BK117 C-2

Training Manual CAT B1

Lifting System

Chapter 01
Lifting System

For training and information only May 2012 01 -- 1

 BK117 C-2
Training Manual CAT B1
Lifting System

Table of Contents

Lifting System -- General Description . . . . . . . . . . . . . . . . . . . . 4 This training document comprises the following ATA chapters:
Main Rotor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main Transmission ATA 63
Main Rotor Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rotor Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Main Transmission Monitoring ATA 63
Inner Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Main Rotor RPM Indication, Warning ATA 62
Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Main Transmission Mounting ATA 63
Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Drive Shaft ATA 63
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rotor Brake System ATA 63
Main Transmission Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Transmission Lubrication System . . . . . . . . . . . . . . . . . . 24 Main Rotor System ATA 62
Main Transmission Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Main Rotor Head ATA 62
Oil Pressure Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Main Rotor Blades ATA 62
Oil Pressure Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil Temperature Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil Temperature Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil Contamination Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main Rotor RPM Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Main Rotor RPM Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mast Moment Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Main Transmission Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Rotor Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Rotor Brake System Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Rotor Brake System Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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Training Manual CAT B1
Lifting System

INTENTIONALLY LEFT BLANK

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 BK117 C-2
Training Manual CAT B1
Lifting System

Lifting System -- General Description

General Main Transmission

The lifting system of the BK117 C-2 is located in the transmission The purpose of the main transmission is
compartment on top of the cabin roof. Its main components are:
-- transmitting power to the main rotor
-- main rotor system -- transmitting power to the tail rotor
-- main rotor blades -- reducing of RPM
-- main transmission -- driving accessory consumers
-- rotor brake system -- transmitting forces from the main rotor to the fuselage
Main Rotor System The main transmission is divided up into the following subassemblies:
The main rotor system is designed as a hingeless Bölkow rotor system -- main transmission housing
with four blades. -- gear assembly
Main Rotor Blades -- lubrication system
-- transmission monitoring system
The main rotor blades, made of glass and carbon fibre reinforced
plastics, generate the lift and propulsion required for flight, and permit -- transmission mount
control of the helicopter around its lateral and longitudinal axes. -- engine drive shafts.

Rotor Brake System

The rotor brake system permits stopping of the main rotor and tail rotor,
after the engines have been shut down. It consists of:
-- brake lever
-- relief valve with reservoir
-- disk brake.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Assembly of the Lifting System

Main Rotor System

Main Rotor Blades

Rotor Brake System

Main Transmission

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Rotor System

General
The main rotor system provides the lift and propulsion of the helicopter.
It is a hingeless 4-blade rotor system, consisting of
-- main rotor head
-- main rotor blades.

Main Rotor Head

The main rotor head is bolted directly to the rotor mast of the main
transmission. The main components of the rotor head are:
-- rotor star with rotor cap
-- inner sleeve assemblies with control levers.

Main Rotor Blades

The four main rotor blades generate the lift and propulsion required for
flight. They are attached to the main rotor head by two bolts for each
blade.

 NOTE Arm Nr. 3 (blue) always on top of the scissors.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Rotor System

Rotor Cap

Rotor Star
Silver Coated Washer Blade Mounting Fork

Control Lever

Silver Coated
Bushing

Special Washer

Special Nut Main Rotor Blade

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Rotor Head

Rotor Star
General Lubrication Housing
The rotor star consists of All bearings are lubricated by oil, which flows by gravity through four
bores of the rotor star. The lubrication housing is installed at the top of
-- rotor star with cap
the rotor star and consists of
-- retaining assembly
-- a cover
-- lubrication housing.
-- a sight gauge
The rotor star is made of titanium. It contains the retaining assembly
-- two air bleed screws.
and the bearings for the inner sleeve. At the top, the lubrication
housing is located. The bearings are lubricated through a bore drilled
into the top of each arm of the star.
The rotor cap creates better stream lines and laminar airflow for the tail
rotor.

