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 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 Aft Fuel Cell — Inspection and Repair...................................... 28-00-00 15
28-15 Aft Fuel Cell — 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 17
28-19 Dual Element Ejector Pump — Removal.................................. 28-00-00 17
28-20 Dual Element Ejector Pump — Inspection................................ 28-00-00 18
28-21 Dual Element Ejector Pump — Installation............................... 28-00-00 18
28-22 Fuel Flow Switches ........................................................................ 28-00-00 18
28-23 Fuel Flow Switches — Removal ............................................... 28-00-00 18
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
28-45 Installation................................................................................. 28-00-00 29

28-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 1
BHT-206L4-MM-4

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

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 43

FIGURES

Figure Page
Number Title Number

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

28-2 Forward Fuel Cells.............................................................................................. 8
28-3 Aft Fuel Cell ........................................................................................................ 12
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
28-7 Fuel Boost Pump Assembly................................................................................ 26

28-00-00
Page 2 Rev. 20 7 NOV 2014 Export Classification C, ECCN EAR99
 BHT-206L4-MM-4

FIGURES (CONT)

Figure Page
Number Title Number

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
28-13 Deleted................................................................................................................ 42

28-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 3/4
 131-IT-2061-4-MM-4

FUEL SYSTEM

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

ma)
ELECTRICAL SYSTEM.
The fuel system is comprised of three
-ti

-C_
interconnected nonself-sealing bladder type Chapter 96
Refer to Volume 10, Chapter 96 for fuel
(CD

a)-°
fuel cells. Two forward fuel cells are located quantity calibration, fuel filter and fuel pump

(CD
under aft facing passenger seat and are electrical circuitry.
0

N-,
crash-resistant. The aft fuel cell is located
under and behind the aft passenger seat and
is a crash-resistant cell. Fuel from the two
28-4. OPERATIONAL CHECK.
forward fuel cells is transferred to the aft fuel

mom
cell by means of a dual element ejector pump Chapter 96
Refer to Volume 10, Chapter 96 for fuel filter,

0-0
which is located between and connected to fuel flow switch, fuel low and fuel pump
both forward fuel cells. Forward fuel cells and caution systems operational checks.
aft fuel cell are vented overboard by a
O^`

,is

common vent line. Each forward fuel cell has

a fuel flow switch located outside the fuel 28-5. TESTING.
cells and adjacent to ejector pump. Left
forward fuel cell has a fuel quantity probe. Aft 1. With throttle off and shutoff valve on,
fuel cell has a fuel boost pump sump located connect air source to vent line.
on bottom of fuel cell. Two fuel boost pumps
are mounted on fuel cell sump. A fuel quantity
0

probe is located in the top of the forward part

'CAUTION'
of aft fuel cell. A fuel quantity transmitter is
located in the top of the aft fuel cell and is
(ate'

electrically connected to the fuel quantity DO NOT APPLY MORE THAN

probes. The fuel cell sump is equipped with a
low fuel switch which is connected to a fuel
=Or
RECOMMENDED PRESSURE AS
(OD

DAMAGE TO THE FUEL SYSTEM

low light located on the pilot caution AND STRUCTURE MAY RESULT.
segmented panel. Also, the fuel cell sump is
(OD

USE MILD SOAP SUDS SOLUTION

equipped with a fuel sump drain solenoid TO LOCATE LEAKS.
valve (figure 28-1).
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
ate-

0.75 to 1.00 psi (5.17 to 6.89 kPa). Shut off

a-.

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.
(DD

cells. Do not attempt to remove or install a

(D

cold fuel cell. 3. Locate and correct any leakage indicated.

0

Reps .+ ;pressure test if leaks are found.

3. Helicopter must be grounded prior to
3'3

performing defueling operations. 4. Remove test equipment from vent line.

28-00-00
Page 5
131-IT-2061-4-MM-4

RIGHT FUEL CELL

VE NT (TOP)

DUAL ELEMENT EJECTOR PUMP

PROBE

INTERCONNECT TUBE
P, MANIFOLD

A L
I_ DUAL ELEMENT
FUEL PUMP
(ELECTRIC)
THERMAL RELIEF VALVES

PROBE INLINE FUEL FILTERS

AND CHECK VALVES

VENT (TOP)
LEFT FUEL CELL
2061-4-M-28-1

Figure 28-1. Fuel system schematic

28-00-00
Page 6
 131-IT-2061-4-MM-4

28-6. FUEL CELLS. NOTE

Fuel system includes three nonself-sealing Removal procedure is the same for

X00
either right or left fuel cell except

o
bladder type fuel cells. The two forward fuel
CD

-(D
cells are located under the aft-facing that the right fuel cell does not have
passenger seats. The aft fuel cell is located a fuel quantity probe. The following

CD='
under and behind the aft passenger seat. procedures is for the left fuel cell.

3. Remove the aft facing seat cushions and

28-7. FORWARD FUEL CELLS. Chapter 25
seat backs (Volume 3, Chapter 25).
Two forward fuel cells are located under the

-Q_
3+'

(CD
O.2

o
aft-facing seats just forward of Station 100.00. NOTE
Fuel cells are nonself-sealing, crash-resistant,
o'0

Cap or cover open fittings and ports

('ten
rubberized fabric. They are secured in place when fittings, lines, or hoses are

(COD
with nylon lacing. The cells have molded type
--I

Q.< removed.
metal fittings at openings and passages for
-00

internal components. Both cells are vented 4. Disconnect straps (35, figure 28-2) and
figure 28-2
and interconnected. Both cells utilize a dual sleeves (36). Disconnect vent hose (30) from
ejector pump mounted between the two cells. each forward cell vent fitting (26). Tie end of

..,.
The ejector pump transfers fuel from the
O-1

m'0

vent hose (30) up out of way as far as

forward fuel cells into the aft fuel cell when flexibility of hose will permit.
either fuel boost pump is operating. The left
forward fuel cell is equipped with a fuel 5. Remove bolts (24) and washers (25).
Ink
quantity probe. Remove vent fitting (26) and packing (27).
CAD

((DD
Remove cover over fuel quantity probe

-D)
6.

a_0U
28-8. REMOVAL.

w<0

nom
(17). Remove bolts (14) and washers (15)

0-4
from fuel quantity probe (17). Carefully lift fuel
quantity probe from fuel cell to gain access to
007

-ti
WARNING
electrical terminals (31). Disconnect electrical
terminals and completely remove fuel quantity
probe. Remove and discard gasket (16).
ALL DEFUELING OPERATIONS Remove bolts (32) at each side of fuel
,-.
=+o

SHOULD BE PERFORMED IN AN quantity probe.

AREA WHERE FIRE HAZARDS
ARE REDUCED TO A MINIMUM. 7. Remove seat panels to expose left fuel
Q_-

cell. Remove cover below center seat panel.

CAUTION
?c;

.................
HANDLE FUEL CELL WITH
EXTREME CARE DURING RESIDUAL FUEL MAY DRAIN
REMOVAL TO AVOID DAMAGE TO FROM FUEL CELLS WHEN
CELL. PROTECT ALL OPENINGS
=m110

REMOVING DRAIN FITTING (19).

