## BOLLETTINO TECNICO N° 

# 139-249

The technical content of this document is approved under the authority of DOA nr. EASA.21J.005 DATE July 13, 2011

REV

. /

Compliance with this bulletin is:

An appropriate entry should be made in the aircraft log book upon accomplishment. If ownership of aircraft has changed, please, forward to new owner. Page 1 of 27 SUBJECT : SOLDER SPLICES P/N D-110-41 INSPECTION.

REASON : to provide the instructions to verify the correct installation of the solder splices.

HELICOPTERS AFFECTED: AW139 helicopters S/N 31248, S/N 31249, from S/N 41001 to S/N 41023, from S/ N 41201 to S/N 412 34, S/N 41236, fr om S/N 41237 to S/N 41255 (except S/N 41240, S/N 41242, S/N 41246, S/N 412 49, S/N 41251 and S/N 41252) and S/N 41257.

COMPLIANCE: within six hundred (600) f light hours or six (6) months or in case of “AVIONIC FAULT” cockpit caution from rece ipt of this Bollettino, whichever comes
first.

## B.T. 139-249

Page 2 of 27 DESCRIPTION: following a case of intermittent noi se in the Co-Pilots audio system, during troubleshooting it was determined that some of the solder splices on the audio panel were the possibl e cause of the issue.
It was discovered that some wires woul d easily pull out from the splice.
The same issue was found on some other so lder splices installed on the aircraft. This Bollettino provides t he instructions to perform a precautionary inspection to verify the correct installation of so lder splices P/N D-110-41 and related wires.

REQUIRED MANPOWER: it is estimated that in order to accomplish this Bollettino one hundred and ten (110) man-hours (MMH) are necessary. Man-hours are based on hands-on time and may vary with personnel and facilities
available.

WARRANTY: N.A.

REQUIRED MATERIALS: the following materials and c onsumable materials, if necessary to accomplish repair procedures described in this bollettino, can be requested to AgustaWestland:
SPEC. / Part Number Description Q.ty Notes D-110-41 Raychem (Tyco) Environmenta l Solder Splices AR (1) (2) M81824/1 Environmental Crimp Splices AR (1) BM100T013 Solvent AR (2) BM100F375 Solder flux AR (2) De-Solder Braid/Tape AR (2)

SPECIAL TOOLS: the following special tools are necessary to accomplish this
Bollettino:

Part Number Description Q.ty Notes Local supply Magnifier (min 4x) 1

## B.T. 139-249

Page 3 of 27 Part Number Description Q.ty Notes Local supply Flashlight 1 Steinel HL1802E/1910/2010 or equivalent Heat Gun (350° F) 1 (1) (2)

Local supply Padded Connector Pliers AR (1) Local supply Crimpers AR (1) Local supply Holdi ng fixture AD-1319 or equivalent AR (1)

Local supply Crimping tool AD-1377 or equivalent AR (1)

Local supply Solder iron AR (2)

Notes: (1) necessary for crimping procedure, only if splice replacement is required; (2) necessary for soldering procedure, onl y if splice replacement is required.

WEIGHT AND BALANCE CHANGES: N.A.

REFERENCES:
9 AW139 Aircraft Maintenance Publication (AMP)

PUBLICATIONS AFFECTED: N.A.

COMPLIANCE INSTRUCTIONS:
1. Prepare the helicopter for a safe ground maintenance. Disconnect the battery and all the electrical power source s and/or the external power supply. Refer to Aircraft Maintenance Publication (AMP), s ee DM n° 39-A-00-20 -00-00A-120A-A.

CAUTION Take care to protect the ar ea in order to avoid any damage to the connector and splices.
2. Remove liners and panels as necessary to get access to the work areas.

## B.T. 139-249

Page 4 of 27 3. With reference to table 1 (applicable to short nose helicopters) or table 2 (applicable to long nose helicopters) and to related figures 1 thru 12, open the applicable connector and perform the inspection of the solder splices as follows:
3.1 Visually inspect the wires for damage and condition. Make sure that the sleeve is not split or cut and that no wire strand poke through the sleeve.