Retaining Assembly
The retaining assembly consists of
-- the central bolt, passing through the rotor star
-- two cover plates
-- four retaining bolts, to retain the tension torsion straps
-- two quadruple nuts, which are fixed by the central bolt to
retain the four bolts
-- a bushing, which functions as a spacer between the
quadruple nuts.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Rotor Star

Air Bleed Screw

Cover

Sight Gauge

Central Bolt

Inner Seal
Needle Bearing
Upper Cover Plate
190
Spacer

Upper Quadruple Nut Needle Bearing

Lower Quadruple Nut Mounting Stud Outer Seal 240

Shim
Retaining Bolt
x4
Lower Cover Plate

Hub Cap
Bracket

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 BK117 C-2
Training Manual CAT B1
Lifting System

Inner Sleeve
General Tension Torsion Straps
An inner sleeve is inserted into each arm of the rotor star. The inner The tension torsion straps restrain the centrifugal forces of the rotating
sleeve transmits the forces from the blades to the rotor star and permits blades. They are designed torsionally flexible to permit control
control of the blade angle by feathering operation. movements. Each tension strap is retained by a bolt, which passes
The main components of the inner sleeve are through the upper and lower quadruple nut. On the outer end it is
retained to the inner sleeve by the outer retaining nut.
-- inner sleeve with blade mounting forks
-- tension torsion strap Needle Bearing Assembly
-- needle bearing assembly The needle bearing assembly is divided into the inner and the outer
-- control lever. bearing. The corresponding bearing races are installed on the inner
sleeve. The bearings themselves are installed in the rotor star. Oil
Inner Sleeve seals are installed adjacent to the bearings to prevent oil leakage.
The inner sleeve including the blade mounting fork are made of Control Lever
titanium. Prior to the installation of the inner sleeve to the rotor head,
the inner bearing races and the tension torsion straps must be The control levers, also called pitch horns, serve as connecting links
assembled. between the rotating pitch links and the blade mounting forks. They are
attached to the blade mounting forks with bolts.
The upper bolt of the pitch links is installed with an anti rotating fixture.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Inner Sleeve

Needle Bearing Race

Spacer

Needle Bearing Race

Inner Sleeve
Bushings
Blade Mounting Fork

Control Lever

Anti Rotating Plate

Control Rod

Locking Strap Torsion Tension Strap

Retaining Nut

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Training Manual CAT B1
Lifting System

INTENTIONALLY LEFT BLANK

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 BK117 C-2
Training Manual CAT B1
Lifting System

Rotor Head with Inner Sleeve installed

Bleed Screw
Inner Seal Quadruple Nut
Outer Seal
Shim
Inner Sleeve Assy

Preconing 2.5°

Retaining Nut

Inner Needle Bearing Central Bolt

Outer Needle Bearing

Retaining Bolt

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Rotor Blades

General Color Marking

The main rotor blade is manufactured from fiber composite materials Each of the four main rotor blades is identified with a different color.
and generate the lift and propulsion required for flight. The flexible Each arm of the main rotor head is coded with the numbers 1 through
blade neck functions as an artificial flap and lead/lag hinge. 4 and their respective colors. In order to avoid having to readjust the
A vibration absorber, installed to the blade neck reduces the vibrations control settings and the blade track when removing or installing the
same main rotor blades, the main rotor blades are reinstalled so that
occurring mainly during flights at low speed and flare maneuvers. The
their respective colors are paired correctly with number/color codes on
vibration absorber consists of a set of pendulum balls attached to a
the rotor head arms.
shaft. The shaft is supported by two ball bearings installed in the
housing. The ball bearings are lubricated by oil, seals prevent oil Color to Number Code Relationship
leakage.
-- Yellow (Master Blade) . = number 1
The blade fitting assembly attached to the blade mounting fork is the -- Green . . . . . . . . . . . . . . . = number 2
connection between the main rotor blade and the main rotor head.
-- Blue . . . . . . . . . . . . . . . . . = number 3
Each blade is retained by a main bolt and a secondary bolt through
bushings integrated in the blade fitting. -- Red . . . . . . . . . . . . . . . . . . = number 4

The main bolt is hollow to permit installation of dynamic balance

weights. The secondary bolt is prevented from turning by an anti
rotation plate.

 NOTE The main rotor blades can be replaced

independently. However, the main rotor must be
tracked and dynamically balanced after a blade
change.

