# ALERT

TRANSLATION OF 

## BOLLETTINO TECNICO N° 

# 119- 39

The technical content of this document is approved under the authority of DOA nr EASA.21J.005. DATE July 02 , 2010

REV. A May 23 , 2011

Compliance with this bulletin is:



# ALERT Page 1 of 1 7

THE REVISION A OF THIS BOLLETTINO TECNICO CANCELS AND SUPERSEDES THE BASIC ISSUE DATED JULY 02, 2010.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SUBJECT: INSPECTION AND MODIFICATION OF THE PILOT CONTROL BOX

ASSY P/N 109

- 0010

- 81

- 103 AND CO

- PILOT CONTROL BOX ASSY P/N 109

- 0010

- 81

- 107 OF THE COLLECTIVE PITCH CONTROL INSTALLATION

.

REASON: Perform an inspection of the subject pilot and co

- pilot control boxes to

verify fo r the correct installation of the engine RVDT control gear locking pin and provide the necessary instructions to modify the subject pilot and copilot control boxes

.

HELICOPTERS AFFECTED:

PART I^, PART II^ and PART III^: All the pilot control box assy P/N 109-0010- 81 -103 and the co-pilot control box assy P/N 109-0010- 81 -107, installed on the Agusta A119 and AW119MKII helicopters and/or in stock.

NOTE The pilot control box assy P/N 109

- 0010

- 81

- 103 and the co

- pilot control box assy P/N 109

- 0010

- 81

- 107 repor ting the mark B.T. 119

- 39 REV.A (ref. figure 7), are not interested in the compliance with this Bollettino Tecnico.

COMPLIANCE:

PART I^: Within the next 5 flight hours after the receipt of this Bollettino and however within and not later than June 15

, 2011.B.T. 119

- 39

Page 2 of 1 7

PART II^: Every 50 flight hours after compliance with PART I^ of this Bollettino until PART III^ compliance.

PART III^: Within and not later than January 31, 2012.

DESCRIPTION:

On an AW119MKII helicopter it has been reported that the two throttle handles, installed on the pilot and co-pilot collective control levers were not moving synchronously and moreover that both the IDLE and FLIGHT were missing on the co-pilot throttle. The investigation ha s revealed that the engine RVDT control gear locking pin, inside the pilot control box assy P/N 109-0010- 81 -103, fell out of its seat that lead to the loss of the pilot and co-pilot engine throttles synchronicity. The actions of Agusta and Triumph Controls LLC, pilot control box assy P/N 109 -0010- 81 -103 and the copilot control box assy P/N 109-0010- 81 -107 supplier; have found the definitive solution at the malfunction, modifying the boxes internal configuration in order to guarantee the lock of the engine RVDT control gear locking pin. This Bollettino is issued in order to provide : PART I^: the necessary instructions to perform a one -time inspection to verify for the correct installation of the engine RVDT pilot control box assy P/N 109-0010- 81 -103 and co-pilot control box P/N 109-0010- 81 -107 gear locking pin. PART II^: the necessary instructions to perform a periodic inspection to verify the fixing strength of the engine RVDT pilot control box assy P/N 109-0010- 81 -103 and co-pilot control box P/N 109-0010- 81 -107 gear locking pin

. PART III^: the necessary instructions to install two lockwired half clamps on the RVDT control gear of the pilot control box assy P/N 109-0010- 81 -103 and copilot control box assy P/N 109- 0010

- 81

- 107 in order to avoid any possible movement of the locking pin. After the compliance with PART III^, the periodic inspection to verify the fixing strength of the engine RVDT pilot control box assy P/N 109-0010- 81 -103 and co-pilot control box P/N 109-0010- 81 -107 gear locking pin described in PART II^ is no longer applicable.

REQUIRED MANPOWER:

The following estimated manpower hours are required for compliance with this Bollettino: PART I^: 1.5 (one and a half hours ); PART II^: 1.5 (one and a half hours); PART III^: 8 (eight hours ).B.T. 119

- 39

Page 3 of 17 WARRANTY:

Within the calendar terms mentioned at point “Compliance”, the parts required to apply the present Bollettino shall be supplied on a free of charge basis by Agusta upon Customer’s request.
Upon application of this Bollettino, Customers are requested to submit to A gusta Warranty Administration the Technical Bulletin Compliance form attached to this Bollettino duly completed in all its parts

, and relevant M.M.I.R. (Maintenance Malfunction Information Report)

.
REQUIRED MATERIALS:

