Maintenance Manual Fuel/Hydraulics: BHT-206A/B-SERIES-MM-4

BHT-206A/B-SERIES-MM-4
MAINTENANCE MANUAL
VOLUME 4
FUEL/HYDRAULICS
NOTICE
The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins
and other directions issued by Bell Helicopter Textron and Airworthiness Directives issued by
the Minister of Transport, Canada, shall be strictly followed. This manual covers 206A, 2068, and
20683 helicopters SN 4 through and including current production. TH-57/TH-67 helicopters are
covered along with the use of manual supplements. 206B1 helicopters are not covered by this
manual.
FOR MODELS 206A, 206B, AND 206B3 HELICOPTERS
COPYRIGHT NOTICE Bell

COPYRIGHT 1998 A Subsidiary of Textron Inc
AND BELL HELICOPTER TEXTRON, POST OFFICE BOX 482 l FORT WORTH, TEXAS 76101
A DIVISION OF TEXTRON CANADA LTD.
ALL RIGHTS RESERVED
07 JANUARY 1998
PROPRIETARY RIGHTS NOTICE
These data are proprietary to Bell Helicopter Textron, Inc. Disclosure,

reproduction, or use of these data for any purpose other than helicopter
operation and/or maintenance is forbidden without prior written authorization
from Bell Helicopter Textron, Inc.
Additional copies of this publication may be obtained by contacting:

Commercial Publication Distribution Center
Bell Helicopter Textron
P.O. Box 482
Fort Worth, Texas 76101
PN
CHAPTER 28 - FUEL SYSTEM
CONTENTS - MAINTENANCE PROCEDURES
Paragraph Chapter/Section Page

Number Title Number Number
FUEL SYSTEM
28-l Fuel system (helicopter S/N 4 through 3566) .................. 28-00-00 3

28-2 Fuel system (helicopters S/N 3567 and subsequent) ........... 28-00-00 3
28-3 Safety Precautions ..................................... 28-00-00 3
28-4 Troubleshooting ........................................ 28-00-00 3
28-5 Operational check ...................................... 28-00-00 3
28-6 Testing ............................................... 28-00-00 3
28-7 Fuel cells (helicopters S/N 4 through 3566) ................... 28-00-00 8
28-8 Fuel cells (helicopters S/N 3567 and subsequent) ............. 28-00-00 8
28-9 Removal (helicopters S/N 4 through 3566) ................ 28-00-00 8
28-l 0 Removal (helicopters S/N 3567 and subsequent) ........... 28-00-00 12
28-11 Inspection and repair ................................... 28-00-00 13
28-12 Cleaning .............................................. 28-00-00 13
28-l 3 Installation (helicopters S/N 4 through 3566) ............... 28-00-00 14
28-14 Installation (helicopters S/N 3567 and subsequent) ......... 28-00-00 15
FUEL DISTRIBUTION
28-l 5 Fuel distribution ........................................... 28-00-00 17

28-16 Fuel pump and filter assembly .............................. 28-00-00 17
28-l 7 Fuel boost pump .......................................... 28-00-00 17
28-l 8 Removal .............................................. 28-00-00 17
28-l 9 Inspection.. ........................................... 28-00-00 17
28-20 Installation ............................................ 28-00-00 17
28-21 Fuel pump cartridge ....................................... 28-00-00 24
28-22 Replacement - fuel pump cartridge in 206-062-673-001
pump ............................................... 28-00-00 24
28-23 Replacement - fuel pump cartridge in 206-062-681-l 01
canister type fuel boost pump .......................... 28-00-00 25
28-24 Replacement fuel pump cartridge in 206-062-681-l 03
pump, canister type .................................. 28-00-00 26
28-25 Fuel shut off valve ......................................... 28-00-00 26
28-26 Removal (helicopters S/N 4 through 153) .................. 28-00-00 26
28-27 Installation ............................................ 28-00-00 26
28-28 Removal (helicopters S/N 154 through 3566) .............. 28-00-00 29
28-29 Installation (helicopters S/N 154 through 3566) ............. 28-00-00 29
28-30 Removal (helicopters S/N 3567 and subsequent) ........... 28-00-00 29
28-31 Inspection ............................................. 28-00-00 29
28-32 Installation (helicopters S/N 3567 and subsequent) ......... 28-00-00 29
28-33 Fuel pressure transducer ................................... 28-00-00 29
28-34 Removal .............................................. 28-00-00 29
28-35 Inspection ............................................. 28-00-00 29
28-36 Installation ............................................ 28-00-00 29
28-37 Fuel quantity - indicating units ............................. 28-00-00 29
28-38 Removal .............................................. 28-00-00 30
28-39 Installation ............................................ 28-00-00 30
28-00-00
Page 1
CONTENTS - MAINTENANCE PROCEDURES (Cont)

28-40 Drainvalve ............................................... 28-00-00 32

28-41 Removal .............................................. 28-00-00 32
28-42 Installation ............................................ 28-00-00 32
28-43 Solenoid valve ............................................ 28-00-00 32
28-44 Removal .............................................. 28-00-00 32
28-45 Installation ............................................ 28-00-00 32
28-46 Cap ..................................................... 28-00-00 32
28-47 Removal .............................................. 28-00-00 32
28-48 Installation ............................................ 28-00-00 32
28-49 Filter element change requirement .......................... 28-00-00 35
28-50 Removal and installation 206-706-603 filter element ........ 28-00-00 35
28-51 Removal and installation 52-2889-016 or 52-3889-016A
fitter element ........................................ 28-00-00 35
28-52 Removal and installation 222-366-621-101 filter element .... 28-00-00 35
28-53 Airframe mounted fuel filter ................................. 28-00-00 35
28-54 Removal .............................................. 28-00-00 41
28-55 Inspection ............................................. 28-00-00 41
28-56 Installation ............................................ 28-00-00 41
28-57 Engine fuel filter ........................................... 28-00-00 41
FIGURES
Figure Page
Number Title Number
28-1 Fuel system ................................................................ 5

28-2 Fuel system ................................................................ 7
28-3 Fuel system schematic.. ..................................................... 9
28-4 Fuel boost pump ............................................................ 18
28-5 Modification of fuel boost pumps .............................................. 23
28-6 Fuel shut off valve ........................................................... 27
28-7 Fuel pressure transducer ..................................................... 30
28-8 Fuel quantity indicator units ................................................... 31
28-9 Drainvalve ................................................................. 33
28-10 Solenoidvalve .............................................................. 33
28-11 Cap and adapter assembly ................................................... 34
28-l 2 206-706-603 Fuel filter assembly .............................................. 36
28-13 52-2889-016 or 52-2889-016A Fuel filter assembly .............................. 37
28-14 222-366-621 Fuel filter assembly .............................................. 38
28-15 Airframe mounted fuel filter assembly .......................................... 39
TABLES
Table Page
Number Title Number
28-1 Troubleshooting fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
28-00-00
Page 2
FUEL SYSTEM
28-l. FUEL SYSTEM (Helicopter S/N 4 28-3. SAFETY PRECAUTIONS.
through 3566). 1. All fueling and defueling operations should be
performed in an area where fire hazards are reduced to
The fuel system (figure 28-l) incorporates a single a minimum.
bladder type fuel cell located below and aft of the
passenger seat (figure 28-l). Installed within the fuel 2. Handle fuel cells with extreme care during removal
cell are two electrically operated boost pumps, lower and installation to prevent damage to cells. Do not
and upper tank indicating unit and sump drain valve. attempt to remove or install a cold fuel cell.
Boost pumps are interconnected and supply fuel 3. Helicopter must be grounded prior to performing
through a single hose assembly to the fuel shutoff valve defueling operations.
and from the shutoff valve to the engine mounted fuel
filter and pump. Boost pumps incorporate pressure 28-4. TROUBLESHOOTING.
switches in discharge ports and drain plugs in the pump
drain port. The fuel cell is filled from the right side and Refer to Chapter 96 for fuel quantity calibration, fuel filter
has a capacity of 76 U.S. gallons (287.66 liters usable). and fuel pump electrical circuitry. Refer to figure 28-3 for
fuel system schematics. Refer to table 28-1 for
Access to boost pumps, lower tank unit and drain valve troubleshooting.
is from the bottom of fuselage and access to upper
indicating unit is gained from a cover plate located on 28-5. OPERATIONAL CHECK.
deck aft of passenger seatback. Access to fuel shutoff Refer to Chapter 96 for fuel filter, fuel flow switch, low
valve and vent line is in the fuel compartment located on fuel pump caution systems operational checks.
the right side of access panel above filler cap.
Provisions are also made in fuel compartment for 28-6. TESTING.
combustion heater fuel, fuel pressure instrument line,
and fuel pump purge line. 1. With throttle off and shutoff valve on, connect air
source to vent line.
28-2. FUEL SYSTEM (Helicopters S/N 3567

and subsequent).
DO NOT APPLY MORE THAN
The fuel system (figure 28-2) incorporates a single RECOMMENDED PRESSURE AS
crash resistant bladder type fuel cell located below and DAMAGE TO FUEL SYSTEM AND
aft of the passenger seat. Installed within the fuel cell are STRUCTURE MAY RESULT. USE MILD
two electrically operated boost pumps, lower and upper SOAP SOLUTION TO LOCATE LEAKS.
tank indicating unit and electrically operated sump drain
NOTE
valve. Boost pumps are interconnected and supply fuel
through a single hose assembly to the fuel shutoff valve, Use regulated low pressure from filtered,
and from shutoff valve to the airframe mounted fuel filter. compressed air source with accurate
Boost pumps incorporate pressure switches in pressure gage, and a shutoff valve.
discharge ports and drain plugs in pump drain ports. The
2. Slowly apply pressure until gage indicates 0.75 to
fuel cell is filled from the right side and has a capacity of
1 .00 psig (5.17 to 6.89 kPa). Shut off air source. The fuel
91 U.S. gallons (344.44 liters usable).
system should hold this pressure for 15 minutes.
Access to boost pumps, lower tank unit and solenoid 3. Alternate Method: Using a water manometer,
drain valve is from the bottom of fuselage and access to test to a reading of 20.76 to 27.68 inches (527.30 to
upper indicating unit is gained from a coverplate located 703.07 mm) of water. The fuel system shall hold this
on deck aft of passenger seatback. Access to fuel reading for 15 minutes.
shutoff valve and vent is in fuel compartment located on 4. Locate and correct any leakage indicated. Repeat
the right side above filler cap. Provisions are made in the pressure test if leaks are found.
fuel compartment for a fuel purging line to be installed
at tank vent fitting for maintenance purposes. 5. Remove test equipment from vent line.
28-00-00
Page 3
Table 28-l. Troubleshooting fuel system
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
Engine fails to light off lnsufficient fuel in cell Fill cell with correct fuel
Insufficient or no fuel pressure to Turn on boost pumps and fuel

engine pump shutoff valve
Boost pump inoperative Check pump per Chapter 96.

Replace pump if required
Fuel contaminated Refer to Allison Engine Company

Engine Operation and Maintenance
Manual
Defective shutoff valve, or valve Replace valve. Refer to Chapter 96

fails to operate when selected
Fuel quantity system not indicating Defective boost pump, tank indicating Refer to Chapter 96
or has incorrect reading units or electrical malfunction
Fuel quantity/pressure circuit Check and replace breaker

breaker
Loose circuit connections Tighten connections
Defective indicator Replace indicator
Improper resistance setting on R5 Check resistance and calibrate

or R6 system
Defective tank unit system Replace tank unit and recalibrate

system
No pressure, fuel pressure gage Air trapped in fuel boost pump Bleed boost pumps. Refer to
fluctuates or has erratic readings paragraph 28-20, step 13
Transducer failure Replace transducer
Fuel pump caution light on Defective boost pump, cartridge or Replace pump, cartridge, or switch
fuel pressure switch. Defective boost (Chapter 96). Replace check valves
pump check valves
Fuel filter caution light on Clogged filter Refer to engine manual
Fuel boost pumps fail to operate Electrical malfunction Refer to Chapter 96

when breaker is closed or circuit
breaker trips
28-00-00
Page 4
TO FUEL
PRESSURE
GAGE
13
STRUCTURE
1
LACE TO
STRUCTURE
TYPICAL
HELICOPTERS S/N 4 THROUGH 3566

206A/BS-M-28-1-1
Figure 28-1. Fuel system (Sheet 1 of 2)
28-00-00
Page 5
DETAIL B SCARF FACING AFT
DETAIL A
1. Fuel shutoff valve 9. Forward fuel boost pump

2. Tee 10. Hose
3. Fuel cell 11. Hose
4. Upper tank unit 12. Cap and adapter assembly
5. Aft fuel boost pump 13. Fitting
6. Lower tank unit 14. Tube
7. Drain valve 15. Vent tube
8. Check valve 16. Filter
NOTES
Helicopters S/N 4 through 153.
A2 Helicopters S/N 154 through 3566.
206A/BS-M-28-1-2
Figure 28-l. Fuel system (Sheet 2)
28-00-00
Page 6
1. Airframe fuel filter

2. Hose
3. Fuel cell
4. Upper tank unit
5. Aft fuel boost pump
6. Lower tank unit
7. Solenoid drain valve
8. Check valves
9. Forward fuel boost p
10.
11. Hose
12. Cap and adapter assembly 13
13. Tube
14. Fuel shutoff valve
15. Hose
16. Clamps 12
17. Tube
18. Tube
19. Fuel cell
attachment
Screws
HELICOPTERS S/N 3567 AND SUBSEQUENT 206A/BS-M-28-2-1
Figure 28-2. Fuel system (Sheet 1 of 2)
28-00-00
Page 7
0.12 IN.
(3.05 mm)
\ SCARF FACING AFT
DRILL ,0.25 IN. (6.35 mm) DIA 1.0 IN.