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Training Manual CAT B1
Lifting System

Blade Attachment and Vibration Absorber

Bonding Jumper
Main Bolt Hub Cap Bracket

Secondary Bolt

Anti Rotation Plate Spring

Blade Mounting Fork

Blade Fitting Assy
Vibration Absorber
Oil Service Screws

Balance Weights Pendulum Weight

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Airfoil Section
The airfoil section generates main rotor blade lifting force. It has a
negative trapezoidal blade geometry with a parabolic swept--back tip
and a negative twist totaling 9.6°.
The blade airfoil is out of the OA series whose cord length increases
towards the blade tip.
Blade Spar
The blade spar consists of glassfiber rovings. They run from the blade
tip to the blade root, around the bushing in the blade fitting area, and
back to the tip. They absorb the tension and bending forces.
Lead Rod
The lead rod in the blade leading edge determines the required
position of the blade center of gravity in the chordwise direction.
Blade Core
The hard-foam blade core provides the supporting structure for the
blade contour and stabilizes the blade skin.
Tuning Mass
Two tuning masses, a small one at the blade tip and a large one in the
leading edge of the center section are integrated in the main rotor
blade. These masses dynamically tune the rotor and reduce the
vibration level.
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BK117 C-2
Training Manual CAT B1
Lifting System
Blade Skin
The blade skin, is made up of two different types of fibers. GRP plies
in the area of the inner part of the blade, and in order to increase
torsional stiffness, carbon fiber at the remaining areas surrounding the
spar, lead rod and blade core.
It ensures that the aerodynamic portion of the blade is provided with
the necessary torsional stiffness. The skin plies on the upper and lower
surfaces of the blade converge at the blade trailing edge where they
are squeezed together to complete a torsion box.
The main rotor blade is painted with coat of PUR lacquer to protect the
composite materials from solar radiation, environmental and weather
influences.
Erosion Protection
A split erosion protection is bonded on the entire length of the blade
leading edge. The split is approx. at the middle of the airfoil section.
The erosion protection is composed of nickel alloy. A PU erosion
protective film is bonded on the butt joint between both parts of the
erosion protection and on the blade neck.
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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Rotor Blade

PU Foil

Tuning Mass
Inner Erosion Outer Erosion
Protection Protection 5128mm
4810mm
4495mm

Erosion Protection

Tuning Mass 2811mm

Bonding Jumper
1748mm

415mm
0mm

Tuning Mass

Blade Core Lead Rod

Glass Fibre Rovings

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 BK117 C-2
Training Manual CAT B1
Lifting System

Lightning Protector Balance Chamber

The tip of the main rotor blade has a copper mesh embedded. In the A balance chamber is incorporated in the main rotor blade near the
event of a lightning strike to the blade tip the copper mesh is blade tip. It accommodates the balance washers used for static
distributing the electrical charge. From the blade tip the electrical spanwise (middle chamber) and chordwise balancing (both outboard
charge is routed to the air frame via chambers) of the main rotor blade. Preliminary settings made in the
balance chamber by the manufacturer ensure that the blades can be
-- the erosion protection
replaced individually.
-- the blade skin
-- a conductive strap in the blade neck  NOTE Presettings must not be changed by the customer.
-- a bonding jumper
-- main rotor head.

Static Discharger
A static discharger is riveted to the blade trailing edge in the blade tip
area. It enables the discharge of static electricity from the helicopter.
A carbon-fiber strap, embedded in the GRP blade skin electrically
connect the static discharger via the carbon blade skin to the bonding
jumper connecting point. The flexible bonding jumper electrically
connects the main rotor blade to the main rotor hub-shaft.

Trim Tabs
Two metal trim tabs and one FRP tab are bonded and, in addition,
riveted to the trailing edge near the blade tip.
The metal trim tabs enable the track of the main rotor blades to be
adjusted so that they all fly in the same tip path plane. Both trim tabs
may be bend to make track adjustments.
The FRP tab reduces the rotor blades control forces and is not
adjustable.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Rotor Blades Components

