INSTALLATION INSTRUCTIONS EXTERNAL AUXILIARY FUEL SYSTEM P/N

Transcription

1 INSTALLATION INSTRUCTIONS EXTERNAL AUXILIARY FUEL SYSTEM P/N Page 1 of 45

2 List of Revisions Rev. Date Pages Description Approved IR 09/12/05 All Initial Release N/C All Updated to Apical Format P. Bravo 3 Revised Figure Revised Section Inserted New Figure Revised Section Revised Section Inserted New Figure Revised Section Inserted New Figure Revised Section Revised Section Revised Section Inserted New Figure Revised Figure Revised Figure Inserted New Figure Inserted New Figure Revised Note Page 2 of 45

3 THE FOLLOWING LIST OF DRAWINGS ARE REQUIRED TO INSTALL THE ERA EXTERNAL AUXILIARY FUEL SYSTEM ON THE BELL HELICOPTER MODELS 412 S/N & SUB (EP): Fuel Tank Installation Tank Assy Fuel Return System Installation Ground Receptacle Installation Fuel Return Cavity Installation Installation Fuel (Block) Mounting Plate Panel Assy, Aft Fuel Cell Floor Installation Float System Modification Installation Aft Lug Cavity Aux Fuel Airframe Wire Routing Aux Fuel Electrical Diagram /212 Aux Fuel Electrical Diagram Installation Overhead Circuit Breaker Panel Assy Installation Dual Bead Sensor/Impact Switch Control Panel Installation Rotorcraft Flight Manual Supplement Installation Instructions Maintenance Instructions Illustrated Parts List Figure 1-0 Page 3 of 45

4 GENERAL S This installation procedure will provide step by step instructions to install the Era External Auxiliary Fuel System on the Bell 412 SP, HP & EP Models S/N's and subsequent. Refer to Bell Helicopter's Standard Practice Manual for torque values not covered by this instruction procedure. 1-2 PREPARATION FOR MODIFICATION (Dwg ) 1. Defuel aircraft - refer to Bell Maintenance Manual, Chapter 12 for defueling instructions. 2. Disconnect electrical power. 3. Remove L/H forward crew seat and other cabin seating as necessary to access and remove panels shown in Figure Remove L/H side panel from center console. 5. Remove wire cover on center windshield post. 6. Open left and right overhead circuit breaker panels. 1-3 AIRFRAME ELECTRICAL HARNESS INSTALLATION (Refer to Figs. 1-2, 1-3, 1-4 & 1-5) (Dwg ) 1. Beginning aft of Sta and inboard of BL 14R, route the electrical harness with overhead console panel connector 28P10, control panel connector 28P1 and dual bead / impact switch connectors 28P3/28P2 forward through center console as shown in Figure 1-2 and Figure Locate the control panel connector 28P1 and wire QA49A22 in the center console if the control panel is to be mounted in the center console. If the control panel is to be mounted on top of the glareshield continue routing connector 28P1 to the top of the glareshield. 3. Locate the dual bead / impact switch connectors 28P2/28P3 for installation in the nose section. Page 4 of 45

5 4. Continue routing connectors 28P1 (control panel) and 28 P10 (overhead console) up through glareshield. Separate 28P1 on top of glareshield and continue routing 28P10 & QA49A22 up existing center windshield wire harness to overhead circuit breaker panel. Figure 1-1: Preparation for Modification Page 5 of 45

