pitch compensation (n2 - governing)

(1)

% n2

(1) Nominal value: Pitch compensation 2 - 4% n2 (refer to chapter 65)

Revision 16

BO 105 CHAPTER 105 Page 9

*

*

*

EUROCOPTER

MAINTENANCE MANUAL BO 105

B. Test fliqht: Hover ing I.G.E. after 5 minutes in one position (1)

i.

nRO

nU n111

MrI MrII TOTI TOT II

100% 100%

(1) (2 ) ( 2 ) ( 3 ) ( 3 )

(4 )

(4 )

RPM Range

Poi 11 Poi 111 Poi ' xm Toi ' 1 Toi 111 Toi I xm n2max

(5 )

(S)

(6)

(7)

(7)

(8)

(9)

100488

(1) Hover in ground effect with nRO = 100% with equalized torque values. After 5 minutes note indicated instrument values (pos. 3 to 8). Ouring hover check helicopter flight behaviour, for example vibrations etc. (9) Maximal indicated n2 with engines trim full forward. Do not exceed max. values of 105%

Forward: .........•...

(1) •••••••••• ,

Lateral left: .......• (1) Turn left:

•••••••••• ,

(1)

,

Rearward: ••.......

(1) •••••••

Lateral right: ...• (1) ••••••• Turn right: .....•• (1)

.

(1) Check for flight behaviour, control position and vibrations

I.T. _a_i_l_r_o_t_o_r_-_·_pe_da_l_f_o_r_ce_s_:_ _._.._._._._._.._._._._._._..

I

_(_1_)_._._ • •_._._._._••_._._._._._ • •_._N_ _

(1) Record indicated values.

For measuring of pedal forces and for nominal values refer to chapter 102.

BO 105 CHAPTER 105 Page 10

MAINTENANCE MANUAL MBB - BO 105

Irrack check: : Balance check.

.

(1)

.

(2)

.

(1) For track check and nominal track values refer to chapter 106 (2) For balance check and nominal balance values refer to chapter 106 j.

Horizontal flight: if possible at 5000 ft Note the external installatións: For performance data and correction values for optional equiprnent refer to FLM. Record operating mode of engine anti-icing system (ON/OFF) ZP

OAT

(1) (2)

MT = 75%

lAS n 2 (3)

Take-off power (8 )

(4) 100%

n

lI

(5)

n

lIl ~I ~II TOT!

(5)

100%

75% (6 )

75%

TOT n

(7)

(7 )

(6)

100489

Proper horizontal flight means altitude changes < 30 ft/min between 2-3 minutes.

NOTE

(1) Nominal value: 5000 ft pressure altitude (altimeter setting 1013 hPa) Record indicated value. (2) Record indicated outside air temperature (OAT) (3) Record indicated air speed

(4) Nominal value: n2 =100%, adjust (5) Record indicated nI RPM, normal range approx. 95-104% (6) Record indicated torque, max. takeoff power (7) Record turbine outlet temperature (TOT) (8) Takeoff power is achieved if one of the max. takeoff power limits as

TOT,

~

or nI are abtained (refer to FLM) .

ITrack check at approx. 110 kts:

(1)

(1) For track check and nominal track values (refer to chapter 106)

BO 105 CHAPTER 105 Page 11

MAINTENANCE MANUAL MBB - BO 105

k.

Single engine power check:

............... ( 1) ......................

Engine - max . performance data (refer to FlM): TOT .. . oC

.......... ( 2) .......

or MT ... %or n, ... % (5 )

ZP

DAT

n2

101

Ml

n,

Engine ,

(3)

(4)

'00%

(6 )

( 7)

(8)

Engine 2

(3)

(4 )

'00%

(6)

(7 )

(8 )

100492

NOTE (1)

Record operating mode of engine anti-icing system (ON/OFF) 5et power lever of engine 2 to IDLE position; pull collective pitch to obtain takeoff power of engine 1 Nominal value: n2 =100% in level flight

(2) Takeoff power is achieved if one of the max. takeoff power limits as TOT, ~ or nI are obtained (refer to FLM). The first obtained max. takeoff limit is authoritative.

*

(3) Pressure altitude: 5L to 10.000 ft (4) to (8) Record indicated values. NOTE

o Perform single engine power check with engine 2 as described above. o Power check evaluation (refer to FLM)

*

BO 105 CHAPTER 105 Page 12

Revision 8

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

1.

Engine governing:

Mn% MTII%

......... ( 1 ) ..........

70 60 50 40 30 40 50 60 70

(2 )

70

100493

NOTE

O

The engine control check can either be performed at constant altitude and different airspeeds or with constand airspeed of 80 KIAS and different altitudes.

o When performing the following check, always move the collectivepitch in one dire~tion and not in the opposite one, otherwise the check must be repeated. (1) Adjust both engines with n2 = 100% to a torque of Mr 70%. Lower collective pitch slowly to obtain an Mr indication of 60% for engine 1. Record Mr values of both engines. Then lower collective pitch step by step to MT engine 1 of 50%, 40%, 30% and record the respective Mr values. Pull collective pitch slowly step by step to Mr engine 1 of 40%, 50%, 60%, 70%, until the respective takeoff power is obtained and record the individual Mr values of both engines. Then lower collective pitch to engine 1 of Mr 70% and record both Mr values. Repeat this procedure two times more and calculate the middle value of aH three. Nominal values: The Mr - differences at the individual measuring points must not exceed 8% Mr, with instaHed phase 1 n2 - governer, 10% MT • The admissible deviation with takeoff power must not exceed 5% Mr. When readjusting the collective pitch to 70% Mr, a max. difference of 3% Mr is admissible. NOTE

If the max. admissible torque difference values are exceeded, the n2 governors must be readjusted (refer to chapter 65) ..

(2) Nominal values, takeoff power: refer to FLM

Takeoff power is achieved if one of the max. takeoff power limits as TOT, MT or nI are obtained (refer to FLM) . Record indicated Mr values at takeoff power.

BO 105 CHAPTER 105 Page 13

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

m.

Diving to VNE (with max. continuous power) Zp

OAT

VNE

(3)

( 4)

(5)

NOTE

Track

(1) ,

(2 )

•••••••• (6) •••••••••••••..•. ; •••..••••••••

-

Observe restrictions due to optional equipment (refer to FLM) .

(1) For max. continuous power refer to FLM (2)

Before starting descent detect adequate for given Zp and note at (5).

VNE

values with

VNE

table

(3) At Zp note indicted value. Initial altitude should be 1000 ft higher

then measuring altitude. (4) At Zp record indicated value (6) Having reached VNE

, stabilize speed and perform track check (refer to chapter 106)

n.

Turns with approx. 100 Kts:

(1)

Left turn up to 45° bank

(2)

Right turn up to 45° bank

(2)

Track check

(3) •••.•••••••.•••..•••••.•

(1) Set power as required

(2) Check flight behaviour and proper indication of instruments (3) Perform track check (refer to chapter 106)

BO 105 CHAPTER 105 Page 14

. .

MAINTENANCE MANUAL 80105

EUROCOPTER

o.

Autorotation (Not re~Jired for type 2 main rotor blades. For explanatory notes on type 2 main rotor blades refer to chapter 14).

*

* * *

Autorotation (constant heading, 70 KIAS)

( 1)

.

Fuel:

(2)

.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .( 3 )

.

Total mass:

zp

OAT (5 )

(4)

nRO (6 )

lAS (7 )

1

11

1

11

(8)

(8)

(9)

(9)

Pitch: down/not down

( 10 )

.

Power lever: FlighUldle

( 11 )

.

Pay attention to rotor RPM acoustic warning or rotor RPM warning Iight respectively

( 12)

.

100494-02

NOTE

For checking and, if necessary, adjusting the autorotation rotor RPM also refer to paragraph 105-5.

(1)

Maintain air speed of 70 KIAS.

(2)

Determine and note total mass of fuel in main and supply fuel tanks.

(3)

Determine and note total mass

(4)

At measuring height note indicated ·.ralue. Measuring height must be at least 2000 ft above ground. Check AR-RPM at approx. 2000 ft above the measuring height.

(5) to (9)

= empty mass + fuel + crew.

At measuring height note indicated values.

(10)

Note position.

(11)

Note position.

(12)

During autorotation check rotor overspeed warning at nRO 103% and 108% for function.

Revision 10

BO lOS CHAPTER 105 Page 15

MAINTENANCE MANUAL BO 105

EUROCOPTER

p.

Standard flight instruments and equiprnent: Airspeed indicator Altimete.r " Vertical speed indicator Mast moment indicator Magnetic compass Clock OAT indicator Rotor brake (from 50% to 0%) Equipment:

--

. . .

(1) . . .

-

(2)

s

"( 3)

.

(1) Check for proper indication and sensitivity (for nominal values refer to chapter 91) (2) Apply rotor brake and reduce nM from 50% to 0%. Nominal value braking time: 25-50 s

*

(3) Check for function q.

I~~~~~~~~~ .~~~~~:~~~~~~ .

.

]

Signatures: NOTEThe report of the functional test flight must be signed by each cre~~emb~r.

BO 105 CHAPTER 105 Page 16

Revision 8

MAINTENANCE MANUAL BO 105

EUROCOPTER

CHECK LISTS - GROUND RUN/FUNCTIONAL TEST FLIGHT

105 - 3

The checks and procedures of the following 5 check lists must be performed in accordance with the steps specified in the matrix (refer to paragraph 105-4). Heltcopter vartant: ••••••••• Regtstr.tton No.: •••••••••••• Oate: •••••••••••••• Serial No.: ••••••••••••••••••••••••••••••• Atrport: •••••••••••••••••••••••• Crew: ••••••••••••••••••••••••••••••••••••• Sross ..ss•••••••••••••••••••• kg Center of gr.vt~............ Fuel: •••••••••••••••••••••••••kg QNH: ••••••••••hP•• QNE•••••••••••••••• ft. Wtnd: ••••' ••• Kts. OAT: •••••••••• ·C .••.........••.••••..........•.......••. Mfsston:

Tlke off: •••••••••••••••••••••••••••••••••••••••• Landing: •••••••••••••••••••••••••••••••••••••••• Fl1ght tf..: ••••••••••••••••••••••••••••••••••••••

•• Prefltght check

.....•..........•.....•...... ..........••............••.•.•...•.•...•••••••.•

B.ttery: •••••••• v•

b. Engfne start: wtth/wtthout EPU

_IX.

O Engtn. 1: Start up tt.e••••••• s. TOT•••• ·C O Engtn. 2: St.rt up tt s. -ax. TOT•••• ·C X· ftrst engtne started - c. 'Mat n tank fue1 p"p -OFFLow fuel w.rn. ltght -OH- at •••••••••••••••• kg

~

~

=

d. Idle

nRo

n1l

"1I1

Mn Mru

TOTI

P.011 I P.011 11 P.011 X. P·fue1 I I 11

TOrU

P'fuel 11

1001,95

Table 105-1

Check list 1 Ground run/functional test flight (1 of 5) BO 105 CHAPTER 105 Page 17

MAlNTENANCE MANUAL BO 105

EUROCOPTER

D1scrtl anc1es l.'lt 2~flt 3.'lt 4.'lt e. Oi1 coo1er warning 1ight ·Off·: ••••••••• 1

n2

f. M.x. RPM (f1at pitch)

nRo n1l n1l1 Mn

Mru

TOTI TOTU P.011 1

EEEE RPM Warnfna P.011. na.fn nRllax

p.onU

1

n

~nl

RPMRange n2llax MT 1n

EEEE

RPM Range Eng. 1: •••••••••••••••••••••• 1 n2 Enl. 2: •••••••••••••••••••••• I n2 80th engtnes: •••••••••••••••••••••• S n2

Electr.

Gen. I: ••••••• y••••••••••• A Gen. 11: ••••••• y••••••••••• A Eng1ne ant1-1cfng on/o": ~ste.:

ATOTI••••·C. A TOTU

~C

Mast MoIent Ind1catfon: ~ .. Green Arel at 70 .. Cycl1c Stfck Pos1t1on for

I

EEEE

Helicopter Models (8-5. CBS-5 and DBS-S for aU other Helicopter Models 75 mm Cydic Stick Position

Break-out

Force~clfc

St1ck:

+

Track check: •••••••••••••••••••••••••••••••••• Balance check: ••••••••••••••••••••••••••••••••

g. Bydrau1ic system-se1ector v.1ve setting

h. Pitch-Compensation: •••••••••••••••••••• 1 1DD496

Table 105-1

BO 105 CHAPTER 105 Page 18

n2

= =

Check list 2 Ground run/functional test flight (2 of 5)

Revision 16

- - - - - - - - - - - - - MEB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105 t. Hovertng I.G.E. after 5 mtnutes tn one posttton

"Ro "11 nHI Mrl MTII TOTI TOTII P.ot 1I

Dtscrepanctes l. flt 2.flt 3.flt 4.flt ,

100% 100%

RPM Range P.OflII P.Oflx. T.on I T.Ofl II T.011& n2mu

Forward:

••.••.••• ~ •• Rearward: ••.•.•••••

Lateral left: •••••••••• Lateral rtght: ••••• Turn left: ••••••••••••• Turn r1ght: •••••••• Ta11 Rotor-Pedal Forces ••••••••••••••••••• N Track check:

=

•••••••••••••••••••••••••••••••••

Balance check: ••••••••••••••••••••••••••••••••

j. Horizontal fltght: tf posstble tn 5000 ft

Note the external tnstallat1ons: ZP

OAT

lAS

n2

Perform. Mya 751

100%

Take-off power %

100%

nll

n1l1

Nrl

MrII

751

751

TOTI

TOTII

Track check at approx. 110 KIAS

En9: anti-icing ON/OFF 100497

Table 105-1

Check list 3 Ground run/functional test flight (3 of 5) BO 105 CHAPTER 105 Page 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

k. Single eng. power check Engine - max. performance data: TOT ••• oC. "T: •••'. nl: •••,

zp

OAT

Eng. 1 Eng. 2

n2

TOT

"T

nl

D1screpancies 1.flt 2.flt 3.flt 4.flt

1001

100'

Eng. anti-1cing OH/OFF 1. Eng. governing

"TI

70 60 SO 40 30 40 SO 60 70

... 70

"Tn m. DiYing to VNE

zp

(IRX.

continuous power) OAT

VNE

Track check:

n. Turns wfth approx. 100 KIAS

=

=

Left turn up to 45° bank Rfght turn Up to 45° bank Track check: •••••••••••••••••••••••••••••••••• 100498

Table 105-1

BO 105 CHAPTER

Page 20

105

Check list 4 Ground run/functional test flight (4 of 5)

MAINTENANCE MANUAL BO 105

EUROCOPTER

*

o. Autorotation Cconstant he.ding. 70 KIAS)

* *

(Not requlred for Type 2 maln rotor bladas. For explanatory notes on type 2 maln rotor bladas rerer to ehapter 14).

Fuel : Total

zp

• • • • • • • • • ti • • • • • • • • • • • • • • • • • • • •

.-55:

DAT

lAS

nRo

I

n2 II

I

kg kg

Discrepancfes l.flt 2.flt 3.flt 4.flt

nl II

Pitch: down/not down Power lever: FlIght/ldle Pay attentlon to Rotor RPM accoustic warning or Rotor RPM warning IIght respectlvely

p. Standard flight 1nstru.ents and equfpant: A1rspeed ind1cator

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

Al ti.ter ..................•................

Vertical speed indicator •••••••••••••••••••• Mast _Glent indicator ••••••••••••••••••••••• M.gnetic campass •••••••••••••••••••••••••••• elOC'k •••••••••••••••••••••••••••••••••••••••

DAT 1ndfcator

.••..........•........•........

· ·

. . .

·

Rotorbrake CfrGl 501 RPM to 01) •••••••••••• 5 Equf..-nt: ••••••••••••••••••••••••••••••••••

.

· ·

.

q. Addit10nal d1screpancies:

. . . .

· · · · Sfgnatures Pl10t Tel.

F11ght Engineer/Crew ..-ber Date

Telo

O.te

Inspector Tel.

Date

100499-02

Table 105-1 Revision 10

Check list 5 Ground run/Functional test flight (5 of 5) BO 105 CHAPTER 105 Page 21/22

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 105 - 4

MATRIX - GROUND RUN/FUNCTIONAL TEST FLIGHT

l.