Copper Mesh

Balance Chamber

Trimming Surface

Static Discharger

Trim Tabs

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission

General Housing
The transmission is constructed as a two stage reduction light weight The main transmission housing consists of two sections made of cast
type. Furthermore, the engine power is transmitted to the accessory magnesium alloy:
units (oil cooler fans and hydraulic pumps). Another task is to transmit
the weight and lifting forces generated by the main rotor system into -- lower housing
the fuselage. This is done via the transmission mounting. -- upper housing.
The lower housing contains the engine input drives, the tail rotor drive,
Leading Particulars
the accessory gear boxes, the oil pumps and the Signal Sensor
Weight approx. 167.5 kg Transmitting Unit for the mast moment indication system.
Gear reduction Main rotor 15.65 The upper housing contains the upper bearings of the gear shafts and
serves as a cover. Additionally the oil filler neck is located here.
Tail rotor 2.5
Speed Drive 6000 RPM
Main rotor 383.4 RPM
Tail rotor output 2396 RPM
Oil quantity approx. 12.5 l
Oil type O--156; MIL--L--23699
Material Magnesium alloy

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission

Vented Filler Neck

Main Transmission
Housing Rotor Mast Assembly
Tail Rotor Output Flange
Tail Rotor Bevel Gear

Oil Cooler Drive

Hydraulic Pump Drive

Input Flange Engine No. 1

Oil Sight Gauge
Freewheel Assembly
Collector Helical Gear
Oil Pump Intermediate Gear LH Engine

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission Gear

General Freewheel Clutches
The gear concept was designed by Kawasaki, Japan. The gears are The engines drive the input drive shafts in a clockwise direction. In this
driven by the two engines and drives the main rotor, the tail rotor, and direction, the freewheel clutches are interlocking the driving and driven
the accessories. parts. The freewheel clutches are effective in the following situations:
The main transmission reduces the input RPM of the two engines to -- When starting the engines, initially only one engine is
the required output RPM for main rotor, tail rotor and accessories. The working. The freewheel clutch to the other engine is
gear is divided up into the following stages: overrun. It will lock if both engines are running at the same
-- input stage RPM.
-- If one engine becomes inoperative, its freewheel clutch is
-- freewheel clutches
overrun and prevents this engine from being driven by the
-- collector stage main transmission.
-- accessory drives. -- If both engines become inoperative, both freewheel
Input Stage clutches are overrun and a landing by autorotation is
possible.
The LH side and RH side engine input drive shafts are installed in the
lower housing assembly. They are provided with freewheel clutches to Collector Stage
prevent a reverse power flow from the main transmission to the The collector stage is the center part of the main transmission. The
engines. The two intermediate gears change the power flow by 90 collector stage is driven by two intermediate gears. It transmits
and pass it to the collector helical gear of the collector stage.
Additionally, the intermediate shafts drive the oil pumps. -- the combined engine power to the main rotor system and
to the tail rotor system
-- the lifting forces into the transmission housing.

Accessory Drives
Accessory drives are installed to drive the oil cooler fans and the
hydraulic pumps. They are located at the LH and RH forward side of
the main transmission and are driven by the intermediate gears.

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Training Manual CAT B1
Lifting System

Main Transmission Gear Schematic

Transmission Race Freewheel Clutch

Engine Race

Main Rotor Mast

Collector Helical Gear

Intermediate Gear
RH Engine Freewheel Assembly
RH Freewheel Clutch
RH Engine Drive

Engine Race
Clutch under Load
Accessory
Drive

Intermediate
Gear LH Engine
Transmission
Oil Pump Drive Race
Clutch Free

Tail Rotor Drive Train

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission Lubrication System

General Oil Pump
The main transmission is provided with an independent redundant The oil pump, attached to the bottom of the main transmission, is
lubrication system of wet sump type. The system consists of two driven by the intermediate shaft. It is a low pressure pump. A screen
identical circuits, each circuit comprises one oil pump with inlet filter prevents damage caused by metallic particles. The oil is supplied to
(screen), one oil filter and one oil cooler with fan. the filter assy via a pressure line.
Both systems are identical and therefore only one system will be Oil Filter Assy
described. The main components of one system are:
Before the oil reaches the oil cooler it passes an oil filter. The filter assy
-- distribution system incorporates a bypass to ensure oil circulation in the event of clogging.
-- oil pump The filter assembly is mounted to the main transmission. From there,
-- oil filter the oil flows via a pressure line to the oil cooler.
-- oil cooler.