6 Figure 1-2: Electrical Wire Harness Installation Page 6 of 45

7 Figure 1-3: Electrical Wire Harness Installation Page 7 of 45

8 Figure 1-4: Ground Stud Installation Page 8 of 45

9 THE INSTALLATION OF THE AUXILIARY TANK WIRING SHOULD FOLLOW EXISTING WIRE HARNESS ROUTING WHEN PRACTICAL. CARE SHALL BE EXERCISED TO PREVENT PLACING THE HARNESS IN AN AREA WHERE MECHANICAL DAMAGE IS LIKELY. USE TY-WRAPS AND SPACERS TO ATTACH AUXILIARY TANK WIRING HARNESS TO EXISTING WIRE HARNESS ASSEMBLIES. REFERENCE Figure 1-5. GROUND WIRES FROM CONNECTORS 28J7 & 28J8 WILL BE MOUNTED ON (4) GROUND STUDS INSTALLED ON BULKHEAD AT STA 74.4 BL 4-7R. REFER TO Figure 1-4. Ground wires from: 28J7 Connector 28J8 QA62A20N Sump drain switch ground QA67A20N QA36A20N Fuel quantity ground Q47A20N LA4A20N Step lights ground LA5A20N QA58A20N Electric sump drain ground QA63A20N QA59A20N Sump drain switch ground QA64A20N AQ33A20N Pump ground QA44A20N 5. At STA. 74.4, route the left portion of the aux. tank wiring harness with connectors 28J7 left tank, 28P5 left pressure switch, 28P6 right pressure switch & 28P4 fuel shutoff valve, following existing wire harness assemblies. Connector 28J7 for the left tank will route to the existing utility light cavity located at STA. 120 on the left side. Connectors 28P4, 28P5, & 28P6 will continue aft following existing wire harness assemblies through STA. 178 and inboard to secondary access panel located between STA's 178 & 211, BL 14L & BL 14R. 6. Route connector 28J8 outboard from STA through BL14R following existing wire assembly to utility light installation located at STA. 120 below the cabin floor. 7. Secure wire harness to existing wire harness assemblies with ty wraps and spacers. Refer to Figure 1-5. Page 9 of 45

10 1-4 OVERHEAD CIRCUIT BREAKER (Dwg ) 1. The connector 28P10 will be connected to the overhead circuit breaker box. Overhead circuit breaker box installation instructions are shown in paragraph Install power connector 28P9. Figure 1-5: Wire Harness Attachment 3. Route power connector 28P9 wires QA212 to existing 28V DC essential Buss Route wire LA 154A22 overhead circuit breaker overlay light to TB3 terminal No. 2 located in overhead console. Route ground wires QA50A20N & QA57A20N to ground stud in overhead circuit breaker box. Page 10 of 45

11 1-5 CONTROL PANEL (Dwg ) 1. If the control panel is mounted on the glareshield, route the control panel overlay light wire QA49A22 to BHT terminal board 27, terminal No. 5-9 for the engine instruments lighting (5 volts). Bell 412 S/N & 212. For Bell 412 S/N and subsequent route wire QA49A22 to terminal block 8TB1 and any vacant 5 volt pin controlled by the engine instrument light rheostat. 2. Route wire QA49A22 to BHT terminal board 13; terminal 5, 6, 7 or 8 for Bell 205A-A1 glareshield installation. 3. If the control panel is mounted in center console, route the control panel overlay light wire QA49A22 to BHT terminal board 12. Terminal No. 1-6 for console instrument lighting (28 volts). Bell 412 S/N , Bell 212 & 205A-A1. For the Bell 412 S/N and subsequent route wire QA49A22 to terminal block 8TB1 and any 24 volt pin controlled by the pedestal light rheostat. 4. Fabricate 2 ground studs for the control panel and G-switch installation. Ground the following wires to terminals listed below. Ground Terminal #1 QA25A20N - QTY IND CASE GROUND QA21A22N - LOW FUEL CASE GROUND QA7A22N - G-SWITCH CASE GROUND Ground Terminal #2 QA26A20N - CONTROL BOX CASE GROUND QA28A20N - CONTROL BOX CASE GROUND QA19A22N - LEFT FUEL LOW QA20A22N - RIGHT FUEL LOW THE CONTROL PANEL INSTALLATION POSITION HAS BEEN VERIFIED BEFORE DELIVERY OF THIS KIT. THE FOLLOWING PART NUMBERS ARE FURNISHED TO ENSURE THE CORRECT OVERLAY IS INSTALLED ON THE CONTROL PANEL. THE GLARESHIELD INSTALLATION REQUIRES OVERLAY P/N (5 VOLTS). CENTER CONSOLE INSTALLATION REQUIRES OVERLAY P/N (28 VOLTS). Page 11 of 45

12 1-6 UTILITY LIGHT MODIFICATION 1. The existing utility light installation located at STA. 120 below the cabin floor is modified to accept connectors 28J7 left side & connector 28J8 right side. Reference Figure 1-6 and Figure 1-7. Figure 1-6: Utility Light Modification Page 12 of 45

