BHT-206L4-MM-4

CHAPTER 28 — FUEL SYSTEM

TABLE OF CONTENTS

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 7
28-7 Forward Fuel Cells......................................................................... 28-00-00 7
28-8 Removal.................................................................................... 28-00-00 7
28-9 Forward Fuel Cell — Inspection ............................................... 28-00-00 9
28-10 Forward Fuel Cell — Cleaning.................................................. 28-00-00 9
28-10A Forward Fuel Cell — Repair ..................................................... 28-00-00 10
28-11 Forward Fuel Cell — Installation............................................... 28-00-00 10
28-12 Aft Fuel Cell ................................................................................... 28-00-00 12
28-13 Aft Fuel Cell — Removal .......................................................... 28-00-00 12
28-13A Aft Fuel Cell — Cleaning .......................................................... 28-00-00 15
28-14 Aft Fuel Cell — Inspection ........................................................ 28-00-00 16
28-14A Aft Fuel Cell — Repair .............................................................. 28-00-00 17
28-15 Aft Fuel Cell — Installation ....................................................... 28-00-00 17
28-16 Fuel Distribution ............................................................................. 28-00-00 18
28-17 Forward Fuel Cell — Distribution Components.............................. 28-00-00 18
28-18 Dual Element Ejector Pump........................................................... 28-00-00 18
28-19 Dual Element Ejector Pump — Removal.................................. 28-00-00 18A
28-20 Dual Element Ejector Pump — Inspection................................ 28-00-00 18A
28-21 Dual Element Ejector Pump — Installation............................... 28-00-00 18A
28-22 Fuel Flow Switches ........................................................................ 28-00-00 18A
28-23 Fuel Flow Switches — Removal ............................................... 28-00-00 18A
28-24 Inspection ................................................................................. 28-00-00 21
28-25 Installation................................................................................. 28-00-00 21
28-26 In-line Fuel Filters .......................................................................... 28-00-00 21
28-27 Removal.................................................................................... 28-00-00 21
28-28 Inspection ................................................................................. 28-00-00 21
28-29 Installation................................................................................. 28-00-00 22
28-30 Fuel Quantity Probe — Forward Fuel Cell ..................................... 28-00-00 22
28-31 Removal.................................................................................... 28-00-00 22
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 23
28-36 Inspection ................................................................................. 28-00-00 23
28-37 Installation................................................................................. 28-00-00 25
28-38 Aft Fuel Cell — Distribution Components ...................................... 28-00-00 25
28-39 Fuel Boost Pump ........................................................................... 28-00-00 25
28-40 Removal.................................................................................... 28-00-00 25
28-41 Inspection ................................................................................. 28-00-00 28
28-42 Installation................................................................................. 28-00-00 28
28-43 Canister Fuel Boost Pump ............................................................. 28-00-00 29
28-44 Removal.................................................................................... 28-00-00 29

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BHT-206L4-MM-4

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

28-45 Installation................................................................................. 28-00-00 29

28-46 Aft Fuel Quantity Probe.................................................................. 28-00-00 30
28-47 Removal.................................................................................... 28-00-00 30
28-48 Inspection ................................................................................. 28-00-00 30
28-49 Installation................................................................................. 28-00-00 30
28-50 Fuel Quantity Transmitter .............................................................. 28-00-00 30
28-51 Removal.................................................................................... 28-00-00 30
28-52 Inspection ................................................................................. 28-00-00 32
28-53 Installation................................................................................. 28-00-00 32
28-54 Fuel Pressure Transducer ............................................................. 28-00-00 32
28-55 Removal.................................................................................... 28-00-00 32
28-56 Inspection ................................................................................. 28-00-00 32
28-57 Installation................................................................................. 28-00-00 32
28-58 Fuel Shutoff Valve.......................................................................... 28-00-00 32
28-59 Removal.................................................................................... 28-00-00 32
28-60 Fuel Shutoff Valve — Installation.............................................. 28-00-00 34A
28-61 Fuel Sump Drain Valve .................................................................. 28-00-00 34A
28-62 Fuel Sump Drain Valve — Removal ......................................... 28-00-00 34A
28-63 Installation................................................................................. 28-00-00 35
28-64 Fuel Filter ....................................................................................... 28-00-00 35
28-65 Removal.................................................................................... 28-00-00 35
28-66 Fuel Filter — Inspection............................................................ 28-00-00 38
28-67 Fuel Filter — Installation ........................................................... 28-00-00 38
28-68 Fuel Filter Element Replacement................................................... 28-00-00 38
28-69 Fuel Low Level Switch ................................................................... 28-00-00 39
28-70 Fuel Low Level Switch — Removal .......................................... 28-00-00 39
28-71 Fuel Low Level Switch — Inspection ........................................ 28-00-00 40
28-72 Fuel Low Level Switch — Installation ....................................... 28-00-00 40
28-73 Fuel Manifold ................................................................................. 28-00-00 40
28-74 Fuel Manifold — Removal ........................................................ 28-00-00 40
28-75 Fuel Manifold — Disassembly .................................................. 28-00-00 41
28-76 Fuel Manifold — Cleaning ........................................................ 28-00-00 41
28-77 Fuel Manifold — Inspection and Repair.................................... 28-00-00 41
28-78 Fuel Manifold — Assembly ....................................................... 28-00-00 41
28-79 Fuel Manifold — Installation ..................................................... 28-00-00 42

FIGURES

Figure Page
Number Title Number

28-1 Fuel System Schematic ...................................................................................... 6

28-2 Forward Fuel Cells.............................................................................................. 8
28-3 Aft Fuel Cell ........................................................................................................ 12A
28-4 Dual Element Ejector Pump and Connecting Tubes........................................... 19
28-5 Fuel Flow Switches, Filters, and Connecting Tubes ........................................... 20
28-6 Interconnect Tube ............................................................................................... 24

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 BHT-206L4-MM-4

FIGURES (CONT)

Figure Page
Number Title Number

28-7 Fuel Boost Pump Assembly................................................................................ 26

28-8 Aft Fuel Quantity Probe....................................................................................... 31
28-9 Fuel Quantity Transmitter ................................................................................... 33
28-10 Fuel Pressure Transducer .................................................................................. 34
28-11 Fuel Shutoff Valve............................................................................................... 35
28-12 Fuel Filter Assembly ........................................................................................... 36

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 BHT-206L4-MM-4

FUEL SYSTEM

28-1. FUEL SYSTEM 28-3. TROUBLESHOOTING OF

ELECTRICAL SYSTEM
The fuel system is comprised of three interconnected
Refer to the BHT-206L4-MM-10, Chapter 96 for fuel
non self-sealing bladder type fuel cells. Two forward
quantity calibration, fuel filter, and fuel pump electrical
fuel cells are located under the aft facing passenger
circuitry.
seat and are crash resistant. The aft fuel cell is located
under and behind the aft passenger seat and is a
28-4. OPERATIONAL CHECK
crash resistant cell. Fuel from the two forward fuel
cells is transferred to the aft fuel cell by means of a
Refer to the BHT-206L4-MM-10, Chapter 96 for fuel
dual element ejector pump which is located between
filter, fuel flow switch, fuel low, and fuel pump caution
and connected to both forward fuel cells. Forward fuel systems operational check.
cells and aft fuel cells are vented overboard by a
common vent line. Each forward fuel cell has a fuel 28-5. TESTING
flow switch located outside the fuel cells and adjacent
to the ejector pump. The left forward fuel cell has a 1. With the throttle off and the shutoff valve on,
fuel quantity probe. The aft fuel cell has a fuel boost connect the air source to the vent line.
pump sump located on the bottom of the fuel cell. Two
fuel boost pumps are mounted on the fuel cell sump. A
fuel quantity probe is located in the top of the forward
part of the aft fuel cell. A fuel quantity transmitter is CAUTION
located in the top of the aft fuel cell and is electrically
connected to the fuel quantity probes. The fuel cell
sump is equipped with a low fuel switch which is D O N O T A P P LY M O R E T H A N
connected to a fuel low light located on the pilot RECOMMENDED PRESSURE AS
caution segmented panel. Also, the fuel cell sump is DAMAGE TO FUEL SYSTEM AND
equipped with a fuel sump drain solenoid valve STRUCTURE MAY RESULT. USE MILD
(Figure 28-1). SOAP SUDS SOLUTION TO LOCATE
LEAKS.

28-2. SAFETY PRECAUTIONS NOTE

1. All fueling and defueling operations should be
performed in an area where fire hazards are reduced
to a minimum.
2. Handle fuel cells with extreme care during
removal and installation to prevent damage to the
cells. Do not attempt to remove or install a cold fuel
cell.
3. Helicopter must be grounded prior to performing
defueling operations.
Use regulated low pressure, filtered,
compressed air source, an accurate
pressure gauge, and a shutoff valve.
2. Slowly apply pressure until the gauge indicates
0.75 to 1.00 PSI (5.17 to 6.89 kPa). Shut off the air
source. The fuel system should hold this pressure for
15 minutes.
3. Locate and correct any leakage indicated. Repeat
pressure test if leaks are found.
4. Remove test equipment from the vent line.

