XX

TRANSLATION OF

BOLLETTINO TECNICO N° 119-38

The technical content of this document is approved

under the authority of DOA nr EASA.21J.005. DATE March 25, 2010

REV. xxxxxxx

Compliance with

this bollettino is:

 

 ALERT Page 1 of 9

SUBJECT:ONE-TIME INSPECTION OF THE 90° GEARBOX ASSY

P/N 109-0440-06-103.

REASON: Perform a one-time inspection of the subject 90° gearbox to verify the 

presence of the bushing P/N 109-0135-14-101 and provide the 

instructions to restore the correct configuration and for the re 

identification to P/N 109-0440-06-105.

HELICOPTERS AFFECTED:

All the Agusta A119 and AW119MKII helicopters equipped with the 90° 

gearbox assy P/N 109-0440-06-103 and all the 90° gearbox assy

P/N 109-0440-06-103 at stock.

COMPLIANCE:

PART I^:

Before the next flight from receipt of this Bollettino.

PART II^:

Within and not later than 5 (five) flight hours from receipt of this Bollettino 

and however within and not later than June 30, 2010 and however before 

the removal of the 90° gearbox inspected as per PART I^. 

DESCRIPTION:

One case of missing bushing P/N 109-0135-14-101 inside the 90° 

gearbox assy P/N 109-0440-06-103 output mast, has been reported on 

an AW119MKII model helicopter.

This Bollettino is issued in order to provide the necessary instructions to 

perform:

PART I^: a one-time inspection to verify the presence of the bushing

P/N 109-0135-14-101 inside the 90° gearbox assy P/N 109-0440-06-103 

 ALERT
B.T. 119-38

Page 2 of 9

output mast and, in case of absence, for the replacement of the gearbox

and some parts of the tail rotor installation with the new 90° gearbox assy 

P/N 109-0440-06-105.

PART II^: the 90° gearbox assy P/N 109-0440-06-103 re-identification to

P/N 109-0440-06-105, in which the inspection has confirmed the bushing 

presence, by means of the installation of an additional nameplate.

REQUIRED MANPOWER:

The following estimated manpower hours are required for compliance 

with this Bollettino:

PART I^: Negligible;

PART II^: 1.5 (one and half).

WARRANTY:

The parts required to apply the present Bollettino shall be supplied on a 

free of charge basis by Agusta upon request except for the consumable 

items.

Upon application of this Bollettino, Customers are requested to submit to 

Agusta Warranty Administration the Technical Bulletin Compliance form 

attached to this Bulletin duly completed in all its parts.

REQUIRED MATERIALS:

PART I^:

The following materials could be required for compliance with PART I^ of 

this Bollettino:

P/N DENOMINATION Q.TY

109-0440-06-105 90° gearbox assy 1

NAS1149C0463R Washer 3

109-0135-02-101 T/R Control rod assy. 1

109-0135-03-101 T/R Lever assy 1

109-0135-05-101 T/R Half scissors assy 4

109-0135-06-101 T/R Fitting assy 1

109-0135-08-101 T/R Scissors sleeve 6

NAS6604D22 Bolt 6

In addition the following consumable material is necessary:

SPECIFICATION DENOMINATION Q.TY

TT-N-95 type 2 Aliphatic naphtha A.R.

(code 531055030)

PART II^:

The following material is required for compliance with PART I^ of this 

Bollettino:

P/N DENOMINATION Q.TY

A149A003A1 Nameplate 1
B.T. 119-38

Page 3 of 9

In addition the following consumable material is necessary:

SPECIFICATION DENOMINATION Q.TY

199-05-002 Adhesive EA934NA A.R.

TY II CL 2 (code 900004603)

TT-N-95 type 2 Aliphatic naphtha A.R.

(code 531055030)

Commercial Abrasive paper n. 220 A.R.

or equivalent

Commercial Masking tape A.R.

SPECIAL TOOLS:

N.A.

WEIGHT AND BALANCE CHANGES:

Negligible.

REFERENCES:

A119 / AW119MKII Maintenance Manual.

PUBLICATIONS AFFECTED:

N.A.

COMPLIANCE INSTRUCTIONS:

PART I^:

(See figures 1÷2)

1. Prepare the helicopter on ground for a safe maintenance, 

disconnect any power supply.

2. Gain access to the tail rotor installation and with reference to 

figure 1, remove the forward boot P/N 109-0135-10 from the hub 

locking nut P/N 109-0135-12.

NOTE

If necessary clean the area to be inspected 

using a clean cloth dampened with aliphatic

naphtha.

3. With reference to figure 2, insert a 0.3 mm thickness gauge 

between the T/R control rod P/N 109-0135-02 and the hub 

locking nut P/N 109-0135-12 keeping the thickness gauge 

against the T/R control rod assy P/N 109-0135-02.

NOTE

Use a thickness gauge that can be inserted 

between the control rod P/N 109-0135-02 

and the T/R hub locking nut

P/N 109-0135-12.
B.T. 119-38

Page 4 of 9

3.1 If the thickness gauge goes in for 5±1 mm the bushing

P/N 109-0135-14-101 is installed, return the fwd boot

P/N 109-0135-10 in its initial position on the T/R hub locking nut

P/N 109-0135-12 and perform steps 7. and 8..