TO PREVENT ENTRY OF FOREIGN
MATERIAL. BE SURE FUEL CELL
8. Remove bolts (20) from drain fitting (19).
-.c

0)a

IS WARM ENOUGH TO BE Remove drain fitting (19). Discard packing

FLEXIBLE.
m

(18).
1. Disconnect battery and external power 9. Remove bolts (3 and 13), with washers,
cam,.

supply. Ground helicopter. and remove tube assembly (7). Discard

E.,

packing (6).
a:)

2. Defuel and purge fuel system (Volume 2,

Chapter
Chapter1212).

28-00-00
Page 7
BHT-2061-4-MM-4

1. Fuel flow switch

2. Dual element ejector pump
3. Bolt
4. Interconnect tube
+-'

5. Retainer
6. Packing
MID

7. Tube
8. Fuel quantity probe electrical wire
9. Seal
10. Thin aluminum washer
11. Bolt
TO AFT
12. Thin aluminum washer FUEL
13. Bolt VENT
14. Bolt
15. Washer
28
COD

16. Gasket
17. Fuel quantity probe
18. Packing
19. Drain fitting
20. Bolt

34
21. Drain valve
22. Packing
23. Left fuel cell
24. Bolt
25. Washer
26. Vent fitting
27. Packing
28. Right fuel cell
ONO

29. Bolt
30. Vent hose
31. Electrical terminals
32. Bolt
33. Bolt lE TORQUE
34. Clamp 50 TO 75 IN-LBS
35. Strap (5.65 TO 8.47 Nm)
36. Sleeve 206L4-M-28-2

Figure 28-2. Forward fuel cells

28-00-00
Page 8
 BHT-2061-4-MM-4

10. Remove bolts (11) and washers (10). 28-10. CLEANING.

Remove seal (9).

11. Remove bolts (29 and 33) from left fuel MATERIALS REQUIRED
cell.
NUMBER NOMENCLATURE
C-003
C-003 Turbine Fuel
' CAUTIO'N '
C-302
C-302 Methyl Alcohol
DO NOT FOLD A COLD FUEL
0

m
CELL. FOLDING MAY CRACK OR .................
DAMAGE A COLD CELL. HEAT
m

m
LAMPS MAY BE USED TO WARM CAUTION
.................
FUEL CELL PRIOR TO FOLDING.
m

IF HOT WATER IS USED TO

mmmmm

m
12. Untie and remove nylon cord lacing CLEAN FUEL CELL, IT IS
securing fuel cell to fuselage structure. R E C O M M E N D E D T H A T

SOCK
000Z
Carefully collapse fuel cell and remove from
TEMPERATURE OF HOT WATER
airframe. Fuel quantity probe electrical wire BE LIMITED TO 160°F (71°C).
(8) is routed through the interconnect tube (4)
HOTTER WATER CONSTITUTES A
and must be guided out of fuel cell and left in
helicopter. HAZARD TO PERSONNEL.

1. Remove all fungus growth from fuel cell

28-9. INSPECTION AND REPAIR. by hand or with a soft scrub brush using
warm or hot water.
1. Inspect the exterior and interior of
-0.

fuselage beneath forward fuel cells for

0)0

indications of fuel leakage.

-z-

figure
2. Inspect fuel cell drain valves (21, figure
vim-

28-2) for evidence of leaks.

28-2 DO NOT USE SOAPS OR STRONG
DETERGENTS WHEN CLEANING

20r
3. Field repairs are permitted on fuel cell in FUEL CELL. CERTAIN POWERFUL
all areas except any radius, any fitting area, DETERGENTS ARE DETRIMENTAL
or to any cut or tear longer than 1.0 inch (25 TO FUEL CELL. SOAPS CAN
mm). Cells with damage beyond these limits REACT WITH FUEL TO FORM A
rim O<2

should be returned for repair to fuel cell COMPOUND WHICH TENDS TO

manufacturer. PLUG FUEL FILTERS. UNDER NO
CIRCUMSTANCES SHOULD
4. Inspect fuel cell to determine METHYL- ETHYL-KETONE OR
manufacturer (marked on fuel cell). A repair SIMILAR SOLVENTS BE USED
o--

kit, complete with all materials and FOR CLEANING FUEL CELLS.
-';7

instructions for making field repairs is

available from cell manufacturer. 2. When fungus is observed in fuel cell, wipe
cell clean with cloths moistened with methyl
U^L

5. Inspect fuel interconnect and vent lines C-302

alcohol (C-302). Burn wiping cloths after
ca)

and fittings for leakage, damage, and cleaning to destroy fungus.

°c)

security.
3. C-003 for cleaning fuel
Use turbine fuel (C-003)
6. Inspect fuel cells for evidence of fungus. cell to assist in protecting inner liner against
0p)

If fungus is present, clean and treat aging if cell remains out of service for several
3(D
o-0

(paragraph 28-10).
paragraph 28-10 weeks without fuel.

28-00-00
Page 9
131-IT-2061-4-MM-4

28-11. INSTALLATION. 4. Place new packing (18) in recess of drain

La)
fitting (19). Position drain fitting below fuel

.-f
cell and fuselage structure and secure with
MATERIALS REQUIRED

--0
bolt (20). Use three undrilled headed bolts
and one drilled head bolt. Install drain valve
(21) with packing (22), if removed. Torque

a))(D@o
..-
Q'^
NOMENCLATURE

1000
aim conk
NUMBER
bolts 50 to 75 inch-pounds (5.65 to 8.47
C-405
C-405 Lockwi re newton-meters). Lockwire drain valve (21) to

0.C
C-405
drilled bolthead with lockwire (C-405).
C-408
C-408 Talcum Powder
C-453
C-453 Tape 5. Position inboard side of fuel cell against
con

fuselage structure with attachment holes

C-480
C-480 Nylon Cord aligned. Install bolts (29 and 33) with thin
aluminum washers. Do not tighten bolts.

NOTE 6. Insert bolts (11) with thin aluminum

washers (10), through interconnect tube

.O+
O.-
5-0
The installation of the right or left flange, seal (9) and into fuel cell. Torque bolts

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
:3.
--O
O^_
(11) 50 to 75 inch-pounds (5.65 to 8.47
newton-meters).
7. 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

forward fuel cell (23 and 28, figure 28-2)
figure 28-2
install bolts (3) with thin aluminum washer.
carefully inspect fuel cell cavity for foreign
((DD

Position packing (6) and retainer (5) against

objects. Ensure all sharp edges and rivet
13,

fuel cell. Install bolts (13), with thin aluminum

C-453
heads are covered with tape (C-453). washers. Torque bolts (3, 13, 29, and 33) 50
to 75 inch-pounds (5.65 to 8.47 newton-
meters).
CAUTION
................. 8. Place gasket (16) on fuel quantity probe

(3D
(17). Connect electrical wires to fuel quantity
HANDLE FUEL CELL WITH
DSO

probe terminals (31). Refer to Volume 12,

EXTREME CARE DURING Chapter
Chapter9898.) Insert fuel quantity probe and
INSTALLATION TO AVOID electrical wiring into fuel cell. Install bolts (14)
°.+(D

DAMAGE TO FUEL CELL. BE SURE with thin aluminum washers (15). Torque bolts
(gyp

FUEL CELL IS WARM ENOUGH TO 50 to 75 inch-pounds (5.65 to 8.47 newton-

BE FLEXIBLE. meters).
E

2. Place seal (9) at outboard end of

-a)
(OD

9. Place fuel cell seat panel over fuel cell.

(CD

(OD

interconnect tube (4), and feed electrical wire Use two long AN4 bolts and screw into fuel
-OM
(T)

(8) through seal, into interconnect port of fuel

+O+
(t)

cell threaded holes at bolts (32) location. Pull

D))

cell, and out fuel quantity probe port. fuel cell up to cover, remove one long bolt,
336
-.0

0-0
?C:

and install bolt (32) with large washer.

