BHT-206L3-MM-4

CHAPTER 28 - FUEL SYSTEM

CONTENTS - MAINTENANCE PROCEDURES

Paragraph Chapter/Section Page

Number Title Number Number

28-1 Fuel system ...................................... 28-00-00 5

28-2 Safety precautions ................................ 28-00-00 5
28-3 Troubleshooting of electrical system .............. 28-00-00 5
28-4 Operational check ................................ 28-00-00 5
28-5 Testing ........................................... 28-00-00 5
28-6 Fuel cells ......................................... 28-00-00 5
28-7 Forward fuel cells ................................ 28-00-00 7
28-8 Removal........................................ 28-00-00 7
28-9 Inspection and Repair .......................... 28-00-00 9
28-10 Cleaning ....................................... 28-00-00 9
28-11 Installation ..................................... 28-00-00 10
28-12 Aft fuel cell ....................................... 28-00-00 11
28-13 Removal........................................ 28-00-00 11
28-14 Inspection and repair ........................... 28-00-00 16
28-15 Installation ..................................... 28-00-00 16
28-16 Fuel distribution .................................. 28-00-00 17
28-17 Forward fuel cell - distribution components ..... 28-00-00 17
28-18 Dual Element Ejector Pump ...................... 28-00-00 18
28-19 Removal........................................ 28-00-00 18
28-20 Inspection ...................................... 28-00-00 18
28-21 Installation ..................................... 28-00-00 18
28-22 Fuel flow switches ................................ 28-00-00 18
28-23 Removal........................................ 28-00-00 20
28-24 Inspection ...................................... 28-00-00 20
28-25 Installation ..................................... 28-00-00 20
28-26 lnline fuel filters .................................. 28-00-00 20
28-27 Removal........................................ 28-00-00 22
28-28 Inspection ...................................... 28-00-00 22
28-29 Installation ..................................... 28-00-00 22
28-30 Fuel quantity probe - forward fuel cell .......... 28-00-00 23
28-31 Removal........................................ 28-00-00 23
28-32 Inspection ...................................... 28-00-00 23
28-33 Installation ..................................... 28-00-00 23
28-34 Interconnect tube ................................. 28-00-00 23
28-35 Removal........................................ 28-00-00 24
28-36 Inspection ...................................... 28-00-00 24
28-37 Installation ..................................... 28-00-00 24
28-38 Aft fuel cell - distribution components ........... 28-00-00 26
28-39 Fuel boost pump.................................. 28-00-00 26
28-40 Removal........................................ 28-00-00 26
28-41 Inspection ...................................... 28-00-00 26
28-42 Installation ..................................... 28-00-00 26
28-43 Canister fuel boost pump ......................... 28-00-00 29
28-44 Removal........................................ 28-00-00 30

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BHT-206L3-MM-4

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

28-45 Installation................................................................................. 28-00-00 30

28-46 Aft Fuel Quantity Probe.................................................................. 28-00-00 30
28-47 Removal.................................................................................... 28-00-00 30
28-48 Inspection ................................................................................. 28-00-00 32
28-49 Installation................................................................................. 28-00-00 32
28-50 Fuel Quantity Transmitter .............................................................. 28-00-00 32
28-51 Removal.................................................................................... 28-00-00 32
28-52 Inspection ................................................................................. 28-00-00 33
28-53 Installation................................................................................. 28-00-00 33
28-54 Fuel Pressure Transducer ............................................................. 28-00-00 33
28-55 Removal.................................................................................... 28-00-00 33
28-56 Inspection ................................................................................. 28-00-00 33
28-57 Installation................................................................................. 28-00-00 33
28-58 Fuel Shutoff Valve.......................................................................... 28-00-00 33
28-59 Removal.................................................................................... 28-00-00 33
28-60 Installation................................................................................. 28-00-00 36
28-61 Fuel Sump Drain Valve .................................................................. 28-00-00 36
28-62 Removal.................................................................................... 28-00-00 36
28-63 Installation................................................................................. 28-00-00 36
28-64 Fuel Filter ....................................................................................... 28-00-00 36
28-65 Removal.................................................................................... 28-00-00 37
28-66 Inspection ................................................................................. 28-00-00 37
28-67 Installation................................................................................. 28-00-00 37
28-68 Fuel Filter Element Replacement................................................... 28-00-00 37
28-69 Low Level Fuel Warning Switch..................................................... 28-00-00 41
28-70 Low Level Fuel Warning Switch — Removal............................ 28-00-00 41
28-71 Low Level Fuel Warning Switch — Inspection.......................... 28-00-00 41
28-72 Low Level Fuel Warning Switch — Installation......................... 28-00-00 41
28-73 Fuel Manifold ................................................................................. 28-00-00 41
28-74 Fuel Manifold — Removal ........................................................ 28-00-00 42
28-75 Fuel Manifold — Disassembly .................................................. 28-00-00 42
28-76 Fuel Manifold — Cleaning (206-064-613-001) ......................... 28-00-00 43
28-77 Fuel Manifold — Cleaning (206-364-604)................................. 28-00-00 43
28-78 Fuel Manifold — Inspection and Repair (206-064-613-001)..... 28-00-00 43
28-79 Fuel Manifold — Assembly (206-064-613-001) ........................ 28-00-00 45
28-80 Fuel Manifold — Installation ..................................................... 28-00-00 45

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 BHT-206L3-MM-4

FIGURES

Figure Page
Number Title Number

28-1 Fuel system schematic ...................................................... 6

28-2 Forward fuel cells ........................................................... . 8
28-3 Aft fuel cell ................................................................. . 13
28-4 Dual element ejector pump and connecting tubes ........................... 19
28-5 Fuel flow switches, filters and connecting tubes ............................. 21
28-6 Interconnect tube ........................................................... . 25
28-7 Fuel boost pump assembly .................................................. 27
28-8 Aft fuel quantity probe ....................................................... 31
28-9 Fuel quantity transmitter ..................................................... 34
28-10 Fuel pressure transducer .................................................... 35
28-11 Fuel shutoff valve ............................................................ 35
28-12 Fuel filter assembly .......................................................... 38
28-13 Fuel manifold P/N 206-064-613-001 ......................................... 44

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 BHT-206L3-MM-4

FUEL SYSTEM

28-1. FUEL SYSTEM. 2 8 -3. T R OUBL E S H OOT I NG OF

ELECTRICAL SYSTEM.
The fuel system is comprised of three
interconnected nonself-sealing bladder type Refer to Volume 10, Chapter 96 for fuel

I
fuel cells. Two forward fuel cells are located quantity calibration, fuel filter and fuel pump
under aft facing passenger seat and are electrical circuitry.
crash-resistant. The aft fuel cell is located
under and behind the aft passenger seat and
28-4. OPERATIONAL CHECK.
is a crash-resistant cell. Fuel from the two
forward fuel cells is transferred to the aft fuel
cell by means of a dual element ejector pump Refer to Volume 10, Chapter 96 for filter, fuel
which is located between and connected to flow switch, low fuel pump caution systems
both forward fuel cells. Forward fuel cells and operational checks.
aft fuel cell are vented overboard by a
common vent line. Each forward fuel cell has 28-5. TESTING.
a fuel flow switch located outside the fuel
cells and adjacent to ejector pump. Left 1. With throttle off and shutoff valve on,
forward fuel cell has a fuel quantity probe. Aft connect air source to vent line.
fuel cell has a fuel boost pump sump located
on bottom of fuel cell. Two fuel boost pumps
are mounted on fuel cell sump. A fuel quantity
probe is located in the top of the forward part
of aft fuel cell. A fuel quantity transmitter is
located in the top of the aft fuel cell and is
D O NOT A P PLY MORE THAN
electrically connected to the fuel quantity
RECOMMENDED PRESSURE AS
probes. The fuel cell sump is equipped with a
DAMAGE TO THE FUEL SYSTEM
low fuel switch which is connected to a fuel
ANS STRUCTURE MAY RESULT.
low light located on the pilot caution
USE MILD SOAP SUDS SOLUTION
segmented panel. Also, the fuel cell sump is
TO LOCATE LEAKS.
equipped with a fuel sump drain solenoid
valve (figure 28-1).
NOTE
28-2. SAFETY PRECAUTIONS. Use regulated low pressure, filtered,
compressed air source, an accurate
1. All fueling and defueling operations pressure gage, and a shutoff valve.
should be performed in an area where fire
hazards are reduced to a minimum. 2. Slowly apply pressure until gage indicates
0.75 to 1.00 psi (5.17 to 6.89 kPa). Shut off
2. Handle fuel cells with extreme care during air source. The fuel system should hold this
removal and installation to prevent damage to pressure for 15 minutes.
cells. Do not attempt to remove or install a
cold fuel cell.
3. Locate and correct any leakage indicated.
Repeat pressure test if leaks are found.
3. Helicopter must be grounded prior to
performing defueling operations.
4. Remove test equipment from vent line.

28-6. FUEL CELLS.

Fuel system includes three nonself-sealing

bladder type fuel cells. The two forward fuel

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BHT-206L3-MM-4

FUEL PRESSURE GAGE

RIGHT FUEL CELL

T (TOP)
tc:
AFT FUEL CELL

DUAL ELEMENT EJECTOR PUMP

INTERCONNECT TUBE

@-+I
PROBE

n=-_+_______
+
NOTE

&
'7E"NT (TOP)
LEFT FUEL CELL
Standpipe position lowered at helicopter S/N 51244 and sub.
206L3-28-1

Figure 28-1. Fuel system schematic

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 BHT-206L3-MM-4

cells are located under the aft-facing passenger seats. 28-8. REMOVAL
The aft fuel cell is located under and behind the aft
passenger seat.
WARNING
28-7. FORWARD FUEL CELLS

Two forward fuel cells are located under the aft-facing ALL DEFUELING OPERATIONS SHOULD
seats just forward of Station 100.00. Fuel cells are BE PERFORMED IN AN AREA WHERE
nonself-sealing, crash-resistant, rubberized fabric. FIRE HAZARDS ARE REDUCED TO A
They are secured in place with nylon lacing. The cells MINIMUM.
have molded type metal fittings at openings and
passages for internal components. Both cells are
vented and interconnected. Both cells utilize a dual CAUTION
ejector pump mounted between the two cells. The
ejector pump transfers fuel from the forward fuel cells
into the aft fuel cell when either fuel boost pump is HANDLE FUEL CELL WITH EXTREME
operating. The left forward fuel cell is equipped with a CARE DURING REMOVAL TO AVOID
fuel quantity probe. D A M A G E TO C E L L . P R O T E C T A L L
OPENINGS TO PREVENT ENTRY OF
FOREIGN MATERIAL. BE SURE FUEL
C E L L I S WA R M E N O U G H T O B E
FLEXIBLE.