NOTE

In this case the 90° gearbox assy 

P/N 109-0440-06-103 must be re-identified 

to P/N 109-0440-06-105 performing the 

PART II^ within the compliance limits of this 

Bollettino.

3.2 If the thickness gauge goes in for more than 6 mm the bushing 

P/N 109-0135-14-101 is not installed, proceed with the following 

steps.

4. In accordance with the instructions given in the 

A119/AW119MKII Maintenance Manual from the helicopter 

remove:

 T/R control rod P/N 109-0135-02;

 T/R lever P/N 109-0135-03;

 N. 4 T/R half scissors assy P/N 109-0135-05;

 T/R fitting assy P/N 109-0135-06;

 N. 6 T/R scissors sleeve P/N 109-0135-08;

 N. 6 T/R sleeve connecting bolts P/N NAS6604D22;

 The 90° gearbox assy P/N 109-0440-06-103.

NOTE

The removed parts must be sent to Agusta.

5. In accordance with the instructions given in the

A119/AW119MKII Maintenance Manual on the helicopter install 

the following efficient parts:

 90° gearbox assy P/N 109-0440-06-105;

 N. 6 T/R sleeve connecting bolts P/N NAS6604D22;

 N. 6 T/R scissors sleeve P/N 109-0135-08-101;

 T/R fitting assy P/N 109-0135-06-101;

 N. 4 T/R half scissors assy P/N 109-0135-05-101;

 T/R lever P/N 109-0135-03-101;

 T/R control rod P/N 109-0135-02-101.

6. In accordance with the instructions given in the 

A119/AW119MKII Maintenance Manual perform the tail rotor 

dynamic balance.

7. Return the helicopter in a ready to flight condition.
B.T. 119-38

Page 5 of 9

8. Record compliance with PART I^ of this Bollettino in the 

helicopter log book.

NOTE

The 90° gearbox assy P/N 109-0440-06-

103 at stock must be visually inspected to 

verify the presence of the bushing

P/N 109-0135-14-101.

If the bushing is not installed the 90° 

gearbox shall be sent to Agusta.

If the bushing is installed, the 90° gearbox

must be re-identified in accordance with 

PART II^.

PART II^:

(See figure 3)

1. Prepare the helicopter on ground for a safe maintenance, 

disconnect any power supply.

2. In accordance with the instructions given in the A119/AW119MKII 

Maintenance Manual remove the fairing P12.

3. Using an etch pen, on the 90° gearbox assy nameplate cross out

the entire P/N 109-0440-06-103.

4. With reference to figure 3, using a punch, write on the nameplate

P/N A149A003A1:

4.1 In the upper square write 109-0440-06-105.

4.2 In the lower square write B.T. 119-38.

5. On the 90° gearbox determine the area where to install the 

nameplate P/N A149A003A1 in proximity of the existing 

nameplate.

6. Pre-fit the nameplate P/N A149A003A1 to ensure a tight fit with 

the 90° gearbox surface.

7. On the 90° gearbox mask the area around the nameplate

P/N A149A003A1 using masking tape.

8. On the 90° gearbox remove only the finish paint from the 

nameplate P/N A149A003A1 installation area using abrasive 

paper n. 220 or finer grit.

9. Rub the surface of the nameplate P/N A149A003A1 to be 

bonded using abrasive paper n. 220 or finer grit.
B.T. 119-38

Page 6 of 9

10. Clean the repaired area with aliphatic naphtha.

11. Mix the components of the adhesive EA934NA using a nonmetallic spatula and wait between 30 and 40 minutes before its

use.

12. Bond the nameplate P/N A149A003A1 on the 90° gearbox. Hold 

the nameplate in position by means of adhesive tape.

NOTE

After the bonding, all around the nameplate 

there should be evidence of adhesive 

squeeze-out; remove any excess adhesive.

13. Leave adhesive to cure for 24 hours at ambient temperature.

14. Remove the adhesive tape and restore the finish and the 90° 

gearbox painting scheme. 

15. In accordance with the instructions given in the A119/AW119MKII 

Maintenance Manual reinstall the fairing P12.

16. Return the helicopter in a ready to flight condition.

17. Record compliance with PART II^ of this Bollettino in the 

helicopter log book.
B.T. 119-38

Page 7 of 9

View A

FIGURE 1

109-0135-12 NUT 109-0135-10 FWD BOOT
B.T. 119-38

Page 8 of 9

FIGURE 2

109-0135-10 FWD BOOT

109-0135-12 NUT

0.30 mm THICKNESS GAUGE

109-0135-02

CONTROL ROD ASSY
B.T. 119-38

Page 9 of 9

 FIGURE 3

A149A003A1 

NAMEPLATE 

Note: 

Remarks:

Informazioni: 

Information:

Al fine di gestire le varianti alla configurazione base, in relazione all’emissione del Bollettino Tecnico, preghiamo di voler compilare il presente modulo in tutte le sue parti e spedirlo all’indirizzo sopra indicato. Si ringrazia 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

21015 Lonate Pozzolo (VA) - ITALY 

Tel.: +39 0331 664600

Fax: +39 0331 664684

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.