"-O
(t)

3. C-408 to fuel cell

Apply talcum powder (C-408)
C"'

Remove opposite long bolt and install bolt

cavity. Insert collapsed fuel cell into fuel cell (32) with large washer. Torque bolts (32) 50
=-5D

(3D

cavity. Lace and tie, using two separate nylon

P))

to 75 inch-pounds (5.65 to 8.47 newton-

C-480
cord (C-480), the top of fuel cell to seat meters).
support using the ten delta fasteners located
vii

on top of each fuel cell.

10. Insert new packing (27) on vent fitting
`.-a)

(26) and install on fuel cell using bolts (24),

with thin aluminum washers (25). Torque bolts
(ii

(CD

28-00-00
Page 10
 BHT-206L4-MM-4

50 to 75 inch-pounds (5.65 to 8.47 newton- ..................

meters). ? CAUTION
.................
11. Untie end of vent hose assembly (30).
Connect vent hose (30) to vent fitting (26). HANDLE FUEL CELL WITH
Torque B-nuts. Secure sleeve (36) with new EXTREME CARE DURING
straps (35). REMOVAL TO AVOID DAMAGE TO
CELL. PROTECT ALL OPENINGS
12. Pressure test fuel cells (paragraph TO PREVENT ENTRY OF FOREIGN

--I
paragraph 28-5
28-5,
Chapter 55).
and Volume 1, Chapter MATERIAL.

13. Install access panel that is located 1. Disconnect battery, and external power

((DD
above dual ejector pump and flow switches. supply. Ground helicopter.

14. Install center seat access panel. 2. Defuel and purge fuel system (Volume 2,
Chapter
Chapter1212).
15. Install cover over fuel quantity probe.
0.)

3. Remove forward facing seat cushions,

..>
O¢,
16. Install seat cushions and backs (Volume seat back and seat bottom (Volume 3,

a)).

E
Chapter 25
3, Chapter 25). Chapter
Chapter2525).
17. Chapter
Service fuel system (Volume 2, Chapter 4. Remove fuel boost pump assembly (8,

(D'0
12
12). figure 28-3) to gain access inside the tank
figure 28-3

0(b
(paragraph 28-40).
paragraph 28-40
18. Connect battery.
5. Remove fuel quantity transmitter (6)

(fl
AFT FUEL CELL.
(paragraph 28-51).
paragraph 28-51
28-12.

The aft fuel cell is a nonself-sealing, crash- 6. Remove aft fuel quantity probe (9)
U-0

resistant, rubberized fabric cell. The cell is (paragraph 28-47).

paragraph 28-47
located below and aft of the aft passenger 7. Remove fittings on top right side of fuel
seat. Mounted in the bottom of fuel cell are
Q.°

cell above fuel filler as follows:

two electrically operated fuel boost pumps,
,-.

electrically operated sump drain, and a low a. Remove fuselage access panel located
level switch installed in the fuel cell sump. A
3.3

fuel quantity probe is installed in the forward

above fuel filler.
top part of aft fuel cell and is electrically
>,a

b. Disconnect fuel supply hose (4) from

QEE
connected to forward fuel cell transmitter and
r+-

,_.

fitting (32, detail B) and manifold (43, detail

((S

aft fuel cell transmitter and a fuel pressure

.«-
30S

C). Remove hose (4). Remove jamnut (29)

LC+'

transducer. The cell has a fuel filler cap

Loa

located on right side of helicopter just aft of and washer (30).

the passenger door. c. Disconnect electrical connector from
fuel pressure transducer (34, detail B).
28-13. REMOVAL.
d. Disconnect inlet tube (1) from fitting
.,...
(3D

-Lo

elbow (33, detail B) and shutoff valve (2).

(')

3(D

WARNING Remove tube (1) and lift fitting (32) from fuel
.-.

=..

cell. Remove and discard packing (31).

PERFORM ALL DEFUELING e. Disconnect vent hose (3) from vent

OP-

m=r

OPERATIONS IN AN AREA WHERE fitting (26).

-D-1

m33

FIRE HAZARDS ARE REDUCED TO

A MINIMUM. f. Remove vent fitting (26) from fuel cell
by removing screws (23), washers (24) and
flange (25). Discard packing (27).
(f)

28-00-00
Page 11
BHT-2061-4-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

CAD
15. Clamps

206L4-M-28-3-1

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

0)D

28-00-00
Page 12
 BHT-2061-4-MM-4

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

FUEL CELL (REF)

3 REF
DETAIL A

16. Washer
17. Screw
Bonding tab
707

18.
19. Retainer
20. Cap and adapter
21. Seal
22. Packing
23. Screw
24. Washer
25. Flange
26. Vent fitting
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 64
65 T 70
43. Manifold
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 FUEL CELL 50 TO 75 IN-LBS
57. Hose (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 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.
22. Remove bolts (70) and washers (69) that attach
tube (68) to fuel cell. Remove tube and discard
packing (67).
23. Remove fuel cell access panel at seatback
attachment area.

9. Disconnect hoses (39, 40, 41, and 42) from 24. Remove screws (13) and washers (12) that
manifold (43). Remove hoses (39 and 40). secure fuel cell to structure at eight places.

10. Remove bolts (38) and washers (37) and remove

manifold (43) from fuel cell.
CAUTION

11. Disconnect hoses (41 and 42) from lower forward

fuel cell connection and remove hoses. DO NOT FOLD A COLD FUEL CELL.
FOLDING MAY CRACK OR DAMAGE A
CO LD CE L L. HE AT L A MP S M AY B E
12. Remove bolts (60) and washers (61) and
USED TO WARM FUEL CELL PRIOR TO
disconnect interconnect assembly (59). Discard
FOLDING.
packing (58). Remove clamp and clip (5) securing fuel
quantity probe harness (7) to interconnect tube (10).
25. If required, heat cell for approximately 2 hours.
Do not exceed 125°F (51.7°C).
13. Withdraw fuel quantity probe harness (7) through
interconnect tube (10) and fitting (51) and stow outside
26. Carefully collapse fuel cell and remove from
fuel cell as indicated.
helicopter.

14. Remove bolt (54), nut (52), washers (53 and 55),
27. Cap and cover open lines.
and clip (56) securing hoses (57) together.

28-14. AFT FUEL CELL — INSPECTION AND

15. Disconnect tubes (48) from hoses (57).
REPAIR

16. Remove bolt (44) and washer (45) securing 1. Inspect the exterior and interior of fuselage
retainer (46) to fuel cell. Remove tubes (48) from beneath fuel cell for indications of fuel leakage.
inside fuel cell. Discard packings (47).
2. Inspect fuel cell drain valve for evidence of leaks.
17. Disconnect clamps (15) securing ejector pump
tube (14) and interconnect tube (10) together.
3. Inspect fuel lines, fittings, and fuel cell covers for
leakage, damage, and security.
18. Remove screw (11) securing clamp and
interconnect tube (10) to fuel cell.
4. Inspect vent hose for leakage, chafing, damage,
and security.
19. Remove bolts (66) and washers (65) that attach
flange (64) and interconnect tube (10) to fuel cell.
Remove interconnect tube and discard packing (63).
CAUTION
20. Disconnect ejector pump tube (14) from tube (68)
and remove from fuel cell.
MAKE SURE ELECTRICAL LEADS FROM
BATTERY RELAY BUS BAR DO NOT
21. Disconnect tube (68) from hose (62). TOUCH VENT HOSE (CHAPTER 96).