The procedures/checks of the matrix (table 105-2) are equivalent to the steps of paragraphs 105-2 and 105-3.

2.

The procedures of the individual checks during ground run/functional test flight must be performed inaccordance with the following matrix.

BO 105 CHAPTER 105 Page 23/24

MAINTENANCE MANUAL SO 105

&

Reason:

Aftar periedicaJ inspection

After replacement 01: main transmission, upper part of main transmission

ProcedurelCheck: 4~

a

Preflight check

b. Engine start c.

Main tank fuel pumps - Low fuel warning Iight

d. Idlecheck

G .R

e.

on coaler warning Iight

f.

Max. RPM check

O

-RPMwarning

U N

- RPM range angine 112

O

- Electrical system: Gen 112

R U N

-Engine antHcing - Mast moment indicator - Break-out forces-cyclic stick

• • • • • • • • • • • • •

After replacement After replacement 01: of: main rotor head, tail rotor, main rotor blades, tail rotor blades rotating control reds, red ends

• •

"

&

•

•

•

•

•

•

•

•

• • •

After replacement 01: mast moment system

Aftar replacement of: fuel pumps, fuel indication system, fuellow warning system

•

• •

• •

• •

•

•

•

•

•

• • • • •

I

• • •

•

•

•

• • • • •

I I

,

I

• I

• •

•

Additional reasons are given in the respective chapters 01 the MM and in the supplementary inspection refar to chapter 101-10. . Table 105-2 Matrix - Ground run! Functional test flight (1 of 2)

CHAPTER 105 Page25126

I

•

• •

h. Pitch compensation

Revision 20

•

•

-Balance g. Hydraulic system - selector valve setting

• •

Alter replacement 01: intermediata gear box. tail rotor transmission, input shaft

I

-Track

I

• •

After replacement . After replacement 01: 01: engine, N1~ovemor. engine modules N2~ovemor

After replacement 01: tandem hydraulic unit

•

•

eeurocopter ~

Reason:

MAINTENANCE MANUAL 80 105

After periodical inspection

ProcedurelCheck: l

L

Hovering LG.E. - Tail rotor pedal forces

• •

After replacement of: Main transmission, upper part of main transmission

After replacement of: main rotor head, main rotor blades, rotating control rods, red ends

After replacement of: tail rotor, tail rotor blades

After replacement of: tandem hydraulic unit

After replacement of: engine, engine modules

After replacement of: N1-governor N2-govemor

•

•

• •

•

•

•

•

•

•

•

- Track -Balance

F U j. N

e

Horizontal t1ight

O k. N A 1.

Single engine power check Engine govering

L m. Diving to VNE

T E

F L

- Track

G o. H

T

Autorotation

&

Rotor RPM warning p.

Standard f1ight instruments Rotorbrake Equipment

• • • • •

I I

• • • •

I

• • • I i !

I

•

Additional reasons are given in the respective chapters of the MM and in the supplementary inspection refer to chapter 101-10. Not required for type 2 main rotor blades. For explanatory notes on type 2 main rotor blades, refer to chapter 14. Table 105-2 Matrix - Ground run I Functional test f1ight (2 of 2)

Revision 20

After replacement of: mastmoment system

I

• • • • • •

•

I

&

• • •

Track

S T n. Tums

.&

•

-Track

T I

"

•

• • • •

After replacement of: intennediate gear box, tail rotor transmission, input shaft

CHAPTER 105 Page27128

After replacement of: fuel pumps, fuel indieation system, fuellow warning system

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 105 - 5

CHECKING AND ADJUSTING THE AUTOROTATION ROTOR RPM

1. General The autorotation rotor RPM must be checked during a test flight. a. The reasons for checking the autorotation rotor RPM are given in the matrix, paragraph 105-4. b. The nominal va1ues fQr the autorotation rotor RPM are given in figure 105-3. 2. Check of autorotation rotor RPM a. Check before test flight, whether the flight conditions (see figure 105-3) are fulfilled. DURING DETERMINATION OF THE AUTOROTATION ROTOR RPM ENSURE THAT THE ROTOR RPM DOES NOT EXCEED 110 %. A ROTOR RPM BETWEEN 104 % AND 110 % MUST NOT BE MAINTAINED FOR LONGER THAN 15 SECONDS ON MODEL S HELICOPTERS.

WARNING

b. Stabilize helicopter at an air speed of 70 KIAS and change to autorotation. Keep collective pitch stick in minimum pitch position. NOTE

During autorotation it is not allowed to supply any power from both engines. If necessary, put power levers back to position "idle".

c. If

n~

'"

does not exceed n2 , set power levers to "idle".

'" '"

d. Repeat check 2 to 3 times. e. Compare actual recorded rotor RPM against nominal values in figure 105-3.H necessary adjust AR-RPM according to step. 3. Values in figure 105-3 apply to helicopters without a blade folding system (blade angle 5° 48' ±20'). Tolerance = ±2 %. On helicopters with blade folding system (blade angle 4° 48' ±20') the autorotation rotor RPM must be 6.9 % greater than that of helicopters without a blade folding system.

Revision 3

BO 105 CHAPTER 105 Page 29

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MaB - BO 105

3. Adjusting the autorotation rotor RPM NOTE

o Changing the length of the control rods by 1 mm changes the rotor RPM by approx. 2.3 %. o On eye bolts with fine thread (at the bottorn end of rnounted control rods) , one full turn of the eye bolt results in a change of length of the control rod of 1.0 mm. In eye bolts with coarse thread (at the top end of rnounted control rods), one full turn of the eye bolt results in a change of length of 1.5 mm.

* * * * *

o If the rotating control rods are lengthened (red thread ends rnust not be visible!), check control rods for freedorn of rnovernent, refer to chapter 41. o To avoid affecting length of all four sarne. Only one eye unlocked, detached

the rnain rotor track, the change in rotating control rods rnust be the bolt on each contol rod is to be and adjusted in incrernents of half a

turno

a. If the autorotation rotor RPM is too high, shorten all four rotating control rods appropriately by the sarne arnount. b. If the autorotation rotor RPM is too low, lengthen all four rotating control rods appropriately by the sarne arnount. c. Install control rods and check that the eye bolts are positioned 45 0 offset to each other, using adjusting device (105-13101 W3), refer to chapter 41. d. Lock the eye bolts,refer to chapter 41. e. Recheck autorotation rotor RPM, refer to step 2. f. Seal split line of control rods to eye bolts, refer to figure 41-82. g. Check rnain rotor systern for freedorn of rnovernent.

BO 105 CHAPTER 105 Page 30

Revision 3

HELICOPTERS - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

SERIAL NO.

FLlGHT NO.

PILor

INSPECTOR

DATE

LANDING

,~

. I

.

-!

-r,+ . ·~t··

i~:

t+" ·t

"1'

. +-!' .

Figure 105-3 Diagram - Autorotation rotor RPM

Revision 2

BO 105 CHAPTER 105 Page 31/32

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

106

T R A C K 1 N G A N D B A L A N C 1 N G O F MA 1 N ROT OR S YS T EM

Table of Contents .

Paragraph

Title

106 - 1

TRACKING OF MAIN ROTOR SYSTEM (using Chadwick-Helrnuth vibrex systern)

3

BALANCING OF MAIN ROTOR SYSTEM (using Chadwick-Helrnuth vibrex systern)

17

TRACKING OF MAIN ROTOR SYSTEM (using tracking kit BO 105 L1 or BO 105 L2

29

BALANCING OF MAIN ROTOR SYSTEM (using tracking kit BO 105 L1 or BO 105 L2)

47

106 - 2 106 - 3 106 - 4

Page

BO 105 CHAPTER 106 Page 1/2

EUROCOPTER

106 - 1

WARNING

MAINTENANCE MANUAL 80 105

TRACKING OF MAIN ROTOR SYSTEM (USING CHADWICK-HELMUTH VIBREX SYSTEM) • CONSIDERABLE CHANGES IN BLADE TRACK AFTER A FEW FLlGHT HOURS OR TRACKING PROBLEMS WHICH CANNOT BE CORRECTED MAY BE AN INDICATION OF LATENT, AND POSSIBLY SERIOUS, TECHNICAL DEFECTS, WHICH CAN POSSIBLY RESULT IN FAILURE OFTHE MAIN ROTOR SYSTEM. • IF IRREGULARITIES OR UNKNOWN PROBLEMS OCCUR DURING BLADE TRACKING, CONSULT THE ECD CUSTOMER SERVICE PRIOR TO NEXT FLlGHT.

NOTE

Attaching hardware andreflectors differ between type 1 and type 2 main rotor blades (type 1 and type 2 blades are more precisely defined in chapter 14).

1. Necessary test equipment and special tools Adjusting device 105-13101 W3 Tab bending tool 105-15103 W2 Tracking reflector bracket 1120-15115 with reflector 8503 for type 2 main rotor blades. The Chadwick-Helmuth "Vibrex Track and Balance System BO 105" Mod No. 6042 may be purchased from ECD or from the manufacturer or one of his representatives. Adress:

Revision 17

Chadwick-Helmuth Co., Inc. 4601 North Arden Drive El Monte, California 91731 USA Tel.: (213) 575-6161 Telex: 194-271

CHAPTER 106 Page3

EUROCOPTER

MAINTENANCE MANUAL BO 105

Chadwick-Helmuth "Vibrex" Track and Balance System BO 105 Model Number 6042 Quantity 1 1 1 1 1 1 1 1 1 1 Set *

* *

1 1

* * 1

1 1 1 1

Nomenclature

1-1od. No.

Balancer/Phazor Strobex Blade Tracker Gram Scale Magnetic Pickup Magnetic Pickup Bracket Magnetic Pickup Cable Accelerometer Accelerometer Bracket M/R Accelerometer Cable Blade Tip Re~ectors (Tape) Tip Targets 1 Reflectors ECO & Circuit protecti~ Module Tracking Reco~2 Balance Chart 2 Clock Angle Corrector Balancer and Strobex Manual Carrying Case Spare Flash Tube

177M-6C 135t-1-11 47 6343 6044 3319-1 4177B 3575 4296-1 6047 6974-1 P/N 105L1-040 6045

&

or or

3597 34B 3.5S

Optional equipment (upon request) to check the "Vibrex" system: 1 Calibrator with 11 Power Supply 110/220 YAC to 28VOC 7146

* & For type 1 main rotor blades * ~ Copy of figure 106-9 or 106-12 * Table 106-1 Test Equipment and Special Too15 *

BO 105 CHAPTER 106 Page 4

Revision 10

EUROCOPTER

2.

MAINTENANCE MANUAL 80 105

Preparatory work a.

Install magnetic pickup 6343 NOTE

Perforrn procedurul steps 1) and 2) only in conjunction with swashplates without integral mounting lug for the magnetic pickup.

1)

Loosen clamp on bearing ring and slide back upper boot. Insta1l rnagnetic pickup bracket 6044 on gimbal ring between swashplate attach points of the longitudinal and lateral controls as shown in fig. 106-1. Ornit washer norrnally installed under nut (3).

2)

Install boot with clamps. Torque clamp screw to 0.5 Nm and secure with locking compound (CM 624). Additionally apply locking compound (CM 623) to thread and screw head. 2

3

4113.2

17~ml

Figure 106-1

Revision 10

1 Magnetic pickup bracket 6044 2 Locking plate 3 Nut

Installation - rnagnetic pickup bracket

BO 105 CHAPTER 106 Page 4A/B

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS 3)

Rotate rotor by hand until soft-iron wiper (1, fig. 106-2) in bearing ring aligns with the hole in the bracket (or integral lug) for the magnetic pickup. TO PREVENT THE MAGNETIC PICKUP ANO SWASHPLATE FROM BEING DAMAGED DUE TO UNINTENTIONAL MAIN ROTOR ROTATION, IT IS NECESSARY TO TURN THE MAIN ROTOR PRIOR TO INSTALLING THE MAGNETIC PICKUP SO THAT THE SOFT-IRON WIPER IN THE ROTATING SWASHPLATE IS POSITIONED DIRECTLY ABOVE THE HOLE IN THE MAGNETIC PICKUP BRACKET. IN THIS RELATIVE POSITION, BLADE 4 WITH THE RED COLOR CODE IS POINTING IN THE DIRECTION OF FLIGHT, THUS PREVENTING THE MAGNETIC PICKUP FROM BEING SCREWED IN TOO FAR.

CAUTION

4)

Install magnetic pickup (3) in magnetic pickup bracket or in mounting lug of swashplate (refer to fig. 106-2). Make sure that there is a gap of at least 1.S mm between soft-iron wiper and magnetic pickup.

S)

Tighten nuts (2) to specified torque and secure with lockwire.

6)

Check swashplate for freedom of movement with cyclic stick pushed to full forward RH position, as in this position minimum clearance exists between magnetic pickup and clevises of rotating pitch links of the swashplate's bearing ringo

100418

1 2 3

Figure 106-2

Soft-iron wiper Nut Magnetic pickup 6343

Installation - magnetic pickup BO 105 CHAPTER 106 Page 5

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

b. Install accelerometer 4177B 1)

Remove LH and RH transmission cowlings as necessary.

2)

Screw accelerometer into accelerometer bracket 3575 as shown in fig. 106-3 and secure with lockwire.

1 Accelerometer bracket 3575 2 Accelerometer 4177B ~'----------2

Figure 106-3 3)

Installation of accelerometer bracket

Install accelerometer bracket without washer as shown in fig. 106-4. Tighten nut to specified torque and secure with split pino

1 Assembled accelerometer bracket 3575 and accelerometer 4177B

Figure 106-4 BO 105 CHAPTER 106 Page 6

Installation of accelerometer

MAINTENANCE MANUAL· BO 105 .

EUROCOPTER

c.

* *

Install reflectors 1) Install reflectors on type 1 main rotor blade NOTE

*

Blade tip reflectors 6047, tip targets 6974-1, or MBB reflectors P/N 105 11-040 may be installed.

Insta1l blade tip reflectors on blade tips as shown in fig. 106-5 and allocate colours or symbols in accordance with fig. 106-6 .

./,-.-( A

(

,

''-...--' DETAlL"

A"

II/l/O~ O ~-~D1~, -~.=-J--~

I<==-="![~f

@

100412

Figure 106-5 Blade No.

3

2

1

4

or Color Codlng Blade Tip fWltctors P/N 6047

blue

reen yellow

red

[JJ[JJ[JJ[JJ

Tip T¡rgets

P/N 6974-1

O O O O bluf

green

yeUow

red

ReflectOr! IGlass)

P/N 10SL1- 040 100417

Revision 10

O O O O white

green

yellow

ftd

Figure 106-6 BO 105 CHAPTER 106 Page 7

MAINTENANCE MANUAL 80 105

EUROCOPTER

* * * * * * * * * * * * * * * * * * * * * * * * * * * *

2)

Install reflectors on type 2 main rotor blades Secure tracking reflector bracket (2, fig. l06-6A) to threaded insert (R = 4375) on underside of blade, using screw (4) and washer (3). The color of the reflector must match the color of the rotor blade (see Table 106-1A). The dowel pin (1) on the tracking reflector bracket must engage in the hole adjacent to the threaded inserto Secure screw to tracking reflector bracket, using lockwire (6). NOTE

Soiled or worn reflectors (5) are difficult to distinguish and therefore should be replaced with new ones. To obtain the strongest possible adhesion of the self-adhesive reflectors, it is necessary to clean thoroughly the depressed bonding surface on the tracking reflector bracket prior to bonding. Take care to use reflectors with same color blades.

1

5

*"

* 2 * 100414 * 1 Dowel pin 5 Reflector * 2 Tracking reflector bracket 6 Lockwire * 3 Washer 7 Main rotor blade, type 2 * 4 Screw * * Figure 106-6A * * * The following table shows the combinations of blade number, blade color and * reflector color in the order in which they can be observed when looking in * the direction of flight. *

* *

Blade no.

* "Á'

*

* * * * * *

3

2

1

4

Color of blade

blue

green

yellow

red

Color of reflector on tracking reflector bracket .

blue

green

yellow

red

Table 106-1A BO 105 CHAPTER 106 Page 8

Revision 10

MAINTENANCE MANUAL 80 105

EUROCOPTER

d.