1. Disconnect battery and external power supply.

Ground helicopter.
MATERIALS REQUIRED
2. Defuel and purge fuel system (Volume 2,
Chapter 12).
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE NOTE

C-302 Alcohol Removal procedure is the same for either
right or left fuel cell except that the right fuel
C-405 Lockwire cell does not have a fuel quantity probe.
The following procedures is for the left fuel
C-430 Nylon Cord cell.
C-403 Talc 3. Remove the aft facing seat cushions and seat
backs (Volume 3, Chapter 25).
C-453 Tape

C-003 Turbine Fuel

NOTE
Cap or cover open fittings and ports when
fittings, lines, or hoses are removed.

4. Disconnect straps (35, figure 28-2) and sleeves

(36). Disconnect vent hose (30) from each forward cell
vent fitting (26). Tie end of vent hose (30) up out of
way as far as flexibility of hose will permit.

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BHT-206L3-MM-4

(Left)
T 2

38 T 2

37

T 2

T 2
T 2

T 2
T 2

T 2

T 2

T 2

T T 2
10 TO 15 IN-LBS 2
37. Fuel flow switch (Right)
T 1 (1.1 TO 1.6 Nm)
38. Clamp 50 TO 75 IN-LBS
T 2 (5.65 TO 8.47 Nm)
206L3_MM_28_0002

Figure 28-2. Forward Fuel Cells

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Page 8 Rev. 25 18 JUL 2019 Export Classification C, ECCN EAR99

5. Remove bolts (24) and washers (25). Remove
vent fitting (26) and packing (27).
6. Remove cover over fuel quantity probe (17).
Remove bolts (14) and washers (15) from fuel quantity
probe (17). Carefully lift fuel quantity probe from fuel
cell to gain access to electrical terminals (31).
Disconnect electrical terminals and completely remove
fuel quantity probe. Remove and discard gasket (16).
Remove bolts (32) at each side of fuel quantity probe.
7. Remove seat panels to expose left fuel cell.
Remove cover below center seat panel.
CAUTION
RESIDUAL FUEL MAY DRAIN FROM
FUEL CELLS WHEN REMOVING DRAIN
FITTING (19).
8. Remove bolts (20) from drain fitting (19). Remove
drain fitting (19). Discard packing (13).
9. Remove bolts (3 and 13), with washers, and
remove tube assembly (7). Discard packing (6).
10. Remove bolts (11) and washers (10). Remove
seal (9).
11. Remove bolts (29 and 33) from left fuel cell.
CAUTION
DO NOT FOLD A COLD FUEL CELL.
FOLDING MAY CRACK OR DAMAGE A
C O L D C E L L . H E AT L A M P S M AY B E
USED TO WARM FUEL CELL PRIOR TO
FOLDING.
12. Untie and remove nylon cord lacing securing fuel
cell to fuselage structure. Carefully collapse fuel cell
and remove from airframe. Fuel quantity probe
electrical wire (3) is routed through the interconnect
tube (4) and must be guided out of fuel cell and left in
helicopter.
Export Classification C, ECCN EAR99
BHT-206L3-MM-4
NOTE
If the tube (7) is being replaced and the
clamps (38) are installed. Transfer the
clamps on the replacement tube.
13. If installed, remove the clamps (38) from the
tube (7).
28-9. INSPECTION AND REPAIR
1. Inspect the exterior and interior of fuselage
beneath forward fuel cells for indications of fuel
leakage.
2. Inspect fuel cell drain valves (21, figure 28-2) for
evidence of leaks.
3. Field repairs are permitted on fuel cell in all areas
except any radius, any fitting area, or to any cut or tear
longer than 1.0 inch (25 mm). Cells with damage
beyond these limits should be returned for repair to
fuel cell manufacturer.
4. Inspect fuel cell to determine manufacturer
(marked on fuel cell). A repair kit, complete with all
materials and instructions for making field repairs is
available from cell manufacturer.
5. Inspect fuel interconnect and vent lines and
fittings for leakage, damage, and security.
6. Inspect fuel cells for evidence of fungus. If fungus
is present, clean and treat (paragraph 28-10).
28-10. CLEANING
CAUTION
IF HOT WATER IS USED TO CLEAN
FUEL CELL, IT IS RECOMMENDED THAT
TEMPERATURE OF HOT WATER BE
LIMITED TO 160°F (71°C). HOTTER
WATER CONSTITUTES A HAZARD TO
PERSONNEL.
1. Remove all fungus growth from fuel cell by hand
or with a soft scrub brush using warm or hot water.
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BHT-206L3-MM-4

1. Prior to installation of either left or right forward

fuel cell (23 and 28, figure 28-2) carefully inspect fuel
CAUTION
cell cavity for foreign objects. Ensure all sharp edges
and rivet heads are covered with tape (C-453) or
sealant (C-308).
DO NOT USE SOAPS OR STRONG
DETERGENTS WHEN CLEANING FUEL
CELL. C E R TA I N POWERFUL
DETERGENTS ARE DETRIMENTAL TO
CAUTION
FUEL CELL. SOAPS CAN REACT WITH
FUEL TO FORM A COMPOUND WHICH
TENDS TO PLUG FUEL FILTERS. UNDER
HANDLE FUEL CELL WITH EXTREME
N O C I R C U M S TA N C E S S H O U L D
CARE DURING INSTALLATION TO AVOID
METHYL-ETHYL-KETONE OR SIMILAR
DAMAGE TO FUEL CELL. BE SURE FUEL
SOLVENTS BE USED FOR CLEANING
C E L L I S WA R M E N O U G H T O R E
FUEL CELLS.
FLEXIBLE.
2. When fungus is observed in fuel cell, wipe cell
clean with cloths moistened with alcohol (C-302). Burn 2. Place seal (9) at outboard end of interconnect
wiping cloths after cleaning to destroy fungus. tube (4), and feed electrical wire (8) through seal, into
interconnect port of fuel cell, and out fuel quantity
probe port.
3. Use turbine fuel (C-003) for cleaning fuel cell to
assist in protecting inner liner against aging if cell
remains out of service for several weeks without fuel. 3. Apply talcum powder (C-408) to fuel cell cavity.
Insert collapsed fuel cell into fuel cell cavity. Lace and
28-11. INSTALLATION tie, using two separate cord (C-480), the top of fuel cell
to seat support using the ten delta fasteners located
on top of each fuel cell.

MATERIALS REQUIRED 4. Place new packing (18) in recess of drain fitting

(19). Position drain fitting below fuel cell and fuselage
Refer to BHT-ALL-SPM for specifications. structure and secure with bolt (20). Use three undrilled
headed bolts and one drilled head bolt. Install drain
NUMBER NOMENCLATURE valve (21) with packing (22), if removed. Torque bolts
50 to 75 inch-pounds (5.65 to 8.47
C-308 Sealant newton-meters) T . Lockwire drain valve (21) to
drilled bolt head with lockwire (C-405).
C-405 Lockwire

C-408 Talcum Powder 5. Position inboard side of fuel cell against fuselage
structure with attachment holes aligned. Install bolts
C-480 Cord (29 and 33) with thin aluminum washers. Do not
tighten bolts.

NOTE
The installation of the right or left fuel cell is
the same except that the left fuel cell has a
fuel quantity probe with electrical wiring.
The following procedure is for the left fuel
cell.
6. Insert bolts (11) with thin aluminum washers (10),
through interconnect tube flange, seal (9) and into fuel
cell. Torque bolts (11) 50 to 75 inch-pounds (5.65 to
8.47 newton-meters) T .
7. If previously removed, install the clamps (38) on
the tube (7). Torque the screw on the clamp T .

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 BHT-206L3-MM-4

8. Slide retainer (5) and packing (6) on tube (7).
Guide formed end of tube (7) into fuel cell. Ensure that
formed end of tube is down. Place packing at inboard
end of tube and install bolts (3) with thin aluminum
washer. Position packing (6) and retainer (5) against
fuel cell. Install bolts (13), with thin aluminum washers.
Torque bolts (3, 13, 29, and 33) 50 to 75 inch-pounds
(5.65 to 8.47 newton-meters) T .
9. Place gasket (16) on fuel quantity probe (17).
Connect electrical wires to fuel quantity probe
terminals (31). Refer to Volume 12, Chapter 98. Insert
fuel quantity probe and electrical wiring into fuel cell.
Install bolts (14) with thin aluminum washers (15).
Torque bolts 50 to 75 inch-pounds (5.65 to 3.47
newton-meters) T .
28-12. AFT FUEL CELL
The aft fuel cell is a nonself-sealing, crash-resistant,
rubberized fabric cell. The cell is located below and aft
of the aft passenger seat. Mounted in the bottom of
fuel cell are two electrically operated fuel boost
pumps, electrically operated sump drain, two seal
drains, and a low level switch installed in the fuel cell
sump. A fuel quantity probe is installed in the forward
top part of aft fuel cell and is electrically connected to
forward fuel cell transmitter and aft fuel cell transmitter
and a fuel pressure transducer. The cell has a fuel filler
cap located on right side of helicopter just aft of the
passenger door.

10. Place fuel cell seat panel over fuel cell. Use two
long AN4 bolts and screw into fuel cell threaded holes
at bolts (32) location. Pull fuel cell up to cover, remove MATERIALS REQUIRED
one long bolt, and install bolt (32) with large washer.
Remove opposite long bolt and install bolt (32) with Refer to BHT-ALL-SPM for specifications.
large washer. Torque bolts (32) 50 to 75 inch-pounds
(5.65 to 3.47 newton-meters) T . NUMBER NOMENCLATURE

C-408 Talc
11. Insert new packing (27) on vent fitting (26) and
install on fuel cell using bolts (24), with thin aluminum C-453 Tape
washers (25). Torque bolts 50 to 75 inch-pounds (5.65
to 3.47 newton-meters) T .
28-13. REMOVAL

12. Untie end of vent hose assembly (30). Connect

vent hose (30) to vent fitting (26). Torque B-nuts.
Secure sleeve (36) with new straps (35). WARNING

13. Pressure test fuel cells (paragraph 28-5, and

Volume 1, Chapter 5). PERFORM ALL DEFUELING
OPERATIONS IN AN AREA WHERE FIRE
HAZARDS ARE REDUCED TO A
14. Install access panel that is located above dual MINIMUM.
ejector pump and flow switches.

15. Install center seat access panel.

CAUTION

16. Install cover over fuel quantity probe.

HANDLE FUEL CELL WITH EXTREME
17. Install seat cushions and backs (Volume3, CARE DURING REMOVAL TO AVOID
Chapter 25). D A M A G E TO C E L L . P R O T E C T A L L
OPENINGS TO PREVENT ENTRY OF
FOREIGN MATERIAL.
18. Service fuel system (Volume 2, Chapter 12).
1. Disconnect battery, and external power supply.
19. Connect battery. Ground helicopter.