HOLE AFT SIDE ONLY - (25.40 mm)
DETAIL A
HELICOPTERS S/N 3567 AND SUBSEQUENT
206A/BS-M-28-2-2
Figure 28-2. Fuel system (Sheet 2)
28-7. FUEL CELL (Helicopters S/N 4 through FIRE HAZARDS ARE REDUCED TO A
3566). MINIMUM.
Fuel cell is a bladder type unit installed in the fuselage

cavity below and aft of passenger seat and laced to
helicopter structure.
HANDLE FUEL CELL WITH EXTREME CARE

28-8. FUEL CELL (Helicopters S/N 3567 and DURING REMOVAL TO AVOID DAMAGE TO
subsequent). FUEL CELL. PROTECT ALL OPENINGS TO
PREVENT FOREIGN MATERIAL FROM
Fuel cell is a crash resistant bladder type fuel cell ENTERING. ENSURE FUEL CELL IS WARM
located below and aft of passenger seat structure. The ENOUGH TO BE FLEXIBLE.
fuel cell is held to structure by screws.
IF FUEL CELL IS PURGED FOR ANY
REASON, AVOID BUILD UP OF
28-9. REMOVAL (Helicopters S/N 4 through 3566). PRESSURE IN FUEL CELL. THERE
SHALL BE NO MEASURABLE BUILDUP
OF PRESSURE IN FUEL CELL DURING
PURGING OPERATION.
ALL DEFUELING OPERATIONS SHALL 1. Ground helicopter. Disconnect battery and external
BE PERFORMED IN AN AREA WHERE power supply.
28-00-00
Page 8
I ENGINE
ENGINE DRIVEN
FUEL PUMP
PRESSURE
VENT
P
L
CHECK VALVE N -SHUTOFF VALVE
INSTALLED ON
HELICOPTERS S/N 254
FUEL FILLER
PURGE LINE
ON HELICOPTERS S/N 254 .
THRU 660,
AND 672 THRU 715
- CHECK
CHECK VALVE
VALVE
BOOST
PUMP
(ELECTRIC)
PRESSURE -PRESSURE
SWITCH SWITCH
CAUTION
LIGHT
HELICOPTERS S/N 4 THROUGH 660, AND 672 THROUGH 715
206A/BS-M-28-3-1
Figure 28-3. Fuel system schematic (Sheet 1 of 3)
28-00-00
Page 9
I
ENGINE FUEL PUMP
I
r-L ...............
PRESSURE
VENT
- AIRFRAME MOUNTED
SWITCH FILTER
INSTALLED ON
HELICOPTERS
JRE GAGE
BOOST
PUMP
(ELECTRIC)
DRAIN
I
VALVE
- FUEL PUMP
CAUTION
LIGHT

206A/BS-M-28-3-2
Figure 28-3. Fuel system schematic (Sheet 2)
28-00-00
Page 10
ENGINE
ENGINE FUEL PUMP

HELICOPTERS SIN 2212 AND FILTER
THRU 3566 PRESSURE
SWITCH
,
CAUTION
LIGHT DRAIN
HELICOPTERS S/N 2122

THRU 3566
-AIRFRAME MOUNTED
CAUTION
LIGHT
206A/BS-M-28-3-3
Figure 28-3. Fuel system schematic (Sheet 3)
28-00-00
Page 11
2. Defuel and purge fuel system (Chapter 12).
3. Remove seat cushions and seat backs (Chapter 25).

HANDLE FUEL CELL WITH EXTREME CARE
4. Remove panel from fuel compartment located on DURING REMOVAL TO AVOID DAMAGE TO
right side above cap and adapter assembly (12, figure FUEL CELL. PROTECT ALL OPENINGS TO
28-l). PREVENT ENTRY OF FOREIGN MATERIAL.
ENSURE FUEL CELL IS WARM ENOUGH TO
BE FLEXIBLE.
5. Remove cap and adapter assembly (12)
(paragraph 28-47).
IF FUEL CELL IS PURGED FOR ANY
6. Disconnect electrical connections from upper and REASON, AVOID BUILDUP OF
lower tank units (4 and 6) and forward and aft fuel boost PRESSURE IN FUEL CELL. THERE
SHALL BE NO MEASURABLE BUILD UP
pumps (5 and 9).
OF PRESSURE IN FUEL CELL DURING
7. Disconnect hose (10) from two check valves (8). PURGING OPERATION.
Remove hose through pump mount opening.
1. Disconnect battery and external power supply.
8. Remove hose (11) from fitting (13). Remove hose Ground helicopter.
from fuel cell (3).
2. Defuel and purge fuel system (Chapter 12).
9. Remove aft fuel boost pump (5) (paragraph 28-18).
3. Remove seat cushions and seat backs (Chapter 25).
10. Remove lower tank unit (6) (paragraph 28-38).
4. Remove access panel from fuel compartment
11. Remove forward fuel boost pump (9) (paragraph located on right side above cap and adapter assembly
28-18). (12, figure 28-2).
12. Remove drain valve (7) (paragraph 28-41). 5. Remove cap and adapter assembly (12)
(paragraph 28-47).
13. Remove upper tank unit (4) (paragraph 28-38).
6. Remove airframe fuel filter (1) (paragraph 28-54).
14. Remove fuel shutoff valve (1) (paragraph 28-26,
7. Remove hose (2).
28-28, or 28-30 as applicable).
8. Disconnect electrical connections from upper and
15. Remove tubes (14 and 15). lower tank units (4 and 6), aft and forward fuel boost
pumps (5 and 9), and solenoid drain valve (7).
16. Remove tee (2).
9. Remove upper tank unit (4) (paragraph 28-38).
17. Collapse fuel cell (3) and remove nylon cords
attaching fuel cell to structure. Remove fuel cell through 10. Remove lower tank unit (6) (paragraph 28-38).
seat opening.
11. Remove solenoid valve (7) (paragraph 28-44).
12. Remove hose (11) from fuel shutoff valve (14) and
28-10. REMOVAL (Helicopters S/N 3567 and check valve (8).
subsequent).
13. Remove clamps (16) hose (15) and tubes (17 and
18).
14. Remove fuel shutoff valve (14) (paragraph 28-26,

28-28, or 28-30 as applicable).
ALL DEFUELING OPERATIONS SHALL 15. Remove hose (10) from two check valves (8).
BE PERFORMED IN AN AREA WHERE
FIRE HAZARDS ARE REDUCED TO A 16. Remove forward fuel boost pump (9) (paragraph
MINIMUM. 28-18).
28-00-00
Page 12
17. Remove aft fuel boost pump (5) (paragraph d. Do not place cells on any surface with sharp
28-l 8). projections which could damage cell.
18. Remove five fuel cell attachment screws (20) e. Do not stack cells except in original shipping
attaching fuel cell (3) to structure. Collapse fuel cell and containers.
remove through seat opening.
f. Do not handle cells when they are too cold to be
28-11. INSPECTION AND REPAIR. flexible.
1. Field repairs are permitted on fuel cell in all areas g. Do not allow cells to remain in strong light any
except any radius, any fitting area, or to any cut or tear longer than absolutely necessary. Do not allow light
longer than 1 inch (25.40 mm). Cells with damage bulbs to contact cell. Fluorescent inspection lights are
beyond these limits should be returned to the fuel cell recommended for use in fuel cells.
manufacturer for repair at one of the addresses listed in
the following paragraphs.
28-12. CLEANING.
2. Inspect fuel cell to determine manufacturer (marked Bladder fuel cell may have accumulated heavy fungus
on the fuel cell). Repair kits, complete with all materials growth due to contaminated fuel and may require the
and instructions for making field repairs, are available following recommended procedures.
from the respective cell manufacturers.
NOTE
a. Order RK-30S repair kit, from Uniroyal Inc., 312
N. Hill Street, Mishawaka, Indiana, 46544. Bladder fuel cell construction used in the
206B helicopter has buna coated fabric inner
b. Order SK-2180-2, repair kit, from Firestone plies. The buna rubber may be attacked to
Coated Fabrics Co., Division of Firestone Tire and some degree by micro-organism action.
Rubber Company, 1200 Firestone Parkway, Akron, Degree of attack is very minor.
Ohio, 44317.
1. Remove fuel cell. Refer to paragraphs 28-9 or
c. Order repair kit, number 2F1-3-42165, (Manual 28-l 0.
AP 30), from Engineered Fabrics Corporation,
2. Presence of fungus in fuel cell is usually caused by
Rockmart, Georgia 30153.
improper servicing and storage of jet fuels. To help
3. Inspect fuel cell immediately prior to installation for alleviate problem of fungus in cells, suitable filters and
damage which may have occurred during crating or water traps should be used in fuel storage tank complex
removal from shipping container. and servicing equipment.
4. Inspect fuel cell for leaks after installation. Refer to NOTE

paragraph 28-13, step 16.
A fuel additive meeting the requirement of
5. Store fuel cells in original shipping containers at specification MIL-I-27686 and approved by
room temperature. Do not store fuel cells where they will the FAA as PFA-55MB is recommended to
be subjected to heat or extremes of humidity. be added routinely to the helicopter fuel cell
while refueling. This is same as anti-icing
6. Handle fuel cells carefully to avoid damage. additive recommended in applicable
Observe the following precautions: JetRanger Flight Manual. (Phillips product
distributed as Prist meets this requirement.)
a. Leave fuel cells in original shipping containers Usually one treatment of PFA-55MB is
until ready to install in helicopter. adequate to kill bacteria and inhibit regrowth
in fuel cell for some time.
b. Do not drag cells or pick up by fittings. Transport
cells on carts. If a cell must be transported outside 3. If evidence of fungus is present in fuel cell,
installation area, place it in original shipping containers. contamination is usually present in fuel filter and the
housing should be thoroughly cleaned, and the filter
c. Do not handle cell with sharp pointed tools. element replaced.
28-00-00
Page 13
4. Remove all fungus growth from fuel cell by hand or TAPE (C-456). ENSURE THAT FUEL CELL
with a soft scrub brush using warm or hot water. IS WARM ENOUGH TO BE FLEXIBLE.
IF HOT WATER IS USED TO CLEAN FUEL DO NOT FOLD A COLD FUEL CELL.
CELL, IT IS RECOMMENDED THAT FOLDING MAY CRACK OR DAMAGE A
TEMPERATURE OF HOT WATER BE COLD FUEL CELL. HEAT LAMPS MAY BE
LIMITED TO 160F (71 C). HOTTER USED TO WARM FUEL CELL PRIOR TO
WATER CONSTITUTES A HAZARD TO FOLDING. HEAT FOR APPROXIMATELY 2
PERSONNEL. HOURS, DO NOT EXCEED 125F (52C).
DO NOT USE SOAPS OR STRONG NOTE

DETERGENTS WHEN CLEANING
FUEL CELL. CERTAIN POWERFUL Either 206-061-675-001 or 206-061-675
DETERGENTS ARE DETRIMENTAL TO THE 003 fuel cell may be used.
BUNA TYPE RUBBER AND SOAPS CAN
REACT WITH FUEL TO FORM A 1. Warm fuel cell (3, figure 28-l) as required. Apply
COMPOUND WHICH TENDS TO PLUG FUEL talcum powder to fuel cell cavities.
FILTERS.
2. Insert collapsed fuel cell (3) through seatback
5. When fungus is observed in fuel cell area, wipe the opening and position forward section of fuel cell under
cell clean with cloths moistened with methyl alcohol seat.
(C-302). Burn wiping cloths after cleaning to destroy
3. Lace bottom aft side of fuel cell (3) to fuselage
fungus.
structure using nylon cord. Tie nylon cord to right aft
lower structure fitting and lace through seven delta
hangers and fittings. Secure end of nylon cord on left
side.
UNDER NO CIRCUMSTANCES SHALL 4. Lace top aft side of fuel cell (3) to fuselage structure
METHYL-ETHYL-KETONE (C-309) OR using nylon cord. Tie nylon cord to right top structure
SIMILAR SOLVENTS BE USED FOR fitting and lace through seven delta hangers and fittings.
CLEANING FUEL CELL.
5. Lace top forward side of fuel cell (3) to fuselage
6. Turbine fuels (C-003) may be used to advantage for structure using nylon cord. Tie nylon cord to right
cleaning fuel cells. Turbine fuels are oily and assist in forward structure fitting and lace through eight delta
protecting cell inner liner against aging if cell remains out hangers and fittings. Loosely tie off nylon cord at last
of service for several weeks without fuel. structure fitting. Allow sufficient slack to provide hand
room for installation of fittings on top of fuel cell.
28-13. INSTALLATION (Helicopters S/N 4 through
6. Lace right and left forward sides of fuel cell (3) to
3566.)
fuselage structure using nylon cord. Tie nylon cord to
fittings and lace through three delta hangers and fittings.
7. Lace bottom forward side of fuel cell (3) to fuselage

structure using nylon cord. Tie nylon cord to structure
INSPECT FUEL CELL CAVITY FOR fitting and lace through seven delta hangers and fittings.
FOREIGN OBJECTS BEFORE
INSTALLATION OF FUEL CELL. EXERCISE 8. Install fitting (2) with tubes (14 and 15).
EXTREME CAUTION TO PRECLUDE
DROPPING OF TOOLS, HARDWARE, ETC. 9. Install fuel shutoff valve (1) (paragraph 28-27,
IN FUEL CELL CAVITY. ENSURE THAT ALL 28-29, or 28-32) as applicable.
SHARP EDGES, CORNERS AND RIVET
HEADS ARE PROTECTED WITH VINYL 10. Install upper tank unit (4) (paragraph 28-39).
28-00-00
Page 14
11. Install drain valve (7) (paragraph 28-42). 20. Install coverplate on aft deck above passenger
seatback.
12. Install forward fuel boost pump (9) (paragraph
28-20). 21. Install seat cushions.
13. Install lower tank unit (6) (paragraph 28-39). 22. Connect battery.
14. Install aft fuel boost pump (5) (paragraph 28-20). 28-14. INSTALLATION (Helicopters S/N 3567 and
subsequent).
15. Install hose (10) to two check valves (8).
16. Connect electrical connections to forward and aft

fuel boost pumps (9 and 5), and upper and lower tank
units (4 and 6). INSPECT FUEL CELL CAVITY FOR
FOREIGN OBJECTS BEFORE
17. Inspect fuel cell (3) installation for security. INSTALLATION. EXERCISE EXTREME
CAUTION TO PRECLUDE DROPPING OF
18. Perform leak test on fuel cell (3) as follows: TOOLS, HARDWARE, OR OTHER FOREIGN
MATERIAL INTO FUEL CELL CAVITY OR
a. Disconnect fuel vent tubes (14 and 15) from tee FUEL CELL.
(2). Connect air source to tee. On helicopter S/N 154
and subsequent disconnect line (15), install cap on tee DO NOT FOLD A COLD FUEL CELL.
(side port) and connect air source to top of tee. FOLDING MAY CRACK OR DAMAGE A
COLD FUEL CELL. HEAT LAMPS MAY BE
USED TO WARM FUEL CELL PRIOR TO
FOLDING, HEAT FOR APPROXIMATELY 2
HOURS. DO NOT EXCEED 125F (52C).
DO NOT APPLY MORE THAN
RECOMMENDED PRESSURE. DAMAGE 1. Apply talcum powder into fuel cell (3, figure 28-l)
TO FUEL CELL AND STRUCTURE MAY cavities and insert collapsed fuel cell through seatback
RESULT. USE A MILD SOAP SUDS opening. Work fuel cell in place and install five fuel cell
SOLUTION TO LOCATE LEAKS. attachment screws (20, figure 28-2).
NOTE 2. Install screws securing cap and adapter assembly

(12) to fuel cell (3) (paragraph 28-48).
Use regulated low pressure, filtered,
compressed air source, an accurate pressure 3. Install forward fuel boost pump (9) (paragraph
gage, and a shutoff valve. 28-20).
b. Apply pressure until gage indicates 1.0 psi 4. Install aft fuel boost pump (5) (paragraph 28-20).
(6.895 kPa). Shut off air source. Fuel cell should hold
this pressure for 15 minutes. 5. Install solenoid drain valve (7) (paragraph 28-45).
6. Install hose (10) to two check valves (8).

c. Alternate Method: Using a water manometer,
test to a reading of 22.76 to 27.68 inches (527.30 to 7. Install fuel shutoff valve (1) (paragraph 28-27,
703.07 mm) of water. The fuel system shall hold this 28-29, or 28-32 as applicable).
reading for 15 minutes.
8. Install tubes (17 and 18), hose (15), and clamps
c. Locate and correct any leakage indicated. (16)
Repeat test if leaks are found.
9. Install lower tank unit (6) (paragraph 28-39).
d. Remove test equipment. On helicopters S/N 154 10. Install upper tank unit (4) (paragraph 28-39).
and subsequent, remove cap from tee (2) and connect
tubes 14 and 15. 11. Connect electrical connections to solenoid drain
valve (7), forward and aft fuel boost pumps (9 and 5),
19. Install fuel cell (3) access panel on seat support. and upper and lower tank units (4 and 6).
28-00-00
Page 15
12. Install airframe mounted fuel filter (1) with hose (2) 16. Install coverplate on aft deck above passenger
(paragraph 28-6). seat back.
13. Inspect fuel cell (3) installation for security.