PART I^ and PART II^: The following materials could be required for compliance with PART I^ and PART II^ of this Bollettino:

P/N DENOMINATION Q.TY NOTES 109

- 0010

- 81

- 103 Pilot control box assy 1 (1) 109

- 0010

- 81

- 107 Co

- pilot control box assy 1 (1)

PART III^: The following materials are r equired for compliance with PART III^ of this Bollettino:

P/N D ENOMINATION Q.TY NOTES 109G7606R01

- 101 Clamp assy kit 2 (2)

Consisting of: 68165

- 1 Upper half clamp .1 68167

- 1 Lower half clamp .1 68169

- 1 Threaded stud .1 ( 3 ) NAS1352C04H8 Scre w .2 MS20995C20 Lockwire .CR 68172

- 1 Foam cube .4 ( 3 )

NOTES: (1) Component modified in accordance with PART III^ of this Bollettino. (2) Alternatively could be provided the P/N 68168- 1. (3) Special tools to remove from the helicopter after this Bollettino compliance.

SPECIAL TOOLS:

N.A.

WEIGHT AND BALANCE CHANGES:

PART I^ and PART II^: N.A. PART III^: Negligible.

REFERENCES:

A119 / AW119 MKII Maintenance Manual.B.T. 119

- 39

Page 4 of 1 7 PUBLICATIONS AFFECT ED:

N.A.

COMPLIANCE INSTRCTIONS:

PART I^ and PART II^: (See figures 1÷2)

1. Prepare the helicopter on ground for a safe maintenance, disconnect any power supply

.

2. Gain access to the pilot control box assy P/N 109

- 0010

- 81

- 103 removing the guard assy P/N 10 9

- 0703

- 07 in accordance with the instructions given in the A119 / AW119 MKII Maintenance Manual

.

3. With reference to figure 1, acting on the four fixing screws open the pilot control box assy P/N 109

- 0010

- 81

- 103 cover.

CAUTION Do not remove the cover until all the four fixing screws are removed, in order to avoid that the screws may fall into the pilot control box assy P/N 109

- 0010

- 81

- 103. If a screw falls into the box assy, must be removed to prevent damage to the aircraft

.

4. With reference to figure 2, ver ify that the gear locking pin is correctly installed in its seat as follows:

4.1 If necessary act on the pilot collective stick engine throttle to set the l ocking pin in central pos ition

, in order to have a perfect view of it

.

4.2 If the locking pin is not pre sent or pa r tially out of its seat or recessed for more than 2.00 mm, immediately replace the pilot control box assy P/N 109

- 0010

- 81

- 103 with a new assy of the

same P/N already modified with PART III^ of this Bollettino

, in accordance with the instructi ons given in the A119 / AW119 MKII Maintenance Manual applying however the PART I^ of this Bollettino.

NOTE The removed pilot control box assy P/N 109-0010- 81 -103 must be returned to Agusta for repair.

4.3 If the inspection at previous step has been perf ormed with favourable exit proceed with step 5 and followings.B.T. 119

- 39

Page 5 of 17 5. Gain access to the co

- pilot control box assy P/N 109

- 0010

- 81

- 107 removing the fairing assy P/ N 109

- 0011

- 88 (or the fairing assy P/N 109

- 0703

- 11

- 101 if the Kit P/N 109

- 0810

- 01 is installed) in accordance with the instructions given in the A119 / AW119 MKII Maintenance Manual

.

6. With reference to figure 1, acting on the four fixing screws open the co

- pilot control box assy P/N 109

- 0010

- 81

- 107 cover.

CAUTION
Do not remove the cover until all the four fixing screws are removed, in order to avoid that the screws may fall into the co-pilot control box assy P/N 109-0010- 81 -107. If a screw falls into the box assy, must be removed to prevent damage to the aircraft.

7. With reference to figure 2, verify that the gear locking pin is correctly installed in its seat as follows :

7.1 If necessary act on the co

- pilot collective stick engine throttle to set the l ocking pin in central pos ition

, in order to have a perfect view of it

.

7.2 If the locking pin is not pres ent or partially out of its seat or recessed for more than 2.00 mm, immediately replace the

co

- pilot control box assy P/N 109

- 0010

- 81

- 107 with a new assy of the same P/N already modified with PART III^ of this Bollettino

, in accordance with the instructio ns given in the A119 / AW119 MKII Maintenance Manual applying however the PART I^ of this Bollettino . Perform step 8 and followings.