Connect test equipment 1)

Connect magnetic pickup cable 3319-1 to magnetic pickup and secure with lockwire.

2)

Using adhesive tape, attach magnetic pickup cable to a suitable point on the main transmission that allows the cable to follow the swashplate movements without being tensioned.

3)

Connect accelerometer cable 4296-1 to accelerometer.

4)

Run magnetic pickup cable and accelerometer cable down RH side of helicopter and through sliding door and secure with adhesive tape.

5)

Install RH and LH transmission cowlings. WARNING

6)

e.

BALANCER/PHAZOR SHALL ONLY BE OPERATED IN CONJUNCTION WITH A CIRCUIT PROTECTION MODULE P/N 6045.

Connect balancer/phazor 177M-6C as follows: a)

Connect circuit protection module to helicopter's 28VDC supply.

b)

Connect balancer/phazor to circuit protection module.

e)

Connect strobex blade tracker' 135M-11 to balancer/phazor.

d)

Connect magnetic pickup cable and accelerometer cable to corresponding channel "A" receptacles of the balancer/phazor.

Set balancer/phazor and strobex Set controls on balancer/phazor and strobex as follows: Balancer/Phazor Magnetic Pickup: Function: R.P.M. Range: R.P.M. Tune: Interrupter Logic:

COITllI\on Track/Channel A (for measuring balance) Xl 424 Single

Strobex "Mode" s\oTitch: RPM dial:

Revision 10

B

678 or slightly less

BO 105 CHAPTER 106 Page 8A

EUROCOPTER

MAINTENANCE MANUAL BO 105

3. Tracking on ground NOTE

o The rotating pitch links of the reference blade (yellow color code) shall not be adjusted to correct blade track unless required. o The 2VEG power receptacle can be powered frorn an EPU on all helicopters. If an EPU is not available, the 2VEG receptacle can be powered by single or dual generator operation on helicopters S/N 7 thru 80, or by dual generator operation only on helicopters S/N 81 and subsequent (refer to chapter 92). o Single-engine operation on helicopters S/N 7 thru 80 does not guarantee that a rotor rprn of 100% will be obtained. This requires slightly reduced settings of "RPM Tune: 424" on the balancer/phazor and of "RPM Dial: 678" on the strobex.

*

* *

a.

Start and run up engine(s) to approx. 99% or 100% rotor rprn and look out for rotor out-of-balance. Switch off engine(s) if IPS reading rernains above 0.4 and balance rnain rotor systern according to para 106-2.

b.

Using the "Strobex Blade Tracker Mod. 13SM-11" (trigger on grip depressed), guide the bearn along blade tip path in direction of flight until the reflectors on the blade tips (type 1 blade) or on the underside of the blade (type 2 blade) becorne visible (s. fig. 106-7). The horizontal distance (spread) between the reflectors can be altered by changing the "RPM" dial setting on the strobex.

BO 105 CHAPTER 106 Page 8B

Revis.ion 10

MAINTENANCE MANUAL BO 105

EUROCOPTER

*

*

EFFECTIVITY Main rotor blades, type 1

*

100290

*

* * * * * * * *k

EFFECTIVITY Main rotor blades, type 2

* * * *

100290.1

* * *

Bild 106-7

Revision 10

BO 105 CHAPTER 106 Page 9

EUROCOPTER

NOTE

c.

MAINTENANCE MANUAL 80 105

Blade no. 1 (yellow reflector or reflector with diagonal stripe running from upper left to lower right side) shall be the reference blade and shall be plotted on the zero line of the Tracking Record.

Determine the amount of track deviation (measured in mm) of the other blades in relation to the reference blade and record in the Tracking Record shown in fig. 106-9.

TRACKING RECORD 2nd

3n1

HOR.ZOl\lTAL FUOHT

HOVEA FLlOHT

GAOUNDRUN 1st

4th

1st

4th

1ft

2~

3n1

4th

321432143214 MM

:liiiii~iii~*1~~~-~~~~~ '6 to 6

o 5 ti)

'6 20

:~~~J[I~~~ C31XA HH---+---+--+--+---.f----iI---1f--

o

A 2

R_lutlo", of roáting pltllh 'ina

o

RnollltioM o, rotatlng pitch IInb

N 1 GH

E 4

---+---+--+--+---.f----.;.I---1f----I---T-I----+---f----I 1L

1R

1

200138.1

Figure 106-8

BO 105 CHAPTER 106 Page 10

Tracking Record with sample track data

o '"

...g~

Set Strobex Mode switch: B

mACKING RECORD

~

R.P.M. Dial: 678

GROUND RUN

1st

2nd

3 rd

HOVER FLlGHT

4th

1st

HORIZONTAL FLlGHT

3-d

2 nd

4th

1st

2 nd

3rd

4th

w

Q o(

no¡ 1-'lQ

e

t-1

~ H

MM

I:':l

... 0

:m

1--'

2S 20

O'l

I u::>

t-3

t-1 PJ (')

15 10 5

;:l

lQ

iW (')

~~ (1) t-3 1:':l0l

I--':::tlO 1--' -1--'1--' 1--'00

N

O'l (J1

..

_.

-.

.

-

-

o-

••

o

-. -

-

~¡§

-- -

1:':l0l

- ._.

~~

~8 '"'O ¡§~

15

o ......

20

Po

25

c

()

_....

Ol:::tl

:m

'"'O::I:

.

-

5 10

o

t-1

t-3

Z

o

;.;1-'-

•

Z

(1)

o

3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1. 4 3 2 1 4 3 2 1 4

IDZ

3 H 2 A N 1 G E 4

I

Ol

o

(J1

--.

en

MAINTENANCE MANUAL BO 105

EUROCOPTER

d.

If the track spread between the highest blade and lowest blade exceeds 10 mm, correct as follows:

WARNING

WHEN ADJUSTING THE ROTATJNG PITCH LINKS DO NOT UNSCREW THE ROD ENDS TO THE EXTENT THAT THE RED MARKING RINGS ON THEIR THREADS ARE EXPOSED.

1)

Loosen jamnuts on the pitch link rod ends of the blade requiring correction and turn pitch link tube. A full (360°) turn clockwise (viewed frora above) will lower the blade tip approximately 10 mm. A full (360°) turn counterclockwise (viewed from above) will raise the blade approximately 10 mm.

2)

Offset the pitch link rod ends device 105-13101 W3.

3)

Torque jamnuts to 8 Nm.

45~

to each other, using adjusting

e.

Repeat tracking check and correct track as necessary.

f.

Inspect main rotor blades for lead-lag. 1)

Sweep the blade tip path in flight direction with the light beam of the Strobex until the reflectors on the blade tips (type 1 blade) or on the underside of the blade (type 2 blade) are visible.

2)

By turning the "RPM" dial setting on the Strobex, try to achieve stacking of all the reflectors at a fixed position in azimuth (see fig. 106-9A).

3)

If all reflectors cannot superimposed, determine the lead-Jag of the deviant blade (see fig. 106-9A for lead-lag tolerance limits).

WARNING

o IF LEAD-LAG AMOUNTS TO MORE THAN 20 mm OR THERE IS REASON FOR DOUBT, CONSULT THE ECD CUSTOi~R SERVICE ABOUT THE AFFECTED BLADE SET BEFORE THE NEX~ FLIGHT.

* *

*

* * *

oLEAD-LAG EXCEEDING 20 mm MAY BE AN INDICATION OF LATENT, ANO POSSIBLY SERIOUS, TECHNICAL DEFECTS, WHICH COULD RESULT IN THE FAiLURE OF THE MAIN ROTOR SYSTEM. 4)

If lead-lag exceeds 20 mm (approx. width of a thumb) , the entire blade set must be removed from service. This applies also in cases where it is impossible to determine whether the lead-lag is within the tolerance limits.

5)

Consult the ECD customer service before next flight using a" blade set such as described in previous step 4).

Revision 10

BO 105 CHAPTER 106 Page 13

* * *

* * *g * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

'"l:lnlJ:l Ql=::::O

~

~~f-' 1-3

I

C>

Examples of permlssible track results

o

f-'l:':l0'1

i

r;oaslble sltuatlons aftsr converglng the reflectora

Impermlsslble lead-Iag left or rlght

Permlsslble lead-l<1g left or rlght

No lead-Iag

~:;l:I

f-'

~

&

8

o

0'\

I

I

1

I

I

I

I

-+--01

&-G---e+e---e- -~-..... l"Zj

Posslble s1tuatlons upon Ideal track result

~ H

ro 1-'

I

&-I--~t\--+

o

o I

0'\

L.;

-t-I

I ...

>20mm ~I

m e

~

::D

1~

-T----1-

I 'J:)

~

I&-Q--e-L----e!O

~

ro

Ql

p. I

1-'

Ql

lO

I,

I

Poss¡bl~

s1tuations upon permlsslble track result

Ó

I O

fU--- --~I "

. I

&-L-~h--+ -(---..-l--VI

~2::3t~mO&

--t--J -

I

& ~

< ..... en

&

..... o

::l .;:..

Display uslng tlp targets P/N 6974-1 and MBB reflectors P!N 105L1-040 Display uslng blade tlp reflectors P!N 6047

&

WARNING

o IF LEAD-LAG AMOUNTS TO MORE THAN 20mm OR THERE IS REASON FOR DOUBT o CONSULT THE MBB CUSTOMER SERVICE ABOUT THE AFFECTED BLADE SET BEFORE THE NEXT FLlGHT. oLEAD-LAG EXCEEDING 20mm MAY BE AN INDICATION OF LATENT. AND POSSIBLV SERIOUS. TECHNICAL DEFECTS. WHICH COULD RESULT IN THE FAILURE OF THE MAIN ROTOR SYSTEM.

~

>

~

m

z

> z ~ 3:

> z e > rm O

.... ~

... ~

EUROCOPTER

4.

MAINTENANCE MANUAL SO 105

Perform hover track. NOTE

O

The main rotor blade track is also affected by the gross mass. At a given setting, the track spread usually increases with decreasing gross mass. To mínimize vibrations it is recommended to perform tracking with mínimum gross mass.

o The rotating pitch link of the reference blade (yellow color code) shall not be adjusted to correct track, unless necessary. o After completion of hover tracking, track spread occurring during ground run can be ignored. a.

Check blade track in hover flight per steps 3. as necessary.

b. 5.

b~

thru f. and adjust

*

*

A maximum track spread of 5 mm between the highest blade and the lowest blade is permissible.

Forward flight tracking NOTE

o Forward flight tracking is accomplished at 120 KIAS and VNE and requires that hover track spread be within the limits. The helicopter airspeed in forward flight can be progressively increased from 80 KIAS to 120 KIAS if the track spread between the highest blade and lowest blade does not exceed 50 mm. If necessary, blade track must be corrected beforehand. o Track spread occurring bending the blade trim not be bent beyond the bending tool 105-15103

a.

in forward flight shall be corrected by tabs. The edges of the trim tabs must end of the graduated scale of tab W2.

Check blade track per steps 3. b.,

Revision ··4

C.

and f. and adjust as necessary.

BO 105 CHAPTER 106 Page 15

*

* *

EUROCOPTER

NOTE

MAlNTENANCE MANUAL BO 105

O

Bending the edge of a trim tab by 1 mm will cause a change in track of approximately 15 mm at the blade tipo

o If a blade amount. To sufficient quired for b;

If the track spread between the highest blade and lowest blade exceeds 5 mm, correct the track of one of these blades as follows: 1)

Position tab bending tool 105-15103 W2 on out-of-track blade as shown in fig. 106-10 and read off initial position of tabs against graduated scale (2).

2)

Bend fig. trim wi11

the tabs as required to correct the out-of-track (refer to 106-10). One scale spacing is equivalent to 1.5 mm. Bending tabs down will lower the blade tip, bending trim tabs up raise the b1ade tipo

NOTE

o Major trim tab changes may affect blade track in hover flight. o Do not exceed max. trim tab adjustrnent (± 5 mm) in relation to chord line of b1ade.

*

*

*

has two trim tabs, bend each tab by the same obtain the required track change, it is to bend each tab by half of the tab bend re a one-tab blade.

c.

Check blade track in hover flight per steps 3. b. thru f. and adjust as necessary. Max. per.missible track spread between highest blade and lowest blade is 5 mm.

d.

Check blade track in forward flight at 120 KIAS and correct repeated1y in accordance with steps 5.b. and c. unti1 the track spread between the highest blade and lowest b1ade does not exceed 5 mm for both fligh regimes.

e.

Check b1ade track at VNE. The maximum per.missible track spread between highest b1ade and lowest blade is 20 mm. Correct track spread in accordance with step 5.b. as necessary.

f.

Torque jamnuts on rotating pitch link rod ends to 8 Nm and secure with lockwire. Sea1 split 1ine of upper rod ends and pitch link tubes with si1icone rubber (CM 612) .

g.

Balance the main rotor system in accordance with para 106-2.

BO 105 CHAPTER 106 Page 16

Revision 16

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2 --.c¡

2---te

3

.L-""';

3 - - - -....

100413

Determining the initia1 position of the trim tab edges

Bending the trim tabs

1 Tab bending tool 105-15103 W2 Sea le of tab bending tool 3 Trim tabs

2

Figure 106-10

Revision 4

BO 105 CHAPTER 106 Page 16A/16B

*

EUROCOPTER

106 - 2

MAINTENANCE MANUAL 80105

BALANCING OF MAIN ROTOR SYSTEM (USING CHADWICK-HELMUTH VIBREX SYSTEM)

WARNING

• CONSIDERABLE CHANGES IN BALANCE AFTER A FEW FLlGHT HOURS OR BALANCING PROBLEMS WHICH CANNOT BE CORRECTED MAY BE AN INDICATION OF LATENT, ANO POSSIBLY SERIOUS, TECHNICAL DEFECTS, WHICH CAN POSSIBLY RESULT IN FAILURE OFTHE MAIN ROTOR SYSTEM. IF NO MORE BALANCE WEIGHTS CAN BE INSERTED INTO THE MAIN BOLT TO ELlMINATE UNBALANCE, THIS MAY ALSO BE AN INDICATION OF A SERIOUS TECHNICAL DEFECT.

• IF IRREGULARITIES OR UNKNOWN PROBLEMS OCCUR DURING BALANCING, CONSULT THE ECO CUSTOMER SERVICE PRIOR TO NEXT FLlGHT. To achieve proper balancing, the blade track must be within the specified tolerances in para 106-1.

NOTE

1. Set controls on balancer/phazor 117M-6C as follows: Magnetic Pickup: Function: R.P.M. range: R.P.M. tune dial: Interrupter logic:

Common Channel A X1 424 Single

2. Balancing on the ground. a. Set rotor RPM to 100%. b.

Functionally test the bafancer/phazor. 1) Press "Test" button. The 12:00 o'clock LEO of the phase meter!!!.Y.S1 come on. 2) Release "Test" button: The resulting LED indication is determined by the phase angle of the point of imbalance. NOTE

The phase meter is a ring of Iights which are equally spaced and numbered 1 to 12 like the dial of a clock. To simplify matters, the phase angle of the point of imbalance is expressed in terms of"time" ("Clock Angle") instead of angular degrees. Hours and half-hours are indicated by Iight emitting diodes (LED's). The format of the Balance Chart is based on the clock-reference system (see fig. 106-12).

c.

Observe "Clock Angle" of illuminated light with ''Test'' button released.

d.

Press "Verify Turn" button and observe "Clock Angle" of iIIuminated light on the phase meter. Keep button depressed and adjust"RPM Time" dial to obtain the clock angle light which was on before the "Verify Tune" button was pressed.

Revision 17

CHAPTER 106 Page 17

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 e.

Release "Verify tune" button and observe "Clock Angle".

f.

Repeat steps d. and e. until there is no change in the "Clock Angle" whether "Verify Time .. button is pressed or released.

g.

Read "Clock Angle" and vibration amplitude (measured in "IPS" = inches per second) from balancer/phazor and record them in the GROUND RUN data section of the Balance Chart. NOTE

o The Rotor system is sufficiently balanced for ground run if the "IPS" reading does not exceed 0.4. o The weight changes required to correct ground run balance and hover balance are not the same for a given "IPS" reading.For this reason, the weight axes labeled G on the Balance Chart (see figs. 106-11 and 106-12) are used for ground run balancing and those labeled H are used for hover balancing.

h.