28-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 15
BHT-206L4-MM-4
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 1.0 inch (25.4 mm). 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 kit, complete with all
materials and instructions for making field repairs is
available from respective cell manufacturer.
7. Inspect cell for evidence of fungus. If fungus is
present, treat (paragraph 28-10).
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 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 TO B E
FLEXIBLE.
2. If required, heat 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.
28-00-00
Page 16 Rev. 11 31 AUG 2010
4. Apply talcum powder (C-408) to fuel cell cavity.
Collapse fuel cell and insert through seatback 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 screws (13, Figure 28-3) and washers (12)
(8 places), to secure fuel cell to airframe structure.
Tighten the screws.
6. Install new packing (67) on tube (68). Insert tube
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 Nm).
7. Connect tube (68) to hose (62).
8. Install new packing (58) on interconnect
assembly (59) and new packing (50) on fitting (51).
Install new packing (63) and flange (64) on
interconnect tube (10).
9. Route fuel quantity probe harness (7) through
fitting (51) and interconnect tube (10) inside fuel cell.
10. Connect interconnect tube (10) and flange (64) to
fuel cell and fitting (51) using washers (65), bolts (66),
and new packings (49). Torque bolts 50 to
75 inch-pounds (5.65 to 8.47 Nm). Install clamp and
clip (5) securing fuel quantity probe harness (7) to
interconnect tube.
11. Connect interconnect assembly (59) to fitting (51)
using washers (61) and bolts (60).
12. Connect ejector pump tube (14) to tube (68).
Connect clamps (15) securing ejector pump tube (14)
and interconnect tube (10) together. Install screw (11)
securing interconnect tube to fuel cell.
13. Install new packings (47) on tubes (48). Insert
tubes 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 Nm).
14. Inside the fuel cell, connect tubes (48) to hoses
(41 and 42). Outside the fuel cell, connect tubes to
hoses (57). Install clip (56) securing tubes together
using bolts (54), washers (53 and 55), and nut (52).
ECCN EAR99

15. Install manifold (43) using washers (37) and bolts
(38). Connect hoses (40, 39, 41, and 42) to manifold.
16. Install new packing (31) on fitting (32). Install
fitting on fuel cell using washer (30) and jamnut (29).
Connect fuel supply hose (4) to fitting.
17. Install fuel pressure transducer (34) on fitting
(32). Connect electrical connector. Install fuel shutoff
valve inlet tube (1) between elbow (33) and fuel
shutoff valve (2).
18. Install new packing (27) on vent fitting (26) and
install using flange (25), washer (24), and screws (23).
Connect vent hose (3) to fitting.
19. Install retainer (28) using washer (36) and bolt
(35). Torque bolt 40 inch-pounds (4.52 Nm) maximum.
20. 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). Make sure that surfaces
are clean for a good bond of bonding tap and retainer.
Torque screws 50 to 75 inch-pounds (5.65 to
8.47 Nm).
21. Deleted.
22. Install fuel quantity transmitter (6) (paragraph
28-53).
23. Install aft fuel quantity probe (9) (paragraph
28-49).
24. Install fuel boost pump assembly (8) (paragraph
28-42).
25. Apply a coating of sealant (C-328) to mating
surface of seatback and fuel cell access panel. Install
the fuel cell access panel with screws and washers.
Tighten the screws.
26. Pressure test fuel system (paragraph 28-5).
27. Install fuselage access panel located above fuel
filler.
ECCN EAR99
BHT-206L4-MM-4
28. Install seatback and seat bottom (Chapter 25).
29. Connect battery.
30. Service 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.
28-19. DUAL ELEMENT EJECTOR PUMP —
REMOVAL
1. Disconnect battery and external power supply.
Ground helicopter.
2. Defuel and purge fuel cells (Chapter 12).
3. Remove aft facing seat cushions and seatbacks
(Chapter 25).
28-00-00
31 AUG 2010 Rev. 11 Page 17
BHT-206L4-MM-4

7. Install cover below center seat panel. Install

NOTE center seat panel.
Cap or cover open fittings and ports when
lines or hoses are removed. 8. Install aft facing seat cushions and seatbacks
(Chapter 25).
4. Remove center seat panel. Remove cover below
center seat panel. Remove center cover between the 9. Connect battery.
two aft seats and cover at forward end of center cover.
10. Service fuel system (Chapter 12) and check for
5. Disconnect tubes (10 and 11, Figure 28-4) at dual leaks (Chapter 5).
element ejector pump (5).
28-22. FUEL FLOW SWITCHES
6. Disconnect hose (6) from dual element ejector
pump (5). The fuel flow switches are located between the two
forward fuel cells and monitor the fuel flow to the dual
7. Remove bolts (1), with washers (2) and slide element ejector pump. Each switch monitors the fuel
tubes (3) outboard. Remove and discard packings (4). flow to its respective element of the dual element
ejector pump.
8. Remove bolt (8) and washer (9) from support (7).
Remove dual element ejector pump (5).
28-23. FUEL FLOW SWITCHES — REMOVAL
28-20. DUAL ELEMENT EJECTOR PUMP —
INSPECTION 1. Disconnect battery and external power supply.
Ground helicopter.
1. Inspect dual element ejector pump and in-line
filters for obstructions. If obstructions are found, 2. Defuel and purge fuel cells (Chapter 12).
remove them with compressed air.
3. Remove aft facing seat cushions and seatbacks
2. Inspect dual element ejector pump for evidence (Chapter 25).
of corrosion.
4. Remove center seat panel by removing perimeter
3. If dual element ejector pump proves to be screws and four screws holding flow switch clips (two
unserviceable, replace pump. screws per switch). Remove cover below center seat
panel.
28-21. DUAL ELEMENT EJECTOR PUMP —
INSTALLATION NOTE
Removal procedure is the same for either
1. Install new packings (4, Figure 28-4) on end of fuel flow switch. The following procedure is
tubes (3). for the left fuel flow switch.
2. Install dual element ejector pump (5) between 5. Disconnect fuel flow switch electrical leads (23,
tubes (3) and just aft of support (7). Install bolt (8) with Figure 28-5).
washer (9). Install bolts (1) with thin washers (2).
Torque bolts 50 to 75 inch-pounds (5.65 to 8.47 Nm).
NOTE
3. Thread B-nut of hose (6) on dual element ejector Cap or cover open fuel lines.
pump and torque.
6. Disconnect hose (17) from elbow (18).
4. Connect tubes (10 and 11).
7. Disconnect tube (28) from union (27).
5. Perform pressure test (paragraph 28-5).
8. Remove nuts (19 and 20) and elbow (18) that
6. Install cover at front of aft facing seat. Install secure fuel flow switch (22) to support clip (16).
cover between the two aft seats. Discard packing (21).

28-00-00
Page 18 Rev. 11 31 AUG 2010 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
10 9. Washer

8 9 h I
10.
11.
Tube
Tube

206L4-M-28-4

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

roc

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

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
206L4_MM_28_0005

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

28-00-00
Page 20 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-4

9. Remove nuts (25 and 26) and union (27) inline check valve is connected between each

"0m

0
securing fuel flow switch (22) to support clip inline filter and fuel flow switch.