17. Install seat cushions.
14. Perform leak test on fuel cell (3).
15. Install fuel cell access panel on seat support. 18. Connect battery.
28-00-00
Page 16
FUEL DISTRIBUTION
28-15. FUEL DISTRIBUTION. 1. Disconnect battery and defuel helicopter (Chapter

12).
Fuel distribution consists of all fuel cell mounted
components which transfer fuel, and monitor fuel 2. Disconnect electrical wiring to forward or aft pumps
quantity, fuel flow, or fuel pressure. (6, figure 28-4).
3. Remove eight bolts (11) with seven washers (12)

28-16. FUEL PUMP AND FILTER and ground lead from fuel pump.
ASSEMBLY.
4. Lower forward or aft pump (6) and disconnect
attached fuel supply hose (2) or interconnect hose (1)
The engine fuel pump and filter assembly are integral
as applicable and remove pump.
units mounted on the aft end of engine. Fuel enters
engine fuel system at inlet port of the pump and passes
5. Cover fuel cell opening to prevent entrance of
through filter before entering gear elements of pump.
foreign material.
Filter draining is accomplished by a drain valve mounted
on filter housing. Fuel filter is monitored by a pressure
6. Remove check valve (4), plug (8), and pressure
differential switch located on lower firewall and
switch (9). Discard all packings (5, 7, and 10).
connected electrically to fuel filter caution light. Refer to
Allison Engine Company Operation and Maintenance
Manual (5W2 for C-l 8 engine or 110W2for C-20 engine)
28-19. INSPECTION.
for detailed maintenance instructions.
1. Inspect electrical connections for condition and
28-17. FUEL BOOST PUMP. security.
Two electrically operated fuel boost pumps are located 2. Inspect pump for cracks and corrosion. Inspect
in the bottom of fuel cell. Pumps are interconnected and ports, packing groove and retaining ring groove for
furnish fuel through one supply line. Pumps are damage.
equipped with check and thermal relief valve, pump
drain port, seal drain port, intake screen, and pump 3. Inspect hoses, tee fitting and check valves for
operating pressure switch located in discharge port of condition.
pump. Pumps are protected by circuit breakers located
in overhead console.
28-20. INSTALLATION.
Fuel pump motor/impeller cartridge can be removed
without removing fuel boost pump assembly. Refer to 1. Prior to installation of aft or forward pumps (6, figure
paragraph 28-22 for replacement of motor/impeller 28-4) modify each pump not previously modified in
cartridge. accordance with figure 28-5, as applicable for pump part
number. Modification of pumps will improve fuel pump
performance and prevent ice clogging of fuel pump inlet
screen(s) when fuel anti-icing additives are not used.
28-18. REMOVAL.
2. Lubricate new packing (10, 5, and 7, figure 28-4)
with approved fuel.
3. Position packing (10) on check valve (4) and install.

ALL DEFUELING OPERATIONS SHALL
BE PERFORMED IN AN AREA WHERE
FIRE HAZARDS ARE REDUCED TO A 4. Remove protective covering from fuel cell
MINIMUM. REFER TO PARAGRAPH 28-3. openings.
28-00-00
Page 17
1. Hose
2. Hose
3. Tee fitting
4. Check valve
5. Packing
6. Pump
SEE NOTE
7. Packing
1
8. Plug
9. Pressure switch \
10. Packing
11. Bolts
12. Washers
FORWARD
NOTE
Typical for forward and aft fuel boost pump.

35 TO 45 IN-LBS (3.95 TO 5.08 Nm)
45 TO 55 IN-LBS (5.08 TO 6.21 Nm)
206-062-681-l 01
FUEL BOOST PUMP
206A/BS-M-28-4-1
Figure 28-4. , Fuel boost pump (Sheet 1 of 5)
28-00-00
Page 18
NO DRAIN PLUG REQD IN SEAL PUMP DRAIN ELECTRICAL

DRAIN PORT
SWITCH
(IN DISCHARGE PORT)
(IN PUMP DRAIN PORT)
206-062-673-001 FUEL PUMP AND
VIEW A-A
DISCHARGE PORT
AND PRESSURE
PUMP DRAIN PORT

AND PLUG
DISCHARGE PORT AND

PRESSURE SWITCH
206-062-673-003 FUEL PUMP AND
206-062-673-001 FUEL PUMP AND

LOCKWIRE REQUIREMENTS (TYPICAL)
VIEW A-A
206A/BS-M-28-4-2
Figure 28-4. Fuel boost pump (Sheet 2)
28-00-00
Page 19
1. Hose
2. Hose
3. Tee fitting
4. Check valve
5. Packing
6. Pump SEE NOTE
7. Packing
8. Plug
9. Pressure switch
10. Packing
11. Bolts
12. Washers
FORWARD -
NOTE
Typical for forward and aft fuel boost
55 IN-LBS (5.08 TO 6.21 Nm)
206-062-681-I 03
FUEL BOOST PUMP
206A/BS-M-28-4-3
28-00-00
Page 20
FORM WIRE
BUNDLE THIS
AREA, SECURE GROUND WIRE TERMINALS
WITH MS3367-1-9 WHT-BLU (OMIT WASHER
UNDER BOLTHEAD)
AN814-4DL PLUG
MS29512-04 PACKING
SWITCH WIRES
ALIGNMENT
ARROWS (–3) (REF)
VALVE LOCKING BAR
206-075-301-003 AN4H5A BOLT (8 REQD)

AN960PD416L WASHER
WASHER UNDER (6 REQD)
BOLTHEAD)
VIEW A-A
VIEW LOOKING UP AT AFT PUMP
GROUND WIRE TERMINALS

WHT-BLU (OMIT WASHER
UNDER BOLTHEAD)
FORM WIRE
BUNDLE THIS
AREA. SECUI .-
WITH MS3367-1-9
VALVE LOCKING BAR
AN814-4DL PLUG
MS29512-04 PACKING
LOCKWIRE
206-301-003
CLAMP (OMIT
WASHER UNDER BOLTHEAD)
VIEW A-A
VIEW LOOKING UP AT FORWARD PUMP
206-062-681-l 01
206A/BS-M-28-4-4
28-00-00
Page 21
FORM WIRE
BUNDLE THIS EXISTING WIRE
AREA, SECURE
WITH MS3367-1-9
206-075-301-003
CLAMP (OMIT GROUND WIRE TERMINALS
WASHER UNDER WHT-BLU (OMIT WASHER
UNDER BOLTHEAD)
SWITCH WIRES
PUMP WIRES
AN814-4DL PLUG
VIEW A-A MS29512-04 PACKING
VIEW LOOKING UP AT AFT PUMP LOCKWIRE
FORM WIRE SWITCH WIRE

BUNDLE THIS
AREA. SECURE
WITH MS3367-1-9 SWITCH
_ .
STRAPS LOCKWIRE
\
206-075-301-003
CLAMP (OMIT A
CARTRIDGE
HANDLE
- AN814-4DL PLUG
MS2951244 PACKING
PUMP WIRES LOCKWIRE
AN4H5A BOLT (8 REQD)

AN960PD416L WASHER
VIEW A-A (6 REQD)
VIEW LOOKING UP AT FORWARD PUMP
206-062-681-l 03

206A/BS-M-28-4-5
28-00-00
Page 22
Remove both front and rear fuel pumps, or

prior to installation of a replacement fuel
pump accomplish the following:
1.3 a. Inspect inlet screen(s) in each fuel pump

for presence of two 0.37 inch (9.39 mm)
holes. If holes are not present, invert pump
so screen(s) are down and drill two 0.37 inch
(9.39 mm) holes. Holes are to be located as
illustrated according to part number of fuel
pump. Ensure all drill filings are removed.
LEAR SIEGLER INC.
MODIFICATION PART NO. RG12650D b. On Globe Industries 164A136 or
PART NO. RG 12650 164A176 fuel pumps locate and drill (No. 60
drill) hole in the outlet port as illustrated in
detail A. Invert pump for drilling operation
and ensure all drill filings have been
removed.
c. Identify fuel pumps as indicated.

5. Position new packing (5) on aft fuel pump (6) and 14. Secure plug (8) and pressure switch (9) using
install in fuel cell opening. Connect tee fitting (3), fuel lockwire. Secure drilled head bolts (11) in pump
supply hose (2) and interconnect hose (1) to pump. mounting flange using lockwire. Refer to bottom view of
applicable pump in figure 28-4.
NOTE 15. Check pumps minimum pressure as follows:
Boltheads and external flange of fuel pumps a. Move helicopter to adequate tiedown facilities
should be clean to provide a good electrical and secure for ground run.
bond. Omit one washer and install pump
ground wire. b. Operate helicopter at flat pitch and 100 percent
rotor speed with generator ON, refer to applicable
6. Position new packing (10) on forward pump (6) and JetRanger Flight Manual.
install in fuel cell opening. Connect interconnect hose
(1) to check valve (4) on forward pump. Secure pump
c. Check each individual pump with other
inoperative. Pump pressure should be 4 psig (27.58
preceding note.
kPa) minimum and caution light segment should be
illuminated for inoperative pump.
7. Install plug (8) and pressure switch (9) in Globe and
Lear Siegler fuel pumps as follows:
NOTE
a. Globe boost pumps. Pumps contain one external
fuel drain port in mounting flange. Plug external fuel Fuel pressure with both pumps in operation
drain port with a new packing (7) and plug (8). is not significant if each pump by itself meets
requirements in step c. above.
NOTE
d. Close both FUEL BOOST circuit breakers.
No plug is required in Lear Siegler fuel Caution light segment should not be illuminated.
pumps at seal drain port.
b. Lear Siegler boost pump. Pumps contain two

external ports in the mounting flange. Plug the fuel drain
28-21. FUEL PUMP CARTRIDGE.
port with a new packing (7) and plug (8).
SPECIAL TOOLS REQUIRED
8. Install plug (8) and pressure switch (9) in pumps (6)
as follows: Number Nomenclature
E2-10-1 Cartridge Removal
a. The pumps contain two external ports in the
mounting flange. When installing pump, plug the fuel
drain port with a new packing (7) and plug (8). 28-22. REPLACEMENT - FUEL PUMP
CARTRIDGE IN 206-062-673-001 PUMP.
b.
(10). 1. Disconnect battery and/or external power supply.
9. Connect electrical wiring to forward and aft pumps 2. Drain fuel from cell (Chapter 12).
(6).
3. Disconnect electrical wiring at applicable fuel pump
10. Inspect installation for security. (6, figure 28-4).
11. Connect battery and close fuel shutoff valve. 4. Remove drain plug (8) and packing (7).
12. Perform leak test on fuel cell (paragraph 28-13, 5. Remove retaining ring.
step 18).
6. Install E2-10-1 special cartridge removal tool in
13. Bleed trapped air from both pumps (6) after pump drain boss and remove motor/impeller cartridge.
refueling by removing drain plug and draining a small
amount of fuel from cell. 7. Clean cartridge hole and retaining ring.
28-00-00
Page 24
8. Lubricate packings furnished on replacement 28-23. REPLACEMENT - FUEL PUMP

motor/impeller cartridge and sides of the cartridge hole CARTRIDGE IN 206-062-681-101 CANISTER TYPE
in mounting flange casting with approved fuel. FUEL BOOST PUMP.
1. Prepare helicopter by disconnecting battery and/or

external power supply.
2. Remove socket head screw from valve locking bar

DO NOT FORCE ECCENTRIC (figure 28-4). Rotate bar clear of cartridge.
CARTRIDGE. DESIGN REQUIRES NOTE
ALIGNMENT ARROWS TO BE WITHIN 3
DEGREES TO BE PROPERLY INSTALLED. Removal of socket head screw will
disconnect electrical negative (-) lead and
will allow valve locking bar to extend, closing
NOTE
off fuel supply to cartridge.
Align arrows on motor/impeller cartridge and 3. Disconnect positive (+) electrical lead from cartridge
on mounting flange. terminal and move wiring clear of cartridge area.
9. Install motor/impeller cartridge in flange with arrows 4. Remove drain plug, (8, figure 28-4), from cartridge
aligned and ensure it is properly seated and retaining center boss and allow trapped fuel to drain. Remove and
ring groove is not obstructed. discard packing.
5. Remove retaining ring securing cartridge in pump

10. Install retaining ring. housing.
11. Install drain plug (8) with packing (7). Secure bolts 6. Install E2-10-l special cartridge removal tool in
(11) using lockwire as shown in view A-A for pump drain plug boss and secure with check nut. Using
206-062-673-001 fuel pump. weight, impact cartridge from pump housing. Remove
tool from cartridge.
7. Clean all foreign matter from cartridge bore and
retaining ring groove in pump housing and from
retaining ring.
DO NOT OVERTIGHTEN POSITIVE (+) 8. Lubricate V747-75-2-033 and V747-75-2-034