13 Figure 1-7: Utility Light Modification Page 13 of 45

14 2. Cut wire L125C22 left utility light and wire L125B22 right utility light near utility light. 3. Remove grommet from utility light cavity. 4. Enlarge hole in utility light cavity to accept connector 28J7 or 28J8. INSTALL THE CONNECTORS WITH THE LARGE KEYWAY POINTING INBOARD FROM THE AIRCRAFT. 5. Install connector 28J8 on the right utility light housing. 6. Install connector 28J7 on the left utility light housing. 7. Install light wire L125C22 into pin W on connector 28J7 and light wire L125 B22 into pin W on connector 28J8. 8. Install ground wires LA4A20N from 28J7 and LA5A20N from 28J8 at ground studs fabricated at bulkhead located at STA Refer to Figure Install ground wires QA33A20N and QA44A20N at ground studs fabricated at bulkhead located at STA BL Install ground wires QA36A20N and QA47A20N at ground studs fabricated at bulkhead located at STA BL4.7. Refer to Figure Remove the end caps from the utility light P/N Remove electrical wire soldered to center conductor. 12. Install wire LA7A20 to the left utility light center conductor. 13. Install wire LA6A20 to the right utility light center conductor. 14. Reinstall caps on utility lights. Page 14 of 45

15 THE UTILITY LIGHTS, WITH ERA JUMPER PLUG 28P7A & 28P8A, ARE INSTALLED WHEN THE AUXILIARY TANKS ARE REMOVED FROM THE AIRCRAFT. 1-7 SUMP SWITCH DRAIN MODIFICATION (Dwg ) THE EXISTING SUMP DRAIN SWITCHES LOCATED ON THE SIDE OF THE AIRCRAFT ARE DE-ACTIVATED AND RELOCATED TO THE AUXILIARY EXTERNAL TANKS SO THE MAIN FUEL SYSTEM AND AUXILIARY SYSTEM CAN BE SAMPLED WHEN THE EXTERNAL TANKS ARE INSTALLED. WHEN THE AUX. TANKS ARE REMOVED AND THE JUMPER PLUG / UTILITY LIGHT ARE INSTALLED THE EXISTING SUMP DRAINS (AIRCRAFT) ARE RE-ACTIVATED. Bell 412 & 212 Right Sump Switch - Reference Figure Locate wires Q35B22, Q36B22, and Q38A22N. These wires are installed on the existing right sump drain switch on the aircraft. 2. The Q38A22N, and original ground wire should be removed from its ground point and spliced into the new Q38A22N wire that is to be installed into pin (a) of connector 28J8. 3. The Q36B22 wire should be cut and spliced back together with the new wire QA65A20 that is to be installed in Pin T of connector 28J8. 4. The wire Q35B22 should be cut and the end that goes down to the sump drain switch, terminal #3 should be spliced to Q35C22 that is to be installed in Pin S of connector 28J8. 5. The Q35B22 wire end that goes forward to the power source is spliced into the QA66A20 that is to be installed into Pin U of connector 28J8. Page 15 of 45

16 INSTALLATION INSTRUCTIONS Bell 412 & 212 Left Sump Switch - Reference Figure Locate the wires Q28B22, Q27B22 and Q30A22N. These wires are coming off the existing sump drain switch on the aircraft. 7. The Q30A22N, an original ground wire, should be removed from its ground point and spliced into the new Q30A22N wire that is installed in pin (a) of the junction connector 28J7. 8. The Q28B22 wire should be cut and spliced back together with the new Q60A20 wire that is installed in pin T of the junction connector 28J7. Figure 1-8: Sump Switch Modification Page 16 of 45

17 9. The wire Q27B22 should be cut, and the end that goes down to the sump drain switch terminal #3 should be spliced to Q27C22 that is installed in pin S of the junction connector 28J The Q27B22 wire end that was cut and goes forward to the power source is spliced into QA61A20 that is installed in pin U of the junction connector 28J DUAL BEAD / IMPACT SWITCH INSTALLATION (Dwg ) (Dwg ) 1. Install the dual bead / impact switch assembly P/N in the nose of the aircraft. The switch must be mounted to a structural component as shown in Figure INSTALLATION OF THE UPPER LEFT / RIGHT AFT ATTACHMENT CAVITY P/N / 002 (Dwg ) 1. Locate and remove panels P/N R/H and L/H located at STA. 172, BL47 R&L, WL To locate and drill the 20 holes, push the lug cavity up and aft until contact is made between the top of the lug cavity and A/C skin. See Figure Mark a light line on A/C skin above lug cavity. Drop the lug cavity.25 inch. 3. Mark and drill at least two holes starting mid range of the vertical bolt path on each end. 4. After the two holes are located and drilled, install the panel, previously removed, on top of the lug cavity and reinstall the assembly. Tighten the two screws until the lug cavity is firmly seated to the A/C structure. 5. Drill the remaining holes alternating between upper and lower holes on the vertical ends of the panel see Figure After each hole is drilled, install a screw and seat cavity against A/C structure. 6. Drill the remaining upper and lower horizontal line of holes. 7. Remove the cavity and panel assembly. Deburr the holes in the lug cavity and trim edges as required. Page 17 of 45

