Division ofTextron Inc.

BASIC ISSUE: 17 October 1975

V.Z

REVISED: 14 January 1977 SERVICE

INSTRUCTION N0. 212-59

z
CHANGED: 11 August 1978
m

-I-
SUBJECT: Auxiliary Fuel Tank Retrofit Kit

O
KIT NUMBER(s) EFFECTIVITY
212-704-101-1 Model 205A and 205A-1
S/N 30001 thru 30260

212-704-101-3 Model 212

00
S/N 30501 thru 30849

212-704-1O1-5*

*Used in conjunction with -1 or -3 kit to update existing

205-706-044-11 or -13, or 205-706-045-11 or -13, Aux. Fuel
O

Kit installation.
O

To Provide improved tank-to-fuel system connectors.

C

PURPOSE:
O

O
Z

AUTHORITY: SECTION I, INSTALLATION INSTRUCTIONS, IS FAA/DER APPROVED

AS SHOWN ON LOG OF REVISIONS/CHANGES

FLIGHT MANUAL REQUIREMENTS: No Flight Manual Supplemental Instruc-

..r

tions required when these kits are installed.

If Ownership of helicopter has changed, please forward this document to new owner.

Additional copies of this document may be obtained by contacting:

Bell Helicopter Textron

P. 0. Box 482
Fort Worth, Texas 76101

Commercial Publication
Distribution Center
SERVICE INSTRUCTION NO. 212-59

LOG OF REVISIONS/CHANGES
SECTION
SECTION III SECTION IV

-00
SECTION II

C/)
REV/
DATE Page Nos. . FAA/DER Approval Page Nos. Page Nos. ' Page Nos.
CHG. i I

Orig. 10/17 1-1 thru 1 Wa. 1

2-1/2-2

(.J
75 1-11 / 1
1- 12

2-1/2-2 3-1 thru

Y-'
REV 1-14- 1-1 thru 4-1 thru
A 77 1-11/1-12C.nat 3-2 4-3/4-4

CHG 8-11- -2,1-3, cam.

A-1 78 -6, 1-7,
nd 1- 8.

EXPLANATORY NOTES:

1. Changes to other than Section I do not require FAA/DER Approval.

2. REVISIONS, identified by alpha characters, supersede the previous issue in its entirety.
3. CHANGES, identified by numerical characters, supersede only a portion of the previous issue.
Insert latest changed pages. Destroy superseded pages.
4. The portion of the S. I. content affected by the current change or revision is indicated by a
°a'

vertical line in the outer margin of the page for textual material, a "pointing hand" in the body
of an illustration, and a shaded border around changed portion of a wiring diagram. An added
illustration, or one having extensive changes, is identified by a vertical line in the outer margin.
ii
 SERVICE INSTRUCTION NO. 212-59

REV/
CHG. REASON Prepared By:

.r{
Orig. To provide installation instructions R. W. LeVine

REV To update superseded parts. R. W. LeVine

A
CHG Engineering update. R. W. LeVine
A-1

iii/iv
 SECTION I
PART I

SERVICE INSTRUCTION NO. 212-59

SECTION I

PART I

212-704-101-1 or -3

AUXILIARY FUEL TANK RETROFIT KIT

H
NOTE

If kit 212-704-101-5 is being installed concur-

H

(D
(1)
rently with this kit, move forward and work Part
}-1

X.1
II before Part I of this Service Instruction.
H

PREPARATION.
F-3
F-'

1.

4-a
Disconnect battery and external power from air-
L=1

4-)

a.

}-I
craft.

Ft,
4-1
b. Drain and purge aircraft fuel system. (Refer to
'Z3

Maintenance and Overhaul Manual.)

Remove access doors on bottom skin to gain ac-
4-i

C.
4-i

cess to fuel system in area to be modified, Station 158.

4-i
(D

d. Remove seats from aft cabin area.

(See figure
F~-'

Install new crossover assemblies as follows:

H

2.

1-1.)
1-1
F-'

NOTE

If Part II has been worked, disregard steps

a. and b.

a. Remove screws securing the two existing covers (205-

r-I

F'-
F-'

062-618) to floor panels, station 158, buttock line 18, right and
(D

left.
 SECTION I

H
PART I SERVICE INSTRUCTION NO. 212-59

'.b
Remove the clamps (4563-125) securing the cover

L.()
'z3
b.

t3'
assemblies to the existing fuel crossover assemblies and remove

(ti
the covers from the helicopter.