Stop rotor.

i.

Fill out "Balance Chart" (fig. 106-12) as follows: 1)

Plot the "Clock Angle" and "IPS" on clock section of the Balance Chart. The point of intersection of the "Clock Angle" (radial line) and "IPS" (circle) is the point of imbalance and is labeled "1".

2)

From point "1", draw a line to each of the G weight axes of the graph, keeping each line parallel to the lines extending perpendicular from the respective axis.

3)

The intersecting points on the weight lines indicate the weights to be added to or removed from the respective trim chambers of the blade bolts in order to correct the existing mass imbalance. Enter the indlcated required weight changes against the applicable blades in the data section of the Balance Chart. NOTE

BO 105 CHAPTER 106 Page 18

The balanced condition of the rotor system is not affected when an equal amount of weight is added to or removed from two opposing blade retaining bolts. If both opposing bolts contain balance weights, the one containing the least amount shal! have al! its weightsremoved and an equal amount of balance weight shall be removed from the opposite one.

- - - - - - - - - - - - - M B B HEL1COPTERS - - - - - - - - - - - - MA1NTENANCE MANUAL MBB - BO 105 4) Example of a balance weight determination. MAl" ROTOR CHART

BO 105

NO.

6346

BALANCE CHART SOfil1 Number : GROUNORUN 3rd 2nd

11t :

ClDckA....

10: 311

"1" ..

0.5

A

o

1\

\ BLADE NO.l I yollo.. ) BLADE NO.2

V

1\

1\

.....

1

wh•

+ 100

......, J

+110

Ip""1

E

Set ........./Phuor f.. ROID, RPM 424

T....

o

1'''''

M

5th

0.05

BLADE NOI

o

4th

·3:00

BLIIDE N0.3

o

lb.... '

HOVER FLlGHT 2nd rd :

ClodlA....

• :00

.7:00

"1""

D.25

D.Dli

A

o

4lh

5lh

BlADI NO. I

M o

BlAD! NO.l

1'''''

V

BlADE N02

E

BLADE NO.3 I bluo I

'yoIlow)

Ip""'

,

~.

.2

.S

...

o:

ra •• lth.. .., .DUnd

H:

,,1ft

ho_'titM

200140.1

Figure 106-11

Example of a balance weight determination, using the Balance Chart shown in fig. 106-12

Assume an "1PS" reading of 0.5 at 10:30 o'clock during ground runo Step 1:

Enter readings of 10:30 and 0.5 in the data section of the Balance Chart, under 1st Ground Run.

Step 2:

Plot these "Clock Angle" and "IPS" readings on the clock section of the Balance Chart and label the point of intersection "1".

Step 3:

From point "1", draw a Ene to each of the G weight axes, keeping each line parallel to the lines extending perpendicular from the respective axis. The weight axes are intersected at the 100 g and 180 g divisions respectively. This calls for the addition of 100 g to blade 1 (yellow) and 180 g to blade 2 (~reen), or the removal of 100 g from blade 3 (blue) and 180 g from blade 4 (red).

BO 105 CHAPTER 106 Page 19

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 Step 4:

Record indicated weight changes in the appropriate data section of the Blade Chart, i. e. +1OO g against "Blade No. 1" and +18 O g against "Blade No. 2".

Step 5:

Make the indicated weight changes, i.e. add 100 g to blade 1 bolt and 180 grams to blade 2 bolt and repeat ground run.Ground run imbalance is now only 0.05 "IPS" at a "Clock Angle" oscillating between 2.00 and 5.00 o'clock.

Step 6:

Record mean "Clock Angle" of 3:00 and "IPS" of 0.05 in the data section of the Balance Chart, under 2nd Ground Run, and plot these values on the clock section of the Balance Chart. Label the point of intersection "2". As the "IPS" reading is less than 0.4 (max. permissible ground run vibration), perform hover balancing.

A balance reading of 0.25 "IPS" at 6:00 o'clock is obtained in hover flight. Step 7:

Record reading of 6:00 o'clock and 0.25 "IPS" in the data section of the Balance Chart, under 1st Hover Flight.

Step 8:

Plot "Clock Angle" and "IPS" on clock section of Balance Chart and label point of intersection "3". From point "3", drawa line to each of the H weight axes, keeping each line parallel to the lines extending perpendicular from the respective axis. The weight axes are intersected at the 230 g and 60 g divisions respectively. These weight changes may be performed as follows.

Possibility 1: the addition of 60 g to blade 4 (red) and 230 g to blade 3 (blue), or Possibility 2: the removal of 60 g from blade 2 (green) and 230 g from blaqe 1 (yellow), or Possibility 3: the addition of 60 g to blade 4 (red) and the removal of 230 g from blade 1 (yellow), or Possibility 4: the removal of 60 g from blade 2 (green) and addition of 230 g to blade 3 (blue). As it is preferable to accomplish dynamic balance by removing weights instead of adding weights opposite the point of imbalance, Possibility 2. would seem to afford the solution, because the bolts in these blades already contain weights from ground balancing. However, the removal of 230 g from blade 1 (yellow), is not possible as the blade bolt only contains 100 g. Thus, possibility 4 is the correct solution.

BO 105 CHAPTER 106 Page 20

-----------------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 This would call for the following weight distribution between the blades: Og Blade 4 (red) Og Blade 1 (yellow)

100 g

Blade 2 (green)

180 g

- 60 g

120 g

Og

+ 230 g

230 g

Blade 3 (blue)

100 g

However, since the balance of the rotor is not affected by the removal of an equal amount of weight from two opposite blade bolts, and because it is better to remove weight than to add it, the 100 g installed in the bolt in blade No. 1 (yellow) are removed and, accordingly, 230 g less 100 g are added to the bolt in blade No. 3 (blue) . This results in the following actual distribution of weights on the blades: Blade 4 (red)

Og

Og

Blade 1 (yellow)

100 g

- 100 g

Og

Blade 2 (green)

180 g

60 g

120 g

Blade 3 (blue)

230 g

- 100 g

130g

This weight distribution also meets the requirement that weights shall not be added to more than two blade bolts. Step 9:

In the "HOVER FLIGRT" data section of the Balance Chart, enter -100 against "Blade No. 1", -60 against "Blade No. 2", and +130 against "Blade No. 3".

Step 10: Repeat balance check of rotor system inhover flight. The "IPS" reading is now 0.05 at between 6:00 and 8:00 O'clock. Record these readings in Balance Chart, under "2nd Rover Flight", thenplot them on the clock section and label the point of intersection "4". Since the "IPS" does not exceed the max. permissible value of 0.05 for hover flight, the rotor system is sufficiently balanced.

BO 105 CHAPTER 106 Page 21/22

N

o

~ I BALANCE CHART

-

1st

GROUNDRUN 2nd 3rd

4th

5th

R Cloc" ""lile E A "IPS" D r-r¡ 1-'. l.Q ~

H

ro 1-'

O Cl"I

I 1-' N

sr. Balancer/Phazor for Rotor RPM 424

\ M

1\

1\

1\

1

'act bllde ls fonnrd

anetlc plcl
(;1

BlADE NO" 1 ud I

O

I yellowl

V

BLADE NO.2 19reenl BLAOE No.3 I bluel

~ H

12

en iftlerrupler ÍI over

Z

t-3

t'l Z

" (red)

BlADE N01

E

Date:

Serial Number :

(TARGET BLADE) ,

~~ t'lo:l

3(bIue)

~~ ;J::>(")

t-'O

o:l

'"I:l

PJ 1-' PJ ;:l

O

1st

(1)

HOVER FLlGHT 2nd 3rd

~~ o:l:;tl 4th

en

5 th

:::r

E

RI CIodt A,.le

t:J:l O

rt"

~I

0'1

(")

PJ H

M

1-' O

"IPS"

BlADE NO." I red I BlADE N01

O V (")

'"I:l:.x:: PJ ;J::> l.Q'"I:l (1)

t-3

t'lo:l N:;tlO W ....... 1-' 1-' NaO .:::. Cl"I (J1

E

I

I yellow I

BLADE N02

I green I

BLADE NO. 3 I blue I

oI

.1I

.2 I

.3 I

.4 I

••5 IPS-ScaJe

G:--H:

... .....

MAINTENANCE MANUAL 80 i05

EUROCOPTER

100419

with cap screw

with inner bolt

* * * * * *

* * * * * * * *

100419.1

with inner bolt and bonding jumper Figure 106-13 j.

Trim chamber - blade bolts

Balance rotor system as follows: Using Gram Scale 47, weigh out the required weights and add them to or remove them from toe trim chamber of the blade bolt. 1)

For trim chambers with cap screw (fig. 106-13): tighten cap screw to specified torque.

2)

For trim chambers with inner bolt (fig. 106-13): specified torque and secure with split pino

Revision 10

tighte~

nut to

BO 105 CHAPTER 106 Page 25

* * *

MAINTENANCE MANUAL BO 105

EUROCOPTER

k.

Measure rotor balance during ground run at 100% rotor RPM. Record and plot "Clock Angle" and "IPS" on the Balance Chart and label the point of intersection "2". NOTE

l.

If point "2" is nearer to the center of the clock face on the Balance Chart than point ¡'1" from the previous ground run, but has a different "Clock Angle" to point "1", the clock must be corrected using the Clock Angle Corrector No. 3597.

1)

Place eyelet A of the "Clock Angle corrector" over point "1" and turn corrector body so that the A-O line passes through the center of the clock face of the Balance Chart.

2)

Rotate pointer of the Clock Angle Corrector so that the A-B line passes through point "2".

3)

The position of the pointer on the scale indicates the number of hours to be added to or substracted froro the "Clock Angles" around the clock face.

4)

Renumber the "Clock Angles" as required.

Continue balancing until "IPS" does not exceed 0.4.

3. Balancing in hover flight

NOTE

o The difference between the "IPS" measured at ground run and that measured after final balancing in hover flight must not exceed 0.5 IPS. o To determine the weight changes required for balancing the rotor in hover fJight, use the H weight axes of the graph on tne clock face.

a.

Determine and correct balance in hover flight in accordance with step 2. Max. permissible "IPS" in hover flight is 0.05.

b.

Check balance during ground run in dccordance with steps 2.a. thru h. 1)

Record "Clock Angle" and "IPS" in GROUND RUN data section of Balance Chart and plot the intersecting point of these values on the clock section.

2)

Measure the distance from this point of imbalance to the last point of imbalance plotted during hover balancing of the rotor system, and compare this length against the "IPS" scale on the bottomof the Balance Chart. Jf the measured length exceeds the total (0.5 "IPS") length of the scale, repeat ground-run balancing of the rotor system according to steps 2. i. thru j. ¡ .

BO 105 CHAPTF.R 106 Page 26

Revision 10

MAINTENANCE MANUAL BO 105

EUROCOPTER

c.

Check balance in hover flight if rotor systern has been rebalanced on ground. If necessary, continue to correct balance in hover flight until the "IPS" does not exceed 0.05 and the distance between the final ground run and hover flight plotted points does not exceed 0.5 rneasured along the "IPS" scale.

4. Rernoval - Vibrex systern a.

Rernove blade tip reflectors (type 1 blades) or reflectors on the underside of blades (type 2 blades) .

b.

Disconnect electrical cables.

c.

Rernove accelerorneter bracket frorn rocker support and re-install previously ornitted washer. Torque nut to 7 Nrn and secure with split pino

d.

Rernove rnagnetic pickup. NOTE

Magnetic pickup bracket 6044 rnay be left perrnanently installed on the swashplate.

If required, rernove rnagnetic pickup bracket and re-install previously ornitted washers under nuts (3, fig. 106-1). Tighten nuts to specified torque. e.

Check locking devices of rotating pitch links and blade bolt trirn chambers.

Revision 10

BO 105 CHAPTER 106 Page 27/28

* * * *

EUROCOPTER

106 - 3

MAINTENANCE MANUAL 80 10S

TRACKING Of MAIN ROTOR SYSTEM (USING TRACKING KIT 80105 L1 OR 80105 L2)

WARNING

• CONSIDERABLE CHANGES IN BLADE TRACK AFTER A FEW FLlGHT HOURS OR TRACKING PROBLEMS WHICH CANNOT BE CORRECTED MAY BE AN INDICATION OF LATENT, AND POSSIBLY SERIOUS, TECHNICAL DEFECTS, WHICH CAN POSSIBLY RESULT IN FAILURE OF THE MAIN ROTOR SYSTEM. • IF IRREGULARITIES OR UNKNOWN PROBLEMS OCCUR DURING BLADE TRACKING, CONSULT THE ECD CUSTOMER SERVICE PRIOR TO NEXT FLlGHT.

NOTE

Attaching hardware and reflectors differ between type 1 and type 2main rotor blades (type 1 and type 2 blades are more precisely defined in chapter 14).

1. Necessary test equipment arid special tools: Tracking kit B0105 L1 (refer to fig. 106-14)

Tracking kit B0105 L2 (refer to fig. 106-15)

Nomenclature

P/N

Nomenclature

P/N

Adjusting device

105-13101W3

Adjusting device

105-13101 W3

Reflectors (1)

105-L1-040

&

105-L1-o40

&:. Tracking reflector

1120-15115 8503

.&

Magnetic pickup (3)

105-L1-o30

Magnetic pickup (3)

105-L2-500

Accelerometer (18)

105-L1-o50

Accelerometer (13)

105-L1-o50

Stroboscopic lamp (8)

135M-9

Stroboscopic lamp (5)

135M-11

Distributor (10)

105-L1-o1 O

Distributor (8)

105-L2-400

Cable (4)

105-L1-o9q

Cable (4)

105-L2-100

Trim tab bending tool

105-15103 W2

Trim tab bending tool

105-15103 W2

&

. bracket (20) with reflector

& .&

.",

:

Reflectors (1) Tracking reflector bracket (14) with reflector

1120-15115 8503

For type 1 main rotor blades For type 2 main rotor blades

Table 106-2

Revision 17

CHAPTER 106 Page 29

MAINTENANCE MANUAL BO 105

EUROCOPTER

19

4

16

15

20

14

18

5 13

o .... 12

O DETAlL

DETAlL

6

A

(é}

B

.~-

..

7

11

* * *

1 2 3

4 5

6

* * * *

7 8

9 10

Reflector Soft-iron wiper Magnetic pickup Cable Stroboscope control unit Knob (On/Off) Knob (adjuster) Stroboscopic lamp Plug 2VEG Distributor

Figure 106-14 BO 105 CHAPTER 106 Page 30

11 12 13

14 15 16 17 18 19 20

Strobex case Control light Fuses Control panel Gain control Knob (Phase adjuster) Main rotor blade, type 1 Accelerometer Main rotor blade, type 2 Tracking reflector bracket

Tracking kit BO 105 11 - tracking setup and connections

Revisio~

10

MAINTENANCE MANUAL 80 105

EUROCOPTER

11

2 3

. 13

10

9

DETAlL

A

4

12

15

5

14

8

6

100244.2

7

1 2 3 4 5 6 7

Reflector Soft-iron wiper Magnetic pickup Cable Stroboscopic lamp Trigger Plug 2VEG

Figure 106-15

Revision 10

8 9 10 11 12 13 14 15

Distributor Knob (adjuster) Knob (On/Off) Stroboscope control unit Main rotor blade, type 1 Accelerometer Tracking reflector bracket Main rotor blade, type 2

Tracking kit BO 105 12 - tracking setup and connections BO 105 CHAPTER 106 Page 31

* * * * * * *

MAINTENANCE MANUAL BO 105

EUROCOPTER

2.

Preparatory work a.

Inslallation - magnetic pickup (see fig. 106-16) NOTE

Perform procedural steps 1) thru 3) only in conjunction with swashplate without integral mounting lug for the magnetic pickup.

1)

Loosen clamp on bearing ring and slide back upper boot.

2)

Install magnetic pickup bracket (2) on girobal ring (1) and secure with nut (7). Ornit the washernormally installed under the nut.

3)

Install boot on bearing ring, using clamp; torque clamp screw to 0.5 Nm and secure with sealing, locking and securing compound (CM 624). Additionally apply sealing, locking and securing compound (CM 623) to thread and head of screw.