18 INSTALLATION INSTRUCTIONS 8. Temporarily reinstall the lug cavities. 9. Using masking tape or other suitable tape, install the aft lug P/N /002 on the lug cavities to hold them into position until the tanks are installed. 10. Installation of aft lug attachments are accomplished in Step 1-16, Installation of Tank Assemblies. Figure 1-9: G-Switch & Dual Bead Installation Page 18 of 45

19 Figure 1-10: Aft Lug Cavity Installation. Page 19 of 45

20 Figure 1-11: Aft Lug Cavity Installation 1-10 CONTROL PANEL MOUNTING ON GLARESHIELD (Dwg ) 1. The control panel cover P/N is designed to pick up 2 ea. existing rivets on the glareshield. Drill out these 2 rivets and enlarge the holes to a #10 diameter drill. Reference Figure Locate and drill the 3rd hole to align with the single insulator on the bottom of the control panel cover. Reference Figure Install 2 ea. braces P/N from the control box to the center windshield post picking up existing fasteners. Reference Figure Install control panel OVERHEAD CIRCUIT BREAKER PANEL ASSEMBLY (Dwg ) Page 20 of 45

21 THE EXISTING OVERHEAD CIRCUIT BREAKER PANEL IS ASSEMBLED USING COUNTERSUNK (426 TYPE) RIVETS (EARLY MODELS) OR ROUND HEAD (470 TYPE) RIVETS (LATER MODELS). THE PANELS WITH ROUND HEAD REVITS WILL REQUIRE THE HINGE ON THE AUX FUEL CIRCUIT BREAKER TO BE MODIFIED. 1. The aux fuel circuit breaker panel will be mounted on the left side of the existing overhead circuit breaker panel using 2 of the 3 existing nut plate assemblies as provided. Ref. Figure 1-13 and Figure 1-14 and drawing Select and drill out 4 rivets, evenly spaced to match aux fuel circuit breaker panel hinge. 3. Fabricate a template as shown in Figure 1-13 to pick up the existing upper 2 nut plates and the 4 rivet holes drilled out in the previous step above. 4. Transfer this template to the aux fuel circuit breaker panel and drill the 4 holes into the hinge assembly. 5. Enlarge the 4 holes in the hinge assembly to #10 hole. Countersink from the inside, the 4 holes to accept the MS screw. 6. Enlarge the 4 holes on the aircrafts overhead circuit breaker panel to a #10 hole. 7. Install 4 each click bond nut plate assemblies as shown on drawing Mix click bond adhesive in accordance with manufacturers instructions written on the packet. 8. Modify the hinge on the aux fuel system circuit breaker panel, if required, to provide clearance for the 470 type head rivets. 9. Touch up hinge with paint as required. 10. Wire brush a minimum of 2 attachment points on the aux fuel circuit breaker hinge and corresponding points on the overhead circuit breaker panel to provide a bond and ground in accordance with MIL-B-5087 Class H Paragraph Install the aux fuel circuit breaker panel as shown on drawing Page 21 of 45

22 Figure 1-12: Control Panel Mounting on Glareshield Page 22 of 45

23 Figure 1-13: Template for Installation of Overhead Circuit Breaker Panel Page 23 of 45

24 . Figure 1-14: Installation of Overhead Circuit Breaker Panel Page 24 of 45

25 INSTALLATION INSTRUCTIONS 1-12 INSTALLATION OF FUEL FUEL QUANTITY DECAL (Dwg , Sheet 7) 1. Install the appropriate fuel quantity decal, next to, or below the R/H fueling point. Reference Figure Figure 1-15: Fuel Quantity Decal Installation Page 25 of 45