C. Disconnect attaching lines from the right crossover

I-'

Q-.
(300184-3), remove attaching hardware and remove crossover from

helicopter.
Install crossover (300184-11) using one packing

F-'
t'`'
d.

fit'
H

(MS29513-236), one packing (MS29513-124), one packing

'z3

(MS29513-223) and previously removed hardware.

f-4

(D
NOTE
t3'

Torque bolts 50 to 70 inch-pounds.

H

Reconnect attaching lines to crossover assembly.

H

e.

NOTE
E-+

If auxiliary fuel tank, retrofit kit

H
err

-r1

212-704-101-5, is being installed con-

currently with this kit, disregard fol-

H

lowing steps (f) and (j).

Install new cover assembly (205-062-618-15), using
o-,
I-1

1 f.

previously removed hardware, and connect to adapter on crossover

1-t

assembly.
r-1

Disconnect attaching lines from left crossover as-

I-h
:z'

g.
.-I

sembly (300184-1, for model 205), (300289-1, for model 212), re-
Fit

10-+
F-h

move attaching hardware and remove crossover assembly from ship.

(CS

1-2 Changed: 11 August 1978

 SERVICE INSTRUCTION NO. 212-59

L(1
SECTION I
PART I

Install crossover assembly (300184-9, for model

t)'
h.

205), (300289-7, for model 212), using one packing (MS29513-236),

L(1
`.j
r-1
one packing (MS29513-124), one packing (MS29513-223) and pre-
viously removed hardware.

NOTE

Torque bolts 50 to 70 inch-pounds.

i. Reconnect attaching lines to crossover assembly.
j. Install new cover assembly (205-062-618-15), using

L(1
'

previously removed hardware, and connect to adapter on crossover

assembly.

3. INSTALLATION OF VALVE - VENT (4150-1-2)

On 212 Helicopters, SIN 30501 thru 30614, perform

r-1
1-'
a.
...

(See figure 1-2

H-'

the following: figure 1-2)

b. Open right and left engine cowling. Remove lower

panels (212-061-207) of plenum chamber in right and left engine

'.3
compartments.

Remove right and left flight idle solenoids (209-

F-'
F11

C.

062-761).
-r1

4-4

Disconnect right and left throttle push-pull tubes

'3"

F-'
d.

(212-060-724) from throttle jackshafts (212-060-737). Disconnect

.s"

right and left throttle jackshafts (212-060-737) from floor assem-

4-I

blies (205-030-173) by removing screws securing fittings (212-060-

r-1

--1

729) to floors. Remove each throttle jackshaft (212-060-737) along

4-(

with inboard and outboard fittings (212-060-729) as an assembly.

Changed: 11 August 1978

4.J

1-3
 SECTION I
PART I SERVICE INSTRUCTION NO. 212-59

CAUTION

Do not move jackshaft excessively dur-

ing removal, or damage to bearings in

fittings (212-060-729) may result, nec-

essitating replacement.

4-1
Disconnect aft end of fire extinguisher tube (212-060-
4-1
e.

s~'
932) and aft end of inboard fuel drain tube, located in the right

'7j
--I
:3,

H
engine compartment above the throttle jackshaft.
(D

f. Disconnect the three fuel lines in the left engine

(1)
(CD

compartment above the left throttle jackshaft. This action is re-

4-I
quired in removal of the left floor assembly (205-030-173).
4-1

r-q
Remove screws securing right and left floor assem-

4-I
9-
H-'

blies (205-030-173) to the helicopter, remove floor assemblies.

.C"

h.
4-1

Disconnect two existing fuel vent tubes (212-060-

646-1) (left side) and (212-060-649-1)
.C",

(right side) from two elbows

4-I

(MS20762-D12-16) located on top of each aft upper fuel cell.

,S'
(CD

((DD

i. Remove both elbows by removing the existing eight

bolts (AN4-4A) and eight washers (AN960PD416L) which secure the two
t-+
I-'

elbows to the fuel cells and existing brackets (205-060-641-3

-HI

and
-4).
 SERVICE INSTRUCTION NO. 212-59 SECTION I
PART I

Install new packings (MS29513-216) in plates (205-

4-J

r-1

r-1
(CD
'IT
060-640) and install two vent valves (4150-1-2) using existing

.i.
hardware previously removed.

k. Reinstall both plates (205-060-640) to fuel cells

using existing hardware and reconnect the two existing fuel vent

4-I

r-1
-r1
tubes (212-060-646-1)(left side) and (212-060-649-1) (right side).