NOTE Lack of solder fillet may indicate overheating.
3.2 Visually inspect the heat ing area. Make sure that t he solder ring shape is not
visible and that a solder fillet is visible on one side of the leads. Refer to figure 13 for wire splices acceptance criteria.
Lack of solder fillet may indicate overheating.
3.3 If the solder splice is damaged or is not acceptable according to figure 13, replace it according to step 7.
3.4 If the solder splice shows no damage and is acceptable according to figure 13, go on with following step 4.
4. Perform a manual pull-test of the splice twis ting the wires.
5. Repeat the pull-test on ev ery splice of the connector.
6. Replace the splices that don’t pass the pull test according to step 7.
7. Replace the defective splices. With refe rence to figure 12 and to figures 14 thru 16,
do as follows:

7.1 Cut the bus wires at the insulation.
7.2 Remove the protective sleeve and prepare the wire according to figure 14 (dimensions are in mm and in inches between brackets).

NOTE As an alternative to steps 7.3. thru 7.5 it is allowed to
solder wires as described in steps 7.6 thru 7.11. The same procedure (steps 7.3 thru 7.5 or steps 7.6 thru 7.11) must be performed on all the splices of the

## B.T. 139-249

Page 5 of 27 same connector if it contains at least one splice to be repaired.
7.3 Slide the sleeve of the splice P/N M81824/1 over the stub wire.
7.4 Using a splice P/N M81824/1, crimp the stub wire and bus wires.
7.5 Slide the sleeve over the crimped sp lice and shrink it using the heat gun.

NOTE Steps 7.6. thru 7.11 are an alternative to procedure described in steps 7.3 thru 7.5. The same procedure (steps 7.3 thru 7.5 or steps 7.6 thru 7.11) must be performed on all the splices of the same connector if it contains at least one splice to be repaired.

NOTE For more details on soldering procedure refer also to AMP, see DM n° 39- A-20-10-17-00A-625A-A.

7.6 Tin the Stub and Bus wires as follows:
7.6.1 Clean wires with solvent (BM100T013).

CAUTION Soldering flux must not penetrate beneath the insulation, as flexure caused by vibrations could cause failures. Tinning on wires must not be less than 1.5 mm (0.06 in) from the insulation. Refer to figure 15.
7.6.2 Using a properly tinn ed soldering iron, apply flux (BM100F375) to the
wire.
7.6.3 Apply soldering iron to the wire to heat it suffici ently to allow the solder to flow, when the solder contacts the wire.
7.6.4 Make sure that solder penetrate to inner strands of wire and that exhibit wetting over the entire tinned area.

## B.T. 139-249

Page 6 of 27 7.6.5 Make sure that there is no dam age to the insulation due to wicking.
7.6.6 Make sure that tinning extend far enough onto the wire to take full advantage of the contact area in the solder connection.

7.6.7 Make sure that the contour of t he individual wire strands remain visible
in the tinned area.
7.6.8 Clean with water and soap.

7.6.9 Rinse in hot water.
7.6.10 Dry carefully.
7.7 Slide the protective sl eeve, approximately 40.0 – 50.0 mm (1.5 - 2.0 in), over
the stub wire. Ensure that there is at appr oximately 9.5 mm (0.375 in) on both sides of the splice. If an excess amount of solder exists on the bus wires, it can be removed using de-soldering braid/wick.

NOTE
The D-110-41 solder sleev e can be used with the solder ring removed, to reduce the opportunity of solder squeeze out resulting in shorting issues.

CAUTION Make sure that no sharp points exist. Sharp points can damage the protective sleeve during installation.
7.8 Solder the paired bus wires (white and blue) to the stub wire.
7.9 After the joint has cooled, ensure that the three wires are soldered.
7.10 Slide the protective sleeve over the solder joint so that the joint is located in the
middle.
7.11 Heat the protective sleeving until the sleeve has reached its minimum size.
8. Carefully reassemble connector and secure backshell. Refer to the AMP applicable
data module.
9. Repeat steps 3 thru 8 for every c onnector listed in table 1 or table 2.

## B.T. 139-249

Page 7 of 27 10. Perform a functional check of the systems re lated to inspected splices, according to the AMP applicable data modules: 39-B-31-61-00-00A-321A-A (Central displa y system - Operational check), 39-B-31-61-00-00A-321C-A (Central display system - Display reversion - Operational check), 39-A-23-52-00-00A-321A-A (Number 2 airbor ne audio system - Operational check), 39-A-23-51-00-00A-321A-A (Number 1 airbor ne audio system - Operational check), 39-A-22-11-00-00A-321A-A (Automatic flight control system - Operational check).
11. Install liners and panels removed at step 2.
12. Report the results of the inspection performed at previous steps 3 thru 8 to AW139 Product Support Engineering ( aw139.mbx@agustawestland.com ).
13. Return helicopter to flight configuration and record for compliance of this bollettino.