LEAD TERMINAL. packings, (furnished with new cartridge) with approved
fuel.
12. Connect electrical leads to the motor/impeller
9. Using hand pressure, install cartridge in pump
cartridge (Chapter 98).
housing with arrows aligned on flanges (within –3
degrees). E2-10-1 special cartridge removal tool may
13. Perform fuel boost pump operational check. be used as a work aid during installation. Do not impact
cartridge as damage to parts may result.
a. Ensure both boost pumps are covered with fuel.
Refuel helicopter as required (Chapter 12). 10. Secure cartridge in pump housing with retaining ring.
11. Install drain plug (8) in cartridge boss with new

b. Connect battery and/or external power supply. packing (7). Double safety plug to adjacent mounting
bolts with lockwire.
c. Turn battery switch on and close fuel boost pump
circuit breaker. Check fuel gage for adequate pressure NOTE
from that pump with other pump inoperative (paragraph
Refer to Chapter 98 for wiring diagram.
28-20, step 15).
12. Rotate valve locking bar over cartridge and in line
d. Turn battery switch off. Check exterior of boost with negative (-) terminal. Insert WHT-BLU negative (-)
pumps for evidence of leakage. lead terminal under bar and secure both with screw.
28-00-00
Page 25
13. Connect WHT-RED positive (+) lead terminal to 9. Secure drain plug to an adjacent bolthead with
positive (+) terminal on cartridge; do not over-tighten. lockwire.
14. Perform fuel boost pump operational check. 10. Connect positive (+) and negative (-) leads to
terminals on cartridge. Do not over-tighten.
a. Ensure both boost pumps are covered with fuel.
Refuel helicopter as required (Chapter 12). 11. Perform fuel boost pump operational check.
b. Connect battery and/or external power supply. a. Ensure both boost pumps are covered with fuel.
Refuel helicopter as required (Chapter 12).
c. Set battery switch to ON and close fuel boost
b. Connect battery and/or external power supply.
pump circuit breaker. Check fuel gage for adequate
pressure from each pump with other pump inoperative c. Set battery switch on ON and close fuel boost
(paragraph 28-20, step 15). pump circuit breaker. Check fuel gage for adequate
pressure from each pump with other pump inoperative
d. Set battery switch to OFF. Check exterior of (paragraph 28-20, step 15).
boost pumps for evidence of leakage.
d. Set battery switch to OFF. Check exterior of
28-24. REPLACEMENT - FUEL PUMP CARTRIDGE boost pumps for evidence of leakage.
IN 206-062-681-103 CANISTER TYPE FUEL BOOST
PUMP. 28-25. FUEL SHUTOFF VALVE.
1. Prepare helicopter by disconnecting battery and/or A motor operated shutoff valve incorporating a thermal
external power supply. relief feature is installed in main fuel supply line and is
located in fuel compartment above fuel filler cap. Valve
2. Disconnect positive (+) and negative (-) leads from is electrically controlled by an ON-OFF switch located
cartridge and move wiring clear of cartridge area (figure on instrument panel and protected by a circuit breaker
28-4). located in overhead console panel. In event of electrical
failure valve will remain in position selected before
3. Remove lockwire, three bolts and washers (one at failure.
handle, two approximately 180 degrees opposite)
securing cartridge in pump housing. 28-26. REMOVAL (Helicopters S/N 4 through 153).
4. Pull cartridge handle and remove cartridge from 1. Pull circuit breaker, remove coverplate above filler
pump housing. The handle contains a cam lever foot cap, and disconnect electrical connector on fuel shutfoff
that provides a mechanical advantage to reduce friction valve.
force of packings when removing cartridge.
2. Disconnect tube (9, figure 28-6).
5. Remove drain plug (8) from cartridge center boss
and discard packing. Install plug replacement cartridge 3. Disconnect pressure indicating tube (1) from cross
with a new packing (7). (2) and remove bolts (3) washers (4) and nuts (5)
securing fuel shutoff valve (6) to bracket (8).
6. Clean all foreign matter from cartridge bore in pump
housing. 28-27. INSTALLATION (Helicopters S/N 4 through
153).
7. Lubricate packings, MS2951 3-136 and
MS29513-033 (furnished with new cartridge) with 1. Position cross (2) fuel shutoff valve (6), and
approved fuel. connector (7) on bracket (8), and install bolts (3),
washers (4), and nuts (5).
8. Install cartridge in pump housing with the two bolt
holes in cartridge flange and housing aligned. Fully seat 2. Connect tube assemblies (1 and 9) and electrical
cartridge in housing with handle closed. Secure connector.
cartridge in housing with three bolts and washers.
Safety boltheads with lockwire (figure 28-4). 3. Install coverplate, and close circuit breaker.
28-00-00
Page 26
206A/BS-M-28-6-1
Figure 28-6. Fuel shutoff valve (Sheet 1 of 2)
28-00-00
Page 27
1. Tube 13. Washer

2. Cross 14. Nut
3. Bolt 15. Valve assembly
4. Washer 16. Bracket
5. Nut 17. Tube
6. Fuel shutoff valve 18. Cross
7. Connector 19. Connector
8. Bracket 20. Fuel shutoff valve
9. Tube 21. Tube
10. Tube 22. Tube
11. Bolt 23. Screw
12. Washer 24. Washer
206A/BS-M-26-6-2
Figure 28-6. Fuel shutoff valve (Sheet 2)
28-00-00
Page 28
28-28. REMOVAL (Helicopters S/N 154 through 2. Connect tubes (21 and 22) to fuel shutoff valve.
3566).
3. Connect electrical connector to fuel shutoff valve.
1. Pull circuit breaker, remove coverplate above the
filler cap, and disconnect electrical connector on fuel 4. Install right side fuel compartment access door.
shutoff valve (15).
2. Provide suitable container to catch fuel and disconnect 28-33. FUEL PRESSURE TRANSDUCER.
tube (10, figure 28-6) and fuel supply tube (17).
The fuel pressure transducer provides a means of
3. Remove bolts (11) washers (12 and 13) and nuts monitoring fuel pressure. The transducer is located on
(14), securing fuel shutoff valve assembly (15) to mount a fitting on top of aft right side of fuel cell.
bracket (16).
28-34. REMOVAL.
28-29. INSTALLATION (Helicopters S/N 154
through 3566). 1. Remove fuselage access panel located above fuel
filter.
1. Position cross (18, figure 28-6) fuel shutoff valve
assembly (15) and connector (19) on mount bracket 2. Disconnect electrical connector (4, figure 28-7).
(16), and install bolts (11) washers (12 and 13) and nuts
(14). 3. Unscrew fuel pressure transducer (3) from fitting
(1). Remove and discard packing (2).
2. Connect tube (lo), fuel supply line (17), and
electrical connector.
28-35. INSPECTION.
3. Install coverplate and close circuit breaker.
1. Inspect transducer for rust or corrosion.
28-30. REMOVAL (Helicopters S/N 3567 and 2. Inspect for bent or broken pins.
subsequent).
1. Remove right side fuel compartment access panel. 28-36. INSTALLATION.
2. Disconnect electrical connector from fuel shutoff 1. Install new packing (2, figure 28-7) on transducer
valve (20, figure 28-6). and screw into fitting (1).
3. Disconnect tubes (21 and 22) from fuel shutoff valve. 2. Connect electrical connector (4).
4. Remove screws (23) with washers (24). Remove 3. Pressurize fuel system and check for leaks
fuel shutoff valve (20). (paragraph 28-6, and Chapter 5).
4. Install fuselage access panel.

28-31. INSPECTION.
1. Inspect fuel shutoff valve for leaks. 28-37. FUEL QUANTITY - INDICATING
UNITS.
2. Inspect fuel lines and electrical connectors for
security. Two float type fuel level transmitting units (tank units)
are installed in fuel cell. The lower unit is mounted in the
tank bottom and monitors fuel level up to horizontal
28-32. INSTALLATION (Helicopters S/N 3567 and surface of cell, under seat; upper unit monitors fuel level
subsequent). in upper section of fuel cell, behind seat, and is mounted
to top of fuel cell. Both indicating units are connected to
1. Position fuel shutoff valve (20, figure 28-6) in place a common quantity indicator. Refer to Chapter 95 for
and install washers (24) and screws (23). calibration procedures and troubleshooting.
28-00-00
Page 29
2. Packing
3. Fuel pressure transducer
4. Electrical connector
206A/BS-M-28-7
Figure 28-7. Fuel pressure transducer
28-38. REMOVAL. 2. Remove protective covers from fuel cell openings

for upper and lower tank unit (1 and 2).
1. Disconnect battery and defuel helicopter (Chapter
12). 3. Insert upper or lower tank units (1 or 2) into fuel cell
opening and secure with three screws (3 or 4) and
2. Disconnect electrical wiring to upper or lower tank washers (5 or 6).
unit (1 or 2, figure 28-8).
NOTE
3. Remove three screws (3 or 4) and washers (5 or 6)
Position float arm of upper tank unit to the
from upper and lower tank units (1 and 2) and remove
right side of helicopter and lower tank unit
from fuel cell. Discard gasket.
float arm forward.
4. Cover fuel cell opening to prevent entrance of
foreign material. 4. Connect electrical wiring to upper and lower tank
units (1 or 2).
5. Remove five screws (7) and washers (8) from tank unit
doubler (9 or 10) and separate doubler from tank unit. 5. Inspect fuel cell installation for security.
6. Connect battery and close fuel shutoff valve.

7. Perform leak test on fuel cell (paragraph 28-l 3, step
1. Position new gasket (11) on inside flange of upper 16).
or lower tank unit (1 or 2, figure 28-8). Install doubler (9
or 10) and secure with five screws (7) and washers (8). 8. Refer to Chapter 95 for fuel quantity calibration.
28-00-00
Page 30
1. Upper tank unit 7. Screw

2. Lower tank unit 8. Washer
3. Screw 9. Doubler
4. Screw 10. Doubler
5. Washer 11. Gasket
6. Washer
206A/BS-M-26-6
Figure 28-8. Fuel quantity indicator units
28-00-00
Page 31
28-40. DRAIN VALVE. 2. Place new packing (3, figure 28-10) on solenoid
valve (3).
Drain valve is a manually operated valve located in
bottom of fuel cell and is used to drain fuel. 3. Install solenoid valve (4) with screw (1) and washers (2).
28-41. REMOVAL.
5. Secure solenoid valve (4) using lockwire.
1. Ground helicopter. Disconnect battery and external
power source.
28-46. CAP.
2. Defuel and purge fuel cell (Chapter 12).
Cap and adapter assembly covers fuel access opening
3. Remove screws (1, figure 28-9) washers (2) and at top of fuel cell.
bolts (3).
28-47. REMOVAL.
4. Remove drain valve (7) with fitting (5) and packings
(4 and 6); discard packings. 1. Ground helicopter and disconnect battery.
28-42. INSTALLATION. 2. On helicopters S/N 4 through 3566, remove screws

(1, figure 28-11) washers (2) retainer (3) cap and
1. Lubricate new packings (4 and 6, figure 28-9) with adapter (4), with packings (6, 7, and 8), and seal (5).
approved fuel before installation. Discard seal (5) and packings.
3. On helicopters S/N 3567 and subsequent, remove

2. Place new packing (6) on drain valve (7).
screws (l), washers (2) retainer (3), hinged cap and
adapter (9), seal (5), and packing (6).
3. Place new packing (4) on fitting (5).
4. Install drain valve (7) with fitting (5). 28-48. INSTALLATION.

5. Secure drain valve (7) in closed position using 1. Lubricate new packings (6, 7, and 8, figure 28-11)
lockwire. with approved fuel before installation.
28-43. SOLENOID VALVE. 2. On helicopters S/N 4 through 3566 place new

packing (6) in fuel cell port.
The solenoid valve is an electrically and manually
3. Install new packing (7 and 8) on cap and adapter (4).
controlled drain valve used to drain fuel from fuel cell.
4. Position seal (5), cap and adapter (4), and retainer
28-44. REMOVAL. (3) in place and secure with washers (2) and screws (1)
1. Ground helicopter. Disconnect battery and external

power source. 5. On helicopters S/N 3567 and subsequent, place
new packing (6) in fuel cell port.
2. Defuel and purge fuel cell (Chapter 12).
6. Prepare hinged cap and adapter assembly and
3. Remove screw (1, figure 28-10) and washer (2). retainer assembly for installation. Using Scotchbrite or
400 grit paper, remove alodine protective finish locally
4. Remove solenoid valve (4) with packing (3). from inboard side of retainer to ensure good electrical
bond.
28-45. INSTALLATION. 7. Install seal (5), hinged cap and adapter (9) retainer
1. Lubricate new packing (3) with approved fuel before

installation. 8. Connect battery and remove ground.
28-00-00
Page 32
1. Screw
2. Washer
3. Bolt
4. Packing
5. Fitting
6. Packing
7. Drain valve
206A/BS-M-28-9
Figure 28-9. Drain valve
1. Screw
2. Washer
3. Packing
4. Solenoid valve
25 TO 35 IN-LBS
(2.63 TO 3.96 Nm)
206A/BS-M-28-10
Figure 28-10. Solenoid valve
28-00-00
Page 33
12
SEE VIEW A
1. Screws
2. Washer NOTES
3. Retainer
A1 Helicopters S/N 4 through 3566.
4. Cap and adapter
5. Seal
A2 Helicopters S/N 3567 and subsequent.
6. Packing
7. Packing
Packing 50 TO 75 IN-LBS (5.65 TO 8.48 Nm).
8.
9. Hinged cap and adapter
206A/BS-M-28-11
Figure 28-11. Cap and adapter assembly
28-00-00
Page 34
28-49. FILTER ELEMENT CHANGE 4. Install bowl (4) on filter body (8) and tighten until
REQUIREMENT. packing (7) contacts filter body. Draw a vertical line on
filter bowl and body.
Airframe mounted fuel filter element shall change at 5. Accomplish steps 5. through 7. of paragraphs 28-50.
same hourly interval as engine fuel filter (located in fuel
pump housing) and after any indication of clogging not
due to removable ice particles. 28-52. REMOVAL AND INSTALLATION -
222-366-621-l 01 FILTER ELEMENT.
1. Remove lockwire securing bowl retainer (4, figure

28-50. REMOVAL AND INSTALLATION - 28-14) and drain valve (1).
206-706-603 FILTER ELEMENT
2. Drain fuel from filter bowl (5) and remove drain valve
1. Remove lockwire securing filter bowl (4, figure (1), retainer nut (2), and packing (3) from filter bowl.
28-12) to filter valve (1).
3. Remove filter bowl (5), packing (8), filter element
(7), and gaskets (6). Discard packings, filter element,
2. Remove filter bowl (4) and filter element (3). Discard and gaskets.
used filter element, and packing (2, 5, and 6).
4. Install filter element (7), and gaskets (6) in filter bowl
3. Install new filter element (3) packings (2, 5, and 6) (5). Ensure that gaskets are installed with concave side
and filter bowl (4). facing the filter element.
5. Lubricate all packings with approved fuel, and