Clean old sealant from fuel cell covers and heli-

'-1

r-1
1.

(1)

',>

}-I
(OD
l-h

copter airframe.

CAUTION

Ensure that old sealant or other foreign objects

4-4

4-4

}-I

r-1
DO NOT enter fuel cell compartments during instal-
I.)

.C4
lation.
`.l

4-1

.i~
Apply a bead of Pro-seal to helicopter airframe where

.}J
M.

}-I
(1)

fuel cell cover is to be installed, and install right and left fuel
cell covers.

Reconnect three fuel lines in left engine compartment.

r-1

4-1

n.

o. Reconnect fire extinguisher tube (212-060-932) and

aft end of inboard fuel drain tube located in right engine compart-
.I)
f-'

ment.

Install right and left throttle jackshafts, right

r-1
H

p.
r-1
F-'

and left flight solenoids, and reconnect throttle push-pull tubes

-4J

Ian

(212-060-724).

Install lower panels (212-961-207) of plenum chambers.

r-4-4

C3'

q.
$-I
 SECTION I SERVICE INSTRUCTION NO. 212-59
PART I

4. RESTORATION AND INSPECTION.

4-1
Service fuel system.

4-)
a.

4-I
Inspect fuel system for leaks.

1-I

4-I
b. (Refer to Section III)
(D
Install access doors.
H

C.
12,

d. Install seats in aft cabin area.

111
e. Reconnect battery.

PARTS REQUIRED PER HELICOPTER.

H

5. H
QUANTITY PART NUMBER NOMENCLATURE
F-'

212-704-101-1 Auxiliary Fuel Tank

(t{
1
Retrofit Kit, Consisting

N4-1
(PC-5) of:

1 212-704-101-3 Auxiliary Fuel Tank

1-7
rte
Retrofit Kit Consisting
(PC-5) of:
2 *4150-1-2 Valve-Vent

I 2 2 205-062-618-15 Cover Assy

1 300184-9 Crossover Assy
1 1 300184-11 Crossover Assy
1 300289-7 Crossover Assy
1 706B2 (4 oz.) Proseal
2 2 MS29513-124 Packing
2 *MS29513-216 Packing
2 2 MS29513-236 Packing

2 2 MS29513-223 Packing

1 1 212-59 Service Instruction

6. WEIGHT AND BALANCE.

4-I

The installation of the 212-704-101-1 or 212-704-101-3

4-1

t5'

kit has negligible effect on weight and balance.

.tom

*To be installed on Model 212 SIN 30501 thru 30614.

1-6
-4J

Changed: 11 August 1978

 SERVICE INSTRUCTION N0. 212-59 SECTION I
PART I

REMOVE: 205-062-618-9 COVER ASSY

r)-
4563-125 CLAMP AND GASKET

m
ADD: r+ 205-062-618-15 COVER ASSY
,J (INSTALL USING EXISTING
HARDWARE) -
REMOVE: 205-062-618-9 COVER ASSY
4563-125 CLAMP AND GASKET
205-062-618-15 COVER ASSY
(INSTALL USING EXISTING
HARDWARE)

mor
BL
0.00

LL
REF

WL
22.00
REF

00

REMOVE: 300184-1 CROSSOVER ASSY

l

300289-1 CROSSOVER ASSY

MS29513-236 PACKING
0.1

ADD: 300184-9 CROSSOVER ASSY

----

BL 300289-7 CROSSOVER ASSY i

14.00 MS29513-236 PACKING

REF BL
MS29513-124 PACKING
u.1

14.00
MS29513-223 PACKING REF
(INSTALL USING EXISTING
G)
Z
X

HARDWARE)
REMOVE: 300184-3 CROSSOVER ASSY
>
>

PACKING
300184-11 CROSSOVER ASSY
.