26 INSTALLATION INSTRUCTIONS 1-13 INSTALLATION OF FAIRING ASSEMBLIES (Dwg ) TEMPORAILY INSTALL THE TANKS TO ALIGN FAIRING FROM CAVITY TO TANKS THE BELL 412 AIRCRAFT WITH SKID MOUNTED EMERGENCY FLOTATION EQUIPMENT REQUIRES THE 2 EXTERNAL HARD MOUNTED FLOAT LINES BE RELOCATED INBOARD. SEE CHAPTER Position left and right fairings to match existing nut plates on cavity. Detail A, Figure Align outboard end of fairings to pick up 3 existing holes on inspection plate as shown in Detail B, Figure The cover P/N / 002 should fit and align with the tank fairings when the aux. tanks are installed. Ref. Figure FUEL RETURN CAVITY INSTALLATION (Dwg ) TEMPORARILY INSTALL TANK AS PER SECTION 1-16, STEPS 1-9. ENSURE AIRCRAFT HAS BEEN PROPERLY DEFUELED. 1. Remove the 2 access covers, Bell P/N These covers are replaced with Era composite cavities P/N / Position, trim and drill the composite cavities to fit the bolt circle for the access covers. See Drawing and Figure THE LARGE FRANGIBLE FITTING WILL BE ON THE AFT SIDE WHEN CORRECTLY INSTALLED. Page 26 of 45

27 3. Drill the composite cavities to pick up nine (9) of the existing bolt circle nut plates. 4. Drill 3 additional holes through the composite material and A/C skin just outboard of the frangible fittings on right and left sides. See Era Dwg , Detail A. 5. Remove composite cavities; debur all holes. 6. Install 5 ea. nut plates on left and 5 ea. nut plates to right aircraft skin. See Figure 1-18 and Dwg Temporarily reinstall the composite cavities. Trim as required to provide adequate edge distance for screws and clearance from drain lines, etc. 8. Remove composite cavities AFT CENTER FUEL CELL (Refer to Figure 1-19 and Figure 1-21) 1. Disconnect fuel lines (5) & (33). 2. Remove bolts (20), washers (41) & spacers (19), retainers (47) from fittings (46). Remove fittings (46). 3. Remove countersunk screws (48) from plate assembly (46). Remove plate (6). 4. Modify the Bell honeycomb panel (4) in accordance with Era Dwg Assemble the stand pipe (2) to the fitting (3) with gasket (17), bolts (14) & washers (15). Torque these bolts to inch lbs. 6. Install fitting (3) with gasket (12) into fuel cell using screws ( ) removed in step 3 above. Torque these screws to inch lbs. Refer to Era Dwg Install Era panel (4) using existing washers (31), screws (30). Torque these screws to inch lbs. 8. Install fitting (1) with O ring (18) into aft right bottom side of the fuel cell using bolts (20) washers (41) spacers (19) & retainers (47). Torque these bolts to inch lbs. Page 27 of 45

28 9. Install hose assemblies (33) & (5). 10. Install preassembled check valves and pressure switch bracket (21) to bottom of panel assembly (4) as shown on Era drawing and Figure Route hoses (10) & (11) from bracket assy (21) to fitting (1). Install hoses and attach add adel clamps as required. 12. Route hoses (8) & (9) to the left & right fuel return cavities (44) & (43). 13. Install hoses (8) & (9) and secure with adel clamps as required. 14. Route hoses (6) & (7) from the fitting assy (3) to the left & right fuel return cavities (44) & (43). 15. Install hoses (6) & (7) to the return cavities and install adel clamp as required. 16. Install pressure switch connectors (34) & (35) to the pressure switches (26). 17. Install L/H & R/H fuel return cavities (43) & (44) as shown on dwg Install oil drain line extensions as shown on dwg Page 28 of 45