'+(?
(15). Discard packing (24) and remove switch
:--
from helicopter.
28-27. REMOVAL.

28-24. INSPECTION. 1. Disconnect battery and external power

-ate
supply. Ground helicopter.
1. Inspect fuel flow switch for rust or
corrosion. 2. Defuel and purge fuel cells (Volume 2,
Chapter
Chapter1212).
2. Ensure fuel flow switch is not clogged or
0

(/)

CAD
obstructed. 3. Remove aft facing seat cushions and seat
Chapter 25
backs (Volume 3, Chapter 25).
28-25. INSTALLATION. 4. Remove passenger compartment floor

,.+
carpeting and fuel system tunnel cover.
figure
1. Install new packings (21 and 24, figure
28-5) in fuel flow switch (22).
28-5
«O-

NOTE
2. Position flow switch (22), with flow arrow
aim

Faying surfaces of tunnel cover and

pointing forward, between support clips (15 fuel cell cover are coated with

3°-
and 16).
CC)

sealant for fume tightness. Use care

to prevent damage during parts
3. Install elbow (18) and nuts (19 and 20)
0)-

removal.
securing switch to support clip (16).
5. Remove molded plastic cover between
4. Install union (27) and nuts (25 and 26) left and right aft facing passenger seats.
securing switch to support clip (15).
(ND

5. Connect fuel flow switch electrical leads NOTE

'-.

(23). Removal of both filters is identical.

6. Connect hose (17) to elbow (18). 6. Cut straps (2 and 8, figure 28-5) securing
figure 28-5

O_)
sleeve (6) at each end of filter (5).
(j)

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

Slide sleeves (6) from filter (5) and

-c^
7.
a0)

C(-O
8. Perform pressure test of fuel system disconnect inlet and outlet hose (3 and 7)

._.
C1)
(paragraph 28-5).
paragraph 28-5 from filter (5).

9. Install cover below seat panel. Install 8. Remove check valve (4) and packing from
center seat panel. outlet end of filter (5). Discard packing.

10. Install aft facing seat cushions and seat 9. Cap or cover open fuel lines.
0

Chapter 25
back (Volume 3, Chapter 25).
28-28. INSPECTION.
11. Connect battery.
1. Inspect inline fuel filters for rust or
Chapter
12. Service fuel system (Volume 2, Chapter corrosion.
12
12).
2. Ensure filters are not clogged or
0

28-26. INLINE FUEL FILTERS. obstructed.

The inline fuel filters are located on the

upstream side of the fuel flow switches. An
28-00-00
Page 21
B HT-206 L4-M M-4

28-29. INSTALLATION. 8. C-328 to faying

Apply sealing compound (C-328)
surfaces on seat installation cover. Install
cover and fill all gaps and voids around entire

>.2-
-.-
MATERIALS REQUIRED periphery to ensure fume tightness.

NUMBER NOMENCLATURE 9. Install molded plastic cover on aft side of

vertical control tunnel.
C-328
C-328 Sealing Compound
10. Install passenger compartment floor
carpeting.
NOTE
z

11. Install passenger aft facing seat backs

(n>
Installation of both filters is identical. Chapter 25
and cushions (Volume 3, Chapter 25).
Assure flow directional arrow on
check valve and sleeve are pointing
a).
>.O

Chapter
12. Service fuel system (Volume 2, Chapter
in proper direction as shown.
^L^,,

12
12).

.-.
1. Install new packing and check valve (4,
0)C

13. Connect battery.

figure 28-5) at outlet end of filter (5).
figure 28-5

2. Connect inlet side of filter (5) to hose (7). 28-30. FUEL QUANTITY PROBE -
U)_.

Slide sleeve (6) over check valve (4) and filter FORWARD FUEL CELL.
(5) and connect outlet end of check valve (4)
to hose (3). The forward fuel quantity probe is one of

>,C
three probes used to monitor the fuel level.
J-,

The forward fuel quantity probe is electrically

0).
3. Secure sleeve in place with two straps (2
C/)

and 8) at hose coupling nuts. connected to the two probes in the aft fuel
cell. Readings from the probes are

(/)
4. Pressure test fuel system for leakage transmitted to a fuel quantity indicator on the
(paragraph 28-5). instrument panel.
o'1

paragraph 28-5

5. Ensure work area is clear and clean of 28-31. REMOVAL.

_n)

foreign objects, and all connections and lines

are tight and secure. 1. Disconnect battery and external power
source. Ground helicopter.
WARNING 2. Defuel and purge fuel cells (Volume 2,
0

Chapter
Chapter1212).

SEAT INSTALLATION COVER AND

zcm

3. Remove aft facing seat cushions and seat

TUNNEL COVER OVER FUEL Chapter 25
backs (Volume 3, Chapter 25).
SYSTEM COMPONENTS MUST BE
SEALED FOR FUME TIGHTNESS. 4. Remove cover over fuel quantity probe.
Remove bolts (14, figure 28-2) with washers
figure 28-2
6. C-328 100 parts
Mix sealing compound (C-328) (15), from fuel quantity probe (17). Carefully
3
con

to 12 parts by weight per instructions of lift quantity probe from fuel cell to gain access
-4,
(3D

manufacturer. to electrical terminals (31). Disconnect

electrical terminals and completely remove
7. C-328 to faying
Apply sealing compound (C-328) fuel quantity probe. Remove and discard
surfaces on tunnel cover. Install cover and fill gasket (16).
all gaps and voids around entire periphery to
ensure fume tightness. 5. Cover open port in fuel cell.
28-00-00
Page 22
 131-IT-2061-4-MM-4

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

1. Inspect electrical connections for

condition and security. MATERIALS REQUIRED

2. Inspect fuel quantity probe for evidence of

4--
NUMBER NOMENCLATURE
corrosion.
C-480
C-480 Nylon Cord
28-33. INSTALLATION.
1. Remove dual element ejector pump

'.Q.
J_0
1. Place new gasket (16, figure 28-2) on fuel
figure 28-2 (paragraph 28-19).
paragraph 28-19
quantity probe.
2. Connect electrical wires to terminals (31) 2. Remove both fuel flow switches
0

on fuel quantity probe (Volume 12, Chapter

Chapter (paragraph 28-23).
paragraph 28-23
98
98).
3. Remove fuel quantity probe (17, figure
figure
3. Guide electrical wire and fuel quantity v0-
28-2 as follows:
28-2)
probe into fuel cell and secure with bolts (14)
(OD

and thin aluminum washers (15). Torque bolts a. Remove cover over top of fuel quantity

0
50 to 75 inch-pounds (5.65 to 8.47 newton- probe.
meters).
b. Remove bolts (14) and washers (15)

.fl
4. Perform calibration check of fuel quantity
°O)

from fuel quantity probe (17). Carefully lift fuel

+a)

v0-
Chapter 96
system (Volume 10, Chapter 96). quantity probe from fuel cell to gain access to
electrical terminals (31).
5. Pressure test fuel system (paragraph 28-
paragraph 28-
5).
5
c. Disconnect electrical terminals and
completely remove fuel quantity probe. Obtain

0.0
NCO
6. Install cover over fuel quantity probe.
a nylon cord (C-480) C-480 or equivalent of

(D
sufficient length to go from top of forward cell

01-+
7. Install seat cushions and backs (Volume
Chapter 25
3, Chapter 25). to front of aft fuel cell. Tie one end of cord to
airframe structure and the other end to wire
8. Connect battery. terminals.