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BHT-206L4-MM-4

ENGINE

A/F MOUNTED
FUEL FILTER

SHUT-OFF
VALVE

RIGHT FUEL CELL

T (TOP)
tc:
AFT FUEL CELL

DUAL ELEMENT EJECTOR PUMP

.------t----,:..r.,--- CHECK VALVES

INTERCONNECT TUBE
MANIFOLD

DUAL ELEMENT

'----1=��::i�tb_lfiii���=--=--=--=-=-==!===- 1
1,------
FUEL PUMP
(ELECTRIC)

THERMAL RELIEF VALVES

FLOW SWITCHES

@-ti
INLINE FUEL FILTERS
PROBE
AND CHECK VALVES

n-_+_______
y �NT (TOP)
LEFT FUEL CELL
206L4-M-28-1

Figure 28-1. Fuel system schematic

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28-6. FUEL CELLS.
Fuel system includes three nonself-sealing
bladder type fuel cells. The two forward fuel
cells are located under the aft-facing
passenger seats. The aft fuel cell is located
under and behind the aft passenger seat.
28-7. FORWARD FUEL CELLS.
Two forward fuel cells are located under the
aft-facing seats just forward of Station 100.00.
Fuel cells are nonself-sealing, crash-resistant,
rubberized fabric. They are secured in place
with nylon lacing. The cells have molded type
metal fittings at openings and passages for
internal components. Both cells are vented
and interconnected. Both cells utilize a dual
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 operating. The left
forward fuel cell is equipped with a fuel
quantity probe.
28-8. REMOVAL.
I
WARNING -
ALL DE FUEL ING OPE RATI ONS
SHOULD BE PERFORMED IN AN
ARE A WHE RE FIRE HAZARDS
ARE REDUCED TO A MINIMUM.
H AN DL E F U E L C EL L W I TH
EX T RE M E C A RE DU R ING
REMOVAL TO AVOID DAMAGE TO
CE LL. PROTECT ALL OPENINGS
TO PREVENT ENTRY OF FOREIGN
MATERIAL. BE SURE FUEL CELL
I S WARM E N O UGH T O BE
FLEXIBLE.
1. Disconnect battery and external power
supply. Ground helicopter.
2. Defuel and purge fuel system (Volume 2,
Chapter 12).
BHT-206L4-MM-4
NOTE
Removal procedure is the same for
either right or left fuel cell except
that the right fuel cell does not have
a fuel quantity probe. The following
procedures is for the left fuel cell.
3. Remove the aft facing seat cushions and
seat backs (Volume 3, Chapter 25).
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.
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).
R emove bolts (32) at each side of fuel
quantity probe.
7. Remove seat panels to expose left fuel
i· · · · · · · · ·1
cell. Remove cover below center seat panel.
CAUTION
•••••••••••••••••
R E SIDUAL FUEL MAY DR AIN
FR O M F U E L CELL S W H E N
REMOVING DRAIN FITTING (19).
8. Remove bolts (20) from drain fitting (19).
Remove drain fitting (19). Discard packing
(18).
9. Remove bolts (3 and 13), with washers,
and remove tube assembly (7). Discard
packing (6).
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BHT-206L4-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)
206L4_MM_28_0002

Figure 28-2. Forward Fuel Cells

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10. Remove the bolts (11) and the washers (10).
Remove the seal (9).
11. Remove the bolts (29 and 33) from the 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 the nylon cord lacing that
secures the fuel cell to the fuselage structure.
Carefully collapse the fuel cell and remove from the
airframe. The fuel quantity probe electrical wire (8) is
routed through the interconnect tube (4) and must be
guided out of the fuel cell and left in the helicopter.
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. FORWARD FUEL CELL — INSPECTION
WARNING
OBEY ALL SAFETY PRECAUTIONS
WHEN YOU DO MAINTENANCE ON
FUEL SYSTEM EQUIPMENT.
CAUTION
OBEY ALL FUEL CELL HANDLING
PRECAUTIONS DURING INSPECTION
O R D A M A G E T O T H E C E L L M AY
OCCUR.
Export Classification C, ECCN EAR99
BHT-206L4-MM-2
NOTE
The following inspection criteria are
primarily intended when the part or
component has been removed from the
helicopter. To accomodate all inspection
requirements, applicable criteria may also
be used when the part or component is
installed on the helicopter.
1. Visually examine the exterior and interior of the
fuselage beneath the forward fuel cells (23 and 28,
Figure 28-2) for signs of fuel leaks.
2. Inspect the fuel cell drain valves (21) for evidence
of leaks.
3. Visually examine the forward fuel cells (23 and
28) for signs of cracks, cuts, tears, and damage to
attachment faces and general fuel cell condition.
Replace damaged forward fuel cell (paragraph 28-8).
4. Inspect the fuel interconnect and vent lines and
fittings for leaks, damage, and security.
5. Inspect the fuel cells for evidence of fungus. If
fungus is present, clean and treat (paragraph 28-10).
28-10. FORWARD FUEL CELL — CLEANING
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-003 Turbine Fuel
C-339 Ethyl Alcohol
WARNING
OBEY ALL SAFETY PRECAUTIONS
WHEN YOU DO MAINTENANCE ON
FUEL SYSTEM EQUIPMENT.
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BHT-206L4-MM-2
CAUTION
OBEY ALL FUEL CELL HANDLING
PRECAUTIONS DURING CLEANING OR
DAMAGE TO THE CELL MAY OCCUR.
CAUTION
DO NOT USE SOAPS OR STRONG
DETERGENTS TO CLEAN THE INTERIOR
OF THE FUEL CELL. SOME SOAPS OR
DETERGENTS CAN CAUSE DAMAGE TO
THE FUEL CELL. SOAPS CAN REACT
WITH TURBINE FUEL (C-003)
( B H T- A L L - S P M ) AND CAUSE
CONTAMINATION IN THE FUEL FILTE
CAUTION
IT IS STRONGLY RECOMMENDED TO
USE DISPOSABLE CLOTHS. IF
R E U S A B L E C L O T H S A R E U S E D TO
REMOVE FUNGUS, MAKE SURE THEY
A R E N O T U S E D TO C L E A N O T H E R
SYSTEMS ON THE HELICOPTER,
O T H E RWI S E C O N TA MI N AT I O N C A N
OCCUR.
CAUTION
IF HOT WATER IS USED TO CLEAN FUEL
C E L L , I T I S R E C O M M E N D E D T H AT
T E M P E RAT UR E O F H O T WATE R B E
L I M I T E D TO 1 6 0 ° F ( 7 1 ° C) . H O T T E R
WATER CONSTITUTES A HAZARD TO
PERSONNEL.
NOTE
Any evidence of fuel leakage must be
identified before cleaning.
1. Remove all fungus growth from the fuel cell by
hand or with a soft scrub brush using warm or hot
water.
28-00-00
Page 10 Rev. 24 18 JUL 2019
2. When fungus is observed in the fuel cell, wipe the
cell clean with cloths moistened with ethyl alcohol
(C-339). Burn the wiping cloths after cleaning to destroy
fungus (BHT-ALL-SPM).
3. Use turbine fuel (C-003) for cleaning the fuel cell
to assist in protecting the inner liner against aging if the
cell remains out of service for several weeks without
fuel.
28-10A. FORWARD FUEL CELL — REPAIR
NOTE
Refer to the General Information Letter (IL)
GEN-04-98 for the applicable shipping
information and to obtain a Return Material
Authorization (RMA) number.
1. If field repair of the forward fuel cells (23 and 28,
Figure 28-2) is not authorized or feasible, return the
part to Bell Helicopter Textron (BHT) for evaluation and
possible repair.
28-11. FORWARD FUEL CELL — INSTALLATION
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-308 Sealant
C-405 Lockwire
C-408 Talcum Powder
C-453 Tape
C-471 Lacing Cord
CAUTION
MAKE SURE THAT YOU REMOVE THE
CAPS AND/OR PLUGS (BHT-ALL-SPM)
FROM ALL OF THE OPEN LINES AND
PORTS OF THE FUEL SYSTEM. THIS
PREVENTS CONTAMINATION OF THE
SYSTEM.
Export Classification C, ECCN EAR99