4)

Rotate main rotor by hand until soft-iron wiper (4) aligns with the hole for the magnetic pickup (3).

5)

Install magnetic pickup (6) in hole (3) of bracket (2), using nuts and washers (5). Make sure that there is a gap of at least 1.5 mm between the soft-iron wiper (4) and the magnetic pickup (6) •

6)

Check swashplate for freedom of movement with cyclic stick pushed to full forward RH position, as in this position there is nlinimum clearance between bracket (2) and the rotating pitch links on the bearing ring of the swashplate.

7)

Lockwire nuts (5) to one another.

BO 105 CHAPTER 106 Page 32

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

,.u-~d"--- 2

'----- 3

,7

~

100418.A

Figure 106-16

1 Gimbal ring 2 Magnetic pickup bracket 3 Mounting lug for magnetic pickup 4 Soft-iron wiper 5 Nuts, washers 6 Magnetic pickup 7 Nut Installation - magnetic pickup

BO 105 106 Page 33

CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO lOS b.

Install accelerometer (refer to fig. 106-17). 1)

Position spacers (4) on tapped holes (S) in flange (6) of support tube of main transmission.

2)

Position accelerometer (7) together with support (3) on spacers (4) and install on flange (6), using screws (1) and washers (2).

3)

Lockwire screws (1) to support (3).

I 5-7

Nm

7 ---ll--

100475

Screw Washer Support 4 Spacer

1 2 3

Figure 106-17

BO lOS CHAPTER 106 Page 34

S Tapped hole 6 Flange 7 Accelerometer

Installation - accelerometer

I

MAINTENANCE MANUAL 80 105

EUROCOPTER

c.

Install reflectors

*

11

1)

Install reflectors on type 1 main rotor blades. a)

b)

*

Color code rotor blades in accordance with table 106-3. Each blade must be marked with the same color as its pitch link.

*

Install reflectors (1, fig. 106-14 and 106-15) to the tip ends of the rotor blades. Blades must be fitted with same color reflectors.

*

o The main rotor blade with yellow color code serves as the reference blade (blade no. 1).

* *

NOTE

*

*

o The rotating pitch link of the reference blade (blade no. 1) must not be adjusted, otherwise the autorational RPM will be altered. Blade sequence during track check Blade No.

3

2

1

4

Color code rotating pitch links

blue

green

yellow

red

Color code rotor blades

blue

green

yellow

red

Color code reflectors

white (blue)

green

yellow

red

* * *

Table 106-3 2)

Install reflectors on type 2 main rotor blades

*

Secure tracking reflector bracket (2, fig. 106-6A) to threaded insert (R = 4375) on underside of blade, using screw (4) and washer (3). The color of the reflector must match the color of the rotor blade (see Table 106-1A). The dowel pin (1) on the tracking reflector bracket must engage in the hole adjacent to the threaded inserto Secure screw to tracking reflector bracket, using lockwire (6). NOTE

Revision 10

The main rotor blade with yellow color code serves as the reference blade (blade no. 1). The rotating pitch link of the reference blade must not be adjusted.

BO 105 CHAPTER 106 Page 35

* * * *

* * *

* * * * *

EUROCOPTER

MAINTENANCE MANUAL BO 105

* NOTE Soiled or worn reflectors (5) are difficult to distinguish * and therefore should be replaced with new ones. To obtain * the strongest possible adhesion of the self-adhesive * reflectors, it is necessary to clean thoroughly the * depressed bonding surface on the tracking reflector * bracket prior to bonding. Take care to use reflectors with * same color blades. * * * * * \ ............ * DETAlL A * * * * * * * 5 * 100414 2 * * 1 Dowel pin 5 Reflector * 2 Tracking reflector bracket 6 Lockwire * 3 Washer 7 Main rotor blade, type 2 * 4 Screw * Figure 106-17A * * * The following table shows the combinations of blade numbeí, blade color and * reflector color in the order in which they can be observed whenlooking in * the direction of flight. * * Blade no. 2 3 1 4 * * Color of blade blue green ye110w red * * Color of reflector blue green ye110w red * * * Table 10 6- 3J1. * * d.

Connect test equipment as fo11o\'IS (refer to figs. 106-14 and 106-15). 1)

Connect cable (4) to magnetic pickup (3) and secure connector with lockwire.

2)

Using adhesive tape, attach cable (4) to main transmission so that it can follow the swashplate movements without being tensioned.

3)

Route cable (4) and accelerometer cable (18, fig. 106-14 or 13, fig. 106-15) down the RH side of the helicopter and through sliding door into the cabin, and secure with adhesive tape.

BO 105 CHAPTER 106 Page 36

Revision 10

MAINTENANCE MANUAL BO 105

EUROCOPTER

4)

Connect other equipment as shown in figure 106-14 or figure 106-15, according to the tracking kit being used.

5)

Connect plug (9, fig. 106-14 or 7, fig. 106-15) to power receptacle 2VEG on instrument panel 2VE. NOTE

o The 2VEG power receptacle can be powered from an EPU on all helicopters. If an EPU is not available, the 2VEG receptacle can be powered by single or dual generator operation on helicopters S/N 7 thru 80, or by dual generator operation only on helicopters S/N 81 and subsequent (refer to chapter 92). o Single-engine operation on helicopters S/N 7 thru 80 does not guarantee that a rotor rpm of 100% will be obtained. This requires slightly reduced settings on the strobex.

e.

Set the strobescope 1)

Connect EPU and switch on power (refer to chapter 92).

2)

Turn knob (7, fig. 106-14 or 9, fig. 106-15) on the stroboscope control unit (5, fig. 106-14 or 11, fig. 106-15) to set the oscillator flash rate specified in table 106-4 for the applicable tracking kit. Tracking kit

Oscillator flash rate

BO 105 L1 (fig. 106-14)

354 (5, fig. 106-18)

BO 105 L2 (fig. 106-15)

674 í1, fig. ,106-10) Table 106-4

3)

Revision 10

Check stroboscope for correct functioning as follows: a)

Depress trigger (6, fig. 106-15) on pistol grip and turn rnain rotor by hand until the soft-iron wiper (2) aligns with the rnagnetic pickup (3). At this point the stroboscopic lamp must light up.

b)

Set knob (6, fig. 106-14 or 10, fig. 106~15) to "ON". The stroboscopic lamp is now operational.

BO 105 CHAPTER 106 Page 36A/B

MAINTENANCE MANUAL 80 105

f;UROCOPTER

Perform the following procedural steps c. dnd d. only if using tracking kit BO 105 L1.

NOTE c)

If the stroboscopic 1amp (8, Hg. 106-14) does not light up when being tested, make the following adjustments.

- Start engines and set rotor RPM to approx. 99% or 100%. - Set gain

control (15) to "O" position using a screwdriver.

- Depress trigger on lamp pistol grip and turn gain control (15) clockwise with a screwdriver until the lamp flashes steadily. Then advance gain control approximately 20° further.

3.

d)

If the lamp still does not operate properly, check lamp connection to magnetic pickup (3).

e)

Disconnect EPU (refer to chapter 92).

Tracking on ground a.

Start engines and set rotor RPM to approx. 99% or 100%.

b.

Aim stroboscopic lamp at the blade tip path in direction of flight and scan path with light beam until a blade tip reflector (type 1 blade) or a reflector on the blade underside (type 2 blade) is seen (see fig. 106-18) . NOTE

* * *

Perform the following procedural steps c. and d. only if using tracking kit BO 105 L1.

c.

Turn knob (16, fig. 106-14) on the control panel (14) until reflector image caught in the beam is visible forward as a spot.

* *

d.

Activate oscillator, using knob (4, fig. 106-18) on the stroboscopic lamp (3), then sight the reflectors as shown is fig. 106-18 and turn knob (10) until the reflector images are spread out. The oscillator flash rate setting (5) must not change in the process. Plot track deviation of the blades in relation to the yellow blade in the Tracking Record (fig. 106-20) as shown in fig. 106-19.

* *

Revision 10

BO 105 CHAPTER 106 Page 37

"*

EUROCOPTER

MAINTENANCE MANUAL 80 105 Tracking kit BO 105 L1

Trackingkit BO 105 L2 -....--2

01----+--4

3--+

01---1--1--

4

IllUl.UII-J--..-+--13S4~ 5

10---'

10

* 100247 * EFFECTIVITY Main rotor blade, type 1 *

100290.2

* * EFFECTIVITY Main rotor blade, type 2 * *

*

* * * * * *

* *

* * * *

*

100290.3

l Oscillator flash rate 2 Stroboscopic lamp (BO 105 L2) 3 Stroboscopic lamp (BO 105 L1) 4 Knob/gain control 5 Oscillator flash rate

*

Figure 106-18

6 Stroboscopic lamp Light beam 8 Reflector (type 1 blade) 9 Line of vis ion 10 Knob/oscillator flash rate 11 Reflector (type 2 blade) 7

Tracking on ground

80 105

CHAPTER 106 Page 38

Revision 10

MAINTENANCE MANUAL 80 105

EUROCOPTER

Perform the following procedural steps e. and f. only if using tracking kit BO 105 L2.

NOTE

e.

Activate oscillator, using knob (4, fig. 106-18) on the stroboscopic lamp (2), then sight the reflectors as shown in fig. 106-18, and turn knob (10) until the reflectors are spread out. The flash rate setting (1) must not change by more than 15 units. NOTE

o Plot reference blade (blade no. 1) on the zero line of the Tracking Record. o The diameter of a reflector is equivalent to approx. 5 mm of track deviation.

f.

Plot track deviation of individual blades relative to reference blade (blade no. 1) on the Tracking Record (fig. 106-20) as shown in (fig. 106-19). Plot reference blade on zero lineo

TRACKING RECORD

~ó

3rd

HORIZONTAL FLlGHT

HOVER FLlGHT

GROUNDRUN 2nd

1st

.z

4th

1st

3 rd

4th

3 21 4 3 2 1 432 1 432 1 4

1st

3rd

2nd

3214321432143214

MM 3Dt;;-!~±~::±:±::E:t::=Ii=~=a::::b

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o

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Send'''I0f trim tabt in millimeten

N 1

°H---+----+---+--+---+---+---+---J----rlI---t---t----1 E 4 1L lR 1

200138.1

Figure 106-19

Revision 10

* * *

Tracking record including sample tracking check and adjustment data

BO 105 CHAPTER 106 Page 39/40

* * *

..... o g

u.J

~

Set Strobex Moda switch: B

TRACKING RECORD

;.

R.P.M. Dial: 678

GROUND RUN

1st

2nd

3 rd

HOVER FLlGHT

4 th

1st

2 nd

HORIZONTAL FLlGHT

4th

3 rd

1 st

2nd

4th

3rd

w

oo(

•

..JO

'TI

3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4

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-

tn

".

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 g.

If the track spread between the highest blade and lowest blade exceeds 10 mm, correct as follows. WARNING

h.

WHEN ADJUSTING THE ROTATING PITCH LINKS DO NOT UNSCREW THE ROD ENDS TO THE EXTENT THAT THE RED MARKING RINGS ON THEIR THREADS ARE EXPOSED.

1)

Remove lockwlre from the rotating pitch link of blade requiring correction and back off jamnut. A 360 0 turn clockwise (viewed from above) will lower the blade tip approximately 10 mm. A 360 0 turn counterclockwise (viewed from above) will raise the blade tip approximately 10 mm.

2)

Orient rod ends 45 0 to each other, using adjusting device 105-13101 W3.

3)

Torque jamnuts to 8 Nm and secure with lockwire.

4)

Check pitch links for freedom of movement.

Repeat tracking check. Re-adjust pitch links if track spread exceeds 10 mm. Max. permissible track spread is 10 mm.

i.' Inspect main rotor blades for lead-lag

* * 1) Perform steps b. thru e. (without making entries in the Tracking * Record) . * * 2) By turning the gain control knob (4, fig. 106-18) on the Strobex, * try to achieve a stacking of all the reflectors at a fixed posi* tion in azimuth (see fig. 106-20A). * * 3) If all reflectors cannot superimposed, determine the lead-lag of * the deviant blade (see fig. 106-20A for lead-lag tolerance limits). * * * o IF LEAD-LAG AMOUNTS TO MORE THAN 20 mm OR THERE IS WARNING * REASON FOR DOUBT, CONSULT THE MBB CUSTOMER SERVICE * ABOUT THE AFFECTED BLADE SET BEFORE THE NEXT FLIGHT. * * oLEAD-LAG EXCEEDING 20 mm HAY BE AN INDICATION OF LA* TENT, ANO POSSIBLY SERIOUS, TECHNICAL DEFECTS, WHICH' * COULD RESULT IN THE FAILURE OF THE MAIN ROTOR SYSTEM. * * 4) If lead-lag exceeds 20 mm (approx. width of a thumb), theentire * blade set must be removed from service. This applies also in cases * where it is impossible to determine whether the lead-lag is within * the tolerance limits. * * 5) Consult the MBB customer service before next flight using a blade * set such as described in previous step 4). *

Revision 4

BO 105 CHAPTER 106 Page 43

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * "'Otxl

QJ:J::O

~~t-> 1-30

~ tr=:! U'1 ~::o

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Possible situations after converglng the reflectors

5:

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Examples o, permlsslble track results

Possible situations upon ideal track result

No lead-Iag

I

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-e---e+-e---e-~-- _.~ . ,

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WARNING

o IF LEAO-LAG AMOUNT5 TO MORE THAN 20mm OR THERE 15 REASON FOR DOUBT. CONSULT THE MBB CUSTOMER SERVICE ABOUT THE AFFECTED BLADE SET BEFORE THE NEXT FLIGHT. oLEAD-LAG EXCEEDING 20mm MAY BE AN INDICATION OF LATENT. ANO POSSIBLy SERIOUS. TECHNICAL DEFECT5. WHICH COULO RESULT IN THE FAILURE OF THE MAlN ROTOR SYSTEM.

'"

1-3

txltr=:! txl::o

- - - - - - - - - - - - - . MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 4.

Hover tracking a.

Set rotor RPM to 100%. NOTE·

o Main rotor blade track is also affected by the gross mass. At a given setting, the track spread usually increases with decreasing gross mass. To minimize vibrations it is recommended to perform tracking with minimum gross mass. o The rotating pitch link of the reference blade (yellow color code) shall not be adjusted to correct track, unless necessary. o After completion of hover tracking, track spread occurring during ground run can be ignored.

b.

Check blade track per step 3. (including step 3. i.) and adjust as necessary. NOTE

5.

* *

Max. permissible track spread between the highest blade and lowest blade is 5 mm.

Track blades in forward flight. a.

Proceed in forward flight to approx. 120 KIAS while observing permissible engine torque and exhaust gas temperature, TOT (refer to FLM) . NOTE

o During forward flight tracking, helicopter airspeed can be increased progressively from 80 to approx. 120 KIAS if track spread between highest blade and lowest blade does not exceed 50 mm. If necessary, track spread rnust be corrected beforehand. o Track spreading that occurs with increasing airspeed in forward flight is corrected by bending the blade trim tabs (3, fig. 106-21). The edges of the trim tabs must not be bent beyond the lirnits of graduated scale (2) of tab bending tool (1).

b.

Check blade track per step 3. (including step 3. i.) and adjust as necessary. NOTE

o Bending the edge of a trim tab by 1 mm will cause a change in track of approx. 15 mm at the blade tipo o If a blade has two trim tabs, bend each tab by the same amount. To obtain the required track change, it is sufficient to bend each tab by half of the tab bend required for a one-tab blade.

Revision 4

BO 105 CHAPTER 106 Page 45

* *

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

2 ---.;¡

2----.. 3 -----

100413

Determining the initial position of the trim tab edges

Bending the trim tabs

1 Tab bending tool 105-15103 W2 Scale of tab bending tool Trimtabs

2 3

Figure 106-21 c.

Bending the trim tabs

If the track spread between the highest blade and lowest blade exceeds 5 mm, correct the track of one of those blades as follows: 1)

Position tab bending tool (1, fig. 106-21) on out-of-track blade as shown in fig. 106-21 and read off initial position of tabs against graduated scale (2).