Distribution System
The distribution system delivers oil to all bearing and gears, the
freewheel assy, the hydraulic pump drive and the blower fan drive. The
distribution system mainly consists of bores and spray nozzles. The
two oil systems are connected by an internal distribution groove. After
lubricating the gears and the bearings the oil flows by gravity into the
oil sump of the lower housing.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Transmission Lubrication System

Internal Distribution
Oil Cooler Fan Indicator Pin
Oil Cooler

High Pressure Relief Valve Bypass

Filter
Filter
Drive Input Oil Pump with Suction Filter
Oil Outlet Oil Sump

Transmission
Housing

Oil Intake with Screen

Oil Filter Assembly
Main Transmission Oil Pump

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 BK117 C-2
Training Manual CAT B1
Lifting System

Oil Cooler
One oil cooler of the main transmission and the oil cooler of one engine
are assembled in one unit. They are mounted sideways to the main
transmission and are accessible via the access door of the
transmission compartment.

Oil Drain Plug

Two oil drain plugs are installed in the bottom of the lower housing.

Sight Gauge
The oil level of the main transmission can be checked through a sight
gauge, located in the middle front section of the lower housing.

Oil Filler Neck

Oil can be filled through the oil filler neck, located on the upper housing
behind the rotor mast. The oil system is vented through the oil filler
neck.

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Training Manual CAT B1
Lifting System

Oil Cooler Assembly

Right Oil Cooler Assembly

Oil Filler Neck

incl. Ventilation

Rear Air Duct

Oil Sight Gauge

From Oil Cooler
Oil Cooler Fandrive
To Oil Cooler
Oil Filter Assembly

Left Oil Cooler Assembly

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission Monitoring

General
For monitoring purposes, the main transmission is provided with
certain indication and warning systems comprising the following:
-- oil pressure
-- oil temperature
-- oil contamination
-- main rotor RPM
-- mast moment.

Oil Pressure Warning

General
The oil pressure of each circuit is monitored by a pressure switch
mounted next to the sensor. If the pressure of any circuit is below
1.0 bar the warning XMSN OIL P on the warning unit illuminates and
an audio warning (gong) is audible.

Oil Pressure Indication

General
The oil pressure of each circuit is sensed by a pressure transmitter
mounted to the upper left and right transmission housing. Each circuit
is indicated on the VEMD digital and by a bar graph display.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission Monitoring Oil Pressure Warning

Pressure Transmitter

Pressure Switch

XMSN Oil Pressure

Indication

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Oil Temperature Caution
General
The oil temperature is monitored by a temperature switch mounted at
the bottom of the main transmission. If the temperature exceeds
105 °C the MASTER caution starts to flash and the caution indication
XMSN OIL T on the center column of the CAD will be displayed.
Circuit Monitoring of the Oil Temperature Caution
The electrical circuit of the oil temperature caution is tested during the
CPDS external test. If there is an interruption, the caution
XMSN OT CT will be displayed on the center column of the CAD.
Oil Temperature Indication
General
The oil temperature is sensed by a temperature probe, mounted at the
bottom of the main transmission and indicated on the VEMD by means
of a digital and bar graph display.
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BK117 C-2
Training Manual CAT B1
Lifting System
Oil Contamination Caution
General
If the oil is contaminated by metal particles this particles will
accumulate on a magnetic plug. The gap of the detector will be closed,
the MASTER caution starts to flash and the caution indication XMSN
CHIP on the center column the CAD illuminates.
Circuit Monitoring of the Oil Contamination Caution
The electrical circuit of the oil contamination caution is tested during
the CPDS external test. If there is an interruption, the caution
XMSN CHP CT will be displayed on the center column of the CAD.
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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission Monitoring

XMSN CHIP
XMSN OIL T
XMSN OT CT
XMSN CHP CT

Oil Temperature Probe

FWD
Oil Temperature
Switch

XMSN Oil Temperature

Indication

Chip Detector

Chip Detector

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Rotor RPM Indication Main Rotor RPM Warning

General
The main rotor RPM is sensed by a magnetic pick--up which receives
the signal from the tail rotor output gear. The RPM is directly indicated
on an analog indicator, using the small pointer marked R at the
instrument panel.
General
The main rotor RPM Warning also uses the magnetic pick--up signal,
which is feed into the warning unit. The warning unit processes the
signal and switches the following warnings at the warning unit and the
intercom system:
-- < 95 % permanent warning light and pulsed tone
-- ≥ 106 % flashing warning light and gong
-- ≥ 110 % flashing warning light and permanent tone