4. Install filter bowl (4) on filter body (7) and tighten install packing (8) in filter body (9).
until packing (5) contacts filter body. Mark a vertical line
on filter bowl and body. 6. Install filter bowl (5) with filter element (7) and
gaskets (6) in filter body and tighten retainer bowl (4)
5. Tighten bowl 60 to 90 degrees past mark.
NOTE 7. Install packing (3) retainer nut (2), and drain valve
(1). Secure drain valve to retainer nut with lockwire.
Turning bowl 60 degrees past the reference
mark will normally prevent any leakage. If 8. Bleed air from fuel system. Refer to Chapter 5
leakage occurs at this point, continue Special Inspection.
tightening to a maximum of 90 degrees (90
degrees represents 150 inch-pounds (16.95 28-53. AIRFRAME MOUNTED FUEL FILTER.
Nm).
A fuel filter is mounted to structure on left side of engine
6. Install lockwire to secure filter bowl (4) to filter valve compartment (right side of forward firewall on
(1). helicopters S/N 3387 and subsequent). Fuel filter (figure
28-15) consists of a replaceable filter element, drain
7. Bleed air from fuel system. Refer to Chapter 5 valve, bypass valve, impending bypass switch, and
Special Inspections. manual test button. The airframe mounted fuel filter
assembly eliminates requirement for adding anti-icing
28-51. REMOVAL AND INSTALLATION - additive to fuel supply when temperatures are below
52-2889-016 OR 52-2889-016A FILTER ELEMENT. 40F (4%). Indication of impending bypass lights the
A/F FUEL FILTER segment on pilot caution panel.
1. Remove lockwire securing filter bowl (4, figure
28-l 3) to filter valve (1). NOTE
2. Using a strap wrench, remove the filter bowl (4) and Filter element must be replaced when caution
filter element (5). Discard used filter element, gaskets light comes on during engine operation. Replace
(6), and packing (7 and 3). filter element at same hourly interval as engine
fuel filter maintenance is performed or 300
3. Install filter element (5), gaskets (6), and packing (7) hours. (Refer to Allison 250-C20 Series
in filter bowl (4). Operation and Maintenance Manual, 10W2.)
28-00-00
Page 35
Bracket
NOTE
On helicopters prior to T.B. 206-81-55 filter
is located near engine pan of left side
engine compartment. Post T.B. 206-81-55
filter is located on forward firewall.
1. Filter valve
2. Packing
3. Filter element
4. Filter bowl
5. Packing
6. Packing
7. Filter body
206A/BS-M-28-12
Figure 28-12. 206-706-603 Fuel filter assembly
28-00-00
Page 36
1. Filter valve
2. Retaining nut
3. Packing
4. Filter bowl
5. Filter element
6. Gasket
7. Packing
8. Filter body
-4
206A/BS-M-28-13
Figure 28-13. 52-2889-016 or 52-2889-016A Fuel filter assembly
28-00-00
Page 37
Drain valve
2. Retainer nut
3. Packing
4. Bowl retainer
5. Filter bowl
6. Gasket
6 7. Filter element
8. Packing
9. Filter body
206A/BS-M-28-14
Figure 28-14. 222-366-621 Fuel filter assembly
28-00-00
Page 38
SWITCHING ASSEMBLY
OUTLET BLEED PORT

0.026 IN. (0.66 mm) DIA A 6
INLET OUTLET
SEE VIEW A 4 J
1’
II
1
SECTION THRU FILTER
OUTLET BLEED
PORT 0.026 IN.
.
(0.66 MM)
DIAMETER L 0.06 IN. (1.52 mm)
VIEW A
Helicopters S/N 2212 through 3386

206A/BS-M-28-15-1
Figure 28-15. Airframe mounted fuel filter assembly (Sheet 1 of 2)
28-00-00
Page 39
7. Packing
2. Filter bowl retainer 8. Packing
3. Drain valve 9. Packing
4. Filter bowl 10. Gasket
5. Filter head 11. Gasket
6. Packing
NOTES
A1 To ensure self-bleeding of fuel filter,

check outlet bleed port with 0.020 inch
(0.51 mm) wire.
A2 On helicopters prior to T.B. 206-81-55
filter is located near engine pan on left
side engine compartment. Post T.B.
206-81-55 filter is located on forward
firewall.

206A/BS-M-28-15-2
Figure 28-15. Airframe mounted fuel filter assembly (Sheet 2)
28-00-00
Page 40
NOTE 4. Refer to applicable JetRanger Flight Manual for
daily inspection requirement.
Refer to Service Instruction No. 206-65 for
detailed installation instructions and wiring
diagrams. 28-56. INSTALLATION.
Purge fuel system after any filter maintenance (Chapter 12). 1. Lubricate all packings with approved fuel.
2. Install new packings (7, 8, and 9).

28-54. REMOVAL.
1. Remove filter element (1, figure 28-l 5) as follows: 3. Install new packing (6) in filter head (5).
a. Cut and remove lockwire securing filter bowl 4. Install filter bowl (4) with filter element (1) and
retainer (2) and drain valve (3). gaskets (10 and 11) into filter head (5). Tighten filter bowl
b. Remove drain valve (3) and drain fuel from filter

bowl (4). 5. Install drain valve (3) and secure with filter retainer
bowl (2) to filter bowl (4) tab using lockwire.
c. Remove filter bowl retainer (2) and filter bowl (4)
from filter head (5). 6. Bleed air from fuel system.
d. Remove filter element (1) from filter bowl retainer NOTE

(2). Discard packings (6, 7, 8, and 9).
When purging airframe and engine fuel
system of air, ensure both fuel boost pumps
28-55. INSPECTION. are on and motor engine for approximately
15 seconds or until no evidence of air is
1. Remove contamination and residual water from coming from the fuel supply hose. In
filter bowl (4). addition, depress airframe fuel filter bypass
indicator button during motoring operation to
2. Examine filter element (1) for evidence of remove air more rapidly.
contamination. Ice crystals and water found present in
the filter element may be removed. No other Refer to Allison 250-C20 Series Operation
contaminant is removable. and Maintenance Manual, 110W2for engine
fuel system maintenance requirements.
3. At each fuel filter element (1) change interval,
remove fitting from outlet port of filter head (5). Using a
7. Run engine and check for fuel leaks.
0.020 inch (0.51 mm) wire, pass wire through outlet
bleed port to ensure that bleed port is not clogged.
NOTE 28-57. ENGINE FUEL FILTER.
Use new filter element replacement kit Refer to Allison 250-C20 Series Operation and
KD651511 (FMC 05160) if element is Maintenance Manual 10W2 for detailed maintenance
contaminated or due for time replacement. instructions.
28-00-00
Page 41/42
CHAPTER 29 - HYDRAULIC SYSTEM
CONTENTS - MAINTENANCE PROCEDURES

HYDRAULIC SYSTEM
29-l Hydraulic system .......................................... 29-00-00 3

29-2 Troubleshooting.. ...................................... 29-00-00 3
29-3 Leakagelimits ......................................... 29-00-00 3
29-4 Flushing .............................................. 29-00-00 10
29-5 Bleeding .............................................. 29-00-00 10
29-6 Functional test using test stand .......................... 29-00-00 12
29-7 Functional test using helicopter system ................... 29-00-00 13
29-8 Pressure adjustment ................................... 29-00-00 13
29-9 Hydraulic system components .............................. 29-00-00 15
29-l 0 Hydraulic pump and reservoir ............................ 29-00-00 15
29-11 Removal .............................................. 29-00-00 15
29-l 2 Inspection and repair ................................... 29-00-00 15
29-13 Installation ............................................ 29-00-00 15
29-14 Hydraulic filter assemblies .................................. 29-00-00 15
29-15 Removal .............................................. 29-00-00 18
29-l 6 Inspection.. ........................................... 29-00-00 18
29-l 7 Installation ............................................ 29-00-00 18
29-18 Hydraulic filter element ..................................... 29-00-00 18
29-l 9 Removal .............................................. 29-00-00 18
29-20 Inspection and cleaning ................................. 29-00-00 18
29-21 Installation ............................................ 29-00-00 19
29-22 Hydraulic solenoid valve ................................... 29-00-00 19
29-23 Removal .............................................. 29-00-00 19
29-24 Inspection ............................................. 29-00-00 22
29-25 Installation ............................................ 29-00-00 22
29-26 Quick disconnects ......................................... 29-00-00 23
29-27 Removal .............................................. 29-00-00 23
29-28 Inspectionand repair ................................... 29-00-00 23
29-29 Installation ............................................ 29-00-00 23
29-30 Hydraulic hoses and tube assemblies ........................ 29-00-00 23
29-31 Removal .............................................. 29-00-00 23
29-32 Inspection and cleaning ................................. 29-00-00 23
29-33 Installation ............................................ 29-00-00 23
29-34 Rotor brake system ........................................ 29-00-00 24
29-35 Troubleshooting ........................................ 29-00-00 24
29-36 Servicing .............................................. 29-00-00 24
29-37 Bleeding .............................................. 29-00-00 24
29-38 Rotor brake system components ............................ 29-00-00 24
29-39 Mastercylinder ........................................ 29-00-00 24
29-40 Removal .............................................. 29-00-00 24
29-41 Inspection ............................................. 29-00-00 29
29-42 Installation ............................................ 29-00-00 29
29-00-00
Page 1
CONTENTS (Con’t)

HYDRAULIC SYSTEM (Cont)
29-43 Rotor brake assembly. ..................................... 29-00-00 29

29-44 Removal .............................................. 29-00-00 29
29-45 Inspection ............................................. 29-00-00 31
29-46 Installation ............................................ 29-00-00 31
29-47 Rotor brake disc .......................................... 29-00-00 31
29-48 Removal .............................................. 29-00-00 31
29-49 Inspection ............................................. 29-00-00 31
29-50 Installation ............................................ 29-00-00 31
FIGURES
Figure Page
Number Title Number
29-1 Hydraulicsystem.. .......................................................... 4

29-2 Hydraulic system schematic .................................................. 5
29-3 Hydraulic system troubleshooting .............................................. 6
29-4 Hydraulic filter and element ................................................... 11
29-5 Hydraulic system pressure regulator valve ...................................... 14
29-6 Hydraulic system components ................................................ 16
29-7 Hydraulic pump and reservoir ................................................. 17
29-8 Hydraulic solenoid valve ..................................................... 20
29-9 Rotor brake system .......................................................... 25
29-10 Rotor brake system troubleshooting ........................................... 26
29-11 Rotor brake master cylinder .................................................. 27
29-l 2 Rotor brake system bleeding .................................................. 28
29-13 Rotor brake assembly removal and installation .................................. 30
29-14 Rotor disc removal and installation ............................................ 32
TABLES
Table Page
Number Title Number
29-l Maximum allowable leakage for in-service components .......................... 9
29-00-00
Page 2
HYDRAULIC SYSTEM
29-1. HYDRAULIC SYSTEM. 29-2. TROUBLESHOOTING.
Figure 29-3 is provided as an aid in hydraulic system

The hydraulic system provides power to operate cyclic troubleshooting. The troubleshooting chart should be
and collective flight control servos. used with other sources of information, such
as hydraulic schematic (figure 29-2), electrical
wiring diagrams, functional test procedures, and other
NOTE detailed procedures in this and other chapters of the
manual.
Helicopters S/N 4 through 497 have

hydraulic powered tail rotor control systems
which are also powered by the hydraulic
system. Helicopters S/N 498 and KEEP HEAD, HANDS, AND OTHER
subsequent do not have hydraulic powered BODY PARTS CLEAR OF MOVING
tail rotor systems, unless a stabilization FLIGHT CONTROLS. HYDRAULIC
augmentation system is installed. The FORCES ARE STRONG ENOUGH TO
hydraulic system consists of the pump/ CAUSE SEVERE INJURY. BE CAREFUL
reservoir regulator assembly, filter, solenoid WHEN MOVING FLIGHT CONTROLS.
valve, tube, and hose assemblies. Pump, ANY MALFUNCTION THAT INTERFERES
regulator, and reservoir are mounted on WITH MOVEMENT OF BOOST-ASSISTED
forward side of transmission oil pump as an FLIGHT CONTROLS CAN CAUSE
assembly. The pump and regulator SERIOUS DAMAGE.
assembly includes a mounting pad for rotor
tachometer generator. Operation of the
hydraulic system is electrically controlled by 29-3. LEAKAGE LIMITS.
an ON/OFF switch mounted on console for
pilot control of the solenoid valve. When The following are guidelines for allowable external
solenoid is energized (ON/OFF switch leakage of in-service hydraulic system components,
OFF), pressurized hydraulic fluid flows to and some methods of measuring such leakage.
the reservoir, bypassing servo actuators.
Refer to figures 29-1 and 29-2 for system 1. Scope - Limits described are only for components
components and to Chapter 98 for hydraulic in service in helicopter hydraulic systems. Intent is to
system wiring diagram. Tail rotor servo is a minimize replacement of hydraulic components which
customer option and may be removed. are still serviceable.
a. These limits may differ from those contained in

SPECIAL TOOLS REQUIRED various specifications for components, which are
intended to control quality, assembly, and proper
functioning of components for procurement.
Components in service sometimes develop leakage
NUMBER NOMENCLATURE
rates in excess of those specification limits, without
Commercial Hydraulic Test Stand, necessarily becoming detrimental to the system or
1000 Psi (6895 kPa) failing to provide reliable operation.
Pressure Maximum,
2.50 Gpm (9.46 liters b. These limits are not to be used as basis for
per minute), 10 Micron acceptance or rejection of components during any
(394 Micro-inch) Filter bench functional test, or systems on new helicopters.
Commercial Pressure Gage 0 to c. These limits are not applicable to self-contained,
1000 Psi (0 to 6895 closed-compartment hydraulic units such as viscous
kPa), Calibrated dampers, liquid springs, or oleo struts.
29-00-00
Page 3
Tachometer generator
Antitorque servo actuator tube (return)
12. Antitorque servo actuator tube (pressure)
4. Pressure hose 13. One way check valve
5. Return hose 14. Solenoid valve
6. Pump and reservoir 15. Servo actuator (cyclic)
7. Scupper drain line 16. Servo actuator (collective)
8. Vent (pump seepage drain) 17. Body seal
9. Pressure regulator valve 18. Packing
NOTE
Helicopters S/N 4 thru 497 and those equipped with stability augmentation system.
206A/BS-M-29-1
Figure 291. Hydraulic system
29-00-00
Page 4
NOTE
------- i
Reset HYD BOOST

circuit breaker.
Figure 29-3. Hydraulic system troubleshooting (Sheet 2)
29-00-00
Page 7
2. Causes of Leakage - Some seepage is normally indicate excessive leakage. Accumulation on a flat area
present, since static or dynamic seals are not or a white-painted surface often appears to be
functionally perfect, due to such causes as: excessive, though it is actually allowable. It is also
possible to have enough components with allowable
a. A film of hydraulic fluid being retained by metal leakage that their combined leakage should be
surfaces such as piston rods, and thus carried past classified as excessive.
seals. This film is necessary for seal lubrication.
4. Leakage Checks - Measurement of leakage
b. Pressure and temperature variations affecting rates, for classification according to tables 29-1, can be
seals. performed as follows:
c. Seals tending to take a permanent set after a a. When hydraulic systems have remained in
period of time. static, unpressurized condition for an appreciable
period of time, leakage checks should not be performed
3. Classification of Leakage - External leakage of immediately after starting operation. Activate systems
hydraulic fluid can be broadly classified as excessive or and operate components several times, then wipe off
allowable. any leaked hydraulic fluid before making leakage
checks.
a. Excessive Leakage: Fluid leakage such that
hydraulic reservoir level may be dangerously lowered or b. Where location of a component does not permit
depleted during normal operation, or a fire hazard may direct observation, it is possible to measure leakage on
be created, or airworthiness of helicopter may be a flat surface, either on part of structure below or a panel
otherwise compromised. temporarily positioned for that purpose. Wipe surface
clean and place a drop of fluid on area, allow it to
b. Allowable Leakage: Fluid leakage such that stabilize, then outline drop area with grease pencil
quantity lost is insignificant, that will have no detrimental before wiping off fluid. Pressurize and cycle the
effect on helicopter operation, and such that correction component to observe leakage rate, comparing wetted
does not warrant maintenance time involved. surface to marked one-drop area.
---
c. General: Leakage usually shows as a c. Where fluid dropping from a component can be
seepage, stain, or wet area. It is possible for allowable directly observed, pressurize and cycle the component
leakage or seepage to collect in a cavity or depression until a drop falls free. Continue operating, observing
in adjacent structure over a period of time and falsely time until next drop to determine leakage rate.
Table 29-l. Maximum allowable leakage for in-service components
COMPONENT FUNCTlON TYPE LEAKAGE RATE

