1. Ferry Fuel System
Reference: Pilot Int’l PI-1200M Manual dtd 12-98

2. Outline Components Normal Operation Emergency Operation
Limitations/Restrictions

3. Components 2 Aluminum Tanks 2 Tank Drain Lines Electric/Manual Pump
2 Sets (4 total) Fuel Selector Assemblies
2 ferry tank selectors
2 aircraft fuel tank selectors
Surge Tank
Vent Line

4. Tanks 120 Gallon Capacity Three Baffles Inside To Reduce Sloshing
Serviced Through Open Port Cap
Mounted on Wooden Shoring
Drain Line Off ‘T’ Fitting on Aft Of Tank

5. Pump Electric Rotary Action (may have one or two electric pumps)
Manual ‘Wobble’ Action
Site Glass on Aft Line
Capability of 90 GPM transfer rate

6. Fuel Selector Assemblies
One set (ferry tank selector) prior to pump
One set (aircraft fuel tank selector) plumbed aft of pump
Manually operated by crew

7. Selector Valve Operation
Valves Closed
Valves Open

8. Ferry System Schematic
To Aircraft
Fuel System
Aircraft
Fuel
Tank
Selector
Valves
Pump
Ferry
Tank
Selector
Valves
Fuel
Tank
Drain Line

9. Aircraft Fuel System Interface

10. Vent System Vent Lines Run From Top Of Fuel Tanks Near Filler Caps...
To surge tank

11. Surge Tank Mounted aft of tanks
Equalizes pressure between the ferry tanks and the cabin
Contains 2 one-way check valves*.
*IN one-way check valve equalizes pressure between the tanks and the cabin during pressurized operation.
OUT one-way check valve equalizes pressure between the tanks and cabin in the event of cabin depressurization.

12. Vent System (Continued)
Through Surge Tank to Aft Vent Probe Assembly
Vent Probe Faces Forward
Has Two Drilled Anti-Ice Holes

13. Vent System Schematic
Vent
Probe
Fuel
Tank
Fuselage
Surge
Tank

14. Normal Operation Prior to Flight:
Fill the system to desired level (not more than 1 to 1½ inches from top).
Place aft end of drain lines outside cabin door and drain about 1 pint from each line into sample bottle (removes moisture).
Test ferry system on ground to purge it of air.

15. Normal Operation In the Air: Take off and climb using normal fuel.
Use fuel until mains are about ½ full.
Open the desired ferry fuel tank selector (recommend both).
Open either or both aircraft fuel tank selectors (can be used to equalize levels).
Turn on either or both ferry fuel pumps.

16. Normal Operation In the Air (continued):
Observe the quantity of fuel in the main fuel tanks - discontinue when they near full to prevent venting overboard.
Observe the fuel flow sight gauge on the ferry pump - when air bubbles appear/increase close the ferry tank selectors, turn off transfer pumps, and close the aircraft fuel tank selectors.

17. Emergency Operation
NOTE: If the aircraft electrical system fails and/or the electric fuel pump(s) become inoperative, fuel can be transferred using the manually operated wobble pump.
Operate the manual wobble pump by moving handle back and forth about one complete stroke per second.
Observe fuel quantities as per normal operation procedures.

18. Emergency Operation
CAUTION: If the aircraft is pressurized and ferry fuel transfer is attempted by any means, fuel is going to transfer rapidly when any aircraft fuel tank selector valve is open because of the cabin pressure differential, without operating either the electric fuel pumps or the manual wobble pump. The IN one-way check valve in the surge tank equalizes the cabin pressure and the air pressure over the fuel in the ferry fuel tanks. Opening the selector valves opens a path for the fuel to the main aircraft fuel tanks, which have only ambient pressure over the fuel. Cabin pressure will then force the fuel out of the ferry fuel tanks into the aircraft main fuel tanks.

19. Limitations/Restrictions
Cabin rate of descent must not exceed 1,500 FPM.
WARNING: Failure to comply could result in the collapse of the tanks. If the 1,500 FPM (cabin) rate of descent is exceeded the air may not flow through the surge tank and tank vent lines fast enough to keep the tank air pressure and cabin air pressure equalized. If an extreme emergency dictates a greater rate of descent then loosening or removal of the tank caps will allow the two air pressures to equalize, but could allow fuel fumes to escape into the cabin.

20. Limitations/Restrictions
Maximum takeoff weight cannot exceed 16,200 pounds.
Vne must not exceed 216 KIAS.
Vmo must not exceed 0.43 mach.
Maximum fuel quantity in the ferry tanks cannot exceed 240 U.S gallons total.
Aerobatics are prohibited.

21. Limitations/Restrictions
Flight into known or forecast moderate or severe turbulence is prohibited.
Occasional light turbulence is permissible.
Ferry flights shall be conducted under VFR conditions to the maximum extent possible.
Transfer fuel during level cruise flight only.
Maximum landing weight 15,400 pounds.

22. Suggestions
The ferry tanks do not have quantity gauges. Monitor fuel truck gauge during servicing.
Completely empty both ferry tanks prior to final destination.
Don’t order the hamburger at Sonderstrom.

23. Questions?