 NOTE All audio warnings except the 110 % permanent

tone can be suppressed by the reset switch on the
cyclic stick grip.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission Monitoring

RPM
Magnetic Pick--up
Rotor RPM

Triple RPM Indicator

Rotor RPM Warning

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 BK117 C-2
Training Manual CAT B1
Lifting System

Mast Moment Indication

General
The mast moment indication system is used to measure and indicate
any bending moments, which occur on the rotor mast.
The system mainly consists of:
-- strain gauge bridge
-- Signal Sensor Transmitting Unit (SSTU)
-- Signal Processing Unit
-- indication on the CPDS.

Function
The Signal Sensor Transmitting Unit (SSTU) produces a voltage signal
which is supplied to the strain gauge bridges, bonded into the rotor
mast. Due to shaft bending, the resistance of the strain gauge bridge
changes, thus modulating the voltage signal. The modulated signal is
transmitted back to the SSTU.
The Signal Processing Unit (SPU) sends a high frequency signal to the
SSTU where the signal is modulated proportional to the bending
moment. The SPU receives this modulated high frequency signal,
transforms it into a proportional voltage signal and transmits it to the
VEMD.
The Signal Processing Unit is installed on the cabin ceiling area behind
the interior panel.

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 BK117 C-2
Training Manual CAT B1
Lifting System

Mast Moment Indication System

OFF 1

ENG1 ENG2
MM EXCEED 10
TRQ 8 12 TRQ OFF 2
XXX.X% 6 XXX.X%
14
VNE
TOT 4 TOT
XXXX C XXXX C SCROLL

2 LIMIT
N1 XXmnXXs N1
XXX.X% XXX.X% RESET

MM

SELECT

Mast Moment Indication

(CPDS SW V2006)

Mast Moment Indication

Strain Gauge Bridge

Signal Sensor Transmitting Unit Signal Processing Unit

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Indication and Warning
The mast moment indication in the VEMD consists of a white marking
with different ranges. The following ranges are allocated to single
colors:
-- Normal range . . . . . . . . no color up to 50 %
-- Caution range . . . . . . . . yellow 50 % to 64 %
-- Maximum . . . . . . . . . . . . red above 64 %
Upon reaching the red bar a warning gong comes on, the red Limit Box
appears and MM is underlined red. All these signals disappear upon
reducing the mast bending moment.
In case of a mast moment higher than 77 % the caution light
MM EXCEED in the center of the CAD will illuminate.
For training and information only May 2012
BK117 C-2
Training Manual CAT B1
Lifting System
Mast Moment Indication / Vectorial Mast Moment System
(VMMS)
If CPDS Software SW V2006 or subsequent is installed and an
upgrade for the SSTU, SPU and a cable is installed, the circular
scale will be available.
Provided the circular scale is configured in the CPDS A/C
Configuration Page, NR>70% and MM angle signal is available the
VMM will be displayed.
The MM indication can be configured at the configuration page
(linear or circular or N/I)
The white dot indicates MM value and the MM direction, to minimize
the MM value, the cyclic stick is to be moved in a manner to bring
the white dot to the center of the scale.
If the MM phase signal (vector) has failed, the Mast moment display
converts to the linear symbology.
 NOTE Anytime the mast moment of 64 % has been
exeeded, the flight report page will show the
message MM OVERLIMIT DETECTED. Maintenance
action according to the AMM has to be performed.
01 -- 36
 BK117 C-2
Training Manual CAT B1
Lifting System

Mast Moment Indication

MM EXCEED

30%

Linear Scale Circular Scale

64% MM 90% MM
77% MM

Yellow Circle 50% MM

Red Circle 64% MM
only displayed when the MM is in
the yellow range or above
only displayed when the white dot
reaches the red circle