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

28-34. INTERCONNECT TUBE. 5. Remove bolts (5) and washers (6).

The forward end of the interconnect tube is 6. Slide interconnect tube (4) forward to
located between the forward fuel cells and allow electrical wire to be pulled out between
routes fuel aft to the aft fuel cell. Inside the aft interconnect tube (4) and fitting (9). Untie
v+-

33=
a)0

(CD
0

fuel cell a tube connected to the interconnect nylon cord and work interconnect tube out.
.3r
((1)

tube serves as a stand-pipe. The fuel quantity Remove seals (1 and 10) and packing (8).
(0n

probe electrical wire is routed from the aft fuel Discard seals and packings.
cell, through the interconnect tube, to the left
.--F

forward fuel cell.

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
Page 23
BHT-206L4-MM-4

*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

206L4-M-28-6

Figure 28-6. Interconnect tube

28-00-00
Page 24
 B HT-206 L4-M M-4

3. Inspect for evidence of leaks at each

connection to the fuel cells and hose of
28-38. AFT FUEL CELL
COMPONENTS.
- DISTRIBUTION
interconnect tube.
Aft fuel cell distribution components include
28-37. INSTALLATION. two fuel boost pumps mounted on a sump
plate in the bottom of the aft fuel cell. One

-C0 -!n
fuel quantity probe is mounted at the top of

3.C

3c-
MATERIALS REQUIRED the forward part of the aft fuel cell. Another
fuel quantity probe and transmitter is attached

QOM
3'r

303
((D
NO.-
at the top of the aft part of the cell. The fuel

(CD
NUMBER NOMENCLATURE distribution system incorporates four one-way
C-480
C-480 Nylon Cord check valves located inside the fuel manifold.
Located directly above the fuel cell in an
externally accessible compartment is a fuel

N..'
-4Q
1. Feed another nylon cord (C-480)C-480 through shutoff valve and a fuel pressure transducer.
interconnect tube (4, figure 28-6) and tie one
figure 28-6
end to retainer (7) and other end to forward
left end of interconnect tube. Place 28-39. FUEL BOOST PUMP.
interconnect tube (4) in approximate position.
HOC

,.+3

Feed first piece of nylon cord through new The electrical fuel boost pump is part of the

o
seal (10). Tie cord in tube to cord in sump assembly and is located in the bottom

HMO
interconnect tube, placing excess cord in of the aft fuel cell. The dual electric boost
tube. Install bolts (12) with washers (11). Do pump transfers fuel through two check valves

Q<)
in the fuel manifold to a single line and then

=;;
not tighten bolts (12). Pull and feed electrical
wires through interconnect tube into left fuel out of the fuel cell to the engine. Two
cell and out fuel quantity probe (17, figure 28-
figure 28- additional check valves and fuel lines allow
-..

2 opening.
2) the boost pumps to operate the ejector pumps

L'5
at the forward fuel cells and transfer fuel from
2. Place new gasket (16) on fuel quantity the forward fuel cells into the aft fuel cell.

-"y
probe (17). Connect electrical terminals (31)
.,.
-.Q0

to fuel quantity probe and insert fuel quantity SPECIAL TOOLS REQUIRED
probe and electrical wiring into fuel cell.
Install bolts (14), with thin aluminum washers
.0,

(-D

(15). Torque bolts 50 to 75 inch-pounds (5.65 NUMBER NOMENCLATURE

(J)

to 8.47 newton-meters).
M81969/14-02 Removal/Installation
Tool
3. Position new packing (8, figure 28-6)
figure 28-6
correctly and install bolts (5), with washers
(b-0

(6), through retainer (7) and into aft fuel cell.

Torque bolts (5) 50 to 75 inch-pounds (5.65 to 28-40. REMOVAL.
8.47 newton-meters).
1. Disconnect battery and ground helicopter.
4. Place new seal (1) between interconnect
tube and right fuel cell. Install bolts (3), with 2. Defuel and purge fuel cells (Volume 2,
,y.

washers (2). Torque bolts (3) 50 to 75 inch- Chapter 1212).

Chapter
=3W
C3)

pounds (5.65 to 8.47 newton-meters).

3. Remove fuel boost pump assembly cover.
E

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

(1)

(5.65 to 8.47 newton-meters). 4. Remove screw (17, figure 28-7), nut (22),
figure 28-7
washer (16 and 23), and spacer (15). Remove
6. Install both fuel flow switches (paragraph retainer (24). I
N0)

paragraph
28-25).
28-25
5. Disconnect in-line junction (detail A) at
7. Install dual element ejector pump electrical terminals (27 and 32) using
0

(paragraph 28-21).
paragraph 28-21 M81969/14-02 tool or equivalent.

28-00-00
Page 25
BHT-206L4-MM-4

CD))m
1. Reducer
2. Packing
3. Pump
4. Packing
5. Washer
6. Bolt
7. Packing
8. Switch, fuel low level

+V+
9. Washer
10. Bolt
11. Packing
12. Drain valve
13. Washer
14. Bolt
28 15. Spacer
16. Washer
17. Screw

00D
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
32. Electrical terminals

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

21 206L4-M-28-7-1

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

28-00-00
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
 131-IT-2061-4-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. Remove screws attaching positive bolts (14) and washer (13). Torque bolts 50 to

Q-1

C(]
terminals (30 and 31) from both boost pump 75 inch-pounds (5.65 to 8.47 newton-meters).

CJ))
cartridges.
e. Place new gasket (18) on cover (19).
8. From beneath the helicopter, push the Secure cover in place with bolts (21) and

.-t

-0O
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

3t0
9. Remove bolts (6) and washers (5). assembly port. Connect fuel hoses to

CND

-,<
reducers (1). From beneath the helicopter,
10. Disconnect fuel hoses to reducers (1). position fuel boost pump in place. Secure with

O,^3
bolts (6) and washers (5). Torque bolts 50 to

U±-
11. Remove pump (3). 75 inch-pounds (5.65 to 8.47 newton-meters).

3. Remove and discard manufacturer

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

0
present. crimp connector on end of wire and install on
.0070

bolt (21) along with aircraft ground wire No.

2. Inspect electrical wiring for condition. Q4A18N (detail A). Install aircraft wiring to
Chapter 98
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

0o4)0
NOTE bolt (21). Install crimp connector on end of
wire. Connect drain valve positive terminal to

0'3
`<.a
If original fuel boost pump assembly
(`n

aircraft wire No. Q21 A22 with in-line junction

.-t
is being reinstalled omit step 1. (detail A) using M81969/14-02 tool.
((DD

1. Assemble new pump assembly as follows:

E

Sri

NOTE
Place new packings (2, figure
a. figure 28-7
28-7) on
Cut wire to correct length before
0
reducers (1) and install in outlet ports of
pump. installing in-line junction.

5. Cut one wire on fuel low level switch (8)

-J1

C-°

to appropriate length to reach same bolt next

p)3.

CAUTION to bolt (21) as drain valve wire. Install crimp

.=a

................. connector on end of wire. Install fuel drain

and fuel level connectors to bolt alon with
DO NOT PLUG THE PUMP SEAL
m

aircraft ground wire No. Q2A18N (detail A).