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.
1. Prior to installation of either left or right forward
fuel cell (23 and 28, Figure 28-2), carefully inspect the
fuel cell cavity for foreign objects. Make sure all sharp
edges and rivet heads are covered with tape (C-453) or
sealant (C-308).
2. Remove the caps and/or plugs from the lines and
the ports of the fuel system.
CAUTION
MAKE SURE THAT THE FUEL CELL IS AT
ROOM TEMPERATURE BEFORE YOU
F O L D O R U N F O L D I T. W H E N Y O U
REMOVE OR INSTALL THE FUEL CELL,
HANDLE IT WITH CARE.
3. Place the seal (9) at the outboard end of the
interconnect tube (4) and feed the electrical wire (8)
through the seal, into the interconnect port of the fuel
cell, and out the fuel quantity probe port.
4. Apply talcum powder (C-408) to the fuel cell cavity.
5. Insert the collapsed fuel cell into the fuel cell
cavity. With two separate lacing cords (C-471), lace and
tie the top of the fuel cell to the seat support with the ten
delta fasteners located on top of each fuel cell.
6. Place the new packing (18) in the recess of the
drain fitting (19). Position the drain fitting below the fuel
cell and the fuselage structure and secure with the bolt
(20). Use three undrilled headed bolts and one drilled
head bolt. Install the drain valve (21) with the packing
(22), if removed. Torque the bolts 50 to 75 inch-pounds
(5.7 to 8.5 Nm) T . Secure the drain valve to the drilled
bolt head with lockwire (C-405).
7. Position the inboard side of the fuel cell against
the fuselage structure with the attachment holes
aligned. Install the bolts (29 and 33) with the thin
aluminum washers. Do not tighten the bolts.
8. Insert the bolts (11), with the thin aluminum
washers (10), through the interconnect tube flange and
Export Classification C, ECCN EAR99
BHT-206L4-MM-2
seal (9) and into the fuel cell. Torque the bolts 50 to 75
inch-pounds (5.7 to 8.5 Nm) T .
9. If previously removed, install the clamps (38) on
the tube (7). Torque the screw on the clamp T .
10. Slide the retainer (5) and the packing (6) on the
tube (7). Guide the formed end of the tube into the fuel
cell. Make sure that the formed end of the tube is down.
Place the packing at the inboard end of the tube and
install the bolts (3) with a thin aluminum washer.
Position the packing and the retainer against the fuel
cell. Install the bolts (13) with the thin aluminum
washers. Torque the bolts (3, 13, 29, and 33) 50 to
75 inch-pounds (5.7 to 8.5 Nm) T .
11. Place the gasket (16) on the fuel quantity probe
(17). Connect the electrical wires to the fuel quantity
probe terminals (31) (BHT-206L4-MM-12, Chapter 98).
Insert the fuel quantity probe and electrical wiring into
the fuel cell. Install the bolts (14) with the thin aluminum
washers (15). Torque the bolts 50 to 75 inch-pounds
(5.7 to 8.5 Nm) T .
12. Place the fuel cell seat panel over the fuel cell.
Use two long AN4 bolts and screw into the fuel cell
threaded holes at the bolts (32) location. Pull the fuel
cell up to the cover, remove one long bolt, and install
the bolt with a large washer. Remove the opposite long
bolt and install the bolt with the large washer. Torque
the bolts 50 to 75 inch-pounds (5.7 to 8.5 Nm) T .
13. Insert the new packing (27) on the vent fitting (26)
and install on the fuel cell using the bolts (24), with thin
aluminum washers (25). Torque the bolts 50 to
75 inch-pounds (5.7 to 8.5 Nm) T .
14. Untie the end of the vent hose assembly (30).
Connect the vent hose to the vent fitting (26). Torque
the B-nuts. Secure the sleeve (36) with the new
straps (35).
15. Pressure test the fuel cells (paragraph 28-5) and
Chapter 5.
16. Install the access panel that is located above the
dual ejector pump and the flow switches.
17. Install the center seat access panel.
18. Install the cover over the fuel quantity probe.
19. Install the seat cushions and backs (Chapter 25).
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BHT-206L4-MM-2

20. Service the fuel system (Chapter 12).

NOTE
Remove only the parts that are necessary
21. Connect the battery.
to do maintenance.

28-12. AFT FUEL CELL 1. Disconnect the battery and external power
supply. Ground the helicopter.
The aft fuel cell is a non self-sealing, crash-resistant,
rubberized fabric cell. The cell is located below and aft 2. Defuel and purge the fuel system
of the aft passenger seat. Mounted in the bottom of the (BHT-206L4-MM-2, Chapter 12).
fuel cell are two electrically operated fuel boost
pumps, electrically operated sump drain, and a low
3. Remove the forward facing seat cushions, seat
level switch installed in the fuel cell sump. A fuel
back, and seat bottom (BHT-206L4-MM-3,
quantity probe is installed in the forward top part of the
Chapter 25).
aft fuel cell and is electrically connected to the forward
fuel cell transmitter and the aft fuel cell transmitter and
a fuel pressure transducer. The cell has a fuel filler cap 4. Remove the fuel boost pump assembly (8,
located on the right side of the helicopter just aft of the Figure 28-3) to gain access inside the tank
passenger door. (paragraph 28-40).

28-13. AFT FUEL CELL — REMOVAL 5. Remove the fuel quantity transmitter (6)
(paragraph 28-51).

MATERIALS REQUIRED 6. Remove the aft fuel quantity probe (9)

(paragraph 28-47).
Refer to BHT-ALL-SPM for specifications.
7. Remove the fittings on the top right side of the
NUMBER NOMENCLATURE fuel cell above the fuel filler as follows:
C-428 Caps and/or Plug
a. Remove the fuselage access panel located
above the fuel filler.

b. Disconnect the fuel supply hose (4) from the

WARNING
fitting (32, Detail B) and the manifold (43, Detail C).
Remove the hose. Remove the jamnut (29) and the
washer (30).
PERFORM ALL DEFUELING
OPERATIONS IN AN AREA WHERE FIRE
c. Disconnect the electrical connector from the
HAZARDS ARE REDUCED TO A
fuel pressure transducer (34, Detail B).
MINIMUM.

d. Disconnect the inlet tube (1) from the fitting

elbow (33, Detail B) and the shutoff valve (2). Remove
the tube and lift the fitting (32) from the fuel cell.
CAUTION
Remove and discard the packing (31).

MAKE SURE THAT YOU INSTALL CAPS
AND/OR PLUGS (C-428) (BHT-ALL-SPM)
ON ALL OF THE OPEN LINES AND
PORTS OF THE FUEL SYSTEM. THIS
PREVENTS CONTAMINATION OF THE
SYSTEM.
e. Disconnect the vent hose (3) from the vent
fitting (26).
f. Remove the vent vitting (26) from the fuel cell
by removing the screws (23), washers (24), and flange
(25). Discard the packing (27).

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 BHT-206L4-MM-2

206L4_MM_28_0003a

Figure 28-3. Aft Fuel Cell (Sheet 1 of 3)

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 BHT-206L4-MM-4

A'
17-----TORQUE
50TO 75 IN-LBS
18 15.6510 8.47 Nml
�
r>. .........

16
20

21

22

FUEL CELL (REF)

3 REF
DETAIL A

REF
\ 33
34
�
16. Washer
17. Screw
18. Bonding tab
19. Retainer 32
20. Cap and adapter
21. Seal
22. Packing
23. Screw TORQUE
24. Washer 401N-LBS 31
25. Flange (4.52Nml
26. Vent fitting MAXI MUM
FUEL CELL (REF)
27. Packing
28. Retainer
29. Jamnut
30. Washer
31. Packing
32. Fitting
33. Elbow
34. Fuel pressure transducer
35. Bolt
36. Washer

206L4-M-28-3-2

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

28-00-00
Page 13
BHT-206L4-MM-4

4 REF
43

2 40

37

38

1 39

4 42 41 3
DETAIL C
MANIFOLD 206-364-604 TYPICAL
41
37. Washer REF 14
38. Bolt
39. Hose
40. Hose T 66 42
41. Hose
42. Hose
65 T 70
43. Manifold
64 44 T
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
56. Clip 50 TO 75 IN-LBS
57. Hose
FUEL CELL
(REF)
T (5.65 TO 8.47 Nm)
58. Packing
59. Interconnect 50
NOTES
60. Bolt 62 7 REF
61. Washer 1 Hose routed to aft boost
51
62. Hose pump fitting.
63. Packing
64. Flange 2 Hose routed to fwd boost
65. Washer pump fitting.
66. Bolt 61 53
67. Packing 60 3 Hose routed to left fuel flow
68. Tube 55 switch (Figure 28-5).
54
69. Washer 58 52
70. Bolt 56 4 Hose routed to right fuel flow
59 57 switch (Figure 28-5).
DETAIL D 206L4_MM_28_0003c

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

28-00-00
Page 14 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-4

g. Remove the retainer (28) from the fuel cell by
removing the bolt (35) and the washer (36).
8. Remove the screws (17), washers (16), retainer
(19), cap and adapter (20), seal (21), and packing
(22). Discard the packing.
9. Disconnect the hoses (39, 40, 41, and 42) from
the manifold (43). Remove the hoses (39 and 40).
10. Remove the bolts (38) and the washers (37) and
remove the manifold (43) from the fuel cell.
21. Disconnect the tube (68) from the hose (62).
22. Remove the bolts (70) and the washers (69) that
attach the tube (68) to the fuel cell. Remove the tube
and discard the packing (67).
23. Remove the fuel cell access panel at the
seatback attachment area.
24. Remove the screws (13) and the washers (12)
that secure the fuel cell to the structure at eight places.

11. Disconnect the hoses (41 and 42) from the lower
CAUTION
forward fuel cell connection and remove the hoses.

12. Remove the bolts (60) and the washers (61) and DO NOT FOLD A COLD FUEL CELL.
disconnect the interconnect assembly (59). Discard FOLDING MAY CRACK OR DAMAGE A
the packing (58). Remove the clamp and clip (5) that C O L D C E L L . H E AT L A M P S M AY B E
secures the fuel quantity probe harness (7) to the USED TO WARM FUEL CELL PRIOR TO
interconnect tube (10). FOLDING.

13. Withdraw the fuel quantity probe harness (7)
through the interconnect tube (10) and the fitting (51)
and stow outside the fuel cell as indicated.
14. Remove the bolt (54), nut (52), washers (53 and
55), and clip (56) that secure the hoses (57) together.
15. Disconnect the tubes (48) from the hoses (57).
25. If required, heat the cell for approximately
2 hours. Do not exceed 125°F (51.7°C).
26. Carefully collapse the fuel cell and remove from
the helicopter.
27. Install caps and/or plugs (C-428) on all open
ports.

16. Remove the bolt (44) and the washer (45) that 28-13A. AFT FUEL CELL — CLEANING
secures the retainer (46) to the fuel cell. Remove the
tubes (48) from inside the fuel cell. Discard the
packings (47). MATERIALS REQUIRED

17. Disconnect the clamps (15) that secure the Refer to BHT-ALL-SPM for specifications.
ejector pump tube (14) and the interconnect tube (10)
NUMBER NOMENCLATURE
together.
C-339 Ethyl Alcohol
18. Remove the screw (11) that secures the clamp
and the interconnect tube (10) to the fuel cell.