For training and information only May 2012 01 -- 37


Main Transmission Mounts
General
The main transmission is attached to the airframe by four vertical
struts, one side load rod and two torque rods, which also serve to
transmit the main rotor forces and moments into the helicopter
airframe.
Vertical Load Struts
Four vertical load struts carry all weight and lifting forces, transmitted
by the main transmission. They are attached to the airframe via the
fuselage fitting assembly and pivoted in spherical bearings. The struts
are attached to the transmission housing with A-shaped support struts
via fittings.
Side Load Rod
One side load rod carries all forces in the lateral direction. The side
load rod is attached via the fuselage fitting and to the transmission via
the transmission fitting.
For training and information only May 2012
BK117 C-2
Training Manual CAT B1
Lifting System
Torque Rods
Two torque rods carry the main rotor reaction torque and forces
created in longitudinal direction. The torque rods are attached to the
airframe via the fuselage fittings, and to the transmission via the
transmission fittings.
Emergency Guides
The lower parts of the transmission fittings are designed as trunnions
which, in connection with the fuselage fittings, form the emergency
guides. In case of a torque rod or side load rod failure the respective
guide will act as an emergency stop and carry the applied forces.
01 -- 38
 BK117 C-2
Training Manual CAT B1
Lifting System

Main Transmission Mounts

A--Shaped
Support Strut

Transmission
Fitting

Torque Rod

Fitting
Emergency
Guide Spherical Bearing
Vertical Load Strut

Fuselage Fitting Side Load Rod

Torque Rod Fuselage Fitting

Fuselage Fitting
Transmission
Fitting
Vertical Load Strut

Side Load Strut

For training and information only May 2012 01 -- 39


Rotor Brake System
Rotor Brake System Type 2
General
The BK117 C-2 is equipped with a rotor brake system to stop the main
rotor as quickly as possible.
The rotor brake system mainly consists of a
-- brake lever, micro switch and a bowden cable
-- brake cylinder with lever, spring damper and reservoir
-- gearbox support with slideway and brake calliper
Brake Lever Assembly
The rotor brake system is actuated by the rotor brake lever located on
the cockpit floor to the right of the pilot seat. A ratchet mechanism
allows the brake lever to be locked in the on position. The tension force
is transferred via the bowden cable to the spring damper. A micro
switch is integrated in the brake lever assembly.
Brake Cylinder Assembly
The piston of the brake cylinder is mechanically linked via a lever to the
spring damper. The spring damper limits the amount of tension force
by means of a compression spring. When the brake lever is raised the
piston extends into the body of the brake cylinder which pressurizes
the brake fluid.
The reservoir is mounted to the brake cylinder and supplies and stores
the brake fluid to the rotor brake system. MAX and MIN markings on
the reservoir show the quantity of oil contained.
For training and information only
BK117 C-2
Training Manual CAT B1
Lifting System
Brake Bracket Assembly
The brake bracket assembly consists of a gearbox support and a slider
way mounted to the support. The slider way can move axially on two
bolts in relation to the support. If the rotor brake is released, a
compression spring pushes the slider way against the stop at the
gearbox support assembly in the opposite direction of the brake disk
rotation. Attached to the slider way is the brake calliper.
Brake Actuator and Brake Disk
The brake actuator is attached to the main transmission housing and
mainly consists of two friction pads, two pistons and one bleed screw.
The distance between the friction pad and the brake disk compensates
for wear and is self adjusting. It is kept constant by a retraction
assembly.
The wear of the brake lining is checked by measuring the clearance
between the brake lining retainer and the plate of the friction pads.
The brake disk is attached to the adapter of the tail rotor drive output
shaft.
 NOTE Use only normal DOT4 brake fluid to refill the
reservoir.
 NOTE Do not operate the rotor brake with rotor speeds
above 50 % RPM, or temperatures below --30 °C.
May 2012 01 -- 40
 BK117 C-2
Training Manual CAT B1
Lifting System

Rotor Brake System (Type 2)

Brake Cylinder
1
Assembly
Brake Bracket
Brake Disk
2

3
6 7 Slider Way

Spring Damper

Reservoir

2
3
4
Brake Lever Assembly
15 Brake Actuator
4

For training and information only May 2012 01 -- 41

 BK117 C-2
Training Manual CAT B1
Lifting System

Indication System
The indication system consists of a micro switch and a rotor brake
switch. They work independent from each other.
If the brake lever is raised about 5 to 10° the micro switch below the
brake lever closes a contact, this causes the caution ROTOR BRK on
the CAD to illuminate.
If the rotor brake is applied and torque is generated e.g. engine start
the slider way counteracts the spring load and moves in relation to the
rotor brake support. By doing so the slider way actuates the rotor brake
switch that causes the caution ROTOR BRK on the CAD to illuminate.
When the brake is released the spring load forces the slider way back
to initial position and the caption will extinguish.