29 Figure 1-16: Fuel Return Cavity Installation Page 29 of 45

30 Figure 1-17: Fuel Return Cavity Installation Page 30 of 45

31 Figure 1-18: Fuel Return Cavity Installation Page 31 of 45

32 Figure 1-19: Fuel System Installation Page 32 of 45

33 Figure 1-20: Check Valve Installation Page 33 of 45

34 Figure 1-21: Fuel System Installation Page 34 of 45

35 1-16 INSTALLATION OF TANK ASSEMBLIES P/N /002 THE BELL 412 AIRCRAFT WITH SKID MOUNTED EMERGENCY FLOTATION EQUIPMENT REQUIRES THE 2 EXTERNAL HARD MOUNTED FLOAT LINES BE RELOCATED INBOARD. SEE CHAPTER Initial tank installation is made at the aircraft's upper hard points at STA and STA With the tank's lugs positioned forward of the aircraft's hard points, temporarily install the NAS bolt at STA and the AN4-16A bolt at STA THIS CONFIGURATION WILL ALLOW THE TANK ATTACHED TO SWING FREELY FOR OTHER INSTALLATIONS. CAUTION ATTEMPTS TO SWING TANK WITH TANK ATTACHED AT ANY OTHER POINT MAY CAUSE DAMAGE. IF TANK DOES NOT SWING FREELY, DO NOT USE FORCE. 3. Connect tank wire harness electrical connector to airframe electrical receptacle at STA (Tank must be in present swinging status to allow routing of tank wire harness electrical connector.) TANK ELECTRICAL CONNECTOR MUST BE CONNECTED TO ALLOW FITTING OF LINKS AND TANK LUGS. DO NOT CONTINUE UNTIL STEP 3 HAS BEEN PERFORMED. 4. Swing the bottom of the tank into position and install AN5-16A bolt at forward upper hard point at STA Position tank as far aft as possible so that upper tank lugs contact airframe hard points in Step 2. Page 35 of 45

36 1- AT THIS TIME AN INITIAL POSITIONING OF THE UPPER AFT LUG P/N AT STA CAN BE MADE BY TAPING THE LUG IN THE AFT CAVITY ASSEMBLY. PREPARE LOWER LINKS FOR BONDING BY WIRE BRUSHING BOTH SIDES OF LINK TO PROVIDE BONDING AND GROUNDING IN ACCORDANCE WITH MIL-B GLASS L&R. USE A CONVERSION COATING CONFORMING TO MIL-C-5541 CLASS IA ON EXPOSED AREAS. 6. Install the two attachment links P/N to the fwd lower hard point. BEFORE ATTEMPTING TO DRILL LOWER TANK MOUNTING LUGS, REVIEW Figure 1-23 FOR VARIOUS CLEARANCE REQUIREMENTS. TRIMMING OF THE LUGS MAY BE REQUIRED. 7. While supporting the tank in position, center the attachment link on the tank's mounting lug and drill tank mounting lug to match attachment links. Use.193 inch (#10) drill bit. Install the two each AN3-12A bolts, AN960PD10 washers, and MS nuts. 8. Shim airframe hard points with AN washers so links are parallel and engage tank lug evenly. See Figure 1-23, Detail D & F. 9. Install the two attachment links P/N to the aft lower hard point at STA. 155., and repeat procedure described in Steps 7 and To mount upper aft lug (which now should be taped into lug cavity), position the tank as far aft as possible and place.048 inch of shims on aft side of tank lug. Untape and move aft lug up against shim. Mark at least 2 of the 8 lug mounting holes on the lug cavity assembly. 11. Remove the bolts from the forward lower attachment lug and from the forward upper lug attachment at STA Page 36 of 45

37 12. Remove the bolt from the aft lower attachment lug at STA Carefully swing tank away from the airframe. 13. Disconnect electrical connector and remove tanks. 14. Remove lug cavity. 15. Drill lug cavity to match lug as marked in Step Drill and rivet top plate and back plate to lug cavity as per Drawing , Detail C or Figure 1-23, Section K-K. 17. Reinstall lug cavity and aft lug as per Drawing or Figure 1-23, Section K-K. 18. Reinstall tanks as per Section 1-16, Steps 1 through Mark aft attachment lug to align with tank lug. 20. Remove bolts as in Steps 11 and Drill aft attachment lug to match tank and debur hole. 22. Install tank as per Section 1-16, Steps 1 through Using a feeler gauge, measure and record the distance between the upper tank lugs and hard points. 24. Temporarily install bolt and STA to prevent tank from swinging during the next step. Page 37 of 45

38 THE FIRST LUG THAT CONTACTS A HARD POINT WILL BE CONSIDERED THE MASTER LUG. THE MASTER LUG WILL NOT REQUIRE ANY SHIMS BETWEEN THE HARD POINT AND TANK LUG, BUT WILL REQUIRE A.100 INCH SHIM UNDER THE NUT AND WASHER SIDE TO MAINTAIN UNIFORM BOLT LENGTH. 25. Shim as necessary between the remaining lug and hard point locations. Shim as close as possible using the shims called out in Figure Figure 1-22, Table Add additional shims as required on bolt to provide proper grip length of bolt. 27. Permanent installation of hardware at each hard point and aft attachment fitting can now be accomplished. Installation and torque should be accomplished in accordance with Figure 1-22 and Figure Install cover P/N / 002 left-hand and right-hand fuel return cavity using MS screws and AN960PD10 washers. Ref. Figure 19.. TRIM FUEL RETURN COVER TO MATCH CAVITIES AND TANK COVER CONTOUR. Page 38 of 45