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BHT-206L3-MM-4
2. Defuel and purge fuel system (Volume 2,
Chapter 12).
3. Remove forward facing seat cushions,
seat back and seat bottom (Volume 3,
Chapter 25).
4. Remove fuel boost pump assembly (8,
figure 28-3) to gain access inside the tank
(paragraph 28-40).
5. Remove fuel quantity transmitter (6)
(paragraph 28-51).
6. Remove aft fuel quantity probe (9, figure
28-3) (paragraph 28-47).
7. Remove fittings on top right side of fuel
cell above fuel filler as follows:
a. Remove fuselage access panel located
above fuel filler.
b. Disconnect fuel supply hose (4) from
fitting (32, detail B) and manifold (43, detail
C). Remove hose (4). Remove jamnut (29)
and washer (30).
c. Disconnect electrical connector from
fuel pressure transducer (34, detail B).
d. Disconnect inlet tube (1) from fitting
elbow (33, detail B) and shutoff valve (2).
Remove tube (1) and lift fitting (32) from fuel
cell. Remove and discard packing (31).
e. Disconnect vent hose (3) from vent
fitting (26).
f. Remove vent fitting (26) from fuel cell
by removing screws (23), washers (24) and
flange (25). Discard packing (27).
g. Remove retainer (28) from fuel cell by
removing bolt (35) and washer (36).
8. Remove screws (17 ), washers (16),
retainer (19), cap and adapter (20), seal (21),
and packing (22). Discard packing.
9. Disconnect hoses (39, 40, 41, and 42)
from manifold (43). Remove hoses (39 and
40).
28-00-00
Page 12
10. Remove bolts (38) and washers (37) and
remove manifold (43) from fuel cell.
11. Disconnect hoses (41 and 42) from
lower forward fuel cell connection and remove
hoses.
12. Remove bolts (60) and washers (61) and
disconnect inter connect assembl y (59).
Discard packing (58). Remove clamp and clip
( 5 ) sec u r i n g e l e c t r i c a l h a r ness ( 7 ) t o
interconnect tube (10).
13. Withdraw fuel probe electrical harness
(7) through interconnect tube (1O) and fitting
(51) and stow outside fuel cell as indicated.
14. Remove bolt (54), nut (52), washers (53
and 55) and clip (56) securing hoses (57)
together.
15. Disconnect tubes (48) from hoses (57).
16. Remove bolt (44) and washer (45)
securing retainer (46) to fuel cell. Remove
tubes (48) from inside fuel cell. Discard
packings (47).
17. Disconnect clamps (15) securing ejector
pump tube (14) and interconnect tube (10)
together.
18. Remove screw (11) securing clamp and
interconnect tube (1O) to fuel cell.
19. Remove bolts (66) and washers (65)
attaching flange (64) and interconnect tube
(10) to fuel cell. Remove interconnect tube
and discard packing (63).
20. Disconnect ejector pump tube (14) from
tube (68) and remove from fuel cell.
21. Disconnect tube (68) from hose (62).
22. Remove bolts (70) and washers (69)
attaching tube (68) to fuel cell. Remove tube
(68) and discard packing (67).
23. Remove screws (13) and washers (12)
securing fuel cell to structure at eight places.
 BHT-206L3-MM-4

1. Fuel shutoff valve inlet tube

2. Fuel shutoff valve
3. Vent hose
4. Fuel supply hose
5. Clamp and clip
6. Fuel quantity transmitter
7. Fuel quantity probe harness
TO FWD/ 8. Fuel boost pump assembly
VENT 9. Aft fuel quantity probe
10. Interconnect tube
11. Screw
12. Washer
13. Screw
14. Ejector pump tube
SEE DETAIL 15. Clamps

SEE DETAIL C

NOTE

ffi Standpipe position lowered at helicopter S/N 51244 and sub.

206L3-28-3-1

Figure 28-3. Aft fuel cell (Sheet 1 of 3)

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BHT-206L3-MM-4

-----TORQUE
50 TO 70 IN-LBS
(5.65TO 8.47Nm)

20

21

22

FUEL CELL (REF)

3 REF
DETAIL A

REF 1
\ 33
34 -25
�
16. Washer
17. Screw
18. Bonding tab
19. Retainer 32
20. Cap and adapter
21. Seal
22. Packing
23. Screw
24. Washer
25. Flange
26. Vent fitting (4.52Nm) FUEL CELL (REF)
27. Packing MAXIMUM
28. Retainer
29. Jamnut
30. Washer
31. Packing @-30
32. Fitting
33. Elbow �29
34. Fuel pressure transducer
35. Bolt
36. Washer

206L3-28-3-2

Figure 28-3. Aft fuel cell (Sheet 2)

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 BHT-206L3-MM-4

43 4 REF 4 REF
43

2 40
4 42
37 37

38 38
3 41
1 39
39 1
40 2
4 42 41 3
HELICOPTERS S/N 51001 THROUGH 51243
MANIFOLD 206-064-613 TYPICAL HELICOPTERS S/N 51244 AND SUBSEQUENT
(ALTERNATE 206-364-604) MANIFOLD 206-364-604 TYPICAL
41 6
37. Washer DETAIL C 42 5
REF 14
38. Bolt
39. Hose
*TORQUE *66
40. Hose 41 5
50 TO 75 IN-LBS
41. Hose
(5.65 TO 8.47 Nm) 65 *70 42 6
42. Hose 64 *44
43. Manifold 69
44. Bolt 45
45. Washer 63 68
46. Retainer
47. Packing 46
67
48. Tube REF 10
49. Packing 49
50. Packing
51. Fitting 47
52. Nut
53. Washer 48
54. Bolt
55. Washer NOTES
56. Clip FUEL CELL
57. Hose 1 Hose routed to aft boost
(REF)
58. Packing pump fitting.
59. Interconnect 50
60. Bolt 62 7 REF 2 Hose routed to fwd boost
61. Washer pump fitting.
51
62. Hose
63. Packing 3 Hose routed to left fuel flow
64. Flange switch (Figure 28-5).
65. Washer
66. Bolt 61 53 4 Hose routed to right fuel flow
67. Packing 60 switch (Figure 28-5).
68. Tube 55
54
69. Washer 58 52 5 S/N 51001 through 51243.
70. Bolt 56
59 57 6 S/N 51244 and subsequent.
DETAIL D 206L3_MM_28_0003c

Figure 28-3. Aft Fuel Cell (Sheet 3 of 3)

28-00-00
ECCN EAR99 30 APR 2010 Rev. 14 Page 15
BHT-206L3-MM-4

instructions for making field repairs is

available from respective cell manufacturer.

7. Inspect cell for evidence of fungus. If

DO NOT F OLD A C OLD F U E L fungus is present, treat (paragraph 28-10).
CELL. FOLDING M A Y CRACK OR
DAM A GE A C OLD CELL. HEAT
LAMPS MAY BE USED TO WARM 28-15. INSTALLATION.
FUEL CELL P RIOR TO FOLDING.
1. Carefully inspect fuel cell cavity for
foreign objects. Ensure all sharp edges and
24. If required, heat cell for approximately
rivet heads are covered with tape (C-453).
two hours. Do not exceed 125 ° F (51.7° C).

25. Carefully collapse fuel cell and remove

from helicopter.

26. Cap and cover open lines.

HAND LE F UEL CE L L WITH
E XT R E M E C A R E D U R I N G
28-14. INSPECTION AND REPAIR. I N ST A L L A T I O N T O A V O I D
DAM AGE TO FUEL CELL. BE SURE
1. Inspect the exterior and interior of FUEL CELL IS WARM ENOUGH TO
fuselage beneath fuel cell for indications of BE FLEXIBLE.
fuel leakage.
2. If required, heat fuel cell for
2. Inspect fuel cell drain valve for evidence approximately two hours. Do not exceed
of leaks. 125 ° F (52 ° C).

3. Inspect fuel lines, fittings, and fuel cell 3. Make a workaid, consisting of a section of
covers for leakage, damage and security. broom handle or equivalent, approximately
five feet (1.8 meters) long. Round off both
4. Inspect vent hose for leakage, chafing, ends and fasten a piece of sponge rubber to

i· · · · · · · · ·i
damage, and security. one end.

4. Apply talc (C-408) to fuel cell cavity. I

CAUTION
•••••••••••••••••
ENSURE E LECTRICAL LE ADS
FROM BATTERY RE LAY BUS BAR
DO NOT TOU C H VENT HOS E
(VOLUME 10, CHAPTER 96).
5. Carefully inspect fuel cell for evidence of
leaks. Field repairs are permitted on fuel cell
in all areas except any radius, any fitting
area, or to any cut or tear longer than one
inch. Cells with damage beyond these limits
should be returned for repair to fuel cell
manufacturer.
6. Inspect fuel cell to determine
manufacturer (marked on fuel cell). A repair
k i t , c o m p l e t e w i th a l l m a t e r i al s a n d
Collapse fuel cell and insert through seat
back opening and position forward section of
cell under seat. Use workaid to restore
collapsed cell to its proper shape by gently
pushing the sponge-covered end of stick
against the sides and bottom of fuel cell.
5. Install new packing (67, figure 28-3) on
tube (68). Insert tube (68) from inside fuel cell
through its respective port. Secure in place
using washers (69) and bolts (70). Torque
bolts 50 to 75 inch-pounds (5.65 to 8.47
newton-meters).
6. Connect tube (68) to hose (62).
7. Install new packing (58) on interconnect
assembly (59) and fitting (51 ). Install new