19. Remove the bolts (66) and the washers (65) that WARNING
attach the flange (64) and the interconnect tube (10) to
the fuel cell. Remove the interconnect tube and
discard the packing (63). OBEY ALL SAFETY PRECAUTIONS
WHEN YOU DO MAINTENANCE ON
20. Disconnect the ejector pump tube (14) from the FUEL SYSTEM EQUIPMENT.
tube (68) and remove from the fuel cell.

28-00-00
Export Classification C, ECCN EAR99 18 JUL 2019 Rev. 24 Page 15
BHT-206L4-MM-4
CAUTION
OBEY ALL FUEL CELL HANDLING
PRECAUTIONS DURING INSPECTION
O R D A M A G E T O T H E C E L L M AY
OCCUR.
CAUTION
DO NOT USE SOAPS OR STRONG
DETERGENTS TO CLEAN THE
INTERIOR OF THE FUEL CELL. SOME
SOAPS OR DETERGENTS CAN CAUSE
DAMAGE TO THE FUEL CELL. SOAPS
CAN REACT WITH TURBINE FUEL
(C-003) (BHT-ALL-SPM) AND CAUSE
CONTAMINATION IN THE FUEL FILTER.
CAUTION
IT IS STRONGLY RECOMMENDED TO
USE DISPOSABLE CLOTHS. IF
REUSABLE CLOTHS ARE USED TO
REMOVE FUNGUS, MAKE SURE THEY
A R E N O T US E D TO C L E A N O T H E R
SYSTEMS ON THE HELICOPTER,
OTHERWISE CONTAMINATION CAN
OCCUR.
NOTE
Any evidence of fuel leakage must be
identified before cleaning.
1. Clean all the fungus growth with a soft scrub
brush and warm water. Wipe the inner liner with a
clean cloth moistened with ethyl alcohol (C-339)
(BHT-ALL-SPM, Chapter 5).
28-00-00
Page 16 Rev. 24 18 JUL 2019
28-14. AFT FUEL CELL — INSPECTION
WARNING
OBEY ALL SAFETY PRECAUTIONS
WHEN YOU DO MAINTENANCE ON
FUEL SYSTEM EQUIPMENT.
CAUTION
OBEY ALL FUEL CELL HANDLING
PRECAUTIONS DURING INSPECTION
O R D A M A G E T O T H E C E L L M AY
OCCUR.
NOTE
The following inspection criteria are
primarily intended when the part or
component has been removed from the
helicopter. To accomodate all inspection
requirements, applicable criteria may also
be used when the part or component is
installed on the helicopter.
1. Visually examine the exterior and interior of the
fuselage underneath the fuel cell for signs of fuel
leaks.
2. Visually examine the aft fuel cell for signs of
cracks, cuts, tears, and damage to attachment faces
and general condition of the fuel cell. Replace a
damaged aft fuel cell (paragraph 28-13).
3. Inspect the fuel cell drain valve for evidence of
leaks.
4. Inspect the fuel lines, fittings, and fuel cell covers
for leaks, damage, and security.
5. Inspect the vent hose for leaks, chafing, damage,
and security.
Export Classification C, ECCN EAR99

CAUTION
MAKE SURE ELECTRICAL LEADS FROM
BATTERY RELAY BUS BAR DO NOT
TOUCH VENT HOSE (CHAPTER 96).
6. Inspect the cell for evidence of fungus. If fungus
is present, treat as per paragraph 28-13A.
28-14A. AFT FUEL CELL — REPAIR
NOTE
Refer to the General Information Letter (IL)
GEN-04-98 for the applicable shipping
information and to obtain a Return Material
Authorization (RMA) number.
1. If field repair of the aft fuel cell is not authorized or
feasible, return the part to Bell Helicopter Textron
(BHT) for evaluation and possible repair.
28-15. AFT FUEL CELL — INSTALLATION
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-328 Sealant
C-408 Talcum Power
C-453 Tape
1. Carefully inspect the fuel cell cavity for foreign
objects. Make sure all sharp edges and rivet heads
are covered with tape (C-453).
CAUTION
HANDLE FUEL CELL WITH EXTREME
CARE DURING INSTALLATION TO AVOID
DAMAGE TO FUEL CELL. BE SURE FUEL
C E L L I S WA R M E N O U G H T O B E
FLEXIBLE.
Export Classification C, ECCN EAR99
BHT-206L4-MM-4
2. If required, heat the fuel cell for approximately
2 hours. Do not exceed 125°F (52°C).
3. Make a workaid, consisting of a section of broom
handle or equivalent, approximately 5 feet (1.8 m)
long. Round off both ends and fasten a piece of
sponge rubber to one end.
4. Apply talcum powder (C-408) to the fuel cell
cavity. Collapse the fuel cell and insert through the
seatback opening and position the forward section of
the cell under the seat. Use a workaid to restore the
collapsed cell to its proper shape by gently pushing the
sponge-covered end of the stick against the sides and
bottom of the fuel cell.
5. Install the screws (13, Figure 28-3) and the
washers (12) (8 places) to secure the fuel cell to the
airframe structure. Tighten the screws.
6. Install the new packing (67) on the tube (68).
Insert the tube from inside the fuel cell through its
respective port. Secure in place using the washers
(69) and the bolts (70). Torque the bolts 50 to
75 inch-pounds (5.7 to 8.5 Nm).
7. Connect the tube (68) to the hose (62).
8. Install the new packing (58) on the interconnect
assembly (59) and the new packing (50) on the fitting
(51). Install the new packing (63) and the flange (64)
on the interconnect tube (10).
9. Route the fuel quantity probe harness (7) through
the fitting (51) and the interconnect tube (10) inside
the fuel cell.
10. Connect the interconnect tube (10) and the flange
(64) to the fuel cell and the fitting (51) using the
washers (65), bolts (66), and new packings (49).
Torque the bolts 50 to 75 inch-pounds (5.7 to 8.5 Nm).
Install the clamp and clip (5) that secure the fuel
quantity probe harness (7) to the interconnect tube.
11. Connect the interconnect assembly (59) to the
fitting (51) using the washers (61) and the bolts (60).
12. Connect the ejector pump tube (14) to the tube
(68). Connect the clamps (15) that secure the ejector
pump tube (14) and the interconnect tube (10)
together. Install the screw (11) that secures the
interconnect tube to the fuel cell.
28-00-00
18 JUL 2019 Rev. 24 Page 17
BHT-206L4-MM-4
13. Install the new packings (47) on the tubes (48).
Insert the tubes from inside the fuel cell through their
respective ports. Secure in place using the retainer
(46), washer (45), and bolt (44). Torque the bolt 50 to
75 inch-pounds (5.7 to 8.5 Nm).
14. Inside the fuel cell, connect the tubes (48) to the
hoses (41 and 42). Outside the fuel cell, connect the
tubes to the hoses (57). Install the clip (56) that
secures the tubes together using the bolts (54),
washers (53 and 55), and nut (52).
15. Install the manifold (43) using the washers (37)
and the bolts (38). Connect the hoses (40, 39, 41, and
42) to the manifold.
16. Install the new packing (31) on the fitting (32).
Install the fitting on the fuel cell using the washer (30)
and the jamnut (29). Connect the fuel supply hose (4)
to the fitting.
17. Install the fuel pressure transducer (34) on the
fitting (32). Connect the electrical connector. Install the
fuel shutoff valve inlet tube (1) between the elbow (33)
and the fuel shutoff valve (2).
18. Install the new packing (27) on the vent fitting (26)
and install using the flange (25), washer (24), and
screws (23). Connect the vent hose (3) to the fitting.
19. Install the retainer (28) using the washer (36) and
the bolt (35). Torque the bolt 40 inch-pounds (4.5 Nm)
maximum.
20. Place the new packing (22) in the groove of the
fuel cell port. Install the seal (21), cap and adapter
(20), and retainer (19) using the washers (16) and the
screws (17). Do not use the washer at the bonding tap
(18). Make sure that the surfaces are clean for a good
bond of bonding tap and retainer. Torque the screws
50 to 75 inch-pounds (5.7 to 8.5 Nm).
21. Install the fuel quantity transmitter (6)
(paragraph 28-53).
22. Install the aft fuel quantity probe (9)
(paragraph 28-49).
28-00-00
Page 18 Rev. 24 18 JUL 2019
23. Install the fuel boost pump assembly (8)
(paragraph 28-42).
24. Apply a coating of sealant (C-328) to the mating
surface of the seatback and the fuel cell access panel.
Install the fuel cell access panel with the screws and
the washers. Tighten the screws.
25. Pressure test the fuel system (paragraph 28-5).
26. Install the fuselage access panel located above
the fuel filler.
27. Install the seatback and the seat bottom
(Chapter 25).
28. Connect the battery.
29. Service the fuel system (Chapter 12) and check
for leaks (Chapter 5).
28-16. FUEL DISTRIBUTION
Fuel distribution consists of all the forward and aft cell
mounted and connected components that either move
or monitor the fuel within the fuel system.
28-17. FORWARD FUEL 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 cell by a tube assembly. Located between the left
forward cell and dual element ejector pump 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 pumps are
operating.
Export Classification C, ECCN EAR99
 BHT-206L4-MM-4

28-19. DUAL ELEMENT EJECTOR PUMP — 2. Install the dual element ejector pump (5) between
REMOVAL the tubes (3) and just aft of the support (7). Install the
bolt (8) with the washer (9). Install the bolts (1) with the
1. Disconnect the battery and external power thin washers (2). Torque the bolts 50 to
supply. Ground the helicopter. 75 inch-pounds (5.7 to 8.5 Nm).