2)

Bend the tabs as required (refer to fig. 106-21). One scale spacing is equivalent to 1.5 mm. Bending trim tabs down will lower the blade tip, bending trim tabs up will raise the blade tipo NOTE

o Do not exceed max. trim tab adjustment (± 5 mm) in relation to chord line of blade. o Recheck track of blades in hover after each trim tab adjustment (refer to step 4.).

d.

Check blade track during horizontal flight, hover flight and ground run at max. permissible speed VNE (refer to FLM) . At VNE, the track spread between the highest blade and lowest blade must not exceed 20 mm. Plot results on Tracking Record (fig. 106-20).

e.

Torque jamnuts on rotating pitch link rod ends to 8 Nm and secure with lockwire. Seal split line of upper rod ends and pitch link tubes with silicone rubber (CM 612).

f.

Balance main rotor system in accordance with para. 106-4.

BO 105 CHAPTER 106 Page 46

Revision 4

EUROCOPTER

106 - 4

MAINTENANCE MANUAL 80 105

BALANCING OF MAIN ROTOR SYSTEM (USING BALANCING KIT B0105 L1 OR B0105 L2)

WARNING

• CONSIDERABLE CHANGES IN BALANCE AFTER A FEW FLlGHT HOURS OR BALANCING PROBLEMS WHICH CANNOT BE CORRECTED MAY BE AN INDICATION OF LATENT, AND POSSIBLY SERIOUS, TECHNICAL DEFECTS, WHICH CAN POSSIBLY RESULT IN FAILURE OF THE MAIN ROTOR SYSTEM. IF NO MORE BALANCE WEIGHTS CAN BE INSERTED INTO THE MAlN BOLT TO ELlMINATE UNBALANCE, THIS MAY ALSO BE AN INDICATION OF A SERIOUS TECHNICAL DEFECT.

• IFIRREGULARITIES OR UNKNOWN PROBLEMS OCCUR DURING BALANCING, CONSULT THE ECD CUSTOMER SERVICE PRIOR 10 NEXT FLlGHT. To achieve proper balancing, the blade track must be within the specified tolerances in para 106-3.

NOTE

1. Necessary test equipment and special tools: Balancing kit B010S L1 (fig. 106-22)

Balancing kit B01 OS L2 (fig. 106-23)

Nomenclature

P/N

Nomenclature

P/N

Accelerometer (2)

105-L1-oS0

Accelerometer (2)

10S-L1-oS0

Magnetic pickup (1)

105-L1-o30

Magnetic pickup (1)

105-L2-S00

Balancer (3)

105-L1-o20

Balancer (3)

105-L1-o20

Cable (9)

105-L1-oaO

Cable (9)

105-L2-oaO

Cable (10)

105-L1-070

Cable (10)

105-L2-1 00

Table 106-4

2. Preparatory work a.

Install magnetic pickup and accelerometer in accordarice with para 106-3, 2.a. und 2.b. If the sandfilter is installed, remove the filter cover near the rotor mast to enable the accelerometer to be installed.

b. Connect test equipment and cables as shown in figures 106-22 and 106-23.

Revision 17

CHAPTER 106 Page 47

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 .

2---+-:=r

3 10----i1

4

9----11

6

~---7

;:¡----8

1 Magnetic pickup 2 Accelerometer 3 Balancer 4 Indicator 5 Toggle switch Figure 106-22

BO 105 CHAPTER 106 Page 48

6 Push button Distributor 8 Plug 2VEG 9 Cable 10 Cable 7

Setup and connection of balancing kit BO 105 L1

- - - - - - - - - - - - - MBB HELICOPTERS - - - - - - " " " " " ' - - - - - - MAINTENANCE MANUAL MBB - BO 105

2---+-rF

3 10----11

9-----11

6

~---7

~~i_--8

1 Magnetic pickup 2 Accelerometer 3 Balancer 4 Indicator 5 Teggle switch Fig. 106-23

6 7 8 9

10

Pushbutton Distributor Plug 2VEG Cable Cable

Setup and connection of balancing kit BO 105 LS2

BO 105 CHAPTER 106 Page 49

HELICOPTERS - - - - - - - - - - - - MAINTENANCEMANUAL MBB - BO 105

-------------MBB

3.

Balancing on ground NOTE

The following procedure is applicable to both tracking kits (BO 105 L1 and BO 105 L2.)

a.

Start engines and set rotor RPM to 100% (refer to FLM) .

b.

Functionally test the balancer by settin~ toggle switch (5) to "Phase" and pressing pushbutton (6). The scale reading on indicator (4) rnust increase or decrease by five units. NOTE

c.

If the phase angle indication is unsteady (at readings of approx. O or 10 units), a stabilized indication can be obtained by pressing pushbutton (6). Subtract 5 units frorn a phase angle reading above 5 units, and add 5 units to a phase angle reading below 5 units.

Check ground run balance as follows: NOTE

1)

BO 105 CHAPTER 106 Page 50

Figure 106-24 only shows a tracking exarnple. For tracking purposes, use a copy of the Balance Data Sheet shown in fig. 106-25 to record and plot balance data. Record the following assurned values in the appropriate colurnns of the data section of the Balance Data Sheet (refer to fig. 106-24) . a)

Line NO.: "G1" (abbreviation for "1st ground run ").

b)

Line SPEED: 100%.

c)

Line AMOUNT: Indicator (4, fig. 106-22 or 106-23) reading with toggle switch set to "AMOUNT", e.g. 7 units.

d)

Line PHASE: Indicator (4) reading with toggle switch set to "PHASE", e.g. 9.2 units.

e)

Line WEIGHT 1: Weight of balance weights in blade bolt prior to weight change, e.g. 93 g.

MAINTENANCE MANUAL BO 105

EUROCOPTER

2)

Plot the assumed PHASE reading of 9.2 units on the Balance Data Sheet by drawing a dotted radial line (refer to fig. 106-24).

3)

Plot the assumed AMOUNT reading of 7 units on the Balance Data Sheet at the point of intersection of the 9.2 PHASE radial line and the 7 A}IDUNT circle (refer to fig. 106-24).

4)

From the point of intersection, draw perpendicular lines to the radial lines representing blades 3 and 4. Values 3.1 and 6.2. are thereby obtained. Convert these values into balance weights. (conversion factor: 1 unit is equivalent to 30 g) Bl3de no. 1: 3.1 x 30 g = 93 g Blade no. 2: 6.2 x 30 g = 186 g NOTE

o Install the previously determined balance weights in the blade bolts of the blades opposite the point of imbalance (i.e. blades 1 and 2) . o Balance weights are allowed in not more than two blade bolts, so find out if blades 3 and 4 contain balance weights. If they do, remove balance weights from these blades in accordance with both previously detennined values.

d.

4.

Repeat balancing on ground until the imbalance reading is less than 5 units.

Balancing in hover NOTE

For this balancing example, assumed balance readings of 4.0 (AMOUHT) and 0.5 (PHASE) are used Ililh the Balance Data Sheet (see fig. 106-24).

a.

Check hover balance in accordance with the procedure for checking ground run balance (refer to step 3.). For this purpose, set toggle switch (5, fig. 106-22 or 106-23) to AMOUNT and press pushbutton (6) to obtain AMOUNT value in hover flight. Read off value on indicator (4) and plot on Balance Data Sheet (see fig. 106-24).

b.

Obtain PHASE value in accordance with the ground run balance procedure (refer to step 3.) and plot on Balance Data Sheet (refer to fig. 106-24).

BO 105 CHAPTER 106 Page 51

MAINTENANCE MANUAL BO 105.

EUROCOPTER

* * * *

c.

Mark point of intersection (point of imbalance) on the balance chart with a delta syrnbol and label it "H1" for 1st hover flight.

d.

Repeat balancing until the imbalance has been reduced to approx. 1. 8-0.8 units.

e.

Measure shortest distance between the points of intersection (point of irnbalance for ground run and hover flight), using the scale of the Balance Data Sheet. Scale:

Distance between two concentric circles equals 1 unit (refer to fig. 106-24).

Nominal value:

Difference in balance between ground run and hover flight must not exceed 5 units.

f.

Shut down engines (refer to FLM).

g.

Remove test equipment.

h.

Remove magnetic pickup (1, fig. 106-22 or 106-23). Reinstall nut (7, fig. 106-16) together with the washer omitted at magnetic pickup installation, and tighten nut to specified torque load.

i.

Remove accelerometer (2,fig. 106-22 or 106-23).

j.

If sand filter is installed, fit filter cover in place at rotor masto

k.

Remove blade tip reflectors (type 1 blade) or reflectors on the underside of the blades (type 2 blades).

l.

Make sure that all locking hardware on control rods and blade bolts is intacto

ffi.

Check for foreign objects.

BO 105 CHAPTER 106 Page 52

Revision 10

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

BALANCE DATA SHEET

I

DATE

¡S/N

~

AMOUNT 1~ 30 GRAM ON BLADE BOLTS eBLADE 2 5

r-+

B LA OE 3

-+-+-+-lf-+-+-~e

ONE UNIT

9,2

o e

MAX. 5 UNITS

READ OFF VALUE

BLADE 4 NO. SPEED AMOUNT PHASE WEIGHT 1

Gl

Hl

100% 100% 4 7 9,2 0.5

• - . 2 3

93 ;

116;

114;

57;

100311

Figure 106-24

Data Balance Sheet containing sample balance data

105 106 Page 53/54

BO CHAPTER

- - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

BALANCE DATA SHEET DATE

S/N

BLADE NO. 1

INSPECTED BY

2

3

4

AMOUNT 1 A 30 GRAM ON BLADE BOLT • BLADE 2

5

• BLADE 3

o

• BLADE 4

NO.

SPEED AMOUNl

PHASE

WEIGHT WEIGHT WEIGHT WEIGHT

1 2 3 4

105.106.1.1

Figure 106-25

Balance Data Sheet BO 105 CHAPTER 106 Page 55/56

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MEB - BO 105

107

BALANC1 NG

OF

TAl L

ROT OR

Table of Contents

Paragraph

Title

Page

107 - 1

STATIC BALANCING WITH MARVEL SUSPENSION BALANCER

107 - 2

STATIC BALANCING WITH BALANCE RIG

18

107 - 3

DYNAMIC BALANCING WITH CHADWICK BALANCER

24

3

BO 105 CHAPTER 107 Page 1/2

-eurocopter

MAINTENANCE MANUAL BO 10S

, . lIII EAOO

CDnpeny

107 - 1

STATIC BALANCING WITH MARVEL SUSPENSION BALANCER

1. General a. Thetail rotor must be statically and dynamically (see para 107-3) balanced, if main components ofthetail rotor, such as blade mounting fork, controllever,laminated strap pack or inner sleeve have been replaced orrepaired or if required by an inspection. Thetail rotor must be statically balanced, iftail rotor blades have been repaired extensively. b.

Iftail rotor blades of configuration I thru IV have been repaced or have not been installed atthe same position again, the tail rotor must be statically balanced. Iftail rotor blades of configuration V have been replaced together of individually, a static balancing of the tail rotor is not necessary.

c.

Minor repairs, such as polishing out corrosion marks or touching up small paint damage, do not require subsequent static balancing of the tail rotor.

d. The MARVEL 7HEL078 suspension balancer is used to statically balance the tail rotors of the following helicopters: 80.105, AII 80 105 helicopter series The balancer is manufactured by THE MARVEL MANUFACTURING COMPANY 204 PASSAIC AVENUE FAIRFIELD, NEW JERSEY 0700G/USA Phone: (201) 227-G090 and can be directly ordered from there, as well as from ECD. 2. Handling

NOTE

The MARVEL suspension balancer is a sensitive instrument comprising precision machined components. Therefore, utmost care should be taken whenever the balancer is used, transported, and maintained. Rough or careless handling ofthe balance indicating arbor, especially handling that would cause the inner parts of the arbor to jo/t against the outer shaft, could be destructive to the arbor and cause erroneous balance indications.

a.

Prior to each use, inspect the suspension balancer as described in step 4.

b.

Perform tail rotor balancing in a room free from air currents and as free from dust as possible.

Revision 24

CHAPTER 107 Page3

MAINTENANCE MANUAL BO 105

c.

After using the balancer, disassemble it in accordance with step 6. and return the components to their proper place in the carrying case, taking particular care to engage the arbor retaining spring.

d. The balance indicating arbor isfilled with dampening oil in orderto provide an accurate balance indication. As the viscosity of the oil is dependent on the temperature, the time can vary for a balance condition to stabilize. In any case, allow time for balance indication to stabilize. e. Ifoil should have leaked out during transport or storage, evidenced by traces ofoil in the carrying case and on the arbor, replenish arbor with oil in accordance with step 7. 3.

Essential equipment and accessory parts a.

MARVEL 7HEL078 suspension balancer comprising the following components (see fig. 107-1): (1) (2) (3) (4) (5) (6) (7) (8)

Balance indicating arbor Back balance weight Anchor ring Rotor hub adapter Locating pins (set of 2) Hex key wrench 1/16 inch Hex key wrench 3/32 inch Kit carrying case assembly

NOTE

b.

P/N 3165 P/N 3262 P/N 3260 P/N 3255 P/N 3172 --------------P/N 3278

Earlier MARVEL 7HEL078 balancing kits included the balance correction gauge P/N 3267. This gauge was used to determine the balance masses for the trim chambers in the tips of the tail rotor blades. However, now that the tail rotor is balanced at the bolts which connect the blades to the blade mounting forks, the balance correction gauge P/N 3267 is no longer required and, therefore, no longer included in the 7HEL078 balancing kit.

Balance masses:

-

Washer, steel

DIN 7349-6.4

(4.6 g)

-

Washer, steel

105-31709.14

(3.9 g)

-

Washer, steel

105-31709.15

(2.4 g)

-

Washer, steel

LN9025-0615L

(0.9 g)

-

Washer, aluminum

LN9025-0615N

(0.3 g)

-

Nut, self-Iocking with split pin

LN9348-06

(2.4 g)

------------

-

Castellated nut with split pin

6

LN9345-06

6

(2.1 g)

------------

Use this washer only to fill the gap between balance washers and castellated nut (Configuration

1, fig. 107-13). CHAPTER 107 Page4

- - - - - - - . , . . . - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

.c:::::>~H---------

5

'--------8

1 2 3 4

Balance indicating arbor Back balance weight Anchor ring Rotor hub adapter

Figure 107-1

5 6 7 8

Locating pins Hex key wrench Hex key wrench Kit carrying case assernbly

Kit carryingcase assernbly

105 107 Page 5

BO CHAPTER

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

4.

Inspection of suspension balancer a.

Inspect suspension balancer for damage and loose parts.

b.

Suspend balance indicating arbor (1, fig. 107-2) from a suitable means of support (e.g. a crane).

c.

Fit back balance weight (2) on the lower end of the arbor and slide it upward to align its upper surface with the ft9ft arbor scale division, then secure in this position with setscrew (6).

1 2 3 4 5 6 7 8

Balance indicating arbor Back balance weight Anchor ring Rotor hub adapter Locating pins Setscrew Setscrew Setscrew

r------"" S +----2

8-------i~

+------4

100501

---------5 Figure 107-2 Marvel suspension balancer assembly

BO 105 CHAPTER

Page 6

107

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 d.

Install anchor ring (3) on the lower end of the arbor and slide it upward to rest against the back balance weight (2). Secure anchor ring with setscrews (7).

e.

Fit rotor hub adapter (4) on lower end of the arbor and push it upward until it abuts. Secure with setscrews (8).

f.

Loosen setscrews (7) and lower anchor ring (3) to seat against the rotor hub adapter (4). Tighten setscrews (7).

g.

Loosen setscrews (6) and lower back balance weight (2) to seat against the anchor ring (3). Tighten setscrews (6).

h.

Insert positioning pins (5) to full extent into the rotor hub adapter.

--

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l:::::=-..~

Figure 107-3

1 2 3

Setscrew Indicator collar Oil seal

Balance indicating arbor BO 105 CHAPTER 107 Page 7

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--!----2 3

Indicator collar Balance indicating arbor 3 Indicator disc

100476

1

2

Figure 107-4 i.