NOTE
The removed co -pilot control box assy P/N 109-0010- 81 -107 must be returned to Agusta for repair.

7.3 If the inspection at previous step has been performed with favourable exit proceed with step 8 and followings

.

8. With reference to figure 1, acting on the fixing hardware close the pilot control box assy P/N 109

- 0010

- 81

- 103 and the co

- pilot control bo x assy P/N 109

- 0010

- 81

- 1 07 covers

.

9. Reinstall the guard assy P/N 109

- 0703

- 07 and the fairing assy P/N 109

- 0011

- 88 (or the fairing assy P/N 109

- 0703

- 11

- 101 if the Kit P/N 109

- 0810

- 01 is installed) inB.T. 119

- 39

Page 6 of 1 7 accordance with the instructions given in the A119 / AW119 MKII

Maintenance Manu al.

10. Return the helicopter to a ready to flight condition

.

11. Record compliance with PART I^ or PART II^ of this Bollettino in the helicopter log book

.

PART III^: (See figures 3÷7)

1. Prepare the helicopter on ground for a safe maintenance, disconnect any po wer supply

.

2. Gain access to the copilot control box assy P/N 109

- 0010

- 81

- 107 removing the fairing assy P/N 109

- 0011

- 88 (or, if installed the dual control kit P/N 109

- 0810

- 01, the guard assy P/N 109

- 0703

- 11) in accordance with the instructions given in the A119 / AW119 MKII Maintenance Manual

.

3. Modify the copilot control box assy P/N 109

- 0010

- 81

- 107 in accordance with the following instructions:

3.1. Remove the four MS51957

- 2 screws fixing the cover P/N 64709

- 1 to the box assy P/N 64703

- 2.

3.2. Remove the cover P/N 64709

- 1 from the box assy P/N 64703

- 2 to expose gear.

CAUTION Remove the cover only after the four fixing screws removal, in order to avoid that the screws may fall into the box assy. If a screw falls into the box assy, must be re moved to prevent damage to the aircraft.

3.3. Place the copilot control box assy in approximate midstroke position rotating the copilot collective stick engine handle to end to travel. Locate the holes in the gear an d rotate the engine handle in the opposite direction two holes.

3.4. Using needle

- nose pliers, place four foam cubes P/N 68172

- 1 into the box assy to protect open spaces in the housing interior (see figure 3).

3.5. Insert the lower half clamp P/N 68167

- 1 with lock wire MS20995C20 already installed in the box assy and position around the hub of the gear. The counterbore of the lower half clamp must mate with the radius of the gear.B.T. 119

- 39

Page 7 of 17 3.6. Thread the threaded stud P/N 68169

- 1 in one hole of the lower half clamp P/N 68167

- 1 until the stud is securely engaged with the lower half clamp.

NOTE The stud is a tool to be used for assembly the clamp assy kit. It is not a permanent part of the copilot control box assy.

3.7. Slide one hole of the upper half clamp P/N 68165

- 1 down the t hreaded stud P/N 68169

- 1 to mate with the lower half clamp P/N 68167

- 1. The counterbore of the upper half clamp must mate with the radius of the gear (see figure 4).

3.8. Rotate the upper half clamp P/N 68165

- 1 slightly to insert the tab through a hole in the gear.

NOTE Ensure the upper half clamp tab is engaged in gear hole.

3.9. Fix the upper half clamp P/N 68165

- 1 to the lower half clamp P/N 68167

- 1 using one NAS1352C04H8 screw. Fingertight the

screw.

3.10. Remove the threaded stud P/N 68169

- 1 and install the secon d NAS1352C04H8 screw fixing the upper half clamp P/N 68165

- 1 to the lower half clamp P/N 68167

- 1. Fingertight the screw

.

3.11. Torque the two NAS1352C04H8 screws to 0.45÷0.62 Nm (4÷5,5 inch

- pounds) and secure the lower half clamp P/N 68167

- 1 using lockwire MS20 995C20 (see figures 5 and 6).

3.12. Remove all loose pieces of lockwire and any other debris that may have fallen into the box assy.

CAUTION
If lockwire or other debris falls into the box assy, must be removed to prevent damage to the aircraft.

3.13. Using needle

- nose pliers, remove the four foam cubes P/N 68172

- 1 from the box assy.

3.14. Place the cover P/N 64709

- 1 in its position on the box assy P/N 64703

- 2 to align screw holes.