2. Defuel and purge the fuel cells (Chapter 12).
3. Remove the aft facing seat cushions and the
seatbacks (Chapter 25).
NOTE
Cap or cover the open fittings and ports
when lines or hoses are removed.
4. Remove the center seat panel. Remove the cover
below the center seat panel. Remove the center cover
between the two aft seats and the cover at the forward
end of the center cover.
3. Thread the B-nut of the hose (6) on the dual
element ejector pump and torque.
4. Connect the tubes (10 and 11).
5. Perform pressure test (paragraph 28-5).
6. Install the cover at the front of the aft facing seat.
Install the cover between the two aft seats.
7. Install the cover below the center seat panel.
Install the center seat panel.
8. Install the aft facing seat cushions and the
seatbacks (Chapter 25).

5. Disconnect the tubes (10 and 11, Figure 28-4) at 9. Connect the battery.
the dual element ejector pump (5).
10. Service the fuel system (Chapter 12) and check
6. Disconnect the hose (6) from the dual element for leaks (Chapter 5).
ejector pump (5).
28-22. FUEL FLOW SWITCHES
7. Remove the bolts (1), with the washers (2) and
the slide tubes (3) outboard. Remove and discard the The fuel flow switches are located between the two
packings (4). forward fuel cells and monitor the fuel flow to the dual
element ejector pump. Each switch monitors the fuel
8. Remove the bolt (8) and the washer (9) from the flow to its respective element of the dual element
support (7). Remove the dual element ejector ejector pump.
pump (5).
28-23. FUEL FLOW SWITCHES — REMOVAL
28-20. DUAL ELEMENT EJECTOR PUMP —
INSPECTION 1. Disconnect the battery and external power
supply. Ground the helicopter.
1. Inspect the dual element ejector pump and the
in-line filters for obstructions. If obstructions are found, 2. Defuel and purge the fuel cells (Chapter 12).
remove them with compressed air.
3. Remove the aft facing seat cushions and the
2. Inspect the dual element ejector pump for seatbacks (Chapter 25).
evidence of corrosion.
4. Remove the center seat panel by removing the
3. If the dual element ejector pump proves to be perimeter screws and the four screws that hold the
unserviceable, replace the pump. flow switch clips (two screws per switch). Remove the
cover below the center seat panel.
28-21. DUAL ELEMENT EJECTOR PUMP —
INSTALLATION NOTE
Removal procedure is the same for either
1. Install the new packings (4, Figure 28-4) on the fuel flow switch. The following procedure is
end of the tubes (3). for the left fuel flow switch.

28-00-00
Export Classification C, ECCN EAR99 18 JUL 2019 Rev. 24 Page 18A
BHT-206L4-MM-4

5. Disconnect the fuel flow switch electrical leads 6. Disconnect the hose (17) from the elbow (18).
(23, Figure 28-5).
7. Disconnect the tube (28) from the union (27).
NOTE
8. Remove the nuts (19 and 20) and the elbow (18)
Cap or cover open fuel lines.
that secure the fuel flow switch (22) to the support clip
(16). Discard the packing (21).

28-00-00
Page 18B Rev. 24 18 JUL 2019 Export Classification C, ECCN EAR99
 BHT-206L4-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
9. Washer
10. Tube

ti
I
11. Tube

2 *l

206L4-M-28-4

Figure 28-4. Dual elem ent ejector pump and connecting tubes

28-00-00
Page 19
BHT-206L4-MM-4

VIEW A

8 10
7
11
6
LEFT FUEL 5 12
4 13
FLOW SWITCH 3 14
2 A

RIGHT FUEL
FLOW SWITCH
17

29 18

T 30 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 10 TO 15 IN-LBS
T (1.1 TO 1.7 Nm)
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 30. Clamp
206L4_MM_28_0005_c02

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

28-00-00
Page 20 Rev. 25 31 AUG 2021 Export Classification C, ECCN EAR99

9. Remove nuts (25 and 26) and union (27)
securing fuel flow switch (22) to support clip
(15). Discard packing (24) and remove switch
from helicopter.
28-24. INSPECTION.
1. Inspect fuel flow switch for rust or
corrosion.
2. Ensure fuel flow switch is not clogged or
obstructed.
28-25. INSTALLATION.
1. Install new packings (21 and 24, figure
28-5) in fuel flow switch (22).
2. Position flow switch (22), with flow arrow
pointing forward, between support clips (15
and 16).
3. Install elbow (18) and nuts (19 and 20)
securing switch to support clip (16).
4. Install union (27) and nuts (25 and 26)
securing switch to support clip (15).
5. Connect fuel flow switch electrical leads
(23).
6. Connect hose (17) to elbow (18).
7. Connect tube (28) to union (27).
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).
28-26. INLINE FUEL FILTERS.
The inline fuel filters are located on the
upstream side of the fuel flow switches. An
BHT-206L4-MM-4
inline check valve is connected between each
inline filter and fuel flow switch.
28-27. 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).
4. Remove passenger compartment floor
carpeting and fuel system tunnel cover.
NOTE
Faying surfaces of tunnel cover and
fuel cell cover are coated with
sealant for fume tightness. Use care
to prevent damage during parts
removal.
5. Remove molded plastic cover between
left and right aft facing passenger seats.
NOTE
Removal of both filters is identical.
6. Cut straps (2 and 8, figure 28-5) securing
sleeve (6) at each end of filter (5).
7. Slide sleeves (6) from filter (5) and
disconnect inlet and outlet hose (3 and 7)
from filter (5).
8. Remove check valve (4) and packing from
outlet end of filter (5). Discard packing.
9. Cap or cover open fuel lines.
28-28. INSPECTION.
1. Inspect inline fuel filters for rust or
corrosion.
2 . Ensure filters are n o t c l o g g e d or
obstructed.
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BHT-206L4-Mllli-4
28-29. INSTALLATION.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-328 Sealing Compound
NOTE
Installation of both filters is identical.
Assure flow directional arrow on
check valve and sleeve are pointing
in proper direction as shown.
1. Install new packing and check valve (4,
figure 28-5) at outlet end of filter (5).
2. Connect inlet side of filter (5) to hose (7).
Slide sleeve (6) over check valve (4) and filter
(5) and connect outlet end of check valve (4)
to hose (3).
3. Secure sleeve in place with two straps (2
and 8) at hose coupling nuts.
4. Pressure test fuel system for leakage
(paragraph 28-5).
5. Ensure work area is clear and clean of
foreign objects, and all connections and lines
are tight and secure.
I WARNING -
SEAT INSTALLATION COVER AND
TUNNE L C O VE R OVER FUEL
SYSTEM COMPONENTS MUST BE
SEALED FOR FUME TIGHTNESS.
6. Mix sealing compound (C-328) 100 parts
to 12 parts by weight per instructions of
manufacturer.
7. Apply sealing compound (C-328) to faying
surfaces on tunnel cover. Install cover and fill
all gaps and voids around entire periphery to
ensure fume tightness.
28-00-00
Page 22
8. Apply sealing compound (C-328) to faying
surfaces on seat installation cover. Install
cover and fill all gaps and voids around entire
periphery to ensure fume tightness.
9. Install molded plastic cover on aft side of
vertical control tunnel.
10. Install passenger compartment floor
carpeting.
11. Install passenger aft facing seat backs
and cushions (Volume 3, Chapter 25).
12. Service fuel system ( Volume 2, Chapter
12).
13. Connect battery.
28-30. FUEL QUANTITY PROBE -
FORWARD FUEL CELL.
The forward fuel quantity probe is one of
three probes used to monitor the fuel level.
The forward fuel quantity probe is electrically
connected to the two probes in the aft fuel
cell. Readings from the probes are
transmitted to a fuel quantity indicator on the
instrument panel.
28-31. REMOVAL.
1. Disconnect battery and external power
source. 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).
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
t o electrical terminals ( 3 1 ) . Disconnect
electrical terminals and completely remove
fuel quantity probe. Remove and discard
gasket (16).
5. Cover open port in fuel cell.
 BHT-206L4-MM-4

28-32. INSPECTION. 28-35. REMOVAL.

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
MATERIALS REQUIRED
condition and security.

2. Inspect fuel quantity probe for evidence of NUMBER NOMENCLATURE

corrosion.
C-480 Nylon Cord
28-33. INSTALLATION.
1. Remove dual element ejector pump
1. Place new gasket (16, figure 28-2) on fuel (paragraph 28-19).
quantity probe.

2. Connect electrical wires to terminals (31)
on fuel quantity probe (Volume 12, Chapter
98).
3. G uide electrical wire and fuel quantity
probe into fuel cell and secure with bolts (14)
and thin aluminum washers (15). Torque bolts
50 to 75 inch-pounds (5.65 to 8.47 newton­
meters).
I 4. Perform calibration check of fuel quantity
system (Volume 10, Chapter 96).
5. Pressure test fuel system (paragraph 28-
5).
6. Install cover over fuel quantity probe.
7. Install seat cushions and backs (Volume
3, Chapter 25).
8. Connect battery.
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) o r 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.

9. Service fuel system (Volume 2, Chapter 4. Remove bolts (3 and 12, figure 28-6) and
12). washers (2 and 11).

5. Remove bolts (5) and washers (6).

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.
6. Slide interconnect tube (4) forward to
allow electrical wire to be pulled out between
interconnect tube (4) and fitting (9). Untie
nylon cord and work interconnect tube out.
Remove seals (1 and 10) and packing (8).
Discard seals and packings.
28-36. INSPECTION.