SERVO ACTUATORS Rod Seal D 1 drop/20 full cycles
(FLIGHT CONTROLS)
Rod Seal S-D 1 drop/l 5 minutes
End Cap S 2 drops/day
Valve Input S-D 1 drop/5 cycles
Valve Input S-D 1 drop/5 minutes
Output Shaft D 1 drop/minute
Output Shaft S-D 1 drop/minute
Housing (mating S 2 drops/day
surfaces)
Flared or Flareless Fittings S None
Compression Seals S 1 drop/30 minutes
D - DYNAMIC S - STATIC S-D - Static leakage
TYPE SYMBOLS: through dynamic seal
29-00-00
Page 9
. -
. I.
29-4. FLUSHING. b. Move cyclic from right aft corner to left forward
corner-until fluid from overboard drain hose is clear.
1. Remove and clean in solvent (C-304) the following
components of the hydraulic system: 7. Place collective in the full up position and repeat
steps 6.a and b.
8. On helicopters with tail rotor servo actuator
installed, actuate tail rotor pedals through complete
travel until fluid from overboard drain hose is clear.
SOLVENT (C-304) IS FLAMMABLE AND
FUMES ARE TOXIC. PROVIDE 9. Disconnect hydraulic test stand and install clean
ADEQUATE VENTILATION. DO NOT USE filter element in filter bowl (7, figure 29-4) (paragraph
NEAR A FLAME. 29-21).
10. Install pump and reservoir (paragraph 29-13).

11. Install pressure hose (4, figure 29-l) and return
hose (5).
USE IF ISOPROPYL ALCOHOL IS
PROHIBITED ON EITHER INTERNAL OR 12. Fill reservoir (6) with hydraulic fluid (C-002) to
EXTERNAL SURFACES OF HYDRAULIC proper level.
COMPONENTS (C-385).
13. Connect a calibrated gage (0 to 1000 psi) (0 to
6895 kPa) to test port of one of the cyclic servo
NOTE
actuators (Chapter 67).
Cap or plug all openings upon completion of 14. Place the hydraulic switch located on helicopter
cleaning operation: console in the OFF position. Start engine.Operate at
flight idle rpm, to bleed air from solenoid valve lines.
a. Hydraulic pump and reservoir (6, figure 29-l). Refer to applicable JetRanger Flight Manual.
Refer to paragraph 29-11.
15. Place the hydraulic switch in ON position and
b. Pressure hose (4) and return hose (5). observe calibrated gage. Pressure should be 600 – 25
psi (4187 – 172 kPa).
c. Filter bowl and element. Reinstall bowl
(paragraphs 29-l 9 and 29-21). 16. Shut down engine. If required, adjust pressure
(paragraph 29-8).
2. Connect ground hydraulic test-stand pressure line 17. Remove calibrated pressure gage and replace
to. pressure quick-disconnect socket (2) (paragraph port plug. Secure with lockwire. Fill reservoir with clean
29-6). hydraulic fluid (C-002) if required.
3. Connect overboard drain hose to the return
quick-disconnect (3), of sufficient length to reach a 29-5. BLEEDING.
container for contaminated fluid.
Bleeding air from hydraulic system may be
4. Start test stand and adjust pressure to 600 psi accomplished with the use of a hydraulic test stand (step
(4137 kPa). 1.) or by operation of helicopter (step 2.).
1. Bleed air from hydraulic system with hydraulic test

5. Cycle collective full up to full down until fluid from stand as follows: .
overboard drain hose to container is clear.
a. Connect hydraulic test stand to helicopter
6. Place collective in full down position and (paragraph 29-6).
accomplish the following steps:
b. Set hydraulic test stand pressure to 600 psi
a: Move cyclic from left aft corner to right forward (4137 kPa) with a flow rate of 2.5 gallons per minute
corner until fluid from overboard drain hose is clear. (9.46 liters per minute).
29-00-00
Page 10
SEE DETAIL AJ
8-
8-
DETAIL A DETAIL B
HELICOPTERS S/N 4 thru 153 HELICOPTERS S/N 154 SUBSEQUENT
20 TO 60 IN-LBS
(2.26 TO 6.78 Nm)
1. Bolt 7. Filter bowl 13. Filter body

2. Washer 8. Filter element 14. Packing
3. Red indicator button 9. Packing 15. Coupling
4. Union 10. Retainer 16. Coupling half
5. Packing 11. Backup ring 17. Body seal
6. Nut 12. Packing 18. Packing
206A/BS-M-29-4
Figure 29-4. Hydraulic filter and element
29-00-00
Page 11
c. Slowly move pilot cyclic and collective controls 5. Apply electrical power to helicopter. Push HYDR
through full travel, a minimum of 10 times, to bleed air SYSTEM circuit in and position HYDRAULIC SYSTEM
from system. switch ON.
d. Fill reservoir with hydraulic fluid (C-002) as 6. Set test stand for minimum flow of 2.5 gallons per
required. minute (9.46 liters per minute) with pressure
compensator adjusted to 600 psi (4137 kPa). Apply 600
e. Repeat substeps c. and d. as required. psi (4137 kPa) to hydraulic system and maintain
pressure for at least 15 minutes. Accomplish the
f. Disconnect hydraulic test stand from helicopter. following checks:
2. Bleed air from hydraulic system by operation of a. While cyclic and collective controls are being
slowly moved, observe movement of hydraulic servo
helicopter as follows:
actuators and check for binding, chafing, and hose
movements which would tend to loosen fittings.
a. Refer to applicable JetRanger Flight Manual.
Start helicopter engine and operate at flight idle. 7. Operate cyclic, collective and antitorque controls, if
tail rotor servo actuator is installed, rapidly through full
b. Slowly move pilot cyclic and collective controls stroke a minimum of 10 times to bleed air from system.
to allowable limits for ground operation. Repeat at least
10 times to bleed air from system. 8. Energize solenoid valve by turning console
hydraulic boost switch to OFF. Cycle cyclic and
C. Refer to applicable JetRanger Flight Manual. collective controls: controls should require more force to
Shut down engine and fill reservoir with hydraulic fluid operate. Turn the hydraulic boost switch ON.
(C-002) to proper level if required.
9. Decrease test stand pressure to zero. Slowly
increase pressure until it can be determined, by
operation of flight controls, that the system is functioning
29-6. FUNCTIONAL TEST USING TEST STAND. with hydraulic power. This should occur at 200 psi (1379
kPa) minimum pressure.
All hydraulic system components, with the exception of
the transmission-driven hydraulic pump, may be 10. Decrease test stand pressure to zero. Check
functionally tested using the following procedures. cyclic and collective servo actuators for operation of the
Refer to paragraph 29-7 for procedure to test irreversible valves by grasping rod ends of three servo
transmission-driven hydraulic pump. actuators and pushing and pulling with approximately 50
pounds (222.40 N) force. Rod ends should not move.
1. Use hydraulic test stand equipped with a 10 micron
11. Disconnect the hydraulic test stand and reconnect
filter and calibrated pressure gage with a range up to
quick-disconnect couplings.
1000 psi (6895 kPa). The test stand must be capable of
producing 1000 psi (6895 kPa) at a minimum flow rate 12. Fill helicopter hydraulic reservoir with hydraulic
of 2.5 gallons per minute (9.46 liters per minute). Clean fluid (C-002) to proper level.
stand and service with hydraulic fluid (C-002) prior to
use. 13. Cut lockwire and remove plug at test port of one
cyclic servo actuator and attach a calibrated hydraulic
2. Inspect helicopter hydraulic system visually to gage to test port. Use gage designed to indicate
ensure all components and lines are attached, cotter pressure up to 1000 psi (6895 kPa).
pins and lockwire installed, and system appears
capable of satisfactory operation. 14. Turn the console hydraulic boost switch to OFF.
Refer to applicable Jet Ranger Flight Manual; start
3. Position hydraulic test stand on right side of engine and operate at flight idle. This will bleed air from
helicopter near transmission/deck. the solenoid valve lines. Turn hydraulic boost switch ON
and observe calibrated gage installed in step 13.
4. Remove forward fairing. Disconnect two Pressure should be 600 – 25 psi (4137 – 172 kPa).
quick-disconnect couplings (2 and 3, figure 29-l). Shut off engine. If required, adjust pressure (paragraph
Connect test stand hoses to coupling halves of two 29-8). Remove calibrated pressure gage and replace
quick-disconnects. port plug. Secure plug with lockwire.
29-00-00
Page 12
29-7. FUNCTIONAL TEST USING HELICOPTER within 600 – 25 psi, (4137 – 172 kPa); adjust as
SYSTEM. follows:
1. If a hydraulic test stand is not available, a functional 3. Cut and remove lockwire on pressure regulating
check of the hydraulic system may be performed using valve housing (9, figure 29-5). Remove housing from
transmission-driven hydraulic pump (6, figure 29-l). pump and reservoir (1).
This test is less comprehensive than the test described
in paragraph 29-6. 4. Remove and discard packings (2 and 3) from
housing (9) and sleeve (4).
2. Inspect helicopter hydraulic system visually to
ensure all components and lines are attached, cotter
pins and lockwire are installed, and system appears
capable of satisfactory operation.
3. Ground run helicopter at flight idle rpm. Position DO NOT SEPARATE PISTON (6) AND
HYDRAULIC SYSTEM switch ON, and push HYDR SPRING (7) FROM SLEEVE (4). DO NOT
SYSTEM circuit breaker in. REMOVE WASHERS (8) FROM VALVE
HOUSING (9) EXCEPT FOR
ADJUSTMENT.
4. Move cyclic and collective controls slowly to
allowable limits for ground operation with engine at flight
idle rpm. Check servoactuators and hoses for binding, 5. To increase pressure, addition of one washer (8) will
chafing, and hose movements which would tend to increase pressure approximately 30 psi (206.85 kPa).
loosen fittings. Removal on one washer will decrease pressure
approximately 30 psi (206.85 kPa).
5. Position HYDRAULIC SYSTEM switch
OFF; greater force should be required to move cyclic 6. Install pressure baffle (5) over threaded end of
and collective controls. sleeve (4). Align cutaway area of the pressure baffle
with the flats on the sleeve.
6. Position HYDRAULIC SYSTEM switch ON. When
engine has been operating a total of 15 minutes, check NOTE
hydraulic system components for leaks (paragraph
29-3). Pressure baffle (5) is required on all pressure
regulator valves.
29-8. PRESSURE ADJUSTMENT. 7. Ensure required number of washers (8) are

installed inside valve housing (9) and that piston (6) and
NOTE spring (7) are correctly positioned in sleeve (4). Thread
valve housing (9).

Check hydraulic system pressure and adjust
as required after replacement of hydraulic
pump and regulator, and/or when it is 8. Lubricate new packings (2 and 3) with hydraulic fluid
suspected that operating pressure of 600 – (C-002) and install on sleeve (4, figure 29-5) and
25 psi (4137 – 172 kPa) is not being housing (9).
maintained.
9. Install pressure regulator valve in pump and
1. Cut lockwire and remove plug at test port of one
cyclic servoactuator and attach a calibrated hydraulic
pressure gage to the test port. Use gage designed to 10. Operate helicopter at 100 percent rotor rpm and
indicate pressure up to 1000 psi (6895 kPa). check hydraulic pressure. If required, adjust quantity of
washers (8) and check hydraulic pressure.
2. Start engine and operate helicopter at 100 percent
rotor rpm and observe hydraulic pressure. Refer to 11. Remove hydraulic test gage and replace plug in
applicable JetRanger Flight Manual. If pressure is not cyclic servo test port. Secure with lockwire.
29-00-00
Page 13
1. Pump and reservoir