.,.
(D

DRAIN PORTS. Connect remaining fuel level switch wire to

3_C.

aircraft wire No. E93A22 with in-line junction

b. Place new packings (29) on plugs (28) Chapter
using M81969/14-02 tool (Volume 12, Chapter
and install in the pump drain ports. 98
98).
c. Place new packing (7) on boss of fuel 6. Tighten bolts (21) to 50 to 75 inch-pounds
low level switch (8). Secure switch in place (5.65 to 8.47 newton-meters).
with one bolt (10) with washer (9) and adapter
(25) with washer (26). Torque bolt (10) and Place washer (16) on screw (17) and
07Q

7.
adapter (25) 50 to 75 inch-pounds. (5.65 to insert through retainer (24). Place spacer (15)
8.47 newton-meters).
28-00-00
NC.

Page 28
 BHT-2061-4-MM-4

on screw (17) and secure into fuel boost 8. Install E2-01-1 slide hammer in pump

-(n
pump sump assembly. Do not tighten. Place drain boss and remove pump cartridge.
washer (23) on adapter (25) and install nut

>S1
(22). Tighten nut (22) and screw (17).
28-45. INSTALLATION.
8. Perform pressure test of fuel system

-,,
y--
E

N-0
(paragraph Chapter 55).
28-5 and Volume 2, Chapter
paragraph 28-5 MATERIALS REQUIRED

9. Connect battery.
NUMBER NOMENCLATURE
10. Perform functional check of fuel quantity
O>,

C-010
C-010 Lubricating Oil
Chapter 96
system (Volume 10, Chapter 96).
E

Chapter
11. Service fuel system (Volume 2, Chapter 1. Clean cartridge hole of all foreign matter.
12
12).
2. Clean retaining ring (34 or 39, figure 28-7,'
figure 28-7
detail A)..
28-43. CANISTER FUEL BOOST PUMP.
3. Lubricate packings on replacement

(D'
0-0
NOTE cartridge and the sides of the cartridge hole in
the mounting flange casting with lubricating
The canister type fuel pump and C-010
oil (C-010).
impeller may be replaced without
draining the fuel system.
'CAUTION'
SPECIAL TOOLS REQUIRED

NUMBER DO NOT FORCE CARTRIDGE INTO

NOMENCLATURE
CANISTER. ECCENTRIC
CARTRIDGE DESIGN REQUIRES

X00
E2-10-1 Slide Hammer
m

ALIGNMENT ARROWS TO BE
WITHIN ± 3 DEGREES TO BE
O-I
-u2

m
28-44. REMOVAL. PROPERLY INSTALLED.

1. Turn helicopter electrical master switch 4. Install cartridge (35 or 36)in flange
(canister) with arrows aligned.
BHT-206L4-FM-1
OFF (BHT-206L4-FM-1).
LPL.

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

--o
_-4

electrical terminal (figure 28-7, detail A).

figure 28-7
When pushing cartridge (35 or
3. Remove hexagon head screws and 36)into place, ensure that cartridge
is properly seated and that retaining
(OD

negative (ground terminal) from boost pump

shutoff lever (33 or 37). ring groove is not obstructed.
can

4. Turn fuel boost pump shutoff lever 5. Install retaining ring (34 or 39).
enough to clear motor and impeller.
6. Install drain plug (36 or 40).
(1)

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

,,.

40). .................

'CAUTION'
6. Remove any remaining obstructions
below cartridge (35 or 38).
DO NOT OVERTORQUE POSITIVE
m

7. Remove retaining ring (34 or 39). ELECTRICAL TERMINAL.

28-00-00
C-4

Page 29
B HT-206 L4-M M--4

7. Connect positive (+) electrical terminal 2. Connect electrical wiring from forward fuel

0
(detail A). cell quantity probe and aft fuel quantity
transmitter to fuel quantity probe (3) electrical

(n-
8. Position fuel boost pump shutoff lever (33 Chapter 98
terminals (Volume 12, Chapter 98).
o`.
0<r

((DD
050
or 37) over screw hole. Install hexagon head
screw and negative electrical terminal. 3. Carefully insert fuel quantity probe (3)

(c1

C+,
and electrical wiring into aft fuel cell (5).

0wQ

,n+
cod
9. Turn master switch ON and turn on fuel Place spacer (9) on top of fuel quantity probe.

(CD
o00

BHT-206L4-FM-1
purnp (13HT-206L4-FM-1). Check for proper
gage pressure and external leaks.
2846. AFT FUEL QUANTITY PROBE.
The aft fuel cell fuel quantity probe is
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.

a)µ-
mounted in the top of forward part of aft fuel
(71

cell. The fuel quantity probe is electrically Perform calibration check of fuel quantity
3C.0
0))

5.

0
connected to the forward fuel cell fuel quantity Chapter 96
system (Volume 10, Chapter 96). I

((DD
probe and to the aft fuel cell fuel quantity
probe and transmitter. 6. Perform pressure test of fuel system

003

0
(paragraph 28-5).
paragraph 28-5
28-47. REMOVAL.
Chapter
7. Service fuel system (Volume 2, Chapter
12 .
12)
1. Disconnect battery and external power
x

source. Ground helicopter.

28-50. FUEL QUANTITY TRANSMITTER.
2. Defuel and purge fuel cells (volume 2,
Chapter
Chapter1212). The fuel quantity transmitter is located in the
top of the aft fuel cell and is electrically
3. Remove screws (6,figure 28-8), cover (7),
figure 28-8 connected to the fuel quantity probes that are
'-'

and gasket (8). Remove bolts (1) and located in the top of the forward and aft fuel
<

washers (2). Remove spacer (9) and carefully cells.

L,<

raise fuel quantity probe (3). When electrical

;-'
O(D

wires are accessible, remove screws securing 28-51. REMOVAL.

electrical wires to fuel quantity probe and
,n.

._f

remove fuel quantity probe from aft fuel cell 1. Disconnect battery and external power
(5). source. Ground helicopter.
4. Remove and discard gasket (4). 2. Defuel and purge fuel cells (Volume 2,
Chapter 1212).
Chapter
5. Cover open port in fuel cell.
3. Remove upholstery and seat cushions
28-48. INSPECTION. Chapter 25
and back (Volume 3, Chapter 25).

1. Inspect electrical connections for 4. Remove upholstery to gain access to top

condition and security. of aft fuel cell. Remove Velcro plastic hat.

5. Disconnect electrical connector from fuel

2. Inspect fuel quantity probe for corrosion.
quantity transmitter (5, figure 28-9).
figure 28-9

28-49. INSTALLATION. 6. Remove screws (1), washer (2), retainer

(3), and seal (4).
1. Place new gasket (4, figure 28-8) on fuel
figure 28-8
quantity probe (3).
28-00-00
Page 30
 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
 131-IT-2061-4-MM-4

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

'--.
to expose electrical wiring on probe. Secure
wires to top area of cell. Disconnect electrical 1. Remove fuselage access panel located

0
wiring from fuel quantity transmitter. Remove above fuel filter.
fuel quantity transmitter from fuel cell.
2. Disconnect electrical connector (4, figure
figure
8. Remove and discard gasket (6) and seal 28-10).
28-10
(4). Cover open port of fuel cell.

((DD
3. Unscrew fuel pressure transducer (3)

vYC
(,,)
.__
28-52. INSPECTION. from fitting (1). Remove and discard packing
(2).
1. Inspect fuel quantity transmitter for

0
corrosion. 28-56. INSPECTION.
2. Inspect electrical wiring for condition. 1. Inspect transducer for rust or corrosion.