1. Inspect flexible bellows for leaks.

2. Inspect interconnect tube for evidence of

corrosion or frayed mesh wires on hose.

28-00-00
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BHT-206L4-MM-4

*TORQUE
50 TO 75 IN-LBS
(5.65 TO 8.47 Nml

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

206L4-M-28-6

Figure 28-6. Interconnect tube

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Page 24

3. Inspect for evidence of leaks at each
connection to the fuel cells and hose of
interconnect tube.
28-37. INSTALLATION.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-480 Nylon Cord
1. Feed another nylon cord (C-480) through
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 t o c o r d 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. Place new seal (1) between interconnect
tube and right fuel cell. Install bolts (3), with
washers (2). Torque bolts (3) 50 to 75 inch­
pounds (5.65 to 8.47 newton-meters).
5. Torque bolts {12) 50 to 75 inch-pounds
(5.65 to 8.47 newton-meters).
6. Install both fuel flow switches (paragraph
28-25).
7. I n s t a l l d u a l e l e m e n t eje c t o r p u m p
(paragraph 28-21).
BHT-206L4-MM-4
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
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 of the fuel cell to 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.
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
M81969/14-02 Removal/Installation
Tool
28-40. REMOVAL.
1. Disconnect battery and ground helicopter.
2. Defuel and purge fuel cells (Volume 2,
Chapter 12).
3. Remove fuel boost pump assembly cover.
4. Remove screw (17, figure 28-7), nut (22),
washer (16 and 23), and spacer (15). Remove
retainer (24). I
5. Disconnect in-line junction (detail A) at I
electrical terminals (27 and 3 2) using
M81969/14-02 tool or equivalent.
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BHT-206L4-MM-4

1. Reducer
31 �� 2. Packing
SEE DETAIL A 3. Pump
30 4. Packing
4 5. Washer
6. Bolt
7. Packing
8. Switch, fuel low level
·
V
0 -

9.
EB s Washer

'-I""-! � �6
10. Bolt
29� 11. Packing
: 12. Drain valve

2B
�
Al� 13.
14.
15.
Washer
Bolt
Spacer
16. Washer
17. Screw
18. Gasket
7 19. Cover
20. Washer
21. Bolt
8
22. Nut
23. Washer
24. Retainer
25. Adapter
26. Washer
27. Electrical terminals
28. Plug
29. Packing
30. Electrical terminals
31. Electrical terminals
32. Electrical terminals

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

J-19
cl)-20
�2 1 206L4-M-28-7-1

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

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Page 26
 BHT-206L4-MM-4

ARROWS MUST ALIGN

FOR CARTRIDGE
FORWARD INSTALLATION AFT AIRFRAME
AIRFRAME WIRING Q3A18
WIRING Q1A18

37
36

38
35
39

34
+ 4
+

33
IN-LINE JUNCTION
- + USE TOOL
M81969/14-02 AFT

+
GND -

FUEL LOW LEVEL SWITCH

CONNECT AIRFRAME
E93A22 WIRING
Q4A18N
AIRFRAME
WIRING FUEL DRAIN
GROUND Q2A18N Q21A22 CONNECT AIRFRAME
AIRFRAME WIRING
GROUND

DETAIL A
VIEW LOOKING UP AT BOTTOM
OF SUMP ASSEMBLY

33. Pump shutoff lever

34. Retaining ring
35. Pump cartridge
36. Drain plug
37. Pump shutoff lever
38. Pump cartridge
39. Retaining ring
40. Drain plug

206L4_MM_28_0007b

Figure 28-7. Fuel Boost Pump Assembly (Sheet 2 of 2)

28-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 27
 BHT-206L4-MM-4

6. Remove ground wires from bolt (21). d. Place new packing (11) on boss of
drain valve (12). Secure valve in place with
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 bolts (14) and washer (13). Torque bolts 50 to
terminals (30 and 31) from both boost pump 75 inch-pounds (5.65 to 8.47 newton-meters).
cartridges.
e. Place new gasket (18) on cover (19).
8. From beneath the helicopter, push the Secure cover in place with bolts (21) and
fuel cell and pump (3) up to aid access to washers (20).
bolts (6) and washers (5).
2. Place new packing (4) in recess of pump
9. Remove bolts (6) and washers (5). assembly port. Connect fuel hoses to
reducers (1). From beneath the helicopter,
10. Disconnect fuel hoses to reducers (1). position fuel boost pump in place. Secure with
bolts (6) and washers (5). Torque bolts 50 to
11. Remove pump (3). 75 inch-pounds (5.65 to 8.47 newton-meters).

3. Remove and discard manufacturer I

28-41. INSPECTION. installed wires from positive terminals (30 and

I
31) of boost pump assemblies. Cut ground
1. Inspect fuel boost pump for corrosion and wires installed on boost pump assemblies at a
condition. Remove any corrosion that is sufficient length to reach bolt (21). Install
present. crimp connector on end of wire and install on
bolt (21) along with aircraft ground wire No.
2. Inspect electrical wiring for condition. Q4A18N (detail A). Install aircraft wiring to I
positive terminals (Volume 12, Chapter 98).
28-42. INSTALLATION.
4. Cut ground wire installed on drain valve
(12) with sufficient length to reach bolt next to
NOTE bolt (21). Install crimp connector on end of
wire. Connect drain valve positive terminal to
If original fuel boost pump assembly aircraft wire No. 021A22 with in-line junction
is being reinstalled omit step 1. (detail A) using M81969/14-02 tool.

1. Assemble new pump assembly as follows:

NOTE
a. Place new packings (2, figure 28-7) on
Cut wire to correct length before
reducers (1) and install in outlet ports of

i. . . . . . . . .i
installing in-line junction.
pump.
5. Cut one wire on fuel low level switch (8)
to appropriate length to reach same bolt next
CAUTION to bolt (21) as drain valve wire. Install crimp
................. connector on end of wire. Install fuel drain
and fuel level connectors to bolt alon with
DO NOT PLUG THE PUMP SEAL aircraft ground wire No. Q2A18N (detail A).
DRAIN PORTS. Connect remaining fuel level switch wire to
aircraft wire No. E93A22 with in-line junction
b. Place new packings (29) on plugs (28) using M81969/14-02 tool (Volume 12, Chapter
and install in the pump drain ports. 98).

I c. Place new packing (7) on boss of fuel

low level switch (8). Secure switch in place
with one bolt (10) with washer (9) and adapter
6. Tighten bolts (21) to 50 to 75 inch-pounds
(5.65 to 8.47 newton-meters).

(25) with washer (26). Torque bolt (10) and 7. Place washer (16) on screw (17) and
adapter (25) 50 to 75 inch-pounds. (5.65 to insert through retainer (24). Place spacer (15)
8.47 newton-meters).

28-00-00
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 BHT-206L4-MM-4

on screw (17) and secure into fuel boost 8. Install E2-01-1 slide hammer in pump
pump sump assembly. Do not tighten. Place drain boss and remove pump cartridge.
washer (23) on adapter (25) and install nut
(22). Tighten nut (22) and screw (17).
28-45. INSTALLATION.
8. Perform pressure test of fuel system
(paragraph 28-5 and Volume 2, Chapter 5). MATERIALS REQUIRED

9. Connect battery.
NUMBER NOMENCLATURE
10. Perform functional check of fuel quantity C-010 Lubricating Oil
system (Volume 1 o, Chapter 96).

11. Service fuel system (Volume 2, Chapter 1. Clean cartridge hole of all foreign matter.
12).

28-43. CANISTER FUEL BOOST PUMP.

NOTE
The canister type fuel pump and
impeller may be replaced without
draining the fuel system.
2. Clean retaining ring (34 or 39, figure 28-7,
detail A).. I
3. Lubricate packings o n replacement
cartridge and the sides of the cartridge hole in
the mounting flange casting with lubricating
oil (C-010).

SPECIAL TOOLS REQUIRED

DO NOT FORCE CARTRIDGE INTO

NUMBER NOMENCLATURE
C AN I S T E R . ECCENTRIC
E2-10-1 Slide Hammer CARTRIDGE DESIGN REQUIRES
A LI GNME N T A R R O W S TO BE
W I THIN ± 3 DE G RE E S TO BE
PROPERLY INSTALLED.
28-44. REMOVAL.

1. Turn helicopter electrical master switch

4. I nstall cartridge ( 3 5 o r 36)in flange I
(canister) with arrows aligned.
OFF (BHT-206L4-FM-1).

I 2. Disconnect fuel boost pump positive (+) NOTE

electrical terminal (figure 28-7, detail A).
3. Remove hexagon head screws and
negative (ground terminal) from boost pump
I shutoff lever (33 or 37).
I
When pushing cartridge (35 or
36)into place, ensure that cartridge
is properly seated and that retaining
ring groove is not obstructed.

I
4. Turn fuel boost pump shutoff lever 5. Install retaining ring (34 or 39).
enough to clear motor and impeller.

I 5. Remove fuel boost pump drain plug (36 or

40).
6.

i· · · · · · · · ·i
Install drain plug (36 or 40).

I
CAUTION
6. Remove any remaining obstructions •••••••••••••••••
below cartridge (35 or 38).
DO NOT OVERTORQUE POSITIVE
7. Remove retaining ring (34 or 39). E LECTRICAL TERMINAL.