2. Packing
3. Packing
4. Sleeve
5. Pressure baffle
6. Piston
7. Spring
8. Washers (AN960-4L)
9. Valve housing
NOTE
Pressure baffle (5) is required on all

pressure regulating valves.
206A/BS-M-29-5
Figure 29-5. Hydraulic system pressure regulator valve
29-00-00
Page 14
12. Secure the pressure regulating valve housing (9) 29-13. INSTALLATION.
to pump and reservoir (1) with lockwire.
1. If removed, position cooling air jacket (5, figure
29-6) on hydraulic pump and reservoir (14). Attach with
29-9. HYDRAULIC SYSTEM COMPONENTS. screws (12), washers (7) and nuts (6). Apply a thin film
of antiseize compound (C-452 or C-012) to the pump
Hydraulic system components consist of pump and splines and mating splines of transmission oil pump and
reservoir (1, figure 29-6), pressure regulator valve (2) tachometer generator.
(located within pump and reservoir assembly), solenoid
(3), hydraulic system filter (4) with replaceable filter 2. Position pump and reservoir assembly (14, figure
element, and quick-disconnects (5 and 6). 29-7) on transmission gasket (15). Secure with three
washers (7) and three nuts (8). Ensure that vent (9) is
NOTE open. No line is required for this vent.
The servo actuator assemblies are 3. Attach scupper drain line (7, figure 29-6). Install
discussed in Chapter 67. pressure and return hoses (8 and 9) to reservoir and
quick-disconnect fittings (5 and 6). Install supporting
hose clamps.
29-10. HYDRAULIC PUMP AND RESERVOIR.
4. Connect tachometer generator (10) wiring.
The hydraulic pump and reservoir assembly is located
on the forward end of the transmission. 5. Attach cooling air hose (2, figure 29-7) to hydraulic
reservoir cooling air jacket (5).
29-11. REMOVAL. 6. Fill reservoir with hydraulic fluid (C-002) to proper

level.
1. Disconnect cooling air hose (2, figure 29-7) at
hydraulic reservoir. NOTE
2. Disconnect wiring at connector plug on tachometer All inspection windows and sight glasses are
generator (10, figure 29-6). to be inspected for cracking, crazing and
discoloration. If any one of these conditions
3. Remove hydraulic fluid from reservoir with a suction is present, the part must be removed and
pump. Dispose of fluid. replaced prior to returning helicopter to
service.
4. Disconnect scupper drain line (7). Disconnect
pressure hose (8) and return hose (9) at 7. Check hydraulic pressure (paragraph 29-8). During
quick-disconnects (5 and 6). operation of helicopter for hydraulic pressure check,
observe system for leaks and ensure that rotor
5. Remove three nuts (8, figure 29-7) and three tachometer generator is operating properly. After
washers (7). Remove hydraulic pump and reservoir removal of hydraulic pressure, check indicator. Check
assembly (14) from transmission. level of hydraulic fluid and add fluid if required.
29-12. INSPECTION AND REPAIR. 29-14. HYDRAULIC FILTER ASSEMBLIES.
1. Inspect pump and reservoir assembly (14, figure Two configurations of filter assemblies are utilized on
29-7) for evidence of cracks, corrosion, or leakage, and the helicopters. Both utilize elements with a filtration
security of mounting. Inspect splines of pump driveshaft rating of 15 microns absolute. The unit utilized on
and coupling for wear. Inspect cooling air jacket (5) for helicopters S/N 154 and subsequent provides a positive
cracks and security, and cooling air hose (2) for indication of restricted flow through the filter element by
deterioration and security. means of a pop-up button (3, figure 29-4) located on
top of the filter body. The button pops up at 70 – 10 psi
2. For repair and overhaul of hydraulic pump and (480 – 69 kPa) differential, and is inoperative below
reservoir refer to BHT-206A/B-SERIES-CR&O manual. 35 – 15F (1.67 – 9.44%).
29-00-00
Page 15
8
RED INDICATOR
BUTTON
SEE DETAIL A
DETAIL A
1. Pump and reservoir 8. Pressure hose

2. Pressure regulator valve 9. Return hose
3. Solenoid valve 10. Tachometer generator
4. Filter assembly 11. Antitorque servo actuator tube (return)
5. Quick-disconnect socket (pressure) 12. Vent (pump seepage drain)
6. Quick-disconnect socket (return) 13. One way check valve
7. Scupper drain line
206A/BS-M-29-6
Figure 29-6. Hydraulic system components
29-00-00
Page 16
1. Clamp 9. Vent (pump seepage drain)

2. Cooling air hose 10. Rotor tachometer generator
3. Clamp mounting pad
4. Clamp 11. Angle
5. Cooling air jacket 12. Screw
6. Nut 13. Channel
7. Washer 14. Pump and reservoir assembly
8. Nut 15. Gasket
206A/BS-M-29-7
Figure 29-7. Hydraulic pump and reservoir
29-00-00
Page 17
29-15. REMOVAL. 5. Attach coupling (15) to mating coupling half (16)
and secure.
1. Disconnect coupling half (16, figure 29-4) from
coupling (16). 6. For installation of filter element (8) refer to
paragraph 29-21.
2. Disconnect tube from union (4).
7. Fill hydraulic reservoir (6, figure 29-l) with hydraulic
3. Remove two bolts (1) with attaching nuts (6) and fluid (C-002) to proper level.
washers (2) securing filter assembly to brackets
mounted on cabin roof. Remove filter assembly. 8. Bleed hydraulic system (paragraph 29-5).
4. Remove coupling (15) and discard packing (14).

29-18. HYDRAULIC FILTER ELEMENT.
5. Remove union (4) and packing (5).
The hydraulic filter element (8, figure 29-4) functions at
6. For removal of element (8) refer to paragraph
high pressure over a wide temperature range. Filtration
29-l 9.
rating is 15 microns absolute. When red indicator button
(3) on return line filter pops up, inspect, clean or replace
hydraulic filter element.
29-16. INSPECTION.
29-19. REMOVAL.
1. Cut and remove lockwire from bowl (7, figure 29-4)

USE OF ISOPROPYL ALCOHOL IS and filter body (13). Remove filter bowl (7) and element
PROHIBITED ON EITHER INTERNAL OR (8).
EXTERNAL SURFACES OF HYDRAULIC
COMPONENTS. 2. Remove and discard backup ring (11) and packings
(9 and 12).
1. Clean filter body (13, figure 29-4) with solvent
(C-304). For inspection and cleaning of element refer to 3. Helicopters S/N 4 through 153 (figure 29-4).
paragraph 29-20. Remove retainer ring and withdraw filter element (8)
from filter bowl (7).
2. Inspect filter body for scratches, nicks, and dents.
4. Helicopters S/N 154 and subsequent (figure 29-4).
3. Inspect threaded ports, coupling, coupling half, and Press end of springs on filter element (8) to disengage
union for damaged threads and fluid leakage. Replace from retention groove in filter bowl (7) and withdraw filter
damaged parts. element from bowl.
4. Inspect red indicator button (3) for proper operation.

29-20. INSPECTION AND CLEANING.
1. Lubricate new packings (5, 9, 12 and 14, figure

29-4) with hydraulic fluid (C-002).
USE OF ISOPROPYL ALCOHOL IS
2. Install new packing (14) on coupling (15) and install PROHIBITED ON EITHER INTERNAL OR
in inlet port of filter body (13). EXTERNAL SURFACES OF HYDRAULIC
COMPONENTS.
3. Install new packing (5) on union (4) and install in
outlet port of filter body (13). 1. Visually inspect filter element (8, figure 29-4) for
damage. If any defects on or near filtering surfaces or
4. Position filter assembly, on bracket on cabin roof. sealing areas of filter are noted, do not clean the
Secure with bolts (l), washers (2), and nuts (6). element; replace it with a new element.
29-00-00
Page 18
2. Clean filter element (8) by vigorous hand-agitation a. Ensure a serviceable packing (9, figure 29-4) is
in one of the following fluids: installed in filter element (8) and is seated in groove.
a. Hydraulic fluid (C-002) b. Press ends of springs on filter element (8) and
insert element in filter bowl (7) until springs engage in
b. Solvent (C-304) retention groove.
c. Safety solvent (C-31 9) c. Install packing (12) and backup ring (11) in filter
body (13).
d. Turbine fuel, JP-4 (C-003)
Secure filter bowl (7) to filter body with lockwire.
e. One half percent liquid detergent (C-318) in
water. Rinse with clear water.
e. Fill hydraulic reservoir (15, figure 29-7) with
hydraulic fluid (C-002) to proper level.
NOTE
f. Bleed hydraulic system (paragraph 29-5).
Hydraulic filter elements are field cleanable
at least three times.
29-22. HYDRAULIC SOLENOID VALVE.
3. Backflush filter element (8) during cleaning
procedure with one of the above fluids, back flushing The solenoid valve (21, figure 29-8) is incorporated in
using 80 to 95 psi (551 to 655 kPa) filtered air pressure. the hydraulic system for turning the system ON and
Direct airflow through element in opposite direction to OFF. The solenoid valve is located forward of
normal fluid flow. This will result in a more thorough transmission work deck area. The solenoid valve is
cleaning. normally de-energized; when HYDR SYSTEM circuit
breaker is in and HYDRAULIC SYSTEM switch is OFF,
4. Dry filter element with filtered air or in oven at 120F electrical power is applied to energize solenoid, which
(48.9%). closes the valve and removes hydraulic pressure from
the servo actuators (figure 29-2).
29-23. REMOVAL.
NOTE
1. Position battery switch OFF and disconnect
All packings must be lubricated with external power if connected.
hydraulic fluid (C-002) prior to installation.
2. Disconnect electrical connector (51) from solenoid
1. For helicopters S/N 4 through 153: valve (21, figure 29-8).
3. Drain hydraulic fluid from reservoir. Place cloths

a. Insert filter element (8, figure 29-4) into filter bowl
around solenoid valve (21) to absorb hydraulic fluid
(7) and secure with retainer (10).
during removal.
b. Install filter bowl (7) into filter body (13) under 4. Disconnect hose assemblies (1, 13, 30, and 33)
backup ring (11) and packing (12). from reducers (2, 12, 29, and 32).
5. On helicopters S/N 498 and subsequent (figure

lockwire. 29-8):
d. Fill hydraulic reservoir (15, figure 29-7) with a. Remove tube assemblies (34) from check valves
hydraulic fluid (C-002) to proper level. (36), and hose assemblies (35) from reducers (37).
e. Bleed hydraulic system (paragraph 29-5). b. Loosen nuts (45) and remove unions (43) and
attached parts as a unit from body (48). Discard
2. For helicopters S/N 154 and subsequent: retainers (46) and packings (47).
29-00-00
Page 19
HELICOPTERS S/N 4 THRU 497
1. Hose assembly 12. Reducer 23. Bolt

2. Reducer 13. Hose assembly 24. Packing
3. Packing 14. Packing 25. Bolt
4. Nut 15. Bolt 26. Packing
5. Packing 16. Packing 27. Body
6. Elbow 17. Retainer 28. Packing
7. Retainer 18. Nut 29. Reducer
8. Nut 19. Elbow 30. Hose assembly
9. Packing 20. Packing 31. Nut
10. Body 21. Solenoid valve 32. Reducer
11. Packing 22. Washer 33. Hose assembly
206A/BS-M-29-8-1
Figure 29-8. Hydraulic solenoid valve (Sheet 1 of 2)
29-00-00
Page 20
45- 46
-46
47-e
34. Tube assembly 43. Union

35. Hose assembly 44. Reducer
36. Check valve 45. Nut
37. Reducer 46. Retainer
38. Packing 47. Packing
39. Packing 48. Body
40. Cross 49. Plug
41. Packing 50. Solenoid valve
42. Packing 51. Electrical connector
206A/BS-M-29-8-2
Figure 29-8. Hydraulic solenoid valve (Sheet 2)
29-00-00
Page 21
6. Disconnect lines from elbows (6 and 19). 3. Install packing (26) and nut (31) on bolt (25) and
tighten. Secure nut (31) with lockwire.
7. Remove lockwire from bolts (23). Remove bolts
(23) and washers (22) from solenoid valve (21) and 4. Install packing (20), retainer (17), nut (18) and
remove solenoid valve assembly from helicopter. elbow (19) in solenoid valve (21).
8. Cap or plug all openings to prevent hydraulic 5. Install packing (16) and bolt (15) in solenoid valve
system contamination. (21).
9. Remove lockwire from nut (8) and remove nut (8) 6. Install packing (14) on bolt (15) and install body (10)
and packing (9) from bolt (15). Discard packing. on bolt (15).
IO. Remove body (10) and packing (14) from bolt (15).
7. Install packing (9) and nut (8) on bolt (15) and
Discard packing.
tighten. Secure nut (8) with lockwire.
11. Remove bolt (15) and packing (16) from solenoid
8. Position solenoid valve (21) on mounting point
valve (21). Discard packing.
forward of hydraulic pump and secure with bolts (23)
and washers (22). Secure bolts with lockwire.
12. Remove elbow (19), nut (18), retainer (17), and
packing (20) from forward end of solenoid valve (21).
Discard packing. NOTE
13. Remove lockwire from nut (31) and remove nut When torquing hose nuts, use a backup
(31), packing (26) and body (27) from bolt (25). Discard wrench on hose end fitting to prevent twisting
packing. of hose.
14. Remove packing (26) from bolt (25) and remove 9. Connect hose assemblies (33, 30, 13, and l), to
bolt and packing (24) from solenoid valve (21). Discard reducers (32, 29, 12, and 2). Tighten all fittings.
packing.
10. On helicopter S/N 498 and subsequent (figure
29-8, sheet 2), disassemble numbered parts previously
29-24. INSPECTION. removed as one unit. Reassemble numbered parts,
using new packings and retainers.
1. Inspect solenoid valve (21, figure 29-7) for damage,
and leakage. a. Install unions (43) into bodies (48) with new
packings (47) and retainers (46). Tighten nuts (45).
2. Inspect electrical connector for damage and inspect
electrical wiring for chafing and condition. b. Connect tube assemblies (34) to check valves
(36) and hose assemblies (35) to reducers (37). If plugs
3. Inspect solenoid valve (21) for damaged thread (49) are installed, tighten and secure with lockwire.
parts and corrosion.
11. Connect electrical connector to solenoid valve
(21).
12. Ensure that all fittings and hydraulic lines are
NOTE
properly positioned.
All packings must be lubricated with
hydraulic fluid (C-002) prior to installation. 13. Fill reservoir to proper level with hydraulic fluid
(C-002).
1. Install packing (24, figure 29-8) and bolt (25) in
solenoid valve (21). 14. Bleed hydraulic system (paragraph 29-5).
2. Install packing (26) on bolt (25) and install body (27) 15. Move cyclic and collective controls through full
on bolt. range of travel, and ensure hoses do not bind or chafe.
29-00-00
Page 22
16. Refer to applicable JetRanger Flight Manual; 29-29. INSTALLATION.

operate helicopter at flight idle and move cyclic,
collective, and antitorque pedals (if boost kit is installed) 1. Lubricate with hydraulic fluid (C-002) and install
through full range of travel several times to ensure all air packing (14, figure 29-4) on coupling (15) and install on
has been bled from the system. Observe installation for filter body (13).
evidence of leaks.
2. Install coupling half (16) on hose assembly.
17. Turn boost to OFF to functionally check solenoid
valve (21). If solenoid valve functions properly, controls 3. Connect quick-disconnects and bleed hydraulic
will require more force to move. system (paragraph 29-5).
18. Shut helicopter down and check hydraulic fluid 29-30. HYDRAULIC HOSES AND TUBE
(C-002) in reservoir for proper fill level. ASSEMBLIES.
The hydraulic hoses and tube assemblies illustrated

29-26. QUICK-DISCONNECTS. (figure 29-l) are used to connect components of the
hydraulic system. Tube assemblies have sleeve end
fittings which are retained by flared ends of tubes.
Two quick-disconnect fittings provide a convenient
means of connecting a hydraulic test stand to helicopter.
Each quick-disconnect is made up of a coupling and a 29-31. REMOVAL.
coupling half (15 and 16, figure 29-4). When
disconnected, each coupling automatically closes to 1. Disconnect hose or tube assembly at connecting
prevent loss of fluid and/or entry of foreign matter. fittings.
2. Remove attaching clamps securing hose or tube