Balance indication of suspension balancer

Loosen setscrews (1, fig. 107-3) in the indicator collar (2) and the oil seal (3). Push indicator collar and oil seal downward against the spring pressure and establish a clearance of 0.05 mm, using a feeler gauge. Tighten setscrews (1). NOTE

After the movements of the balancer have stabilized, the indicator collar (1, fig. 107-4) must be concentric with the black indicator disc (3) in the top surface of the arbor (2).

Check relationship of indicator collar and disco It must be concentric as shown in fig. 107-4.

j.

If the above balance condition is attained, the tail rotor may then be balanced in accordance with the procedure outlined in step 5. Loosen setscrews (1, fig. 107-3) of indicator collar (2) and oil seal (3). The oil seal and indicator collar are forced upward by the spring tension. Tighten setscrews. The balance indicating arbor is now protected against impact damage.

1)

2)

If the above balance condition is not attained, remedy possible arbor malfunction in accordance with step k.

BO 105 CHAPTER 107 Page 8

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k. Troubleshooting - Marvel suspension balancer TROUBLE SYMPTOM

POSSIBLE CAUSE

CORRECTlVE ACTION

l. No reaction from indicating surfaces

Foreign material or friction betwe,en indicator collar and arbor

Wipe indicating surfaces with a clean, lint-free cloth. Reposition indicator collar to provide required clearance between indicator collar and arbor

A resin-like deposit has for.med on the inner surface of the arbor

Drain dampening oil (107-1, step 7.). Flush inner parts with petroleurn or Freon. Refill with new oil (107~1, step 7.) Check for concentricity of indicating surfaces (107-1, step 4.)

2. Indicator collar is not concentric with black indicator disc

A resin-like deposit has for.med on the inner surface of the arbor

Drain dampening oil (107-1, step 7.). Flush inner parts of arbor with petroleurn or Freon. Refill with new oi! (107-1, step 7.) Check for concentricity" of indicating surfaces (107-1, step 4.)

Darnaged balance indicating arbor

Table 107-1

Return arbor to rnanufacturer for repair: THE MARVEL MANUFACTURING COMP ANY 204 PASSAIC AVENUE FAIRFIELD, NEW JERSEY 07006 TEL. (201) 227-6090

Troubleshooting

BO 105 CHAPTER 107 Page 9

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5.

Balancing of tail rotor a.

Preparatory wOrk 1)

Perform inspection of balancer as described in step 4.

2)

Remove locating pins (5, fig. 107-2) from rotor hub adapter.

3)

Remove rotor hub adapter (4) from the arbor (1) by loosening the setscrew (8).

4)

Screw in the threaded pressure ring (2, fig. 107-5) of the rotor hub adapter (1) until it seatsagainst the fork of the adapter.

100503

1 Rotor hub adapter 2 Threaded pressure ring

Figure 107-5

BO 105 CHAPTER

Page 10

107

Rotor hub adapter

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S)

Place tail rotor on suitable support and install rotor hub adapter (4, fig. 107-6) on tail rotor hubo

6)

Turn the blade mountings forks so that the borehole in the inboard shoe of the strap pack assembly is aligned with the borehole in the inner sleeve.

7)

Pin together the tail rotor hub and rotor hub adapter with 10cating pins (2), taking care that the fitted bolts of the control levers (3) rest on the upper surface of the locating pins. 1nsert locating pins to full extent.

8)

Center the tail rotor hub in the rotor hub adapter fork. 1f necessary, determine axial playwith feeler gauge and remove play equally at both ends to achieve symmetrical installation. Fix hub and fork in their relative positions by screwing the threaded pressure ring (1) downward to seat against the tail rotor hubo

3

2

4

~

\ 1

2

1 Threaded pressure ring 2 Locating pin Figure 107-6

3

3 Control lever 4 Rotor hub adapter

Assembled tail rotor and rotor hub adapter

BO 105 CHAPTER 107

Page 11

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9)

Install assembled rotor hub adapter and tail rotor hub to full depth on the lower end of the arbor and tighten setscrew (8, fig. 107-2).

10)

Loosen setscrews in the back balance weight (1, fig. 107-7) and position back balance weight so that its upper surface aligns with the ft9 4/16 inch ft position on the arbor scale. Retighten setscrews.

'--------2 3

3

1 Back balance weight 2 Anchor ring 3 Blade mounting bolts with balance bolts Figure 107-7 Assembled tail rotor and balancer BO

105

CHAPTBR 107

Page 12

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b.

11)

Loosen setscrew in anchor ring (2, fig. 107-7) and slide anchor ring upwards to seat against the back balance weight. Retighten setscrew.

12)

Loosen setscrews (1, figure 107-3) of indicator collar (2) and oil seal (3). Press indicator collar and oil seal down against the spring pressure, and establish a clearance of 0.05 mm using feeler gauge. Tighten setscrews (1).

Balancing NOTE

o To perform tail rotor balancing, both blade mounting bolts are fitted with balance bolts (3, fig. 107-7) that have provisions for adding balance masses as required. o The balance bolts may be either fully or partially threaded. Self-locking nuts, LN9348-06, are installed on fully threaded bolts and castellated nuts LN9345-06 on partially threaded ones (see fig. 107-13). When using partially threaded balance bolts, select an appropriate combination of balance washers whose combined thickness enables proper clamp-up by the castellated nut and safetying of the latter with a split pino Should the total mass of the combined balance washers assembled on the balance bolt exceed the actual mass required for balancing the tail rotor, the surplus mass must be compensated for by also adding an equal mass to the balance bolt located diagonally opposite. On fully threaded balance bolts the balance washers need not be combined to bridge any unthreaded portion of bolt shank.

1)

Install the appropriate nut on all four balance bolts, and insert the split pino

2)

Check balance condition of tail rotor. Wait for balancer to provide a stabilized balance indication. The tail rotor is sufficiently balanced if the rim of the indicator collar is within the area of the black indicator disc as shown in fig. 107-8 (residual unbalance is equal to or less than 0.08 Ncm).

BO 105 CHAPTER 107 Page 13

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100476.1

Maximum permissible out of ba- . lance. Rim of indicator collar aligns with edge of black indicator disc Figure 107-8

Perfect balance. Rim of indicator collar is concentric with the black indicator disc

Balance condition of tail rotor

3)

If the rim of the indicator collar is within the black indicator disc, disassemble tail rotor head and balancer as described in step 6.

4)

If the rim of the indicator collar overlaps the edge of the black indicator disc (out of balance exceeds 0.08 Ncm, fig. 107-9), perfor.m tail rotor balancing as described in step 5).

Max permissible out of balance exceeded. Indicator collar overlaps edge of black indicator disco 100476.2

Figure 107-9 BO 105 CHAPTER

Page 14

107

Balance condition of tail rotor

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NOTE

O

The tail rotor is balanced by adding balance masses to those balance bolts which are located opposite the exposed area of the black indicator disco

o Egual balance masses on diagonally opposing balance bolts have no effect on tail rotor balance because they counterbalance each other. Accordingly equal balance masses can be removed from diagonally opposite balance bolts without changing the tail rotor's balance condition. This al so means that egual balance masses can be added to diagonally opposite partially threaded balance bolts to obtain proper clamp-up by the nut, without changing the balance condition. As a rule, however, the balance mass should be kept to a minimum.

5)

Balance the 'tail rotor with the balance masses specified in para 107-3, by installing the balance masses on the appropriate balance bolts, and then observing the relative position of the indicating surfaces. The rim of the indicator collar must be within the edge limits of the black indicator disc (residual out-of-balance is equal to or less than 0.08 Ncm).

6)

Disassemble tail rotor and balancer as described in step 6.

7)

Clamp up the balance mas ses on the blade retaining bolts with the nuts and torque nuts to 4 Nm. Safety nuts with split pins.

BO 1105 CHAPTER 107 Page 15

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6.

Disassembly of suspension balancer a.

Engage arbor retaining spring by releasing the setscrews (1, fig. 107-3) to allow indicator collar (2) and oil seal (3) to slide upward. Secure setscrews (1) by tightening them slightly.

b.

Remove assembled rotor hub adapter (4, fig. 107-2) and rotor head from arbor (1) by loosening setscrew (8).

c.

Detach tail rotor from the rotor hub adapter (4, fig. 107-6) by screwing back the threaded pressure ring (1) and removing the locating pins (2) .from the rotor hub adapter. Place tail rotor on a suitable surface.

d.

Disassemble suspension balancer and place individual parts in the carrying case.

105 CHAPTER 107 Page 16

BO

MAINTENANCE MANUAL 80 105 7. Maintenance

NOTE

• Maintenance of the suspension balancer is limited to changing the dampening oil and flushing the balance indicating arbor. This work should be performed at half-year intervals. • The oil change can be performed faster if the balance indicating arbor is heated to approx. 50 oC, using a hot-air gun or similar.

a.

Remove setscrews (1 , fig. 107-10) and drain dampening oil.

b. Clean balance indicating arbor by immersing it in petroleum or Freon for approx. 1/2 hour. Then flush arbor interior by squirting solvent from a wash bottle into the lower borehole until it flows out of the upper borehole. Repeat this procedure approx. 10 times. c.

Using wash bottle, fill arbor reservoir with dampening oil (mineral oil SAE40) through lower borehole until oil flows out of the upper borehole. Install and tighten both setscrews (1).

d.

Remove residual oil from balance indicating arbor, indicator collar and black indicator disc with a clean, lint-free cloth.

e.

Inspect suspension balancer in accordance with step 4.

2

(

1"

"''''i'\!i''''''i''''''\'íf" 'g¡'

J..~"",,~.. ~

1

1 Setsrew 2 Banlance inidcating arbor

Figure 107-10

Balance indicating arbor

CHAPTER 107 Page 17

MAINTENANCE MANUAL 80 105

107 - 2

STATIC BALANCING WITH BALANCE RIG

1. General a. Thetail rotor must be statically and dynamically (see para 107-3) balanced, ifmain components ofthetail rotor, such as blade mounting fork, controllever,laminated strap pack or inner sleeve have been replaced or repaired or if required byan inspection. Thetail rotor must be statically balanced, iftail rotor blades have been repaired extensively. b.

Iftail rotor blades of configuration Ithru IV have been repaced or have not been installed atthe same position again, the tail rotor must be statically balanced. If tail rotor blades of configuration V have been replaced together of individually, a static balancing of the tail rotor is not necessary.

c.

Minor repairs, such as polishing out corrosion marks or touching up small paint damage, do not require subsequent static balancing of the tail rotor.

2. Balancing the tail rotor Special tools:

a.

Balance rig Balance tool Eccentric disks

105-31702 W7 105-31702 W3 105-31702 W18

Installation oftail rotor in balance rig (seefig. 107-11). 1) Set up and level balance rig in a draught-free room. Check rollers for smooth and easy operation and lubricate with Iight oil, if necessary.

2) Obtain dimension "A" of balance tool (dimension is indicated on balance tool). See fig. 107-11. 3) Obtain dimension "B" across outer faces of bushings in inner sleeve. See fig. 107-11. 4) To compensate for difference between dimensions "A" and "B", select 2 shims of equal thickness so that the fcillowing requirement is meto Dimension "B" must be at least 0.01 mm greater than dimension "A". For available shim thicknesses see to fig. 107-11.

5) Install assembled tail rotor head and blades in balance rig as shoWn in fig. 107-11. a) Remove setscrews (5) b) Remove cover plate (4) and install tail rotor head together with previously selected shims (7) installed one on each side. c) Re-install cover plate (4) and secure with screws. d) Tighten setscrews (5). e) Position and tighten eccentric disks (3) on fitted bolt of each bellcrank and secure with nuts.

CHAPTER 107 Page 18

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MAINTENANCE MANUAL MeB - BO 105

4

5

TABLE OF AVAl LABLE SHlMS (two of each) mm 0.975 1.000 1.025 1.050 1.075 1.100

B---t 33111.1

1 2 3 4 5 6 7 8 9 10

Balance washers Inner sleeve Eccentric disk (105-31702 W18) Cover plate Setscrew Bolt Shim Blade mounting fork Balance rig Bushing

Figure 107-11

Installation of the tail rotor head in the balance rig 80 105 CHAPTER 107 Page 19/20

1.125 1.150 1.175 1.200 1.225 1.250

1.275 1.300 1.325 1.350 1.375 1.400

----.;.....---------MBB HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 b.

Balancing the tail rotor 1)

Position tail rotor on balance rig and set tail rotor blades perpendicular to the rotational axis (zero position of flapping angle). The tail rotor blade must be equidistant from each side of the blade rig.

2)

Rotate tail rotor to horizontal position and check if this position is maintained. NOTE

3)

When the balance washers have been added, install nut as well and insert the split pino

If the horizontal position of the tail rotor is not maintained, add balance washers to one of the two blade retaining bolts of the lighter,upward moving blade (for balance washer weights refer to figure 107-12) or remove balance weights from one of the two blade retaining bolts of the heavier, downward moving blade, until the tail rotor remains horizontal.

, direction of rotation

fwd blade retaining bolt aft blade retaining bolt

fwd blade retaining bolt aft blade retaining bolt

33113

Figure 107-12

Balance washer locations

BO 105 CHAPTER 107 Page 21

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Rotate tail rotor to vertical position and check if this position is maintained. If the ftupperft blade moves backwards, make one of the following balance adjustments: NOTE

When the balance washers have been added, install nut as well and insert the split pino

a)

Remove balance weights from aft blade retaining bolt of ftupperft blade (see figure 107-12) and add to fwd blade retaining bolt.

b)

Add identical weights to fwd blade retaining bolt of ftupperft blade and aft blade retaining bolt of ftlowerft blade.

c)

Remove identical weights from aft blade retaining bolt of ftupperft blade and fwd blade retaining bolt of ftlowerft blade.

If ftupperft blade moves forwards, proceed aecording to substeps a) thru e) except perform 'remove' instead of 'add' and vice versa. Continue balance correction (adding and removing balance washers) until the tail rotor maintains a vertical position. Take care to aehieve optimum balaneing by using a minimum of balance weights. 5)

Turn tail rotor thru 180 0 and check whether it remains vertical. If necessary, add or remove weights in accordance with step 4).

6)

Re-check tail rotor balance in horizontal and vertical positions and perform steps 3) and 4), as necessary.

7)·

If configuration 1 is installed, use balance washers fig. 107-13) to fill the gap between the final position of the eastellated nut and the balance washers. Torque nut and secure with split pin (refer to fig. 107-13). Take care to add the same mass of this type of washer to the diagonally opposite blade retaining bolt in order to preelude a renewed out-of-balance condition.

6 ,

If eonfiguration 11 is installed, torque stop nut and install split pin in the hole in the end of the stud (see fig. 107-13).

BO 105 CHAPTER 107 Page 22

MAINTENANCE MANUAL BO 105

Configuration 11

Configuration I

Balance washers

Split pin

Balance masses: - Washer, steel

DIN 7349-6.4

(4.6 g)

- Washer, steel

105-31709.14

(3.9 g)

- Washer, steel

105-31709.15

(2.4 g)

- Washer, steel

LN9025-0615L (0.9 g)

- Washer, aluminum

LN9025-0615N (0.3 9)6 LN9348-06 (2.4 g)

- Nut, self-Iocking with split pin - Castellated nut with split pin

6

LN9345-0G (2.1 g)

Use this washer only to fill the gap between balance washers and castellated nut (Configuration 1)

Figure 107-13 Revision 12

Stacking of balance washers and masses CHAPTER 107 Page 23

MAINTENANCE MANUAL 80105

107 - 3

DVNAMIC BALANCING WITH CHADWICK BALANCER The tail rotor must be statically and dynamically (see para 107-3) balanced, if main components of the tail rotor, such as blade mounting fork, controllever, laminated strap pack or inner sleeve have been replaced or repaired or if required byan inspection. The tail rotor must be statically balanced, if tail rotor blades have been repaired extensively.

NOTE

If tail rotor blades of configuration I thru IV have been repaced or have not been installed at the same position again, the tail rotor must be statically balanced. If tail rotor blades of configuration V have been replaced together of individually, a static balancing of the tail rotor is not necessary. . Minor repairs, such as polishing out corrosion marks or touching up small paint damage, do not require subsequent static balancing of the tail rotor. 1. Necessary equipment and accessory parts. a.