28-00-00
Page 29
 BHT-206L4-MM-4
1 7. Connect positive (+) electrical terminal
(detail A).
8. Position fuel boost pump shutoff lever (33
or 37) over screw hole. Install hexagon head
screw and negative electrical terminal.
9. Turn master switch ON and turn on fuel
pump (BH T-206L4-FM- 1 ). Check for proper
gage pressure and external leaks.
28-46. AFT FUEL QUANTITY PROBE.
The aft fuel cell fuel quantity probe is
mounted in the top of forward part of aft fuel
cell. The fuel quantity probe is electrically
connected to the forward fuel cell fuel quantity
probe and to the aft fuel cell f u el qu antity
p robe and transmitte r.
28-47. REMOVAL.
1. Disconnect battery and external power
source. G round helicopter.
2. Defuel and purge fuel cells (volume 2,
Chapter 12).
3. Remove screws (6,figure 28-8), 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 for
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).
28-00-00
Page 30
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. Carefully insert fuel quantity probe (3)
and electrical wiring into aft fuel cell (5).
Place spacer (9) on top of fuel quantity probe.
Ensure 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.
5. Perform calibration check of fuel quantity
system (Volume 10, Chapter 96). I
6. Perform pressure test of fuel system
(paragraph 28-5).
7. Service fuel system (Volume 2, Chapter
1 2}
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).
 BHT-206L4-MM-4

8
5

T 1

9 NOTCH
FACING AFT

SEE DETAIL A 3

T
4 AF

1. Bolt
2. Washer
3. Fuel quantity probe
4. Gasket
5. Aft fuel cell
6. Screw
7. Cover
8. Gasket
9. Spacer
DETAIL A
50 TO 75 IN-LBS
T (5.65 TO 8.47 Nm)

206L4_MM_28_0008

Figure 28-8. Aft Fuel Quantity Probe

28-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 31
 BHT-206L4-MM-4

7. Carefully left fuel quantity transmitter (5) 28-55 . R EMOVAL.

to expose electrical wiring on probe. Secure
wires to top area of cell. Disconnect electrical 1. Remove fuselage access panel located
wiring from fuel quantity transmitter. Remove above fuel filter.
fuel quantity transmitter from fuel cell.
2. Disconnect electrical connector (4, figure
8. Remove and discard gasket (6) and seal 28- 1 0).
(4). Cover open port of fuel cell.
3. U nscrew fuel pressure tra nsducer (3)
28-52 . I N S P ECTI O N . from fitti ng (1). Remove and discard packing
(2).
1 . Inspect fuel q uant i ty trans m i tter for
corrosion. 28-56. I N S P ECTI O N .

2. I nspect electrical wiri ng for condition. 1. Inspect transducer for rust or corrosion.

28-53 . I N STAL LATIO N . 2. Inspect for bent or broken pi ns.

1. Install new seal (4, figure 28-9) between 28-57 . I N STALLATI O N .

airframe structure and open port of fuel cell.
1. Install new packing (2, figure 28-10) on
2. Place new gasket (6) on fuel quantity transducer and screw into fitting (1).
transmitter (5) and parti ally insert into fuel
cell. Connect electrical wiring from inside fuel 2. Connect electrical connector (4).
cell to fuel q uant i t y probe (Volume 12 ,

I Chapter 98). Seat fuel quantity transmitter (5)

in fuel cell.
3. Pressuri ze fuel system and check for
leaks (paragraph 28 - 5 , and Volume 2 ,
Chapter 5).
3. Place retainer (3) over top of fuel quantity
transmitter. Secure in place with screws (1) 4. Install fuselage access panel.
and washers . (2). Torque screws 30 to 40
inch-pounds (3.39 to 4.52 newton-meters).
28-58. FUEL SHUTOFF VALVE.
4. Perform pressure test of fuel system
(paragraph 28-5). The fuel shutoff valve is located above the aft
fuel cell serv i c i ng port and i s electri cally
5. Connect battery. operated.

I 6. Perform calibration check of fuel quantity 28-59. R EMOVAL.

system (Volume 10, Chapter 96).
7. I nstal l upholstery and seat cushions and
back (Volume 3, Chapter 25).
8. Service fuel system (Volume 2, Chapter
1 2).
28-54. FUEL PRESSURE TRANSDUCER.
The fuel pressure transducer provi des a
means of mon itori ng fuel pressure i n the
system. The transducer is located on a fitting
on top of the aft right side of the aft fuel cell.
1. Disconnect battery and external power
supply.
2. Remove access panel above fuel filler
port.
3. Remove inlet tube (3 , figure 28-11) from
inlet port of fuel shutoff valve (2). Remove
tube (7) from outlet port of fuel shutoff valve
(2). Cap open lines.
4. Disconnect electrical connector (1) from
fuel shutoff valve.

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Page 32
 BHT-206L4-MM-4

►
TOR QUE --------
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
206L4-M-28-9

Figure 28-9. Fuel q uantity transm i tter

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Page 33
BHT-206L4-MM-4

Figure 28-10. Fuel Pressure Transducer

28-00-00
Page 34 Rev. 20 7 NOV 2014 Export Classification C, ECCN EAR99
 BHT-206L4-MM-4

5. Remove the hat bin above the rear seat
(Chapter 25). Remove the screws (4) and the washers
(5) that secure the fuel shutoff valve (2) to the fuselage
structure, and remove the fuel shutoff valve.
28-60. FUEL SHUTOFF VALVE — INSTALLATION
6. Install the fuselage access panel.
28-61. FUEL SUMP DRAIN VALVE
The fuel sump drain valve is located in the fuel boost
pump sump and is electrically operated.

1. Position the fuel shutoff valve (2, Figure 28-11) in

the compartment above the fuel filler port and secure SPECIAL TOOLS REQUIRED
in place with the screws (4) and the washers (5).
Tighten the screws.
NUMBER NOMENCLATURE

2. Install the inlet tube on the inlet port of the fuel M81969/14-11 Removal/Installation
shutoff valve (2). Install the tube (7) on the outlet port Tool
of the fuel shutoff valve. Tighten the coupling nuts.

28-62. FUEL SUMP DRAIN VALVE — REMOVAL

3. Connect the electrical connector (1) to the fuel
shutoff valve.
1. Disconnect the battery and the external power
source (Chapter 96). Ground the helicopter.
4. Install the hat bin above the rear seat
(Chapter 25). 2. Defuel and purge the fuel cells (Chapter 12).

5. Connect the battery (Chapter 96). Apply fuel 3. Disconnect the in-line junction (Figure 28-7,
pressure to the fuel system and check for evidence of Detail A) at the positive terminal (27) with the removal/
leaks (Chapter 5). installation tool (M81969/14-11) or equivalent.

28-00-00
Export Classification C, ECCN EAR99 7 NOV 2014 Rev. 20 Page 34A/34B
 BHT-206L4-MM-4

AFT FUEL C ELL

6 1. Electrical connector 5. Washer

2. Fuel shutoff valve 6. Support structure
3. I nlet tube 7. Outlet tube
4. Screw
D ET A I L A 206L4-M-28- 1 1

F i g u re 28-1 1 . Fuel sh utoff valve

4. Disconnect ground wire from bolt (21). 6. Connect battery.

5. Remove bolts (14), washer (13), and 7. Service fuel system (Volume 2, Chapter
remove drain valve (12). Discard packing 1 2).
( 1 1 ).
28-64. FUEL FILTER.
6. Cover open port.
The airframe mounted fuel filter is mounted
28-63. INSTALLATION. on the forward firewall on the right side of the
power plant. The fuel filter is equipped with a
built-in filter bypass valve and impending
1. Place new packing (11, figure 28-7) on
bypass switch that is electrically connected to
boss of drain valve (12).
a segment in the caution panel.
2. Secure drain valve (12} to fuel boost
pump sump with bolts (14) and washers (13). 28-65. REMOVAL.
Torque bolts 50 to 75 inch-pounds (5.65 to
8.47 newton-meters). 1. Disconnect battery and external power
source.
I 3. Connect in-line junction (detail A) at
positive terminal (27) using M81969/14-02 2. O pen engine cowling on right side.
tool or equivalent.
3. Disconnect inlet hose (9, figure 28-12),
4. Connect ground wire to bolt (21). outlet hose (2), and drain hose (12} from fuel
filter (6).
5. Perform pressure test of fuel system
(paragraph 28-5).

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Page 35
BHT-206L4-MM-4

T 4

T 2

T 4

206L4_MM_28_0012a

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

28-00-00
Page 36 Rev. 24 18 JUL 2019 Export Classification C, ECCN EAR99
 BHT-206L4-MM-4

20 TO 25 IN-LBS T 1 T 3
T 1 (2.8 TO 5.6 Nm) 1

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

100 TO 150 IN-LBS

T 3 (11 TO 16 Nm) 2

235 TO 265 IN-LBS

T 4 (27 TO 29 Nm)

NOTES
1 Applicable to fuel filter P/N 222-366-621-101.