28-53. INSTALLATION. 2. Inspect for bent or broken pins.

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

figure 28-9 28-57. INSTALLATION.
airframe structure and open port of fuel cell.
1. Install new packing (2, figure 28-10) on
figure 28-10
2. Place new gasket (6) on fuel quantity
.-.

transducer and screw into fitting (1).

transmitter (5) and partially insert into fuel
0

cell. Connect electrical wiring from inside fuel 2. Connect electrical connector (4).
cell to fuel quantity probe (Volume 12,
+,.)

Chapter
Chapter9898). Seat fuel quantity transmitter (5)
(CD

3. Pressurize fuel system and check for

I in fuel cell. leaks (paragraph 28-5, and Volume 2,
paragraph 28-5

E
Chapter
Chapter5 5).
3. Place retainer (3) over top of fuel quantity
(CD

>,-

transmitter. Secure in place with screws (1) Install fuselage access panel.
COD

4.
and washers (2). Torque screws 30 to 40
U)-

inch-pounds (3.39 to 4.52 newton-meters).

4. Perform pressure
(paragraph 28-5).
paragraph 28-5
28-58. FUEL SHUTOFF VALVE.
test of fuel system
The fuel shutoff valve is located above the aft
fuel cell servicing port and is electrically
..-

5. Connect battery. operated.

6. Perform calibration check of fuel quantity
O(0

28-59. REMOVAL.
Chapter 96
system (Volume 10, Chapter 96).
E

1. Disconnect battery and external power

7. Install upholstery and seat cushions and supply.
Chapter 25
back (Volume 3, Chapter 25).
2. Remove access panel above fuel filler
Chapter
8. Service fuel system (Volume 2, Chapter
port.
12
12).
3. Remove inlet tube (3, figure 28-11) from
figure 28-11
(CD

28-54. FUEL PRESSURE TRANSDUCER. inlet port of fuel shutoff valve (2). Remove
tube (7) from outlet port of fuel shutoff valve
v--

The fuel pressure transducer provides a (2). Cap open lines.

-SD
cam

fl-

means of monitoring fuel pressure in the

system. The transducer is located on a fitting 4. Disconnect electrical connector (1) from
on top of the aft right side of the aft fuel cell. fuel shutoff valve.
28-00-00
Page 32
 BHT-206L4-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
206L4-M-28-9

Figure 28-9. Fuel quantity transmitter

28-00-00
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

1. Electrical connector 5. Washer

2. Fuel shutoff valve 6. Support structure
3. Inlet tube 7. Outlet tube
4. Screw
206L4-M-28-11

Figure 28-11. Fuel shutoff valve

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

5. Remove bolts (14), washer (13), and Chapter

7. Service fuel system (Volume 2, Chapter
_^`

remove drain valve (12). Discard packing 12

12).
(11).
28-64. FUEL FILTER.
6. Cover open port.
0

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
Place new packing (11, figure built-in filter bypass valve and impending
1. 28-7) on
figure 28-7
boss of drain valve (12). bypass switch that is electrically connected to
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.
0O.

Torque bolts 50 to 75 inch-pounds (5.65 to

--{

,-+

8.47 newton-meters). 1. Disconnect battery and external power

,-+

source.
3. Connect in-line junction (detail A) at
positive terminal (27) using M81969/14-02 2. Open engine cowling on right side.
tool or equivalent.
3. Disconnect inlet hose (9, figure 28-12),
figure 28-12
1(Q

4. Connect ground wire to bolt (21). outlet hose (2), and drain hose (12) from fuel
+-'
0

filter (6).
5. Perform pressure test of fuel system
(paragraph 28-5).
paragraph 28-5

28-00-00
Page 35
BHT-206L4-MM-4

lE TORQUE
50 TO 70 IN-LBS
15.65 TO 7.91 Nm)

1. Forward firewall 10. Packing

2. Outlet hose 11. Nut
3. Fitting 12. Drain hose
4. Packing 13. Drain valve
5. Electrical connector 14. Mount bracket
^_'
c.)

6. Fuel filter 15. Washer

7. Packing 16. Washer
8. Fitting 17. Bolt
..O
DC)

206L4-M-28-12-1
9. Inlet hose

Figure 28-12. Fuel filter assembly (Sheet 1 of 2)

28-00-00
00)

Page 36
 131-IT-2061-4-MM-4

MANUAL
PRESS-TO-TEST
BUTTON

* TORQUE
25 TO 50 IN-LBS
(2.82 TO 5.65 Nm)

18. Filter head

19. Packing
20. Seal
21. Filter bowl
22. Retainer
23. Seal
24. Filter element

22*
DETAIL A
FILTER ELEMENT REPLACEMENT 206L4-M-28-12-2

Figure 28-12. Fuel filter assembly (Sheet 2)

28-00-00
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

(15 and 16) from top of fuel filter. Remove fuel filter (6). MATERIALS REQUIRED

28-66. FUEL FILTER — INSPECTION Refer to BHT-ALL-SPM for specifications.

1. Inspect fuel filter bowl for corrosion. NUMBER NOMENCLATURE

C-405 Lockwire
2. Inspect electrical connector for condition.
C-414 Shear Wire
28-67. FUEL FILTER — INSTALLATION

NOTE
MATERIALS REQUIRED Filter element must be removed for
inspection whenever caution light comes on
Refer to BHT-ALL-SPM for specifications. during engine operation.
NUMBER NOMENCLATURE Replace element at same hourly interval as
the engine fuel pump filter, or whenever
C-405 Lockwire
contamination cannot be removed.

1. Position fuel filter (6, Figure 28-12) under mount
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 Nm) and lockwire (C-405).
At each fuel filter element change interval,
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
that bleed port is not clogged.

2. Connect electrical connector (5) to top of fuel

filter (6).

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

or drain valve (13) were removed. Connect inlet hose
1. Open right engine cowling.
(9), outlet hose (2), and drain hose (12) to fuel
filter (6).
2. Open drain valve (13, Figure 28-12) and drain
4. Connect battery. fuel from filter bowl (21).

5. Pressurize fuel system and check for leaks at fuel 3. Disconnect drain hose (12) and remove drain
filter (Chapter 5). valve (13). Remove and discard packing (10).

6. Close and secure engine cowling. 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.

28-00-00
Page 38 Rev. 11 31 AUG 2010 ECCN EAR99

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 Nm).
10. Install 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 (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
B E F O RE P UR G IN G A IR F RO M T HE
AIRFRAME AND ENGINE FUEL SYSTEM,
BE SURE TO GROUND THE
HELICOPTER.
BOTH FUEL BOOST PUMPS MUST BE
ON DURING PURGING OPERATIONS.
14. 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
Export Classification C, ECCN EAR99
BHT-206L4-MM-4
clean container. Refer to Rolls-Royce Operation and
Maintenance Manual 14W2PM.
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).
15. 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).
28-00-00
7 NOV 2014 Rev. 20 Page 39
BHT-206L4-MM-4

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.

28-00-00
Page 40 Rev. 20 7 NOV 2014 Export Classification C, ECCN EAR99
 BHT-206L4-MM-4

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.

28-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 41
BHT-206L4-MM-4

Figure 28-13. Deleted

28-00-00
Page 42 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-4

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.

28-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 43/44