## B.T. 139-249

Page 8 of 27 TABLE 1: list of connectors affected on short nose helicopters: 410XX series
CONNECTOR REF DES SPLICE REF DES LOOM PART NUMBER REFER TO FIGURE A1-5P1 SP113 3G9C02A001 2 A1-5P1 SP114 3G9C02A001 2 A1-7P2 SP434 3G9C02A001 2 A1-7P2 SP435 3G9C02A001 2 A1-NICP1 SP478 3G9C02A001 4 A1-NICP1 SP479 3G9C02A001 4 A1-NICP1 SP496 3G9C02A001 4 A1-NICP1 SP497 3G9C02A001 4 A1-NICP1 SP512 3G9C02A001 2 A1-NICP1 SP513 3G9C02A001 2

A2-5P1 SP428 3G9C02B001 2 A2-5P1 SP429 3G9C02B001 2 A2-7P2 SP111 3G9C02B001 2 A2-7P2 SP112 3G9C02B001 2 A2-NICP1 SP470 3G9C02B001 4 A2-NICP1 SP471 3G9C02B001 4 A2-NICP1 SP486 3G9C02B001 4 A2-NICP1 SP487 3G9C02B001 4 A2-NICP1 SP504 3G9C02B001 4 A2-NICP1 SP505 3G9C02B001 4

A30P3 SP468 3G9B02B002 3 A30P3 SP469 3G9B02B002 3 A30P3 SP484 3G9B02B002 3 A30P3 SP485 3G9B02B002 3 A30P3 SP502 3G9B02B002 3 A30P3 SP503 3G9B02B002 3 A31P3 SP476 3G9B02A002 3 A31P3 SP477 3G9B02A002 3 A31P3 SP494 3G9B02A002 3 A31P3 SP495 3G9B02A002 3 A31P3 SP510 3G9B02A002 1 A31P3 SP511 3G9B02A002 1 A42P3 SP472 3G9B02B002 3 A42P3 SP473 3G9B02B002 3 A42P3 SP490 3G9B02B002 3 A42P3 SP491 3G9B02B002 3 A42P3 SP500 3G9B02B002 3

## B.T. 139-249

Page 9 of 27 CONNECTOR REF DES SPLICE REF DES LOOM PART NUMBER REFER TO FIGURE A42P3 SP501 3G9B02B002 3 A7-6P1 SP603 3G9B02A002 5 A7-6P1 SP604 3G9B02A002 5 A7-6P1 SP615 3G9B02A002 5 A7-6P1 SP616 3G9B02A002 5 A7-6P3 SP446 3G9B02A002 5 A7-6P3 SP447 3G9B02A002 5 A7-6P3 SP474 3G9B02A002 3 A7-6P3 SP475 3G9B02A002 3 A7-6P3 SP492 3G9B02A002 3 A7-6P3 SP493 3G9B02A002 3 A7-6P3 SP508 3G9B02A002 1 A7-6P3 SP509 3G9B02A002 1 A8-6P1 SP607 3G9B02B002 5 A8-6P1 SP608 3G9B02B002 5 A8-6P1 SP611 3G9B02B002 5 A8-6P1 SP612 3G9B02B002 5 A8-6P3 SP452 3G9B02B002 5 A8-6P3 SP453 3G9B02B002 5 A8-6P3 SP466 3G9B02B002 3 A8-6P3 SP467 3G9B02B002 3 A8-6P3 SP482 3G9B02B002 3 A8-6P3 SP483 3G9B02B002 3 A8-6P3 SP498 3G9B02B002 3 A8-6P3 SP499 3G9B02B002 3 A95P3 SP230 3G9B02A002 1 A95P3 SP231 3G9B02A002 1 A95P3 SP232 3G9B02A002 3 A95P3 SP233 3G9B02A002 3 A95P3 SP238 3G9B02A002 3 A95P3 SP239 3G9B02A002 3 HP14P1 SP424 3G9B02B001 1 HP14P1 SP425 3G9B02B001 1 HP15P1 SP426 3G9B02B001 1 HP15P1 SP427 3G9B02B001 1 HP16P1 SP420 3G9D02B001 2 HP16P1 SP421 3G9D02B001 2

