EUROCOPTER MAINTENANCE MANUAL B 0 105

867 CARTRIDGE-TYPE FUEL PUMP

Table of Contents

Paragraph Title Page

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867 1 DESCRlPTlON - FUEL PUMP ................................................. 3
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867 2 TROUBLESHOOTING - FUEL PUMP ........................................... 3
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867 3 INSPECTION FOR CONDlTlON - FUEL PUMP ......... .......................... 3
867 - 4 REMOVAL AND INSTALLATION - FUEL PUMP ............... ................... 4
867 - 5 REMOVAL AND INSTALLATION - PUMP CARTRIDGE ................. .......... 6

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867 -1 DESCRlPTlON - CARTRIDGE-TYPE FUEL PUMP

1. General
The fuel pump is driven by a motor housed in the pump cartridge. When it becomes necessary to replace
the pump motor, the pump cartridge can be removed without having to remove the entire fuel pump.

2. Description
The fuel pump consists of a sealed pump housing and a pump cartridge incorporating the motor and
impeller.

3. Operation
Fuel is drawn in through a valve installed in the pump housing and is then pumped into the fuel line by the
impeller housed in the pump cartridge. The pump delivers 7.5 literslmin. at 1.7 bar (25 psi) maximum.

867 -2 TROUBLESHOOTING FUEL PUMP -

Troubleshootingshall be performedin conjunctionwith fuel systemtroubleshootingper Chapter 62, para. 62-2.

867 -3 INSPECTION FOR CONDlTlON FUEL PUMP -

1. Remove screws (22, fig. 867-1) and remove cover plate (21).

2. Visually inspect fuel pump for leakage in the mounting area. If leakage is evident, remove pump cartridge
per para. 867-6 and replace 0-rings (24 and 25).

3. Inspect screws (14,16,17 and 20) and nuts (27) for tightness. If necessary, retighten screws and nuts and
secure with lockwire. For torque on nuts refer to fig. 867-1.

4. lnspect bonding jumpers (5) and (9) and electrical lead (6) for damage and tight connection. Replace if
damaged.

5. Attach cover plate (21) to bottom shell with screws (22).

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867 -4 REMOVAL AND INSTALLATION FUEL PUMP -

WARNING T 0 AVOlD FlRE AND EXPLOSION HAZARDS DUE T 0 SPARKING, ALL
REGULATIONS AND PRECAUTIONS REGARDING HANDLING OF HIGHLY
FLAMMABLE MATERIALS SHALL BE STRICTLY OBSERVED.

1. Remove fuel pump.

a. Defuel the helicopter per Chapter 06.

b. Disconnect battery and EPU from aircraft electrical System (refer to Chapter 92).

WARNING BEFORE THE FUEL PUMP IS REMOVED IT IS NECESSARY T0 PURGE

THE ASSOCIATED FUEL TANK OF FUEL VAPORS T 0 AVOlD FlRE AND
EXPLOSION HAZARDS.

C. Purge fuel cell with air or nitrogen:

1) Open all drain valves by pushing up and turning the valve stem.

2) Remove fuel filler cap and insert the purging medium delivery hose into the fuel cell. Seal the gap
between the delivery hose and the filler neck with adhesive tape (CM 614).

3) Purge the fuel tank using either filtered, compressed air for approx. 2 hours at 2 to 4 bar or nitrogen
for 2 hours at a flow rate of 0.5 kglmin.

4) When purging has been completed, remove the delivery hose and wait approx. 1 hour before
continuing with the removal procedure.

d. Remove screws (22, fig. 867-1) and remove Cover plate (21).

e. Unscrew and remove Allen screw (17) together with electrical lead (6).

f. Remove lockwire (7).

CAUTION T 0 AVOlD DAMAGING THE FUEL PUMP VALVE, D 0 NOT SET THE PUMP
DOWN ON THE VALVE AND D 0 NOT TOUCH THE VALVE WlTH SHARP
OBJECTS.

g. Remove Allen screw (16), rotate fuel shutoff lever arm (8) away from the pump cartridge, and remove
bonding jumper (9) and washer (15).

h. Detachconnectingpiece (4) and attachedfuel line by removing screw (14), washer (13), 0-rings (10,12)
and spacer (11). Discard O-rings (10,12).

i. Remove nuts (27) together with washers (28) and bonding jumper (5). and detach pump housing (3)
together with pumpcartridge(26)and gasket (2) from bolt ring (1) of fuel cell. If connectingpiece (4) is hard
to dislodge from the fuel pump, force it up off its seat by threading an M6 screw of suitable length into the
bore.

NOTE If the fuel pump is to be sent for repair, be Sure to include the connecting piece.
lnstead of removing the connecting piece located in the tank, you are recom-
mendedto send the connectingpiece of the replacementfuel pump to the repair
facility.

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2. Install fuel pump.

CAUTION T 0 AVOlD DAMAGING THE FUEL PUMP VALVE, D 0 NOT SET THE PUMP
DOWN ON THE VALVE AND D 0 NOT TOUCH THE VALVE WlTH SHARP
OBJECTS.

a. Inspect gasket (2) for condition and replace if found to be damaged.

b. Lubricate gasket with grease (CM 101) and fit it on the mountingflange of pump housing (3).