ADD:
-

MS29513-124 PACKING
NN-

MS29513-236 PACKING
MS29513-223 PACKING
(INSTALL USING EXISTING
G)

HARDWARE)

VIEW LOOKING FORWARD

Figure 1-1. Installation of Crossover Assemblies

Changed: 11 August 1978 1_7

..
 I'd En
>1 tij
d n
H H
H
PART I

H O
SECTION

z
REMOVE: 205.060-641-3 BRACKET REMOVE: 205-060-641-4 BRACKET H
MS20762-D12-16 ELBOW 212-060-649-1 MS20 762-131 2-1 6 ELBOW

N°'
NON
205-060.640-1 PLATE TUBE ASSEMBLY (REF) 205-060-640-1 PLATE
MS295 1 3-2 1 6 PACKING MS29513-216 PACKING
(AND EXISTING HARDWARE) 212-060-646-1 (AND EXISTING HARDWARE)

A0)
ADD: 4150-1-2 VALVE VENT TUBE ASSEMBLY (REF) ADD: 4150-1-2 VALVE VENT
MS295 1 3-2 1 6 PACKING M529513-216 PACKING
(INSTALL USING EXISTING BL (INSTALL USING EXISTING
HARDWARE)- 0 . 00 (REF) HARDWARE)

111
.......................................-...........w

205-060-605-13 N
FUEL CELL (REF) I F-1
N
I
Ui
SERVICE INSTRUCTION NO. 212-59

Changed:
VIEW LOOKING FORWARD

`-\
212-59-1-2

August 1978
Figure 1-2. Valve-Vent Installation
(Model 212 5/N 30501 thru 30614) '
 SECTION I

F-1
SERVICE INSTRUCTION NO. 212-59
PART II

INSTALLATION INSTRUCTIONS

C!1

H
PART

E-1

H
II

mot'

L(1
212-704-101-5

AUXILIARY FUEL TANK RETROFIT KIT

a,'

1. PREPARATION.

4-1
a. Disconnect battery and external power from aircraft.
r-1

(13
b. Drain and purge fuel system. (Refer to Maintenance
C,'

and Overhaul Manual.)

C. Remove access door on bottom skin to gain ac-

(D

cess to fuel system in area to be modified, Station 158.

-I-1

4-)

Install new adapter assemblies as follows: (See figure 1-3

figure 1-3.)
(t3

2.

(DD

L(1
Remove the right and left auxiliary fuel tanks (205-
(t1

a.

706-044 or 205-706-045) from the aircraft.

Remove fitting (205-062-612-3) from the bottom of

(+')

b.

each tank.

Install adapter (AE98777N) using one seal (MS27194-20),

(ti

(CI

C.

one packing (MS29513-124), and previously removed hardware, to each tank.

d. Reinstall auxiliary fuel tank.

3. RESTORATION AND INSPECTION.

a. Service fuel system.

b. Inspect fuel system for leaks. (Refer to Section III.)

C. Install access doors.

d. Reconnect battery.
 H
SECTION I
PART II SERVICE INSTRUCTION NO. 212-59

4. PARTS REQUIRED PER HELICOPTER.

QUANTITY PART NUMBER NOMENCLATURE

E-+

1 212-704-101-5 Auxiliary Fuel Tank

P-,
(PC-3) Retrofit Kit

((DD
Consisting of:

4-)
1
2 AE98777N Adapter Assy

2 MS27194-20 Seal

2 MS29513-124 Packing

1 212-59 Service Instruction

WEIGHT AND BALANCE.
H

5.
4-t

.s~
The installation of the 212-704-101-5 kit has negligible

F-'
CTS
,C;

effect on Weight and Balance.

4-J

1:,
 SERVICE INSTRUCTION NO. 212-59 SECTION I
PART II

REMOVE: 205-062-612-3 FITTING

(DI-
EXISTING CLAMP AND
GASKET
ADD: AE98777N ADAPTER ASSY
MS27194-20 SEAL
A
MS29513.124 PACKING
(INSTALL USING EXISTING HARDWARE)

REMOVE: 205-062-612-3 FITTING

G)_
EXISTING CLAMP AND
GASKET
ADD: AE98777N ADAPTER ASSY
MS27194-20 SEAL
MS29 51 3-1 24 PACKING
(INSTALL USING
EXISTING HARDWARE)-

VIEW LOOKING FWD

212-59-1-3

Figure 1-3. Installation of Adapter Assemblies

1-11/1-12
SERVICE INSTRUCTION NO. 212-59 Section II

SECTION II

E-i
H
'Z,
H
OPERATING INSTRUCTIONS

(Not Applicable)

F-'
't3
"C)
 SERVICE INSTRUCTION NO. 212-59 SECTION III

SECTION III

H
H

H
H
H
H
MAINTENANCE

t31
I-'
Perform leak checks on 212-704-101-1, -3, or -5 Kit as follows:

LEAK CHECK PROCEDURE.