HP1J1 SP430 3G9B02A001 1

## B.T. 139-249

Page 10 of 27 CONNECTOR REF DES SPLICE REF DES LOOM PART NUMBER REFER TO FIGURE HP1J1 SP431 3G9B02A001 1 HP2J1 SP432 3G9B02A001 1 HP2J1 SP433 3G9B02A001 1 HP3J1 SP422 3G9D02A001 2 HP3J1 SP423 3G9D02A001 2 PL24P1 SP450 3G9B02B002 5 PL24P1 SP451 3G9B02B002 5 PL24P1 SP454 3G9B02B002 5 PL24P1 SP455 3G9B02B002 5 PL24P1 SP609 3G9B02B002 5 PL24P1 SP610 3G9B02B002 5 PL24P1 SP613 3G9B02B002 5 PL24P1 SP614 3G9B02B002 5 PL8P1 SP448 3G9B02A002 5 PL8P1 SP449 3G9B02A002 5 PL8P1 SP456 3G9B02A002 5 PL8P1 SP457 3G9B02A002 5 PL8P1 SP605 3G9B02A002 5 PL8P1 SP606 3G9B02A002 5 PL8P1 SP617 3G9B02A002 5 PL8P1 SP618 3G9B02A002 5

## B.T. 139-249

Page 11 of 27 TABLE 2 List of connectors affected on long nose helicopters: 31248, 31249 and 412XX series

CONNECTOR REF DES SPLICE REF DES LOOM PART NUMBER REFER TO FIGURE A1-5P1 SP115 3G9A02A225 9 A1-5P1 SP117 3G9A02A225 9 A1-7P2 SP119 3G9A02A225 9 A1-7P2 SP121 3G9A02A225 9 A1-NICP1 SP1053 3G9A02A217 6 A1-NICP1 SP1055 3G9A02A217 6 A1-NICP1 SP1075 3G9A02A218 7 A1-NICP1 SP1077 3G9A02A218 7 A1-NICP1 SP1087 3G9A02A219 8 A1-NICP1 SP1089 3G9A02A219 8

A2-5P1 SP128 3G9A02B224 9 A2-5P1 SP130 3G9A02B224 9 A2-7P2 SP124 3G9A02B224 9 A2-7P2 SP126 3G9A02B224 9 A2-NICP1 SP1080 3G9A02B217 6 A2-NICP1 SP1082 3G9A02B217 6 A2-NICP1 SP1108 3G9A02B218 7 A2-NICP1 SP1110 3G9A02B218 7 A2-NICP1 SP1112 3G9A02B219 8 A2-NICP1 SP1114 3G9A02B219 8

A30P3 SP1092 3G9A02B217 6 A30P3 SP1094 3G9A02B217 6 A30P3 SP1100 3G9A02B218 7 A30P3 SP1102 3G9A02B218 7 A30P3 SP1120 3G9A02B219 8 A30P3 SP1122 3G9A02B219 8 A31P3 SP1063 3G9A02A217 6 A31P3 SP1065 3G9A02A217 6 A31P3 SP1079 3G9A02A218 7 A31P3 SP1081 3G9A02A218 7 A31P3 SP1099 3G9A02A219 8 A31P3 SP1101 3G9A02A219 8 A42P3 SP1088 3G9A02B217 6 A42P3 SP1090 3G9A02B217 6 A42P3 SP1096 3G9A02B218 7 A42P3 SP1098 3G9A02B218 7 A42P3 SP1124 3G9A02B219 8 A42P3 SP1126 3G9A02B219 8

## B.T. 139-249

Page 12 of 27 CONNECTOR REF DES SPLICE REF DES LOOM PART NUMBER REFER TO FIGURE A7-6P1 SP1025 3G9A02A205 11 A7-6P1 SP1027 3G9A02A205 11 A7-6P1 SP1037 3G9A02A206 11 A7-6P1 SP1039 3G9A02A206 11 A7-6P3 SP1013 3G9A02A203 11 A7-6P3 SP1015 3G9A02A203 11 A7-6P3 SP1059 3G9A02A217 6 A7-6P3 SP1061 3G9A02A217 6 A7-6P3 SP1071 3G9A02A218 7 A7-6P3 SP1073 3G9A02A218 7 A7-6P3 SP1091 3G9A02A219 8 A7-6P3 SP1093 3G9A02A219 8 A8-6P1 SP1030 3G9A02B204 11 A8-6P1 SP1032 3G9A02B204 11 A8-6P1 SP1042 3G9A02B205 11 A8-6P1 SP1044 3G9A02B205 11 A8-6P3 SP1022 3G9A02B203 11 A8-6P3 SP1024 3G9A02B203 11 A8-6P3 SP1084 3G9A02B217 6 A8-6P3 SP1086 3G9A02B217 6 A8-6P3 SP1104 3G9A02B218 7 A8-6P3 SP1106 3G9A02B218 7 A8-6P3 SP1116 3G9A02B219 8 A8-6P3 SP1118 3G9A02B219 8 A95P3 SP1067 3G9A02A217 6 A95P3 SP1069 3G9A02A217 6 A95P3 SP1083 3G9A02A218 7 A95P3 SP1085 3G9A02A218 7 A95P3 SP1095 3G9A02A219 8 A95P3 SP1097 3G9A02A219 8 HP14J1 SP204 3G9B02B217 9 HP14J1 SP206 3G9B02B217 9 HP15J1 SP200 3G9B02B217 9 HP15J1 SP202 3G9B02B217 9 HP1J1 SP205 3G9B02A213 9 HP1J1 SP207 3G9B02A213 9 HP2J1 SP201 3G9B02A213 9 HP2J1 SP203 3G9B02A213 9 PL24P1 SP1016 3G9A02B237 11 PL24P1 SP1018 3G9A02B237 11