28-00-00
Page 16

packing (63) and flange (64) on interconnect
tube (10).
8. Route fuel probe electrical harness (7)
through fitting (51) and interconnect tube (10)
inside fuel cell.
9. Connect interconnect tube (1 O) and flange
(64) to fuel cell and fitting (51) using washers
(65) and bolts (66). Torque bolts (66) 50 to 75
inch-pounds (5.65 to 8.47 newton-meters).
Install clamp and clip (5) securing electrical
harness (7) to interconnect tube (10).
10. Connect interconnect assembly (59) to
fitting (51) using washers (61) and bolts (60).
11. Connect ejector pump tube (14) to tube
(68). Connect clamps (15) securing ejector
pump tube (14) and interconnect tube (1 O)
t o g e t h e r. I n s t a l l s c r e w ( 1 1 ) s e c u r i n g
interconnect tube (1 O) to fuel cell.
12. Install new packings (47) on tubes (48).
Insert tubes (48) from inside fuel cell through
their respective ports. Secure in place using
retainer (46), washer (45), and bolt (44).
Torque bolt 50 to 75 inch-pounds (5.65 to
8.47 newton-meters).
13. Inside the fuel cell, connect tubes (48) to
hoses (41 and 42). Outside the fuel cell,
connect tubes (48) to hoses (57). Install clip
(56) securing tubes (48) together using bolts
(54), washers (53 and 55), and nut (52).
14. Install manifold (43) using washers (37)
and bolts (38). Connect hoses (4, 39, 41, and
42) to manifold (43).
15. Install new packing (31) on fitting (32).
Install fitting (32) on fuel cell using washer
(30) and jamnut (29). Connect fuel supply
hose (4) to fitting (32).
16. Install fuel pressure transducer (34) on
fitting (32). Connect electrical connector.
Install inlet tube (1) between elbow (33) and
shutoff valve (2).
17. Install new packing (27) on vent fitting
(26) and install using flange (25), washer
(24), and screws (23). Connect vent hose (3)
to fitting.
BHT-206L3-MM-4
18. Install retainer (28) using washer (36)
and bolt (35). Torque bolt 40 inch-pounds
(4.52 newton-meters) maximum.
19. Place new packing (22) in groove of fuel
cell port. Install seal (21), cap and adapter
(20) and retainer (19) using washers (16) and
screws (17). Do not use washer at bonding
tap (18). Ensure that surfaces are clean for a
good bond of bonding tap (18) and retainer
(19). Torque screws (17) 50 to 75 inch­
pounds (5.65 to 8.47 newton-meters).
20. Install seat back and seat bottom. Install
washers (12) and screws (13) at eight places
to secure fuel cell in position. Use long AN4
bolts as required for installation aid.
2 1. Install fuel quantity transmitter (6)
(paragraph 28-53).
22. Install aft fuel quantity probe (9, figure
28-3) (paragraph 28-49).
23. Install fuel boost pump assembly (8,
figure 28-3) (paragraph 28-42).
24. Pressure test fuel system (paragraph 28-
5 and Volume 2, Chapter 5).
25. Install fuselage access panel located
above fuel filler.
26. Connect battery.
27. Service fuel system (Volume 2, Chapter
12).
28-16. FUEL DISTRIBUTION.
Fuel distribution consists of all the forward
and aft cell mounted and connected
components which either move or monitor the
fuel within the fuel system.
28-17. FORWARD F U E L CELL -
DISTRIBUTION COMPONENTS.
Forward fuel cell distribution components
include a dual element ejector pump that
serves both forward fuel cells. The dual
element ejector pump is located between the
forward fuel cells and is attached to each fuel
28-00-00
Page 17
BHT-206L3-MM-4
cell by a tube assembly. Located between the
left forward cell and dual element ejector
p u m p are both fuel flow switches.
Components of the fuel distribution system
located inside the forward fuel cells are a fuel
quantity probe in the left forward fuel cell and
an ejector pump tube in each cell. An
interconnect tube serves as a crossover
between the two forward cells.
28-18. DUAL ELEMENT EJECTOR
PUMP.
The dual element ejector pump (5, figure 28-
4) is located between the forward fuel cells
and is connected to them by tube assemblies.
The ejector pump continually sends fuel from
the forward fuel cells to the aft fuel cell when
the fuel boost pump is operating.
28-19. REMOVAL.
1. Disconnect battery and external power
supply. Ground helicopter.
2. Defuel and purge fuel cells (Volume 2,
Chapter 12).
3. Remove aft facing seat cushions and seat
backs (Volume 3, Chapter 25).
NOTE
Cap or cover open fittings and ports
when lines or hoses are removed.
4. Remove center seat panel. Remove cover
below center seat panel. Remove center
cover between the two aft seats and cover at
forward end of center cover.
5. Disconnect tubes (1o and 11, figure 28-4)
at ejector pump (5).
6. Disconnect hose (6) from dual element
ejector pump (5).
7. Remove bolts (1), with washers (2) and
slide tubes (3) outboard. Remove and discard
packings (4).
28-00-00
Page 18
8. Remove bolt (8) and washer (9) from
support (7). Remove dual element ejector
pump (5).
28-20. INSPECTION.
1. Inspect dual element ejector pump and
inline filters for obstructions. If obstructions
are found, remove them with compressed air.
2. Inspect dual element ejector pump for
evidence of corrosion.
3. If dual element ejector pump proves to be
unserviceable, replace pump.
28-21. INSTALLATION.
1. Install new packings (4, figure 28-4) on
end of tubes (3).
2. Install dual element ejector pump (5)
between tubes (3) and just aft of support (7).
Install bolt (8) with washer (9). Install bolts (1)
with thin washers (2). Torque bolts (1) 50 to
75 inch-pounds (5.65 to 8.47 newton-meters).
3. Thread B-nut of tube (6) on dual element
ejector pump and torque.
4. Connect tubes (1O and 11).
5. Perform pressure test (paragraph 28-5).
6. Install cover at front of aft facing seat.
Install cover between the two aft seats.
7. Install cover below center seat panel.
Install center seat panel.
8. Install aft facing seat cushions and seat
backs (Volume 3, Chapter 25).
9. Connect battery.
10. Service fuel system (Volume 2, Chapter
12).
28-22. FUEL FLOW SWITCHES.
The fuel flow switches are located between
the two forward fuel cells and monitor the fuel
flow to the dual element ejector pump. Each
 BHT-206L3-MM-4

*TORQUE
50 TO 75 IN-LBS
(5.65 TO 8.47 Nm)

1. Bolt
2. Washer
3. Tube
4. Packing
5. Dual element ejector pump
6. Hose
7. Support
8. Bolt
10 9. Washer

81
10. Tube

ti
I
11. Tube

��� � 2 *
l

206L3-28-4

Figure 28-4. Dual element ejector pump and connecting tubes

28-00-00
Page 19
BHT-206L3-MM-4

switch monitors the fuel flow to its respective 28-25. INSTALLATION.

element of the dual element ejector pump.
1. Install new packings (21 and 24, figure
28-5) in fuel flow switch (22).
28-23. REMOVAL.
2. Position flow switch (22), with flow arrow
1. Disconnect battery and external power
pointing forward, between support clips (15
supply. Ground helicopter.
and 16).
2. Defuel and purge fuel cells (Volume 2,
3. Install elbow (18) and nuts (19 and 20)
Chapter 12).
securing switch to support clip (16).
3. Remove aft facing seat cushions and seat
4. Install union (27) and nuts (25 and 26)
backs (Volume 3, Chapter 25).
securing switch to support clip (15).
4. Remove center seat panel by removing
5. Connect fuel flow switch electrical leads
perimeter screws and four screws holding (23).
flow switch clips (two screws per switch).
Remove cover below center seat panel.
6. Connect hose (17) to elbow (18).

NOTE 7. Connect tube (28) to union (27).

Removal procedure is the same for
either fuel flow switch. The following
procedure is for the left fuel flow
switch.
5. Disconnect fuel flow switch electrical
leads (23, figure 28-5).
NOTE
Cap or cover open fuel lines.
6. Disconnect hose (17) from elbow (18).
8. Perform pressure test of fuel system
(paragraph 28-5).
9. Install cover below seat panel. Install
center seat panel.
10. Install aft facing seat cushions and seat
back (Volume 3, Chapter 25).
11. Connect battery.
12. Service fuel system (Volume 2, Chapter
12).

7. Disconnect tube (28) for union (27). 28-26. INLINE FUEL FILTERS.
8. Remove nuts (19 and 20) and elbow (18) The inline fuel filters are located on the
securing fuel flow switch (22) to support clip upstream side of the fuel flow switches. An
(16). Discard packing (21). inline check valve is connected between each
inline filter and fuel flow switch.
9. Remove nuts (25 and 26) and union (27)
securing fuel flow switch (22) to support clip
(15). Discard packing (24) and remove switch SPECIAL TOOLS REQUIRED
from helicopter.
NUMBER NOMENCLATURE
28-24. INSPECTION.
None
1. Inspect fuel flow switch for rust or
corrosion.

2. Ensure fuel flow switch is not clogged or

obstructed.

28-00-00
Page 20
 BHT-206L3-MM-4

VIEW A
ROUTING FOR S/N 51244
AND SUBSEQUENT 8 10
7
11
6
LEFT FUEL 5 12
4 13
FLOW SWITCH 3 14
2 A

ROUTING FOR
1 S/N 51001 THROUGH
51243 SHOWN

RIGHT FUEL
FLOW SWITCH
17

29 18

16
15
19
20
21
22
27
24
28 25 23
26

1. Dual element ejector pump 11. Inline fuel filter 21. Packing
2. Strap 12. Sleeve 22. Fuel flow switch
3. Hose 13. Check valve 23. Electrical leads
4. Check valve 14. Strap 24. Packing
5. Inline fuel filter 15. Support clip 25. Nut
6. Sleeve 16. Support clip 26. Nut
7. Hose 17. Hose 27. Union
8. Strap 18. Elbow 28. Tube
9. Clip 19. Nut 29. Interconnect tube
10. Strap 20. Nut
206L3_MM_28_0005

Figure 28-5. Fuel Flow Switches, Filters and Connecting Tubes

28-00-00
ECCN EAR99 30 APR 2010 Rev. 14 Page 21
BHT-206L3-MM-4

MATERIALS REQUIRED 28-28. INSPECTION.

1. Inspect inline fuel filters for rust or

NUMBER NOMENCLATURE corrosion.
C-328 Sealing Compound
2. Ens ure f i l t ers a r e not clo gged or
obstructed.
NOTE
28-29. INSTALLATION.
For informa t i on on consuma ble
materials, refer to BHT- ALL- SPM
manual. NOTE
Installation of both filters is identical.
28-27. REMOVAL. Assure flow directional arrow on
check valve and sleeve are pointing
1. Disconnect battery and external power in proper direction as shown.
supply. Ground helicopter.
1. Install new packing and check valve (4,
2. Defuel and purge fuel cells (Volume 2, figure 28-5) at outlet end of filter (5).
Chapter 12 ).
2. Connect inlet side of filter (5) to hose (7).
3. Remove aft facing seat cushions and seat Slide sleeve (6) over check valve (4) and filter
backs (Volume 3 , Chapter 25). (5) and connect outlet end of check valve (4)
to hose (3 ).
4. Remove passenger compartment floor
carpeting and fuel system tunnel cover. 3. Secure sleeve in place with two straps (2
and 8) at hose coupling nuts.

NOTE 4. Pressure test fuel system for leakage

( paragraph 28-5).
Faying surfaces of tunnel cover and
fuel c ell cover are coated with
5. Ensure work area is clear and clean of
sealant for fume tightness. Use care
foreign objects, and all connections and lines
to prevent damage during parts
are tight and secure.
removal.

5. Remove molded plastic cover between

left and right aft facing passenger seats. I WARNING'

NOTE SEAT INSTALLATION COVER AND

TUN N E L C OV ER OV ER F U EL
Removal of both filters is identical.
SYSTEM COMPONENTS MUST BE
SEALED FOR FUME TIGHTNESS.
6. Cut straps (2 and 8, figure 28-5) securing
sleeve (6) at each end of filter (5).
6. Mix sealing compound (C-328) 100 parts
to 12 parts by weight per instructions of
7. Slide sleeves (6) from filter (5) and
manufacturer.
disconnect inlet and outlet hose (3 and 7)
from filter (5).
7. Apply sealing compound (C-328) to faying
surfaces on tunnel cover. Install cover and fill
8. Remove check valve (4) and packing from all gaps and voids around entire periphery to
outlet end of filter (5). Discard packing. ensure fume tightness.
9. Cap or cover open fuel lines.