For training and information only May 2012 01 -- 42

 BK117 C-2
Training Manual CAT B1
Lifting System

Rotor Brake System (Type 2)

1
2
3
ROTOR BRAKE

Rotor Brake Switch

Rotor Brake Support

Micro Switch Slider Way

Brake Lever
15

Brake Lever Assembly

Brake Bracket Assembly

For training and information only May 2012 01 -- 43


Rotor Brake System Type 1
General
The BK117 C-2 is equipped with a rotor brake system to stop the main
rotor as quickly as possible.
The rotor brake system mainly consists of a
-- brake lever, micro switch and master cylinder
-- pressure relief valve and the reservoir
-- brake actuator and the brake disk.
Brake Lever Assembly
The rotor brake system is actuated by the rotor brake lever located on
the cockpit floor to the right of the pilot seat. A ratchet mechanism
allows the brake lever to be locked in the on position. The piston of the
master cylinder is mechanically linked to the brake lever and produces
the pressure needed.
Reservoir and Pressure Relief Valve
The oil reservoir is installed on a support at the cabin roof. The
reservoir supplies and stores the brake fluid to the rotor brake system.
MAX and MIN markings on the reservoir show the quantity of oil
contained.
The relief valve is installed next to the oil reservoir; it protects the brake
system from excessive pressure. If the system pressure becomes
excessive the valve opens and the brake fluid returns to the oil
reservoir.
For training and information only
BK117 C-2
Training Manual CAT B1
Lifting System
Brake Actuator and Brake Disk
The brake actuator is attached to the main transmission housing and
mainly consist of two friction pads, two pistons and one bleed screw.
The distance between the friction pad and the brake disk compensates
for wear and is self adjusting. It is kept constant by a retraction
assembly.
The wear of the brake lining is checked by measuring the clearance
between the brake lining retainer and the plate of the friction pads.
The brake disk is attached to the adapter of the tail rotor drive output
shaft.
 NOTE Use only normal engine oil (Mil--L--23699) to refill
the reservoir.
 NOTE Do not operate the rotor brake with rotor speeds
above 50 % RPM, or temperatures below --30 °C.
Indication System
The indication system consists of a micro switch.
If the brake lever is raised about 5 to 10° the micro switch below the
brake lever closes a contact, this causes the caution ROTOR BRK on
the CAD to illuminate.
May 2012 01 -- 44
 BK117 C-2
Training Manual CAT B1
Lifting System

Rotor Brake System (Type 1) Brake Lining Retainer

Brake Lining
and Plate

Rotor Brake
Housing

Reservoir

Pressure
Relief Valve

Piston
FWD

Brake Disk

Main Transmission Flange

Brake Lever
ROTOR BRAKE

Micro Switch
Master Cylinder

For training and information only May 2012 01 -- 45

 BK117 C-2
Training Manual CAT B1
Lifting System

Drive Shaft

General
Two driveshafts connect the engines to the free wheel units of the main
transmission. They transmit the power of the engines to the main
transmission. In addition, they correct for any variations in length or
misalignment between the engine outputs and the main transmission
inputs. For this purpose the driveshaft has flexible diaphragm at each
end.

Assembly
Each drive shaft assembly consists of an engine stub shaft and an
flexible shaft which are screwed together.

Engine Stub Shaft

The engine stub shaft is inserted onto the splines of the power output
gear.

Flexible Shaft
The flexible shaft is the connecting link between the engine stub shaft
and the input flange of the main rotor transmission and absorbs minor
angular displacements.

For training and information only May 2012 01 -- 46

 BK117 C-2
Training Manual CAT B1
Lifting System

Drive Shaft

Engine Stub Shaft

Flexible Drive Shaft

Flange
Transmission Input Flange Diaphragma

Side View

For training and information only May 2012 01 -- 47