29-27. REMOVAL. assembly to helicopter and remove.
3. Cap or plug openings to prevent system

1. Grasp coupling (15, figure 29-4) of contamination.
quick-disconnect, push toward filter assembly and turn
counterclockwise to disconnect the quick-disconnects.
29-32. INSPECTION AND CLEANING.
2. Remove couplings (15) and coupling halves (16)
from hoses and from the filter assembly. Be prepared to 1. Inspect hose and tube assemblies for evidence of
catch hydraulic fluid when couplings are removed from chafing, crimping, or damaged threads.
hoses and filter assembly.
2. Inspect hose and tube assemblies for leakage.
3. Cap or plug openings to prevent system Refer to table 29-1, for maximum allowable leakage for
contamination. in-service components.
3. Clean hose and tube assemblies with solvent

(C-304) prior to installation.
29-28. INSPECTION AND REPAIR.
1. Inspect coupling and coupling halves for cracks, 29-33. INSTALLATION.

distortion, and proper locking when the two couplings
are joined. NOTE
When torquing hose nuts, use a backup

2. Repair coupling by removing and replacing coupling wrench on hose end fittings to prevent
halves. twisting of hoses.
3. Repair coupling halves by removing and replacing 1. Install hose or tube assemblies and secure with
packings. clamps and supports, as required. Ensure there will be
29-00-00
Page 23
no chafing between hose or tube assemblies and 3. On helicopters S/N 4 through 2211 (rotor brake
helicopter components. assemblies incorporating single bleed valve), open
bleed valve (2, figure 29-l 2) of left rotor brake assembly
2. Fill hydraulic reservoir (15, figure 29-7) with (3) and attach a clean rubber bleed hose (1) on valve
hydraulic fluid (C-002) to proper level. Bleed hydraulic extension. Place other end of hose in container to
system (paragraph 29-5). receive discharged fluid.
3. Inspect for hydraulic fluid leaks while system is 4. Slowly pull handle (4) down and hold in position. Do
pressurized. not allow handle to move back into stowed position.
5. Close bleed valve (2) and return handle (4) to

stowed position (up). Replenish fluid in master cylinder.
29-34. ROTOR BRAKE SYSTEM.
6. Repeat steps 4 and 5 until discharged fluid is free
The rotor brake system provides a positive means of of air bubbles.
stopping main and tail rotors. The rotor brake is a
completely self-contained hydraulic system. It is 7. Remove right rotor brake assembly (3) from cap
operated by a handle located on the right of the assembly (8) (do not disconnect hose assembly).
overhead console. Rotor brake system is shown in
figure 29-9. 8. Rotate removed rotor brake assembly (3, figure
29-12) so bleed valve (2) is in up position.
29-35. TROUBLESHOOTING. 9. insert suitable block between brake linings and

repeat steps 4. through 6.
Figure 29-10 provides troubleshooting procedures for
the rotor brake system. 10. Install rotor brake assembly on cap assembly
(paragraph 29-46).
11. On helicopters S/N 2212 and subsequent (rotor

29-36. SERVICING. brake assemblies incorporating two bleed valves),
bleed from top bleed valves (steps 3. through 6.).
1. Remove forward fairing (Chapter 71).
12. Install forward fairing (Chapter 71) and close left
2. Remove filler cap (1, figure 29-11) from master and right engine cowl panels.
cylinder.
NOTE 29-38. ROTOR BRAKE SYSTEM

COMPONENTS.
Operating handle (12) must be in stowed
(up) position while filling reservoir.
29-39. MASTER CYLINDER.
3. Fill master cylinder with hydraulic fluid (C-002) to
bottom of filler neck (16). WARNING)
4. Replace filler cap.

CLEANING HYDRAULIC COMPONENTS
5. Install forward fairing (Chapter 71). SHALL BE ACCOMPLISHED WITH
SOLVENT (C-304) ONLY. DO NOT USE
ALCOHOL.
29-37. BLEEDING.
29-40. REMOVAL.
1. Remove forward fairing (Chapter 71) and open left
and right engine cowl side panels. 1. Remove forward fairing (Chapter 71).
2. Check master cylinder for proper fluid level 2. Remove screws (14, figure 29-11) and washers (13)
(paragraph 29-36). and remove trim panel (15), if installed.
29-00-00
Page 24
1. Rotor brake assembly

2. Rotor brake disc
3. Master cylinder
206A/BS-M-29-9
Figure 29-9. Rotor brake system
29-00-00
Page 26
1. Filler cap 9. Bracket

2. Nut 10. Nutplate assembly
3. Elbow 11. Master cylinder
4. Tube assembly 12. Operating handle
5. Bolt 13. Washer
70 TO 120 IN-LBS 14. Screw
6. Washer seal
(7.91 TO 13.56 Nm) 15. Trim panel
7. Retainer
8. Packing 16. Filler neck
206A/BS-M-29-11
Figure 29-l 1. Rotor brake master cylinder
29-00-00
Page 27
1. Bleed hose
2. Bleed valve
4. Handle
5. Bleed container
206A/BS-M-29-12
Figure 29-12. Rotor brake system bleeding
29-00-00
Page 28
3. Disconnect tube assembly (4). 7. Position aft nutplate (10) with two holes over aft
mounting holes of master cylinder.
4. Loosen nut (2) and rotate elbow (3) to clear opening
in cabin roof. 8. Install bolts (5) and washer seals (6) through roof
bracket (9), master cylinder mounting holes and
5. Remove four bolts (5) and washer seals (6). nutplate (10).
6. Remove forward and aft nutplate assemblies (10). 9. Repeat steps 7. and 8. for forward nutplate.
7. Remove master cylinder (11) from ceiling inside NOTE

cabin.
Do not tighten bolts until after adhesive is
applied.
8. Remove elbow (3) and discard packing (8) and
retainer (7).
10. Apply a bead of adhesive (C-308) around edge of
slotted hole cutout on top of cabin roof. Work adhesive
9. Cap or plug openings to prevent contamination of
in between contact surfaces of roof skin and master
hydraulic system.
cylinder mounting plate.
IO. Clean adhesive from faying surfaces of roof skin 11. Tighten mounting bolts (5).
and master cylinder mounting plate.
12. Wipe off excess adhesive squeezed from between
mounting plate and roof.
29-41. INSPECTION.
13. Rotate elbow (3) to align with tube assembly (4).
1. Inspect master cylinder for evidence of leakage,
corrosion and damage.
2. Inspect mechanical linkage for distortion and wear 15. Connect tube assembly (4) to elbow (3).
that would affect function.
16. Apply adhesive to fill hole in cabin roof around
3. Refer to BHT-206A/B-SERIES-CR&O for repair of master cylinder to prevent standing water.
master cylinder.
17. Install trim panel (15) with washer (13) and screw
(14), if removed.
18. Fill and bleed rotor brake hydraulic system
1. Thread nut (2, figure 29-l 1) onto elbow (3). (paragraphs 29-36 and 29-37).
2. Place new retainer (7) in groove of nut (2). 19. Install forward fairing (Chapter 71).
3. Lubricate new packing (8) with hydraulic fluid

29-43. ROTOR BRAKE ASSEMBLY.
(C-002).
4. Position packing (8) against retainer. 29-44. REMOVAL.
5. Install elbow (3) in port on top of master cylinder. 1. Open left and right engine cowl side panels.
Rotate elbow to clear opening in cabin roof.
2. Remove hose assembly (11 and 12, figure 29-13)
NOTE from rotor brake assembly.
Do not tighten nut (2). 3. Cut lockwire and remove bolt (9), washer (2), and
shim washer (1).
6. Align four bolt holes of master cylinder over four
matching holes in roof bracket (9) and overhead panel 4. Remove nut (4) washer (7), shim washer (1 and 5)
inside cabin roof. and bolt (6).
29-00-00
Page 29
1. Shim washer 5. Washer 9. Bolt

2. Washer 6. Bolt IO. Spacer
3. Rotor brake assembly 7. Washer 11. Hose assembly
4. Nut 8. Cap assembly 12. Hose assembly
NOTE
A1 Maximum shim thickness = 0.130. In. (3.30 mm)

Mean shim thickness = 0.053 In. (1.35 mm)
A Shim washer thickness each bolt (6 and 9)

must be equal within 0.004 In. (0.10 mm)
A3 Shim washer (1) required to make gaps equal

within 0.020. 206A/BS-M-29-13
Figure 29-13. Rotor brake assembly removal and installation
29-00-00
Page 30
5. Remove rotor brake assembly (3) from cap 29-47. ROTOR BRAKE DISC.
assembly (8).
29-48. REMOVAL.
29-45. INSPECTION.
1. Remove air induction fairing (Chapter 71).
1. Inspect rotor brake assembly for corrosion and
2. Remove rotor brake assemblies (paragraph 29-44).
damage.
3. Remove main driveshaft (Chapter 63).
2. Inspect rotor brake assembly for evidence of
leakage. 4. Remove four nuts (6, figure 29-14), washers (2 and
5), and bolts (1) attaching rotor brake disc (4) and ring
3. Refer to BHT-206A/B-SERIES-CR&O for repair of (3) to aft coupling (9).
rotor brake assembly.
5. Remove aft coupling (9) from main driveshaft (8)
(Chapter 63) and remove rotor brake disc (4) and ring
29-46. INSTALLATION. (3).
1. Loosely install rotor brake assembly (3, figure

29-49. INSPECTION.
29-l 3) on cap assembly (8) with bolt (9), washer (2), and
shim washer (1).
1. Inspect rotor disc for any discoloration indicating
evidence of overheating. Replace overheated rotor
2. Loosely install bolt (6), washers (5) shim washer disc.
(l), washer (7) and nut (4).
2. Inspect rotor disc for any distortion or warping.
NOTE Replace distorted or warped rotor disc.
On helicopters S/N 3217 and subsequent,

use spacer (10) instead of shim washer (1). 29-50. INSTALLATION.
3. Tighten (but do not torque) nut (4) and bolt (9). 1. Slide ring (3, figure 29-14) then rotor brake disc (4)
on main driveshaft (8).
4. Measure gaps A and B, figure 29-12, section A-A.
Gaps must be equal within 0.004 inch (0.010 mm). Add 2. Position ring (3) on rotor brake disc (4).
or remove shim washers (1) as required to obtain proper
3. Mate rotor brake disc and ring with aft coupling (9)
gaps.
with washers (5) between disc and coupling.
4. Install four bolts (1) and washers (2) through rotor

with lockwire.
6. Install hose assemblies (11 and 12) on brake 5. Reinstall main driveshaft (Chapter 63).
assemblies.
6. Reinstall rotor brake assemblies (paragraph
7. Bleed rotor brake system (paragraph 29-37). 29-46).
8. Close left and right engine cowl side panels. 7. Install air induction fairing (Chapter 71).
29-00-00
Page 31
1. Bolt (4 places)
2. Washer
3. Ring
4. Rotor brake disc
5. Washer
6. Nut
a. Main driveshaft
9. Aft coupling
50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)
206A/BS-M-29-14
Figure 29-14. Rotor disc removal and installation
29-00-00
Page 32

Maintenance Manual Fuel/Hydraulics: BHT-206A/B-SERIES-MM-4

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Maintenance Manual Fuel/Hydraulics: BHT-206A/B-SERIES-MM-4

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BHT-206A/B-SERIES-MM-4

FOR MODELS 206A, 206B, AND 206B3 HELICOPTERS

COPYRIGHT NOTICE Bell

PROPRIETARY RIGHTS NOTICE

These data are proprietary to Bell Helicopter Textron, Inc. Disclosure,

Additional copies of this publication may be obtained by contacting:

Paragraph Chapter/Section Page

28-l Fuel system (helicopter S/N 4 through 3566) .................. 28-00-00 3

28-l 5 Fuel distribution ........................................... 28-00-00 17

CONTENTS - MAINTENANCE PROCEDURES (Cont)

Paragraph Chapter/Section Page

28-40 Drainvalve ............................................... 28-00-00 32

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

28-1 Troubleshooting fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

28-2. FUEL SYSTEM (Helicopters S/N 3567

Table 28-l. Troubleshooting fuel system

INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

Insufficient or no fuel pressure to Turn on boost pumps and fuel

Boost pump inoperative Check pump per Chapter 96.

Fuel contaminated Refer to Allison Engine Company

Defective shutoff valve, or valve Replace valve. Refer to Chapter 96

Fuel quantity/pressure circuit Check and replace breaker

Loose circuit connections Tighten connections

Defective indicator Replace indicator

Improper resistance setting on R5 Check resistance and calibrate

Defective tank unit system Replace tank unit and recalibrate

Transducer failure Replace transducer

Fuel filter caution light on Clogged filter Refer to engine manual

Fuel boost pumps fail to operate Electrical malfunction Refer to Chapter 96

HELICOPTERS S/N 4 THROUGH 3566

Figure 28-1. Fuel system (Sheet 1 of 2)

DETAIL B SCARF FACING AFT

1. Fuel shutoff valve 9. Forward fuel boost pump

A2 Helicopters S/N 154 through 3566.

Figure 28-l. Fuel system (Sheet 2)

1. Airframe fuel filter

HELICOPTERS S/N 3567 AND SUBSEQUENT 206A/BS-M-28-2-1

Figure 28-2. Fuel system (Sheet 1 of 2)

\ SCARF FACING AFT

DRILL ,0.25 IN. (6.35 mm) DIA 1.0 IN.

HELICOPTERS S/N 3567 AND SUBSEQUENT

Figure 28-2. Fuel system (Sheet 2)

Fuel cell is a bladder type unit installed in the fuselage

HANDLE FUEL CELL WITH EXTREME CARE

HELICOPTERS S/N 4 THROUGH 660, AND 672 THROUGH 715

Figure 28-3. Fuel system schematic (Sheet 1 of 3)

HELICOPTERS S/N 661 THROUGH 671, AND 676 THROUGH 2211

Figure 28-3. Fuel system schematic (Sheet 2)

ENGINE FUEL PUMP

HELICOPTERS S/N 2122

Figure 28-3. Fuel system schematic (Sheet 3)

3. Remove seat cushions and seat backs (Chapter 25).

14. Remove fuel shutoff valve (14) (paragraph 28-26,

4. Inspect fuel cell for leaks after installation. Refer to NOTE

DO NOT USE SOAPS OR STRONG NOTE

7. Lace bottom forward side of fuel cell (3) to fuselage

16. Connect electrical connections to forward and aft

NOTE 2. Install screws securing cap and adapter assembly

6. Install hose (10) to two check valves (8).

13. Inspect fuel cell (3) installation for security.

28-15. FUEL DISTRIBUTION. 1. Disconnect battery and defuel helicopter (Chapter

3. Remove eight bolts (11) with seven washers (12)

3. Position packing (10) on check valve (4) and install.