28-00-00
Page 22
 BHT-206L3-MM-4

8. Apply sealing compound (C-328) to faying 28-32. INSPECTION.

surfaces on seat installation cover. Install
cover and fill all gaps and voids around entire
1. I n s p e c t e l e c t r i c a l c o n n e c t i o n s f o r
periphery to ensure fume tightness.
condition and security.

9. Install molded plastic cover on aft side of

2. Inspect fuel quantity probe for evidence of
vertical control tunnel.
corrosion.
10. Install passenger compartment floor
carpeting. 28-33. INSTALLATION.

11. Install passenger aft facing seat backs 1. Place new gasket (16, figure 28-2) on fuel
and cushions (Volume 3, Chapter 25). quantity probe.

12. Service fuel system (Volume 2, Chapter

2. Connect electrical wires to terminals (31)
12).
on fuel quantity probe (Volume 12, Chapter
98).
13. Connect battery.
3. Guide electrical wire and fuel quantity
28-30. FUEL QUANTITY PROBE - probe into fuel cell and secure with bolts (14)
FORWARD FUEL CELL. and thin aluminum washers (15). Torque bolts
50 to 75 inch-pounds (5.65 to 8.47 newton­
The forward fuel quantity probe is one of meters).

three probes used to monitor the fuel level.
The forward fuel quantity probe is electrically
connected to the two probes in the aft fuel
c e l l. R e a d i n g s f r o m t h e p r o b e s a r e
transmitted to a fuel quantity indicator on the
instrument panel.
I
4. Perform calibration check of fuel quantity
system (Volume 10, Chapter 96).
5. Pressure test fuel system (paragraph 28-
5).

28-31. REMOVAL. 6. Install cover over fuel quantity probe.

1. Disconnect battery and external power 7. Install seat cushions and backs (Volume
source. Ground helicopter. 3, Chapter 25).

2. Defuel and purge fuel cells (Volume 2, 8. Connect battery.

Chapter 12).
9. Service fuel system (Volume 2, Chapter
3. Remove aft facing seat cushions and seat 12).
backs (Volume 3, Chapter 25).

4. Remove cover over fuel quantity probe.

Remove bolts (14, figure 28-2) with washers
(15), from fuel quantity probe (17). Carefully
lift quantity probe from fuel cell to gain access
to electrical terminals (31 ). Disconnect
electrical terminals and completely remove
fuel quantity probe. Remove and discard
gasket (16).
5. Cover open port in fuel cell.
28-34. INTERCONNECT TUBE.
The forward end of the interconnect tube is
located between the forward fuel cells and
routes fuel aft to the aft fuel cell. Inside the aft
fuel cell a tube connected to the interconnect
tube serves as a stand-pipe. The fuel quantity
probe electrical wire is routed from the aft fuel
cell,- through the interconnect tube, to the left
forward fuel cell.

28-00-00
Rev.1 Page 23
BHT-206L3-MM-4

SPECIAL TOOLS REQUIRED 6. Slide interconnect tube (4) forward to

allow electrical wire to be pulled out between
interconnect tube (4) and fitting (9). Untie
NUMBER NOMENCLATURE nylon cord and work interconnect tube out.
Remove seals (1 and 10) and packing (8).
None
Discard seals and packings.

MATERIALS REQUIRED 28-36. INSPECTION.

NUMBER NOMENCLATURE 1. Inspect flexible bellows for leaks.

C-480 Nylon Cord 2. Inspect interconnect tube for evidence of

corrosion or frayed mesh wires on hose.

NOTE 3. Inspect for evidence of leaks at each

connection to the fuel cells and hose of
For information on consumable interconnect tube.
materials, refer to BHT-ALL-SPM
manual.
28-37. INSTALLATION.

28-35. REMOVAL. 1. Feed another nylon cord (C-480) through

1 . Remove dual element ejector pump
(paragraph 28-19).
2. Remove both fuel flow switches
(paragraph 28-23).
3. Remove fuel quantity probe (17, figure
28-2) as follows:
a. Remove cover over top of fuel quantity
probe.
b. Remove bolts (14) and washers (15)
from fuel quantity probe (17). Carefully lift fuel
quantity probe from fuel cell to gain access to
electrical terminals (31).
c. Disconnect electrical terminals and
completely remove fuel quantity probe. Obtain
a nylon cord (C-480) or equivalent of
sufficient length to go from top of forward cell
to front of aft fuel cell. Tie one end of cord to
airframe structure and the other end to wire
terminals.
interconnect tube (4, figure 28-6) and tie one
end to retainer (7) and other end to forward
left end of interconnect tube. Place
interconnect tube (4) in approximate position.
Feed first piece of nylon cord through new
s e a l ( 1 0) . T i e c o r d in t u b e to cord i n
interconnect tube, placing excess cord in
tube. Install bolts (12) with washers (11). Do
not tighten bolts (12). Pull and feed electrical
wires through interconnect tube into left fuel
cell and out fuel quantity probe (17, figure 28-
2) opening.
2. Place new gasket (16) on fuel quantity
probe (17). Connect electrical terminals (31)
to fuel quantity probe and insert fuel quantity
probe and electrical wiring into fuel cell.
Install bolts (14), with thin aluminum washers
(15). Torque bolts 50 to 75 inch-pounds (5.65
to 8.47 newton-meters).
3. Position new packing (8, figure 28-6)
correctly and install bolts (5), with washers
(6), through retainer (7) and into aft fuel cell.
Torque bolts (5) 50 to 75 inch-pounds (5.65 to
8.47 newton-meters).

4. Remove bolts (3 and 12, figure 28-6) and 4. Place new seal (1) between interconnect
washers (2 and 11). tube and right fuel cell. Install bolts (3), with
washers (2). Torque bolts (3) 50 to 75 inch­
5. Remove bolts (5) and washers (6). pounds (5.65 to 8.47 newton-meters).

28-00-00
Page 24
 BHT-206L3-MM-4

7
*TORQUE
50 TO 75 IN-LBS
(5.65 TO 8.47 Nm)

1. Seal
2. Washer
3. Bolt
4. Interconnect tube
5. Bolt
6. Washer
7. Retainer
8. Packing
9. Fitting
10. Seal
11. Washer
12. Bolt
13. Tube
14. Packing
15. Retainer

206L3-28-6

Figure 28-6. Interconnect tube

28-00-00
Page 25
 BHT-206L3-MM-4

5. Torque bolts (12) 50 to 75 inch-pounds 28-40. REMOVAL.

(5.65 to 8.47 newton-meters).
1. Disconnect battery and ground helicopter.
6. Install both fuel flow switches (paragraph
28-25). 2. Defuel and purge fuel cells (Volume 2,
Chapter 12).
7. I n s t a l l d u a l e l e m e n t e j e c t o r p u m p
(paragraph 28-21). 3. Remove fuel boost pump assembly cover.

28-38. AFT FUEL CELL - DISTRIBUTION
COMPONENTS.
Aft fuel cell distribution components include
two fuel boost pumps mounted on a sump
plate in the bottom of the aft fuel cell. One
fuel quantity probe is mounted at the top of
the forward part of the aft fuel cell. Another
fuel quantity probe and transmitter is attached
at the top of the aft part of the cell. The fuel
distribution system incorporates four one-way
I check valves located inside the fuel manifold.
Located directly above the fuel cell in an
externally accessible compartment is a fuel
shutoff valve and a fuel pressure transducer.
28-39. FUEL BOOST PUMP.
The electrical fuel boost pump is part of the
sump assembly and is located in the bottom
of the aft fuel cell. The dual electric boost
pump transfers fuel through two check valves
in the fuel manifold to a single line and then
out o f the fuel cell t o the engine. Two
additional check valves and fuel lines allow
the boost pumps to operate the ejector pumps
at the forward fuel cells and transfer fuel from
the forward fuel cells into the aft fuel cell.
4. Remove screw (17, figure 28-7), nut (22),
washer (16 and 23), and spacer (15). Remove
retainer (24).
5. Disconnect splines at electrical terminals
(27 and 32) using M81969/14-02 tool or
equivalent.
6. Remove ground wires from bolt (21).
7. R e m o v e s c r e w s a t t a c h i n g p o s i t i v e
terminals (30 and 31) from both boost pump
cartridges.
8. From beneath the helicopter, push the
fuel cell and pump (3) up to aid access to
bolts (6) and washers (5).
9. Remove bolts (6) and washers (5).
10. Disconnect fuel hoses to reducers (1).
11. Remove pump (3).
28-41. INSPECTION.
1. Inspect fuel boost pump for corrosion and
condition. Remove any corrosion that is
present.

SPECIAL TOOLS REQUIRED 2. Inspect electrical wiring for condition.

NUMBER NOMENCLATURE 28-42. INSTALLATION.

M81969/14-02 Removal/Installation
Tool NOTE

If original fuel boost pump assembly

MATERIALS REQUIRED is being reinstalled omit step 1.

1. Assemble new pump assembly as follows:

NUMBER NOMENCLATURE
a. Place new packings (2, figure 28-7) on
None reducers (1) and install in outlet ports of
pump.

28-00-00
Page 26
 BHT-206L3-MM-4

1. Reducer
2. Packing
3. Pump
4. Packing
5. Washer
6. Bolt
7. Packing
8. Switch
9. Washer
10. Bolt
11. Packing
12. Drain valve
13. Washer
14. Bolt
15. Spacer
16. Washer
17. Screw
18. Gasket
19. Cover
20. Washer
21. Bolt
22. Nut
23. Washer
24. Retainer
25. Adapter
26. Washer
27. Electrical terminals
28. Plug
29. Packing
30. Electrical terminals
31. Electrical terminals

*TORQUE
50 TO 75 IN-LBS
(5.65 TO 8.47 Nm)

'

�19
cl,-20
i-*21 206L3-28-7-1

Figure 28-7. Fuel boost pump assembly (Sheet 1 of 2)

28-00-00
Page 27
BHT-206L3-MM-4

ARROWS MUST ALIGN

FOR CARTRIDGE
INSTALLATION 1. Pump shutoff lever
FORWARD
AFT AIRCRAFT 2. Retaining ring
WIRING WIRING 3. Pump cartridge
Q3A18 Q1A18 4. Drain plug
5. Pump shutoff lever
6. Pump cartridge
7. Retaining ring
8. Drain plug
3

1
SPLICE

FUEL LIGHT
--.....::::=====:=:::P CONNECT
AIRCRAFT
Q4A18N WIRING
AIRCRAFT
WIRING
FUEL DRAIN
GND
Q2A18N Q21A22 CONNECT
AIRCRAFT AIRCRAFT
GND WIRING

DETAIL A

VIEW LOOKING AT BOTTOM

OF SUMP ASSEMBLY
206L3-28-7-2

Figure 28-7. Fuel boost pump assembly (Sheet 2)