".4

1.

Visually inspect the racheted connector to ensure

'TS
a.

H-
positive engagement of the locking ratchets.

-44
I

-r1
'ZS

-I-)
Cap main fuel line and vent connections.
b''

b.

(D
Use regulated low-pressure, filtered, compressed air

(1)
1-0
C.

r-1
source with a manometer or accurate pressure gage and a shutoff valve.
1-1

E-1

CAUTION
H

Do not apply excessive pressure, as severe

t:7

(D

damage to cells and structure may result.

r51

1-1

(D
F-'

Q-.
If the auxiliary fuel tanks are installed concurrently
t-h

7v'
H

4-1
H

r'-1

d.
(D

with the 212-704-101-1 or -3 kit, apply pressure until gage indicates

r-I

(`7

0.5 psig in cells and crossover tubes. Shut off air source.

If the auxiliary fuel tanks are not installed with the

4-J

((DD
H

l-1

e.

212-704-101-1 or -3 kit, apply pressure until gage indicates 2.5 psig.

F-'

Shut off air source.

For the 212-704-101-5 kit, apply pressure until gage

H

f.
t1)

4-1

Shut off air source.

H

indicates 0.5 psig in cells.

g
r-1

Cells should retain their initial pressure for 15

4-1

(D
(1)

minutes in steps d through f. 1

'Z3

I-'

h. Locate and correct any leakage indicated by loss of

4-l

pressure and repeat tests until results prove satisfactory.

(D

Changed: 11 August 1978 3-1

SECTION III SERVICE INSTRUCTION NO. 212-59
H

4-I
Remove all caps and plugs used to close off system

Q.,
i.

being tested if test results prove satisfactory.

4-J

4-I

U)
j. Fuel the helicopter to capacity and visually inspect
((DD

(D

(D
connection for leaks prior to installing and securing the access

r1-
1-I

covers.

3-2 Changed: 11 August 1978

 SERVICE INSTRUCTION NO. 212-59 Section IV

SECTION IV

PARTS CATALOG I

1. GENERAL.

F-'
This section lists and illustrates assemblies, sub-assemblies,

and detail parts of subject kit.

p.)

--1
1-0

Refer to General Information Section of the basic helicopter

-4-)
1-1

I-h
"Illustrated Parts Breakdown" for detailed explanation of usage of

'Z7
t-'
F-'

(t-

this parts catalog section.

Section IV SERVICE INSTRUCTION NO. 212-59

Figure 4-1. Retrofit Kit, Aux. Fuel Tank

4-2
 SERVICE INSTRUCTION NO. 212-59 Section IV

(1) (2) (3) (4) (5) (6)

FIGURE & UNIT MODELS

INDEX PART NUMBER D E S C R I P T 10 N PER USABLE ON
NUMBER ASSY NP

000
""1
4-1 212-704-101-1 RETROFIT KIT AUX FUEL TANK .................. 1

C)0

.7- OHO
C+7
212-704-101-3 RETROFIT KIT AUX FUEL TANK .................. 1

u'1
212-704-101-5 RETROFIT KIT AUX FUEL TANK .................. 1

Ifs
'"'
- 1 AE98777N ADAPTER ASSY (91663) (USE ON -5)........... 2
t+1
MS29513-124 .PACKING.. ... ......................... 2
MS27194-20 SEAL (USE ON -5)...........................

:-M
r-I
300184-11 CROSSOVER ASSY (70628) (USE ON -1 AND -3)..

-IN
- 2 1

H.-1
- 3 MS29513-236 PACKING (USE ON -1 AND -3) ................. 2
'11/

- 4 MS29513-223 PACKING (USE ON -1 AND -3) ................. 2

-It

- 5 MS29513-124 .PACKING.. .................................. 2

r-1

205-052-618-15
r-I

- 6 COVER ASSY (USE ON -1 AND -3) .............. 2 1

- 7 4150-1-2 VALVE (81823) (USE ON -3) .................. 2
MS29513-216

000
PACKING (USE ON -3)........................

C.'
- 8 2
- 9 300184-9 CROSSOVER 70628 USE ON -1) .............. 1
M628

r-4
300289-7 CROSSOVER

."d
USE ON -3) .............. 1

Changed: 11 August 1978

4-3/4-4