C. Secure connectingpiece (4) together with attached fuel line to pump housing (3),using screw (14), new
0-rings (10,12), spacer (11) and washer (13).

d. Fit pump housing (3) together with pumpcartridge (26) and gasket (2) in fuel tank and attach to bolt ring
together with bonding jumper (5), using screws (27) and washers (28). For torque on nuts refer to fig.
867-1.

e. Rotate fuel shutoff lever arm back in line with its mating hole in the pump cartridge.

f. Press upward on the connected end of the fuel shutoff lever arm so that valve spring bottoms and install
washer (15), bonding jumper (9) and Allen screw (16).

g. Wire-lock Allen screw (16) to screw (14).

h. Connect electrical lead (6).andsecure with Allen screw (17).

i. Apply a coat of corrosion preventive lacquer (CM 501) to bonding jumper (9).

j. Refuelfuel System according to Chapter 06 and functionally test fuel pump per Chapter 92, para. 92-79.

k. Visually inspect fuel pump for leakage in mounting area.

I. Attach Cover plate (21) to bottom shell with screws (22).

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867 - 5 -
REMOVAL AND INSTALLATION FUEL PUMP CARTRIDGE
Special tools: Cartridge pulling tool E2-10-1 (Airborne Freight Corporation)

WARNING T 0 AVOlD FlRE AND EXPLOSION HAZARDS DUE T 0 SPARKING, ALL

REGULATIONS AND PRECAUTIONS REGARDING HANDLING OF HIGHLY
FLAMMABLE MATERIALS SHALL BE STRICTLY OBSERVED.

Before replacing a pump cartridge in the main fuel tank, 25 liters of fuel shall be removed

I from the supply tank (refer to defueling in Chapter 06).

Defueling is not required when replacing a pump cartridge in the supply tank.

1. Remove pump cartridge.

a. Disconnect battery and EPU from aircraft electrical system (refer to Chapter 92).

b. Remove screws (22, fig. 867-1) and remove Cover plate (21).

C. UnscrewAllen screw (17) and remove together with electrical lead (6).

d. Remove lockwire (7).

e. Remove Allen screw (16), rotate fuel shutoff lever arm (8) 180" away from the pump cartridge, and
remove bondingjumper (9) and washer (15).

f. Catch fuel spillage in a suitable container.

g. Remove lockwire from blanking screw (20).

h. Unscrew and remove blanking screw (20) while holding drain boss (23).

i. Remove cartridge retaining ring (18).

j. Thread pullingtool E2-10-1 into drain boss.

k. Remove pump cartridge (26) from pump housing (3) by pulling down the heavy slider of pulling tool
E2-10-1 sharply against the bolt head.

2. lnstall pump cartridge.

a. lnspect 0-rings and screws for condition and replace as necessary.

b. Lubricate Grings (24 and 25) on new pump cartridge (26) and cartridge seating surface in the pump
housing (3) with grease (CM 101).

NOTE The arrow on pump housing (3) must align with the arrow on pump cartridge (26) to
within f 3".
Do not use pulling tool E2-10-1 to install the pump cartridge. Use hands only.

C. Insert pump cartridge (26) by hand into pump housing (3) and ensure it is.correctlyseated.

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d. lnstall cartridge retaining ring (18).

e. Lubricate new 0-ring (19) with grease (CM 101).

f. lnstall blanking screw (20) together with 0-ring (19) in drain boss (23) and wire-lock blankingscrew to
pump housing (3).

g. Rotate fuel shutoff lever arm (8) back in line with its mating hole in the pump cartridge

h. Press upwardon the connectedend of the fuel shutofflever arm so that valve spring bottoms and install
washer (15), bondingjumper (9) and Allen screw (16).

i. Wire-lock Allen screw (16) to screw (14).

j. Connect electrical lead (6) and secure with Allen screw (17).

k. Apply a coat of corrosion preventive lacquer (CM 501) to bonding jumper (9).

I. Functionally test fuel pump per Chapter 92, para. 92-79.

m. Visually inspect fuel pump for leakage in mounting area.

n. Attach Cover plate (21) to bottom shell with screws (22).

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1 Bolt ring on fuel tank

2 Gasket
3 Pump housing
4 Connecting piece
5 Bonding jumper
6 Electrical lead
7 Lockwire
8 Fuel shutoff lever arm
9 Bonding jumper
10 0-ring
11 Spacer
12 0-ring
13 Washer
14 Screw
15 Washer
16 Allen screw
17 Allen screw
18 Retaining ring
19 0-ring
20 Blanking screw
21 Cover plate
22 Screw
23 Drain boss
24 0-ring
25 0-ring
26 Pump cartridge
27 Nut
28 Washer
29 Valve stem
30 Pulling tool E2-10-1

Figure 867-1 Cartridge-type fuel pump (1 of 2)

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Pump cartridge
with pulling tool

lnstalled condition
Viewed from below

1
Aligning arrows

Figure 867-1 Fuel pump ( 2of2 )

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