28-00-00
Page 28
 i· · · · · · · · ·i
CAUTION
•••••••••••••••••
DO NOT PLUG THE PUMP SEAL
DRAIN PORTS.
b. Place new packings (29) on plugs (28)
and install in the pump drain ports.
c. Place new packing (7) on boss of
switch (8). Secure switch in place with one
bolt (10) with washer (9) and adapter (25)
with washer (2 6). Torque bolt (10) and
adapter (25) 50 to 75 inch-pounds. (5.65 to
8.47 newton-meters).
d. Place new packing (11) on boss of
drain valve (12). Secure valve in place with
bolts (14) and washer (13). Torque bolts 50 to
75 inch-pounds (5.65 to 8.47 newton-meters).
e. Place new gasket (18) on cover (19).
Secure cover in place with bolts (21) and
washers (20).
2. Place new packing (4) in recess of pump
assembly port. Connect fuel hoses to
reducers (1). From beneath the helicopter,
position fuel boost pump in place. Secure with
bolts (6) and washers (5). Torque bolts 50 to
75 inch-pounds (5.65 to 8.47 newton-meters).
3. Remove manufacturer installed wires from
positive terminals (30 and 31) of boost pump
assemblies. Cut ground wire from boost pump
assemblies at a sufficient length to reach bolt
(21). Apply crimp connector to end of wire
and install on bolt (21) along with aircraft
ground wire No. Q4A 18N. Install aircraft
wiring to positive terminals (Volume 12,
Chapter 98).
4. Cut drain valve wire and install connector
with sufficient length to reach bolt next to bolt
(21) . Connect drain valve (12) positive
terminal to aircraft wire No. E93A22 with
connector using M81969/14-02 tool.
NOTE
Cut wire to correct length before
applying connector (Volume 12,
Chapter 98).
BHT-206L3-MM-4
5. Cut one wire on fuel level switch to
appropriate length to reach same bolt next to
bolt (21) a s d r a i n valve wire. Install
connector. Install fuel drain and fuel level
connectors to bolt. Attach aircraft ground wire
No. Q2A18N. Install remaining fuel level
switch wire No. E93A22 to aircraft positive
with connector using M81969/14-02 tool
(Volume 12, Chapter 98).
6. Tighten bolts (21) to 50 to 75 inch-pounds
(5.65 to 8.47 newton-meters).
7. Place washer (16) on screw (17) and
insert through retainer (24). Place spacer (15)
on screw (17) and secure into fuel boost
pump sump assembly. Do not tighten. Place
washer (23) on adapter (25) and install nut
(22). Tighten nut (22) and screw (17).
8. Perform pressure test of fuel system
(paragraph 28-5 and Volume 2, Chapter 5).
9. Connect battery.
10. Perform functional check of fuel quantity
system (Volume 10, Chapter 96).
11. Service fuel system (Volume 2, Chapter
12).
28-43. CANISTER FUEL BOOST PUMP.
NOTE
The canister type fuel pump and
impeller may be replaced without
draining the fuel system.
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
E2-10-1 Slide Hammer
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-01O Lubricating Oil
28-00-00
Page 29
BHT-206L3-MM-4

NOTE 4. Install cartridge in flange (canister) with

arrows aligned.
F or information on consumable
materials, refer to BHT-ALL-SPM
manual. NOTE

When pushing cartridge into place,

28-44. REMOVAL. ensure that cartridge is properly
seated and that retaining ring groove
1. Turn helicopter electrical master switch is not obstructed.
OFF (BHT-206L3-FM).
5. Install retaining ring.
2. Disconnect fuel boost pump positive (red)
electrical terminal. 6. Install drain plug.

3. Remove hexagon head screws and

negative (ground terminal) from boost pump
shutoff lever.

4 . Turn fuel boost pump shutoff lever

DO NOT OVERTORQUE POSITIVE
enough to clear motor and impeller.
ELECTRICAL TERMINAL.
5. Remove fuel boost pump drain plug.
7. Connect positive electrical terminal.
6. Remove any remaining obstructions
8. Position fuel boost pump shutoff lever
below cartridge.
over screw hole; install hexagon head screw
and negative electrical terminal.
7. Remove retaining ring.
9. Turn master switch ON and turn on fuel
8. Install E2-01 -1 slide hammer in pump
pump (BHT-206L3-FM). Check for proper
drain boss and remove pump cartridge.
gage pressure and external leaks.

28-45. INSTALLATION.
28-46. AFT FUEL QUANTITY PROBE.
1. Clean cartridge hole of all foreign matter.
The aft fuel cell fuel quantity probe is
mounted in the top of forward part of aft fuel
2. Clean retaining ring.
cell. The fuel quantity probe is electrically
connected to the forward fuel cell fuel quantity
3. L ubricate packings on replacement
probe and to the aft fuel cell fuel quantity
cartridge and the sides of the cartridge �ol� in
probe and transmitter.
the mounting flange casting with lubricating

i· · · · · · · · ·i
oil (C-010).
28-47. REMOVAL.

CAUTION
1. Disconnect battery and external power
••••••••••••••••• source. Ground helicopter.

DO NOT FORCE CARTRIDGE INTO
C A N I STE R . E C C E NTR I C
CARTRIDGE DESIGN REQUIRES
A L I G N ME N T A R R OWS TO BE
WIT H I N ± 3 DEG R E E S TO BE
PROPERLY INSTALLED.
2. Defuel and purge fuel cells (volume 2,
Chapter 12).
3. Remove fuel quantity probe from aft fuel
cell (5, figure 28-8) as follows:
a. Helicopter S/N 51001 through 51334. I
Remove bolts (1, detail A) and washers (2).

28-00-00
Page 30
 BHT-206L3-MM-4

""'--�
�
'/
��
5

I
-8
�
SEE DETAIL A __J TORQUE
SEE DETAIL 8 50 TO 75��N��B"�-
(5.65 TO 8.47 Nm)' �
1==::t
2
I

{oKhl__g
AFT
NOTCH FACING
�I
' I
3- o <> ob
0
0

TORQUE -----�Q--1
50 TO 75 IN-LBS � 4
(5.65 TO 8.47 Nm) @-2

�
o o
i I
10
FORWARD
NOTCH FACING

4 5

DETAIL A DETAIL 8

HELICOPTER S/N 51001 THRU 51334 HELICOPTER S/N 51335 AND SUBQ

1. Bolt 6. Screw
2. Washer 7. Cover
3. Fuel quantity probe 8. Gasket
4. Gasket 9. Spacer
5. Aft fuel cell 10. Spacer
206L3-28-8

Figure 28-8. Aft fuel quantity probe

28-00-00
Page 31
BHT-206L3-MM-4
Carefully raise fuel quantity probe (3). When
electrical wires are accessible remove screws
securing electrical w�res to fuel quantity probe
and remove fuel quantity probe from aft fuel
cell (5).
b. Helicopter S/N 51335 and subsequent.
Remove screws (6, detail B), cover (7), and
gasket (8). Remove bolts (1) and washers (2).
Remove spacer (9) and carefully raise fuel
quantity probe (3). When electrical wires are
accessible, remove screws securing electrical
wires to fuel quantity probe and remove fuel
quantity probe from aft fuel cell (5).
4. Remove and discard gasket (4).
5. Cover open port in fuel cell.
28-48. INSPECTION.
1. I n s p e c t e l e c t r i c a l c o n n e c t i o n s f o r
condition and security.
2. Inspect fuel quantity probe for corrosion.
28-49. INSTALLATION.
1. Place new gasket (4, figure 28-8) on fuel
quantity probe (3).
2. Connect electrical wiring from forward fuel
cell quantity probe and aft fuel quantity
transmitter to fuel quantity probe (3) electrical
terminals (Volume 12, Chapter 98).
3. Install fuel quantity probe in aft fuel cell
as follows:
a. Helicopter S/N 51001 through 51334.
Carefully insert fuel quantity probe (3, figure
28-8, detail A) and electrical wiring into fuel
cell (5). Secure fuel quantity probe with six
bolts (1) and washers (2). Torque bolts (1) 50
to 75 inch-pounds. (5.65 to 8.47 newton­
meters).
NOTE
Ensure lower spacer is properly
bonded to aft fuel cell. Also, ensure
notch in lower spacer is facing
forward.
28-00-00
Page 32 Rev. 1
b. Helicopter S/N 51335 and subsequent.
Carefully insert fuel quantity probe (3) and
electrical wiring into aft fuel cell (5). Place
spacer (9) on top of fuel quantity probe.
Ens ure notch is facing aft. Secure fuel
quantity probe with bolts (1) and washers (2).
Torque bolts (1) 50 to 75 inch-pounds (5.65 to
8.47 newton-meters). Install gasket (8), cover
(7), and screws (6).
4. Connect battery.
I
5. Perform calibration check of fue� quantity
system (Volume 10, Chapter 96).
6. Perform pressure test of fuel system
(paragraph 28-5).
7. Service fuel system (Volume 2, Chapter
12) .
28-50. FUEL QUANTITY TRANSMITTER.
The fuel quantity transmitter is located in the
top of the aft fuel cell and is electrically
connected to the fuel quantity probes that are
located in the top of the forward and aft fuel
cells.
28-51. REMOVAL.
1. Disconnect battery and external power
source. Ground helicopter.
2. Defuel and purge fuel cells (Volume 2,
Chapter 12).
3. Remove upholstery and seat cushions
and back (Volume 3, Chapter 25).
4. Remove upholstery to gain access to top
of aft fuel cell. Remove Velcro plastic hat.
5. Disconnect electrical connector from fuel
quantity transmitter (5, figure 28-9).
6. Remove screws (1), washer (2), retainer
(3), and seal (4).
7. Carefully left fuel quantity transmitter (5)
to expose electrical wiring on probe. Secure
wires to top area of cell. Disconnect electrical
 BHT-206L3-MM-4

wiring from fuel quantity transmitter. Remove 28-55. REMOVAL.

fuel quantity transmitter from fuel cell.
8. Remove and discard gasket (6) and seal
(4). Cover open port of fuel cell.
28-52. INSPECTION.
1. Remove fuselage access panel located
above fuel filter.
2. Disconnect electrical connector (4, figure
28-10).

1. Inspect fuel quantity transmitter for 3. Unscrew fuel pressure transducer (3)
corrosion. from fitting (1). Remove and discard packing
(2).
2. Inspect electrical wiring for condition.
28-56. INSPECTION.

1. Inspect transducer for rust or corrosion.

28-53. INSTALLATION.

1. Install new seal (4, figure 28-9) between

airframe structure and open port of fuel cell. 2. Inspect for bent or broken pins.