39 Figure 1-22: Upper Lug Attachment Details Page 39 of 45

40 Figure 1-23: Lug Attachment Details Page 40 of 45

41 Figure 1-24: Lug Attachment Details Page 41 of 45

42 1-17 EFS SYSTEM WEIGHTS The following chart documents actual weights for each tank and airframe kit. SYSTEM COMPONENT WEIGHT DESCRIPTION P/N WEIGHT ARM MOM L/H External Tank Assy R/H External Tank Assy Airframe installation EFS UNUSABLE FUEL WEIGHT This chart documents unusable fuel for the EFS for the appropriate "in-flight" cruise attitude as shown for each model. UNUSABLE FUEL External Tank Assy's:) 412 WT ARM MOM OPERATIONAL TEST PROCEDURES - Ground Test 1. Main Fuel System Capacity at or below 225 gals. (1530 lbs.) 2. Aircraft power or external power - OFF 3. Add approximately 20 gals (135 lbs.) of fuel to each aux tanks. 4. Aircraft power or external power - ON 5. Aux tank control panel transfer pumps - ON 6. Aux tank quantity indication for L/H & R/H tank - D 7. TANK EMPTY & LOW PRESSURE Lights - Not Illuminated. 8. Main Fuel System fuel quantity gage - Increasing 9. Aux Fuel System fuel quantity gage - Decreasing Page 42 of 45

43 FUEL IN THE AUX TANKS MAY BE TRANSFERRED AT UNEVEN RATES FROM EACH TANK 10. Aux Tank TANK EMPTY & LOW PRESSURE Lights may cycle ON and OFF until fuel is transferred from the aux tanks. 11. Turn each transfer pump off after TANK EMPTY Light remains ON. REFERENCE ENCLOSED INSTRUCTIONS FOR HYSOL EA9320 AND PRECAUTIONS FLOAT SYSTEM MODIFICATION (Refer to Figure 1-25) (Dwg ) Aircraft with the skid mounted emergency flotation system installation will require the two hard lines that run from the tee near the fwd cross tube to a bracket near the aft cross tube to be modified. Two float lines are included in the installation kit for aircraft with existing emergency flotation equipment. REFER TO BELL HELICOPTER SERVICE INSTRUCTION FOR INSTRUCTION S REGARDING ALL S, CAUTIONS, & WARNINGS ASSOCIATED WITH A CHARGED SYSTEM. REFER TO BELL HELICOPTER SERVICE INSTRUCTION TO COMPLY WITH STEPS 1 THROUGH 3 BELOW. 1. Disconnect the aft left and right float line hose assemblies P/N AE K Disconnect and remove the left tube assembly P/N and right tube assembly P/N Remove the left and right aft support assemblies P/N /116. Ref. drawing , Detail A & B, and Figure Page 43 of 45

44 THE FOLLOWING LIST OF ITEMS REMOVED WILL NOT BE REINSTALLED AS PART OF THE FLOAT LINE RELOCATION TUBE ASSEMBLY TUBE ASSEMBLY SUPPORT ASSEMBLY SUPPORT ASSEMBLY FITTING 4. Temporarily install the new left and right tube assemblies P/N /010 to the forward attach tee. 5. Align the tube to provide a relocated line inboard of the aft lower hard point located at STA right and left and BL Install the angle by drilling out 2 existing rivets and replacing with angle and longer rivets. The angle may be installed facing forward or aft to accommodate alignment. See Detail B on drawing or Figure Install the offset plate P/N facing fwd or aft. 8. Install the restrictor with washer and nut into the off set plate. Install the aft hose assemblies. 9. Install 2 each tabs P/N as shown adjacent to each tube assembly. Ref. drawing or Figure Install adel clamps to tee support and tube assembly after adhesive has cured. 11. Torque all fittings, nuts and bolts to standard torque. Page 44 of 45

45 Figure 1-25: Float System Modification Page 45 of 45