Pedal positioner MBB 105-31702W25 orsteel measuringtape, approx. 300 mm long (commercial item).

b. Chadwick-Helmuth 'VibrexTrack and Balancesystem BO 105, Model No. 6042" with the following component parts: Quantity

Description

1

Balancer/Phazor Strobex Blade Tracker Gram Scale Accelerometer Accelerometer Bracket Accelerometer Cable Reflective Target Patches Circuit Protection Module D.C. Extension Cable Tail Rotor Balance Chart Clock Angle Connector Balancer and Strobex Manual

1 1 1 1 1 1 Set

1 1 Block 1

1

Mod. No. 177M-6C 135M-11 47 4177B

6411 4296-2 4270 6045 3529 63476 3597

6 or local fabrication (see figure 107-21 for original). c.

Balance masses

A: B: C:

D: E: F:

F:

Washer, steel Washer, steel Washer, steel Washer, steel Washer, aluminum Nut, self-Iocking with split pin Castellated nut with split pin

DIN 7349-6.4 105-31709.14 105-31709.15 LN9025-0615L LN9025-0615N LN9348-06 ------------LN9345-06 -------------

(4.6 (3.9 (2.4 (0.9 (0,3

g)

g) g) g) g) 6

(2.4 g) (2.1 g)

Letters A, B, C, D, E and F refer to the masses listed in the "Tail Rotor Charl". 6 Use this washer only to fill the gap between balance washers and castellated nut (Configuration 1, fig.107-13).

CHAPTER 107 Page 24

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NOTE

The Chadwick-Helmuth "Vibrex Track and Balance System BO 105" Mod. 6042, may be purchased from MBB or directly from the manufacturer or one of its representatives. Addresses:

Chadwick-Helmuth Co., Inc. 4601 North Arden Drive El Monte, California 91731 USA Tel: (213) 575-'6161 Telex: 194-271 Messerschmitt - Bolkow - Blohm GmbH Kundendienst, Hubschrauber Postfach 80 11 40 8000 Munich 80 West Germany

2.

Preparatory Work. NOTE

Prior to dynamic balancing, the tail rotor must be statically balanced and properly installed, and the pendulum absorbers correctly adjusted.

a.

Direct nose or tail of helicopter to the wind.

b.

Screw accelerometer p/N 4177B (1, figure 107-14) into accelerometer bracket (2) or (3) and secure with lockwire.

2--T

3--+

1 Accelerometer p/N 4177B 2 Accelerometer bracket pIN 6411 3 Accelerometer bracket P IN 6411

new configuration

Figure 107-14

Accelerometer BO 105 CHAPTER 107 Page 25

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1 Accelerometer cable p/N 4296-2 / I

/

Figure 107-15

Installation - accelerometer

c.

Mount accelerometer bracket p/N 6411 on tail rotor transmission as shown in figure 107-15, and tighten hexagon screws to specified torque.

d.

Bond reflective target FIN 4270 to one of the two blade mounting forks as shown in figure 107-16. Degrease bonding area prior to this step.

Figure 107-16 BO 105 CHAPTER

Page 26

107

Attachment of reflective target

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Connect accelerometer cable p/N 4296-2 (1, figure 107-15) to accelerometer.

f.

Route accelerometer cable (1) over vertical stabilizer and round tail boom to LB side shell of fuselage as shown in figure 107-17, and attach with adhesive tape at intervals of approximately 50 cm. Degrease adhesion areas prior to this step.

3

2

1 Accelerometer cable p/N 4296-2 2· D.C. extension cable P/N 3529 3 Circuit protection module p/N 6045 4 Balancer 5 Stroboscope

Figure 107-17

Accelerometer cable connections

BO 105 CHAPTER 107 Page 27

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NOTE

O

Pedal positioner 105-31702 W25 may be used only for adjustment made during ground running of the helicopter.

O

Use of the pedal positioner facilitates adjustment, but is not compulsory; the required pedal displacement may instead be established using a measuring tape. The spacing between the left displaced pedal and the right pedal sha1l be: 60 millimeters (2.36 inch)

g.

Mount pedal positioner 105-31702 W25 on right-hand pedals as shown in figure 107-18. Check pedals for freedom of movement.

Figure 107-18

BO 105 CHAPTER 107 Page 28

Installation of pedal positioner on RH pedals

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CAUTION

THE BALANCER/PHAZOR MAY BE OPERATED ONLY IN CONJUNCTION WITH CIRCUIT PROTECTION MODULE P/N 6045.

h.

Connect circuit protection module 6045 (3, figure 107-17) to helicopter's 28VDC power supply, and D.C. extension cable 3529 to receptacle of circuit protection module.

i.

Route D.C. extension cable (2, figure 107-17) out of cabin and along LH side shell of fuselage to meet accelerometer cable (1) as shown in figure 107-17. Tie the two cables together at intervals with adhesive tape or similar.

j.

Connect balancer/phazor as follows:

k.

1)

Connect connector line of balancer/phazor to free plug of D.C. extension cable.

2)

Connect accelerometer cable to "accelerometer B" receptacle of balancer/phazor.

3)

Connect strobex blade tracker to "strobex" receptacle of balancer/phazor.

Set balancer/phazor and strobex as follows: 1)

2)

Balancer/phazor function:

B

R.P.M. Range:

XlO] tail rotor rpm 2219 min

R.P.M. Tune:

222

Strobex "Mode" switch:

A

_1

No other settings on the balancer/phazor and the strobex blade tracker have any effect. The pházor indication, in particular, is of no significance.

BO 105 CHAPTER 107 Page 29

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Determination of imbalance NOTE

O

Imbalance is determined during ground runo

o The helicopter power receptacle is energized only when both engines are running or an EPU has been connected. If only one engine is running, there is no guaranteethat 100 % rotor rpm can be achieved. This means that the "RPM Tune" setting on the balancer/phaser would have te be slightly reduced. O

The balance condition of the tail rotor depends to a large extent on the blade angles; the balance condition is therefore determined for three different blade angles in each test runo

O

The rotor blade attached to the blade mounting fork to which the reflective target is fixed, shall be called "blade 1" or "target blade". The blade retaining bolts shall be numbered as shown in figure 107-19.

Target

300398

Figure 107-19

BO 105 CHAPTER 107 Page 30

Rotor blade with reflective target attached to the blade mounting fork

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

a.

Enter serial numbers of tail rotor blades under "BLADE SN." in "Correction" data section of Tail Rotor Balance Chart. See figure 107-20. The rotor blade with the attached reflective target is the "target blade" .

b.

Determine balance masses already installed on all blade retaining bolts of the statically balanced tail rotor and enter them under "MASS" next to their respective bolts in the correction tableo

c.

Set tail rotor rpm to approx. 99 %.

d.

Adjust balancer/phazor to tail rotor rpm as follows: Slowly tUrn the "R.P.M. Tune" dial (preset to 222) through the 219 to 224 range until the "IPS" meter pointer makes maximum deflection.

e.

Determine vibration amplitude ("IPS") as follows: 1)

Move left pedal backward until both "B" marks on pedal positioner 105-31702 W25 are in alignment. NOTE

The light beam from the strobex blade tracker is reflected back to it by the reflective target attached to the blade mounting fork. To make the target visible, make the light beam hit it perpendicularly. When directing the light bea~, hold strobex close to line of sight and look directly over the top of it. Recornmended spacing between tail rotor and strobex is approximately 5 meters.

2)

Press trigger switch on Strobex grip and point strobex towards blade mounting forks to locate the reflective target. The target appears as a stationary image at sorne angular position within a circular area. The target can be compared with the hour hand and the circular area with the face of a clock. Read and record angular position ("Clock Angle") of reflective target.

3)

Press "VERIFY TUNE" button on balancer/phazor whilst observing the "Clock Angle" of the target with the strobex. If target moves away from original position, i.e. position prior to pressing "VERIFY TUNE" button, keep "VERIFY TUNE" button pressed and adjust "R.P.M. Tune" until target returns to position observed before "VERIFY TUNE" button was pressed. Release button and observe "Clock Angle" again. Repeat 'adjustment procedure until target remains in same position whether "VERIFY TUNE" button is pressed or released. Record this "Clock Angle" in the clock line of the "Reading" section of the Tail Rotor Balance Chart shown in fig. 107-20, under column B (= backward displacement of left pedal) . BO 105 CHAPTER 107 Page 31

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NOTE

Release trigger switch on Strobex grip before reading the "IPS" on the Balancer.

4)

Read and record "IPS" (vibration amplitude measured in inches per second) in "Reading " data section of the Tail Rotor Balance Chart (fig. 107-20), under column B.

5)

Place LH pedal parallel to RH pedal so that marks B and F of the pedal positioner are in alignment.

6)

Take balance readings at this new blade angle as described in steps e.2) to e.4), and record "IPS" and "Clock Angle" in nReading" data section, under column ~ (Pedals ~arallel) .

7)

Move LH pedal forward so that both F marks of the pedal positioner are in alignment.

8)

Take balance readings at this new blade angle as described under steps e.2) to e.4), and record against ftIPS ft and ftClock Angle ft in ftReading ft data section, under column F (LH Pedal Korward) .

9)

Shut down engines.

10) If the ftIPS ft of all three points of imbalance, i.e. B,P and F, is 0.2 or less, the tail rotor is sufficiently balanced. Remove vibrex system as described in step 4. 11) Determine the mean point of imbalance R from the three individual points of imbalance B, P and F as follows: a)

Plot the ftClock Angles ft and ftIPS ft of imba1ance points B, P and F on the clock section of the Tail Rotor Balance Chart, and label these points B1, P1 and F1. Refer to the example in figure 107-20.

b)

Connect points B1, P1'and F1 to forro a triangle.

c)

To obtain the mean point of imbalance R, bisect any two sides of the triangle and draw lines from the midpoints to the opposite corners of the triangle. The point of intersection of theses lines is the mean point of imbalance R.

BO 105 CHAPTER 107 Page 32

_ _ _ _ _ _ _ _ _ _ _ _ _ MBB HELICOPTERS - - - - - - - - - - - - . MAINTENANCE MANUAL MBB - BO 105 ~eading RUN NO. LH "EDAL POSITION

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HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-------------MBB

f.

Determining balance masses and where to put then, using the Tail Rotor Balance Chart. 1)

From the mean point of rectangular grid lines intersection points on masses te be added to, retaining bolts of the NOTE

imbalance R1, draw lines parallel to the to intersect the weight lines. The the weight lines indicate the amount of or removed from the respective blade blade mounting forks.

o Identical balance masses on diagonally opposite blade retaining bolts cancel each other out. If the mas ses are unequal, only the difference between them has any effect. o The minimum balance mass installed on a blade retaining bolt is 2.4 grams, i.e. mass of the nut and split pino If a balance mass of less than 2.4 grams is required on one of the bolts, this balance mass can be removed, if present, from the bolt diagonally opposite, or the minimum mass of 2.4 grams (nut and split pin) can be added to the bolt in question and a mass of 2.4 g less the actual required balance mas; then added to the diagonally opposite bolt. o To prevent errors from occurring during the distributionof balance masses, it is recornmended that a nut and split pin always be installed on affected blade retaining bolts which require balance masses of less than 2.4 g. At the same time, the same mass shall be added to the diagonally opposite bolt by installing washers or the nut and split pino

2)

Enter the amount of balance masses required for the respective blade retaining bolts in the nCorrection n data section. The preferred balance mass combination would be one obtained by removing any existing static balance masses from the statically balanced tail rotor, rather than by adding additional balance masses.

3)

Make up the required balance masses indicated in the nCorrection n data section by selecting the appropriate masses from the available balance masses A, B, C, D, E and F. Use Gram Scale 47 to weigh out the balance masses.

BO 105 CHAPTER 107 Page 34

HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

-----------~-MBB

4.

Balancing the tail rotor.

NOTE

o Ideal tail rotor balance is normally obtained by repeatly correcting the balance until no further improvement is possible. This is achieved by making several test runs and balance mass changes until points of imbalance of 0.2 IPS or less are obtained. o The blade retaining bolts may be either fully or partially threaded. Self-locking nuts, LN9348-06, are installedon fully threaded balance bolts, castellated nuts LN9345-06 on partially threaded ones (see fig. 107-13). When using partially threaded blade retaining bolts, select an appropriate combination of balance masses whose combined thickness enables proper clamp-up by the castellated nut and safetying of the latter with a split pino Should the total mass of the balance masses assembled on the blade retaining bolt exceed the actual mass required for balancing the tail rotor, the surplus mass must be compensated for by also adding an equal mass to the blade retaining bolt located diagonally opposite. On fully threaded blade retaining bolts the balance mas ses need not be combined to bridge any unthreaded portion of bolt shank.

a.

Remove self-locking or castellated nuts from blade retaining bolts and add the balance mass combinations made up according to step 3.f.3) to the respective bolts, or remove masses, as appropriate.

b.

Torque self-locking or castellated nuts to 4 Nm and secure with split pins.

c.

Set tail rotor rpm to approx. 99%.

d.

Determine points of imbalance for all three LH pedal positions (B, P and F) in accordance with steps 3.e.1) to 3.e.8) and record them in the "Reading" data section of the Tail Rotor Balance Chart.

e.

Shutdown engines.

f.

If the nIPS n of each of the points of imbalance, B, P, and F is 0.2 or less, the tail rotor is suffi¿iently balanced. Remove vibrex system as described in step 5.

BO 105 CHAPTER 107 Page 35

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105 g.

Determine the mean point of imbalance R2 from imbalance points B2, P2 and F2 as described in step 3.e.l1) and make up the required balance masses as specified under step 3.f.3) . The index n2 n indicates that the test run concerned is the second test runo The imbalance points plotted on the chart should therefore be given this index for purposes of distinction. Similarly, the imbalance points in further test runs are marked with the indices n3, 4, ... n.

NOTE

o The amounts of balance mass and the phase (ftClock Angle ft ) of the balance diagram have been establ~shed experimentally and reflect the average for helicopters of a given type. However, these values may vary according to the equipment, service life, play in bearings and joints etc. of the helicopter. For this reason, the chart provided should be considered as an example and must be matched to the individual helicopter as necessary. Correction of the balance chart avoids unnecessary test runs. o If mean point of imbalance R2 does not move towards the center of the chart afte~ the first balance correction trial, correct the phase (clock numbering) of balance diagram with nClock Angle Corrector 3597 ft as described in step h.

h.

Correct balance chart as follows: 1)

First determine the balance mass of either the span or chord axis, preferably the span axis, as- described in step 2.f. Balance and check tail rotor as described in steps 3.a. through f.

2)

Determine mean point of imbalance R3 from imbalance points B3, P3 - and F3 as described in step 3.e.ll) .

3)

Place eyelet nA ft of ftClock Angle Corrector 3597 n over the mean point of imbalance R2 and rotate corrector body so that the A-O line is parallel to the grid lines which extend from the ftnot yet balanced n axis. Do not alter fixed part of nClock Angle Corrector ft .

4)

Rotate pointer of ftClock Angle Corrector n so that the A-B line goes through mean point of imbalance R3.

BO 105 CHAPTER 107 Page 36

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

i.

5.

5)

The A-B line intersects a scale which indicates the number of hours to be added to or substracted from the clock angles around the clock face.

6)

Re-number the clock on the chart accordingly. The balance chart is now matched to the helicopter (correct orientation of clock to weight axes) .

7)

As appropriate, add or remove the balance masses determined in step 3.f. at the blade retaining bolts of the unchanged spanor chord axis. Balance tail rotor as described in step 4. until the "IPS" at each of the points of imbalance B, .P and F is 0.2 or less.

Removal of Vibrex System a.

Remove pedal positioner P/N 105-31702 W25 from the pedals.

b.

Disconnect circuit protection module, balancer/phazor and strobex from one another.

c.

Remove D.C. extension cable and accelerometer cable from helicopter. NOTE

Accelerometer bracket 6411 may remain permanently installed on tail rotor transmission.

d.

Remove accelerometer bracket from tail rotor transmission, if necessary. Re-install previously omitted washers LN9016-06K. Tighten hexagon screws to specified torque (see fig. 107-15).

e.

Check nuts for specified torque as described in step 4.a.2) and split pins on balance bolts for security.

BO 105 CHAPTER 107 Page 37

- - - - - - - - - - - - - M B B HELICOPTERS - - - - - - - - - - - - MAINTENANCE MANUAL MBB - BO 105

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