2. Place new gasket (6) on fuel quantity

transmitter (5) and partially insert into fuel
28-57. INSTALLATION.

cell. Connect electrical wiring from inside fuel
cell t o fuel quantity probe (Volume 12,
Chapter 98). Seat fuel quantity transmitter (5,
figure 28-9) in fuel cell.
3. Place retainer (3) over top of fuel quantity
transmitter. Secure in place with screws (1)
and washers (2). Torque screws 30 to 40
inch-pounds (3.39 to 4.52 newton-meters).
4. Perform pressure test of fuel system
(paragraph 28-5).
5. Connect battery.
1. Install new packing (2, figure 28-10) on
transducer and screw into fitting (1).
2. Connect electrical connector (4).
3. Pressurize fuel system and check for
leaks (paragraph 28-5, and Volume 2,
Chapter 5).
4. Install fuselage access panel.
28-58. FUEL SHUTOFF VALVE.
The fuel shutoff valve is located above the aft

I 6
. Perform calibration check of fuel quantity
system (Volume 10, Chapter 96).
fuel cell servicing port and is electrically
operated.

7. Install upholstery and seat cushions and

back (Volume 3, Chapter 25). 28-59. REMOVAL.

8. Service fuel system (Volume 2, Chapter 1. Disconnect battery and external power
12). supply.

2. Remove access panel above fuel filler

28-54. FUEL PRESSURE TRANSDUCER. port.

The fuel pressure transducer provides a 3. Remove inlet tube (3, figure 28-11) from
means of monitoring fuel pressure in t he inlet port of fuel shutoff valve (2). Remove
system. The transducer is located on a fitting tube (7) from outlet port of fuel shutoff valve
on top of the aft right side of the aft fuel cell. (2). Cap open lines.

4. Disconnect electrical connector (1) from

fuel shutoff valve.

28-00-00
Rev.1 Page 33
BHT-206L3-MM-4

TORQUE--------•
30 TO 40 IN-LBS
(3.39 TO 4.52 Nm)

1. Screw
2. Washer
3. Retainer
4. Seal
5. Fuel quantity transmitter
6. Gasket
206L3-28-9

Figure 28-9. Fuel quantity transmitter

28-00-00
Page 34
 BHT-206L3-MM-4

SEE DETAIL A

DETAIL A
1

\
\11
1. Fitting
2. Packing
3. Fuel pressure transducer
4. Electrical connector 206L3-28-10

Figure 28-10. Fuel pressure transducer

AFT FUEL CELL

6 1. Electrical connector 5. Washer

4 2. Fuel shutoff valve 6. Support structure
3. Inlet tube 7. Outlet tube
""� 4. Screw
DETAIL A 5 206L3-28-11

Figure 28-11. Fuel shutoff valve

28-00-00
Page 35
BHT-206L3-MM-4

5. Remove upholstery above rear seat.
Remove screws (4) and washers (5) securing
fuel shutoff valve (2) to fuselage structure,
and remove fuel shutoff valve.
28-60. INSTALLATION.
1. Position fuel shutoff valve (2, figure 28-
11) in compartment above fuel filler port and
secure in place with screws (4) and washers
(5).
2. Install inlet tube on inlet port of fuel
shutoff valve (2). Install tube (7) on outlet port
of fuel shutoff valve (2).
3. Connect electrical connector (1) to fuel
shutoff valve.
4. Replace upholstery above rear seat.
5. Connect battery. Apply fuel pressure to
fuel system and check for evidence of leaks
(Volume 2, Chapter 5).
2. Defuel and purge fuel cells (Volume 2,
Chapter 12).
3. Disconnect splice at positive terminal (27,
figure 28-7) using M81969/14-02 tool or
equivalent.
4. Disconnect ground wire from bolt (21 ).
5. Remove bolts (14), washer (13), and
remove drain valve (12). Discard packing
(11).
6. Cover open port.
28-63. INSTALLATION.
1. Place new packing (11, figure 28-7) on
boss of drain valve (12).
2. Secure drain valve (12) to fuel boost
pump sump with bolts (14) and washers (13).
Torque bolts 50 to 75 inch-pounds (5.65 to
8.47 newton-meters).

6. Install fuselage access panel. 3. Connect splice at positive terminal (27)

using M81969/14-02 tool or equivalent.
28-61. FUEL SUMP DRAIN VALVE.
4. Connect ground wire to bolt (21 ).
The fuel sump drain valve is located in the
fuel boost pump sump and is electrically 5. Perform pressure test of fuel system
operated. (paragraph 28-5).

6. Connect battery.
SPECIAL TOOLS REQUIRED
7. Service fuel system (Volume 2, Chapter
12).
NUMBER NOMENCLATURE

M81969/14-02 Removal/Installation 28-64. FUEL FILTER.

Tool
The airframe mounted fuel filter is mounted
on the forward firewall on the right side of the
MATERIALS REQUIRED power plant. The fuel filter is equipped with a
built-in filter bypass valve and impending
bypass switch that is electrically connected to
NUMBER NOMENCLATURE a segment in the caution panel.
None
SPECIAL TOOLS REQUIRED

28-62. REMOVAL.
i\lUMBER NOMENCLATURE
1. Disconnect battery and external power None
source. Ground helicopter.

28-00-00
Page 36
 BHT-206L3-MM-4

5. Connect inlet hose (9), outlet hose (2), and drain

hose (12) to fuel filter (6).
MATERIALS REQUIRED
6. Connect battery.
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE 7. Pressurize fuel system and check for leaks at fuel
filter (Volume 2, Chapter 5).
C-405 Lockwire
8. Close and secure engine cowling.

28-68. FUEL FILTER ELEMENT REPLACEMENT

28-65. REMOVAL SPECIAL TOOLS REQUIRED

1. Disconnect battery and external power source.

NUMBER NOMENCLATURE
2. Open engine cowling on right side.
M81969/14-11 Removal/Installation
Tool
3. Disconnect inlet hose (9, Figure 28-12), outlet
hose (2), and drain hose (12) from fuel filter (6).

4. Disconnect electrical connector (5) from top of MATERIALS REQUIRED

fuel filter (6).
Refer to BHT-ALL-SPM for specifications.
5. Cut lockwire and remove bolts (17) and washers
(15 and 16) from top of fuel filter. Remove fuel filter (6). NUMBER NOMENCLATURE

C-405 Lockwire
28-66. INSPECTION
C-414 Lockwire
1. Inspect fuel filter bowl for corrosion.

2. Inspect electrical connector for condition. NOTE

28-67. INSTALLATION
1. Position fuel filter (6, Figure 28-12) under
mounting bracket (14) top flange with washers (15)
between filter and bracket. Secure in place with bolts
(17) and washers (16). Torque bolts 50 to 70
inch-pounds (5.65 to 7.91 newton-meters) T and
lockwire (C-405).
2. Connect electrical connector (5) to top of fuel filter
(6).
Filter element must be removed for
inspection whenever caution light comes on
during engine operation. Replace element
at same hourly interval as the engine fuel
pump filter, or whenever contamination
cannot be removed.
At each fuel filter element change interval,
remove fitting from outlet port of filter head.
Using a piece of lockwire (C-414), pass
wire through outlet bleed port to assure that
bleed port is not clogged.

3. Install new packings (4, 7, or 10), if fittings (3 or 8)

or drain valve (13) were removed.

4. Torque the fittings (3 and/or 8), as applicable T .

28-00-00
Export Classification C, ECCN EAR99 18 JUL 2019 Rev. 25 Page 37
BHT-206L3-MM-4

T 3

T 2

T 3

206L3_MM_28_0012a

Figure 28-12. Fuel Filter Assembly (Sheet 1 of 2)

28-00-00
Page 38 Rev. 25 18 JUL 2019 Export Classification C, ECCN EAR99
 BHT-206L3-MM-4

T 1

25 TO 50 IN-LBS
T 1 (2.8 TO 5.6 Nm)

50 TO 70 IN-LBS
T 2 (5.6 TO 7.9 Nm)

235 TO 265 IN-LBS

T 3 (27 TO 29 Nm)

206L3_MM_28_0012b

Figure 28-12. Fuel Filter Assembly (Sheet 2 of 2)

28-00-00
Export Classification C, ECCN EAR99 18 JUL 2019 Rev. 25 Page 39
BHT-206L3-MM-4
NOTE
For information on consumable
materials, refer to BHT-ALL-SPM
manual.
1. Open right engine cowling.
2. Open drain valve (13, figure 28-12) and
drain fuel from filter bowl (21).
3. Disconnect drain hose (12) and remove
drain valve (13). Remove and discard packing
(10).
4. Cut lockwire and unscrew retainer {22)
from filter head (18). This will free filter bowl
(21) from filter head.
5. Remove filter element (24) from filter bowl
(21 ). Discard seals (20 and 23) and packing
(19)
NOTE
Use new filter element kit if filter is
contaminated.
6. Install new packing (19) in filter head
(18).
7. Install new seal (20) in filter head (18)
and new seal (23) in bottom of filter bowl (21).
Install seals with concave side facing
element.
8. Install filter element (24) in filter bowl
(21).
9. Position filter bowl (21) on filter head (18)
and secure by screwing retainer (22) into filter
head. Torque retainer 25 to 50 inch-pounds
(2.82 to 5.65 newton-meters).
10. Apply lockwire (C-405) between retainer
(22) and filter bowl (21).
11. Use new packing (10) and install drain
valve (13) using nut (11).
12. Connect drain hose (12) to drain valve.
13. Pressurize fuel system and check for
leaks at fuel filter (Volume 2, Chapter 5).
28-00-00
Page 40
!WARNING -
BE AWARE OF POTENTIAL FIRE
HAZA RD OF FUEL IN AN OPEN
CONTAINER.
BEFORE PURGING AIR FROM THE
AIRFRAME AND ENGINE FUEL
SYSTEM, BE SURE TO GROUND
THE AIRCRAFT.
BOTH FUEL BOOST PUMPS MUST
B E O N DUR I N G P U R G I N G
OPERATIONS.
14. Prior to next flight purge entrapped air
from airframe fuel filter as follows:
a. Deactivate engine ignition system by
opening ignition circuit breakers.
b. Disconnect engine fuel supply hose
from fuel nozzle on combustion chamber
case. Place hose in a clean container. (Refer
to Allison Operation and Maintenance Manual
14W2PM.)
c. Turn battery switch ON and open
throttle to fuel open position. Turn fuel valve
switch and both boost pump switches ON
(BHT-206L3-FM).
d. Wit h manual press-to- test button
p r e s s e d a n d h e l d, m o t o r engine for
approximately 15 seconds or until there is no
evidence of air coming from fuel supply hose.
e. Close throttle and turn fuel valve switch
and battery switch OFF (BHT-206LS-FM).
f. Reconnect fuel supply hose to fuel
nozzle. Tighten coupling nut to 80 to 120
inch-pounds (9.04 to 13.56 newton-meters).
(Refer to Allison Operation and Maintenance
Manual 14W2PM.)
 BHT-206L3-MM-4

g. Activate engine ignition system by closing 28-71. LOW LEVEL FUEL WARNING SWITCH —
ignition circuit breaker (BHT-206L3-FM). INSPECTION

h. Ground run helicopter with both boost pumps 1. Inspect low level fuel warning switch for corrosion
on at 100% N2 for 2 minutes to ensure any entrapped and condition. Remove any corrosion that is present.
air is purged from airframe and engine fuel systems
(BHT-206L3-FM). 2. Inspect electrical wiring for condition.