2 Applicable to fuel filter P/N 222-366-621-103.

206L4_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. 24 Page 37
BHT-206L4-MM-4

4. Disconnect electrical connector (5) from top of 28-68. FUEL FILTER ELEMENT
fuel filter (6). REPLACEMENT

5. Cut lockwire and remove bolts (17) and washers

MATERIALS REQUIRED
(15 and 16) from top of fuel filter. Remove fuel filter (6).
Refer to BHT-ALL-SPM for specifications.
28-66. FUEL FILTER — INSPECTION
NUMBER NOMENCLATURE

1. Inspect fuel filter bowl for corrosion. C-405 Lockwire

C-414 Shear Wire

2. Inspect electrical connector for condition.

NOTE
28-67. FUEL FILTER — INSTALLATION
Filter element must be removed for
inspection whenever caution light comes on
during engine operation.
MATERIALS REQUIRED
Replace element at same hourly interval as
Refer to BHT-ALL-SPM for specifications. the engine fuel pump filter, or whenever
contamination cannot be removed.
NUMBER NOMENCLATURE
At each fuel filter element change interval,
C-405 Lockwire remove fitting from outlet port of filter head.
Using a piece of shear wire (C-414), pass
wire through outlet bleed port to make sure
1. Position fuel filter (6, Figure 28-12) under mount that bleed port is not clogged.
bracket (14) top flange with washers (15) between
filter and bracket. Secure in place with bolts (17) and 1. Open right engine cowling.
washers (16). Torque bolts T and lockwire (C-405).
2. Open drain valve (13, Figure 28-12) and drain
fuel from filter bowl (21).
2. Connect electrical connector (5) to top of fuel
filter (6).
3. Disconnect drain hose (12) and remove drain
valve (13). Remove and discard packing (10).
3. Install new packings (4, 7, or 10) if fittings (3 or 8)
or drain valve (13) were removed. Connect inlet hose 4. Cut lockwire and unscrew retainer (22) from filter
(9), outlet hose (2), and drain hose (12) to fuel head (18). This will free filter bowl (21) from filter head.
filter (6).
5. Remove filter element (24) from filter bowl (21).
Discard seals (20 and 23) and packing (19).
4. Connect battery.

NOTE
5. Pressurize fuel system and check for leaks at fuel
filter (Chapter 5). Use new filter element kit if filter is
contaminated.

6. Close and secure engine cowling. 6. Install new packing (19) in filter head (18).

28-00-00
Page 38 Rev. 24 18 JUL 2019 Export Classification C, ECCN EAR99

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. For fuel filter P/N 222-366-621-101, position filter
bowl (21) on filter head (18) and secure by screwing
retainer (22) into filter head. Torque retainer T .
10. For fuel filter P/N 222-366-621-103, position filter
bowl (21) on filter head (18) and secure by screwing
retainer (22) into filter head. Torque retainer T .
11. Install lockwire (C-405) between retainer (22) and
filter bowl (21).
12. Use new packing (10) and install drain valve (13)
using nut (11).
13. Connect drain hose (12) to drain valve.
14. Pressurize fuel system and check for leaks at fuel
filter (Chapter 5).
WARNING
B E AWA R E O F P O T E N T I A L F I R E
HAZARD OF FUEL IN AN OPEN
CONTAINER.
CAUTION
BEFORE PURGING AIR FROM THE
AIRFRAME AND ENGINE FUEL SYSTEM,
BE SURE TO GROUND THE
HELICOPTER.
BOTH FUEL BOOST PUMPS MUST BE
ON DURING PURGING OPERATIONS.
15. Prior to next flight, purge entrapped air from
airframe fuel filter as follows:
a. Open ignition circuit breakers.
b. Disconnect engine fuel supply hose from fuel
nozzle on combustion chamber case. Place hose in a
clean container. Refer to Rolls-Royce Operation and
Maintenance Manual 14W2PM.
Export Classification C, ECCN EAR99
BHT-206L4-MM-4
c. Turn battery switch ON and open throttle to full
open position. Turn fuel valve switch and both boost
pump switches ON (BHT-206L4-FM-1).
d. With manual press-to-test button pressed and
held, motor 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-206L4-FM-1).
f. Reconnect fuel supply hose to fuel nozzle.
Tighten coupling nut to 80 to 120 inch-pounds (9.04 to
13.56 Nm). Refer to Rolls-Royce Operation and
Maintenance Manual 14W2PM.
g. Activate engine ignition system by closing
ignition circuit breaker (BHT-206L4-FM-1).
h. Ground run helicopter with both boost pumps
on at 100% N2 for 2 minutes to ensure any entrapped
air is purged from airframe and engine fuel systems
(BHT-206L4-FM-1).
16. Close and secure engine cowling.
28-69. FUEL LOW LEVEL SWITCH
The fuel low level switch is mounted through the
bottom of the fuel boost pump assembly located in the
aft fuel cell. The fuel low level switch is electrically
connected to the FUEL LOW segment of the caution
panel.
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
M81969/14-11 Removal/Installation
Tool
28-70. FUEL LOW LEVEL SWITCH — REMOVAL
1. Disconnect battery and ground helicopter.
2. Defuel and purge fuel cells (Chapter 12).
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3. Remove screw (17, Figure 28-7), nut (22),
washer (16 and 23), and spacer (15). Remove retainer
(24).
4. Disconnect in-line junction (Detail A) at positive
electrical terminal (32) using removal/installation tool
(M81969/14-11) or equivalent.
5. Disconnect ground wire from bolt (21).
6. Remove bolts (10) and washers (9).
7. Remove fuel low level switch (8).
28-73. FUEL MANIFOLD
A dual-branched fuel manifold is installed near the fuel
boost pump assembly in the aft fuel cell. During
operation of the fuel boost pumps, fuel is supplied to
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
normally closed. During normal operation, fuel
pressure causes the poppet valves to open and
remain open.
28-74. FUEL MANIFOLD — REMOVAL

8. Remove and discard packing (7).

WARNING
28-71. FUEL LOW LEVEL SWITCH —
INSPECTION
PERFORM DEFUELING OPERATIONS IN
AN AREA WHERE FIRE HAZARDS ARE
1. Inspect fuel low level switch (8, Figure 28-7) for
REDUCED TO A MINIMUM.
corrosion and condition. Remove any corrosion that is
present.

2. Inspect electrical wiring for condition. CAUTION

28-72. FUEL LOW LEVEL SWITCH —

INSTALLATION
1. Install a new packing (7, Figure 28-7) on fuel low
level switch (8).
2. Place fuel low level switch (8) through hole in
sump plate. Install bolts (10) and washers (9). Tighten
the bolts.
HANDLE FUEL CELL WITH EXTREME
CARE TO AVOID DAMAGE. PROTECT
ALL OPENINGS TO AVOID ENTRY OF
FOREIGN MATERIAL.
1. Disconnect battery and external power supply
(Chapter 96). Ground helicopter.
2. Defuel and purge fuel system (Chapter 12).

3. Connect in-line junction (Detail A) at positive
electrical terminal (32) using removal/installation tool
(M81969/14-02) or equivalent.
4. Connect ground wire to bolt (21).
5. Place retainer (24) to bottom of sump plate and
install screw (17), nut (22), washers (16 and 23), and
spacer (15).
3. Remove forward facing seat cushions, seatback,
and seat bottom (Chapter 25).
4. Remove fuel boost pump assembly (8,
Figure 28-3) to gain access to inside of aft fuel cell
(paragraph 28-40).
5. Disconnect fuel supply hose (4), and hoses (39,
40, 41, and 42, Detail C) from fuel manifold (43).

6. Connect the battery (Chapter 96).

7. Do a Fuel Low Caution System Operational Test
(Chapter 96) and check for leaks.
8. Service fuel system (Chapter 12).
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.

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6. Remove bolts (38, Detail C), washers (37), and

NOTE
fuel manifold (43).
For purposes of cleaning, it is not
necessary to remove unions from fuel
28-75. FUEL MANIFOLD — DISASSEMBLY manifold ports.

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

compressed air at 60 PSI (414 kPa), flush fuel
CAUTION manifold through inlet ports.

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

DO NOT DISASSEMBLE FUEL compressed air at 25 PSI (172 kPa), backflush fuel
MANIFOLD 206-364-604. REMOVAL OF manifold through outlet ports.
CAPS, POPPETS, AND/OR SPRINGS
MAKES CALIBRATION BY
MANUFACTURER NECESSARY AFTER 3. Dry fuel manifold using clean, dry, low pressure
ASSEMBLY. MAINTENANCE FOR THIS compressed air.
FUEL MANIFOLD IS LIMITED TO
CLEANING BY FLUSHING. IF MANIFOLD 28-77. FUEL MANIFOLD — INSPECTION AND
FAILS TO OPERATE PROPERLY AFTER REPAIR
FLUSHING, RETURN MANIFOLD TO A
BELL HELICOPTER TEXTRON
1. Inspect external parts for cleanliness, cracks, and
APPROVED FACILITY FOR REPAIR.
other damage.

28-76. FUEL MANIFOLD — CLEANING

2. Inspect unions for damaged threads and other
damage.

MATERIALS REQUIRED
3. Remove contaminates from parts.
Refer to BHT-ALL-SPM for specifications.
4. Replace cracked and/or damaged parts.
NUMBER NOMENCLATURE

C-003 Turbine Fuel 28-78. FUEL MANIFOLD — ASSEMBLY

CAUTION CAUTION

DO NOT DISASSEMBLE FUEL DO NOT DISASSEMBLE OR ASSEMBLE

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 TEXTRON
APPROVED FACILITY FOR REPAIR.
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 HELICO PTER TEXTRON
APPROVED FACILITY FOR REPAIR.

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28-79. FUEL MANIFOLD — INSTALLATION

WARNING
1. Attach fuel manifold (43, Figure 28-3, Detail C)
using washers (37) and bolts (38).
PERFORM REFUELING OPERATIONS IN
2. Connect fuel supply hose (4), and hoses (39, 40, AN AREA WHERE FIRE HAZARDS ARE
41, and 42, Detail C) to fuel manifold (43). REDUCED TO A MINIMUM.

3. Install fuel boost pump assembly (8) (paragraph

5. Refuel helicopter (Chapter 12).
28-42).

4. Install forward facing seat cushions, seatback, 6. Connect battery and external power supply.
and seat bottom (Chapter 25) Remove ground connection.

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