## B.T. 139-249

Page 13 of 27 CONNECTOR REF DES SPLICE REF DES LOOM PART NUMBER REFER TO FIGURE PL24P1 SP1026 3G9A02B203 11 PL24P1 SP1028 3G9A02B203 11 PL24P1 SP1034 3G9A02B204 11 PL24P1 SP1036 3G9A02B204 11 PL24P1 SP1038 3G9A02B205 11 PL24P1 SP1040 3G9A02B205 11 PL24P2 SP1138 3G9A02B202 11 PL24P2 SP1140 3G9A02B202 11 PL38P1 SP265 3G9B02A204 11 PL38P1 SP267 3G9B02A204 11 PL8P1 SP1009 3G9A02A203 11 PL8P1 SP1011 3G9A02A203 11 PL8P1 SP1021 3G9A02A204 11 PL8P1 SP1023 3G9A02A204 11 PL8P1 SP1029 3G9A02A205 11 PL8P1 SP1031 3G9A02A205 11 PL8P1 SP1033 3G9A02A206 11 PL8P1 SP1035 3G9A02A206 11

## B.T. 139-249

Page 14 of 27 Figure 1

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Page 15 of 27 Figure 2

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Page 16 of 27 Figure 3

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Page 17 of 27 Figure 4

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Page 18 of 27 Figure 5

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Page 19 of 27 Figure 6

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Page 20 of 27 Figure 7

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Page 21 of 27 Figure 8

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Page 22 of 27 Figure 9

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Page 23 of 27 Figure 10

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Page 24 of 27 Figure 11

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Page 25 of 27 Figure 12EXAMPLES OF CORRECTMANUFACTURING INSTALLATIONS(NOTES 1 AND 2 IN FIGURES 1 THRU 11)

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Page 26 of 27 Figure 13

Figure 14

DETAIL A WIRES TO BE SPLICED

DETAIL B WIRES TO BE TINNED AND SOLDERED

## B.T. 139-249

Page 27 of 27 Figure 15Note: Remarks:

Informazioni: Information: Al fine di gestire le varianti alla configur azione base, in relazione all’emissione de l Bollettino Tecnico, preghiamo di voler compilare il presente modulo in tutte le sue parti e sped irlo all’indirizzo sopra indicato. Si ring razia per la gentile collaborazione data. We request your cooperation in filling this form, in order to keep out statistical data relevant to aircraft configuration up- to-date. The form should be filled in all its parts and sent to the above address. We thank you beforehand for the information given. **MODULO APPLICAZIONE BOLLETTINO TECNICO** TECHNICAL BULLETIN COMPLIANCE FORM Data: Date:

Numero: Number:

Revisione: Revision: Prego spedire a questo indirizzo: Please send to the following address: 

### AGUSTA **S.p.A.** CUSTOMER SUPPORT & SERVICES - ITALY PRODUCT SUPPORT ENGINEERING DPT. Via del Gregge, 100 2101 5 Lonate Pozzolo (VA) - I T ALY T el

. : +39 0331 664600 Fa x : +39 0331 66468 4

Telefono: Telephone:

Fax:

Data Applicazione B.T.: B.T. Compliance Date: Denominazione Cliente ed Indirizzo: Customer Name and Address:

Modello Elicottero

Helicopter Model S/N Matricola Tail Number Ore Totali Total Hours Ore D.U.R. T.S.O.