15. Close and secure engine cowling. 28-72. LOW LEVEL FUEL WARNING SWITCH —
INSTALLATION
28-69. LOW LEVEL FUEL WARNING SWITCH

SPECIAL TOOLS REQUIRED

The low level fuel warning switch is mounted through
the bottom of the fuel boost pump assembly located in
the aft fuel cell. The low level fuel warning switch is NUMBER NOMENCLATURE
electrically connected to the caution panel.
M81969/14-02 Removal/Installation
Tool
28-70. LOW LEVEL FUEL WARNING SWITCH —
REMOVAL
1. Place new packing (7, Figure 28-7) on low level
fuel warning switch (8).
SPECIAL TOOLS REQUIRED
2. Place low level fuel warning switch (8) through
hole in sump plate. Install bolts (10) and washers (9).
NUMBER NOMENCLATURE
3. Connect splice at positive terminal to low level
M81969/14-02 Removal/Installation fuel warning switch (8) using M81969/14-02 tool or
Tool equivalent.

1. Disconnect battery and ground helicopter. 4. Connect ground wire to bolt (21).

2. Defuel and purge fuel cells (Chapter 12). 5. Place retainer (24) to bottom of sump plate and
install screw (17), nut (22), washers (16 and 23), and
spacer (15).
3. Remove screw (17, Figure 28-7), nut (22),
washers (16 and 23), and spacer (15). Remove
6. Connect battery.
retainer (24).

7. Service fuel system (Chapter 12).

4. Disconnect positive terminal from low level fuel
warning switch (8) using M81969/14-02 tool or
equivalent. 28-73. FUEL MANIFOLD

A dual-branched fuel manifold is installed near the fuel

5. Disconnect ground wire from bolt (21). boost pump assembly in the aft fuel cell. During
operation of the fuel boost pump, fuel is supplied to
6. Remove bolts (10) and washers (9). the fuel manifold, which routes the fuel flow for engine
operation and fuel transfer. The fuel manifold has two
valves with poppets that are lightly spring loaded and
7. Remove low level fuel warning switch.
normally closed. During normal operation, fuel
pressure causes the poppet valves to open and
8. Remove and discard packing (7). remain open.

28-00-00
ECCN EAR99 30 APR 2010 Rev. 14 Page 41
BHT-206L3-MM-4
NOTE
Fuel manifold 206-364-604-101 may be
used as an alternate for 206-064-613-001
on S/N 51001 through 51243.
There are two fuel manifold models. The first is P/N
206-064-613-001 on helicopters S/N 51001 through
51243. The second is P/N 206-364-604-101 on
helicopters S/N 51244 and subsequent.
28-74. FUEL MANIFOLD — REMOVAL
WARNING
PERFORM DEFUELING OPERATIONS IN
AN AREA WHERE FIRE HAZARDS ARE
REDUCED TO A MINIMUM.
CAUTION
HANDLE FUEL CELL WITH EXTREME
CARE TO AVOID DAMAGE. PROTECT
ALL OPENINGS TO AVOID ENTRY OF
FOREIGN MATERIAL.
1. Disconnect the battery and external power
supply. Ground the helicopter.
2. Defuel and purge the fuel system (Chapter 12).
3. Remove the forward facing seat cushions, seat
back, and seat bottom (Chapter 25).
4. Remove the fuel boost pump assembly (8,
Figure 28-3) to gain access to the inside of the aft fuel
cell (paragraph 28-40).
5. Disconnect the fuel supply hose (4, Figure 28-3),
and hoses (39, 40, 41, and 42, Detail C) from the fuel
manifold (43).
NOTE
Tag hoses to identify for proper connection.
A string may be tied to each hose fitting and
retained outside aft fuel cell to prevent
hoses from falling to bottom of cell.
28-00-00
Page 42 Rev. 22 15 MAY 2015
6. On helicopters S/N 51001 through 51243,
disconnect the clamp installation that attaches the
interconnect tube to the manifold. Leave the hardware
in place on the tube.
7. Remove the bolts (38, Figure 28-3, Detail C),
washers (37), and fuel manifold (43).
28-75. FUEL MANIFOLD — DISASSEMBLY
CAUTION
DO NOT DISASSEMBLE FUEL
MANIFOLD 206-364-604. REMOVAL OF
CAPS, POPPETS, AND/OR SPRINGS
MAKES CALIBRATION BY
MANUFACTURER NECESSARY AFTER
ASSEMBLY. MAINTENANCE FOR THIS
FUEL MANIFOLD IS LIMITED TO
CLEANING BY FLUSHING. IF MANIFOLD
FAILS TO OPERATE PROPERLY AFTER
FLUSHING, RETURN MANIFOLD TO A
BELL HELICOPTER APPROVED
FACILITY FOR REPAIR.
NOTE
For purposes of cleaning, it is not
necessary to remove unions from fuel
manifold ports.
1. As applicable to fuel manifold 206-064-613-001,
index mark the valve assembly positions before
removal. Do not intermix the valve parts and/or
positions. Do not remove the spring guides (press
fitted inside inlet ports). Do not disassemble the
poppet valves.
2. Cut lthe ockwire and remove each valve
assembly consisting of the end fitting (5,
Figure 28-13), poppet valve (8), spring (9), and
packings (4, 6, and 7).
3. Remove the spring (9) and poppet valve (8) from
each end fitting (5).
4. Remove the plug and bleeder (3).
5. Remove and discard all packings.
Export Classification C, ECCN EAR99
 BHT-206L3-MM-4

28-76. FUEL MANIFOLD — CLEANING

(206-064-613-001)
CAUTION

SPECIAL TOOLS REQUIRED

DO NOT DISASSEMBLE FUEL
MANIFOLD 206-364-604. REMOVAL OF
NUMBER NOMENCLATURE CAPS, POPPETS, AND/OR SPRINGS
MAKES CALIBRATION BY
Commercial Ultrasonic Cleaner MANUFACTURER NECESSARY AFTER
ASSEMBLY. MAINTENANCE FOR THIS
FUEL MANIFOLD IS LIMITED TO
CLEANING BY FLUSHING. IF MANIFOLD
MATERIALS REQUIRED FAILS TO OPERATE PROPERLY AFTER
FLUSHING, RETURN MANIFOLD TO
Refer to BHT-ALL-SPM for specifications. BELL HELICOPTER APPROVED
FACILITY FOR REPAIR.
NUMBER NOMENCLATURE

C-304 1 Drycleaning Solvent NOTE

NOTE: For purposes of cleaning, it is not

necessary to remove unions from fuel
1 Use if ultrasonic cleaner is unavailable. manifold ports.

1. Using clean turbine fuel (C-003) and filtered

1. Using ultrasonic cleaner, remove all compressed air at 60 PSI (414 kPa), flush fuel
contaminates from parts. manifold through inlet ports.

NOTE 2. Using clean turbine fuel (C-003) and filtered

compressed air at 25 PSI (172 kPa), backflush fuel
If ultrasonic cleaner is not available, agitate manifold through outlet ports.
parts in drycleaning solvent (C-304) to
remove all contaminants.
3. Dry fuel manifold using clean, dry, low pressure
2. Dry parts using clean, dry, low pressure compressed air.
compressed air.
28-78. FUEL MANIFOLD — INSPECTION AND
28-77. FUEL MANIFOLD — CLEANING REPAIR (206-064-613-001)
(206-364-604)
1. Inspect parts for cleanliness, cracks, and other
damage.
MATERIALS REQUIRED
2. Inspect unions for damaged threads and other
Refer to BHT-ALL-SPM for specifications. damage.

NUMBER NOMENCLATURE 3. Remove contaminants from parts.

C-003 Turbine Fuel

4. Replace cracked and/or damaged parts.

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BHT-206L3-MM-4

NOTES

&. Unions not shown in five open ports. Do not remove

unions for purposes of cleaning manifold.

&, Do not disassemble or attempt to adjust poppet.

-----J-�
1

::=::
9-----­
1. Manifold body
� 2. Packing
3. Plug and bleeder
*4. Packing
*5. End fitting
8� *6. Packing
*7. Packing
*8. Poppet valve
*9. Spring

* Part of valve assembly

206L3-28-13

Figure 28-13. Fuel manifold PIN 206-064-613-001

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 BHT-206L3-MM-4

28-79. FUEL MANIFOLD — ASSEMBLY not return to closed position, disassemble valve
(206-064-613-001) assembly and check for binding. Also, check spring for
proper seating in spring seat.

MATERIALS REQUIRED 9. Repeat step 7 for opposite poppet valve (8). If

necessary, repeat step 8.
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE 10. Using lockwire (C-405) or shear wire (C-414),

secure each end fitting (5) to manifold body (1).
C-405 Lockwire

C-414 Shear Wire 11. For any union removed, install union and new
packing.

NOTE
28-80. FUEL MANIFOLD — INSTALLATION
To prevent intermixing parts during
assembly, refer to markings.
1. Attach fuel manifold (43, Figure 28-3, Detail C)
using washers (37) and bolts (38).
1. Install new packing (2, Figure 28-13) on plug and
bleeder (3) and install in manifold body (1).
2. On helicopters S/N 51001 through 51233,
connect clamp installation to attach interconnect tube
2. Install new packings (6 and 7) on each end
to manifold. Use existing hardware kept on tube.
fitting (5).

3. Connect fuel supply hose (4, Figure 28-3) and

3. Install new packing (4) on each poppet valve (8).
hoses (39, 40, 41, and 42, Detail C) to fuel
manifold (43).
4. Place poppet valve (8) in each end fitting (5).
Place spring (9) on top of each poppet valve.
4. Install fuel boost pump assembly (8, Figure 28-3)
(paragraph 28-42).
5. Hold manifold body (1) and valve assembly
upright and vertical. Carefully thread valve assembly
5. Install forward facing seat cushions, seat back,
into manifold body. Torque 27 to 33 foot-pounds (36.6
and seat bottom (Chapter 25).
to 44.7 Nm).

6. Repeat step 5 for opposite valve assembly.

WARNING

7. Obtain a 4 to 5 inch (100 to 125 mm) length of

welding rod or equivalent, 1/8 inch (3.17 mm) or less in PERFORM REFUELING OPERATIONS IN
diameter. Carefully insert rod into inlet of end fitting (5) AN AREA WHERE FIRE HAZARDS ARE
and lightly depress poppet valve (8) approximately REDUCED TO A MINIMUM.
1/16 inch (1.58 mm) to open position. Release poppet
valve. 6. Refuel helicopter (Chapter 12).

8. Poppet valve (8) is lightly spring loaded and 7. Connect battery and external power supply.
should return to closed position. If poppet valve does Remove ground connection.

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