3.15. Secure the c over P/N 64709

- 1 to the box assy P/N 64703

- 2 using the four MS51957

- 2 screws.B.T. 119

- 39

Page 8 of 1 7

3.16. In the area shown in figure 7, using an etch pen, on the copilot control box assy P/N 109

- 0010

- 81

- 107 mark B.T. 119

- 39 REV.A.

4. Gain access to the pilot control box assy P/N 109

- 0010

- 81

- 103 removing the pilot seat P/N 109

- 0702

- 98, the guard assy P/N 109

- 0703

- 07 and the central cover assy P/N 109

- 0313

- 54 in accordance with the instructions given in the A119 / AW119 MKII Maintenance Manual

.

5. Modify the pilot control box assy P/N 10 9

- 0010

- 81

- 103 in accordance with the following instructions:

5.1. Remove the four MS51957

- 2 screws fixing the cover P/N 64737

- 1 to the box assy P/N 64734

- 2.

5.2. Remove the cover P/N 64737

- 1 from the box assy P/N 64734

- 2 to expose gear.

CAUTION Remove the cover only after the four fixing screws removal, in order to avoid that the screws may fall into the box assy. If a screw falls into the box assy, must be removed to prevent damage to the aircraft.

5.3. Place the pilot control box assy in approximate midstroke position rotating the pilot collective stick engine handle to end to travel. Locate the holes in the gear and rotate the engine handle in the opposite direction two holes.

5.4. Using needle

- nose pliers, place four foam cubes P/N 68172

- 1 into the box assy to protect open spaces in the housing interior (see figure 3).

5.5. Insert the lower half clamp P/N 68167

- 1 with lo ckwire MS20995C20 already installed in the box assy and position around the hub of the gear. The counterbore of the lower half clamp must mate with the radius of the gear.

5.6. Thread the threaded stud P/N 68169

- 1 in one hole of the lower half clamp P/N 68167

- 1 until the stud is securely engaged with the lower half clamp.

NOTE The stud is a tool to be used for assembly the clamp assy kit. It is not a permanent part of the pilot control box assy.B.T. 119

- 39

Page 9 of 17 5.7. Slide one hole of the upper half clamp P/N 68165

- 1 down the thre aded stud P/N 68169

- 1 to mate with the lower half clamp P/N 68167

- 1. The counterbore of the upper half clamp must mate with the radius of the gear (see figure 4).

5.8. Rotate the upper half clamp P/N 68165

- 1 slightly to insert the tab through a hole in the ge ar.

NOTE Ensure the upper half clamp tab is engaged in gear hole.

5.9. Fix the upper half clamp P/N 68165

- 1 to the lower half clamp P/N 68167

- 1 using one NAS1352C04H8 screw. Fingertight the

screw.

5.10. Remove the threaded stud P/N 68169

- 1 and install the second NAS1352C04H8 screw fixing the upper half clamp P/N 68165

- 1 to the lower half clamp P/N 68167

- 1. Fingertight the screw.

5.11. Torque the two NAS1352C04H8 screws to 0.45÷0.62 Nm (4÷5,5 inch

- pounds) and secure the lower half clamp P/N 68167

- 1 using lockwire MS2099 5C20 (see figures 5 and 6).

5.12. Remove all loose pieces of lockwire and any other debris that may have fallen into the box assy.

CAUTION If lockwire or other debris falls into the box assy, must be removed to prevent damage to the aircraft

.

5.13. Using needle

- nose pliers, remove the four foam cubes P/N 68172

- 1 from the box assy.

5.14. Place the cover P/N 64737

- 1 in its position on the box assy P/N 64734

- 2 to align screw holes.

5.15. Secure the cov er P/N 64737

- 1 to the box assy P/N 64734

- 2 using the four MS51957

- 2 screws.

5.16. In the area shown in figure 7, using an etch pen, on the pilot control box assy P/N 109

- 0010

- 81

- 103 mark B.T. 119

- 39 REV.A.

6. Reinstall the guard assy P/N 109

- 0703

- 07, the cover as sy P/N 109

- 0313

- 54, the fairing assy P/N 109

- 0011

- 88 (or, if installed the dual control kit P/N 109

- 0810

- 01, the guard assy P/N 109

- 0703

- 11) and the pilot seat P/N 109

- 0702

- 98 inB.T. 119

- 39

Page 10 of 1 7 accordance with the instructions given in the A119 / AW119 MKII

Maintenance Manual.

7. Return the helicopter to a ready to flight condition

.

8. Record compliance with PART III^ of this Bollettino in the helicopter log book

.B.T. 119

- 39

Page 11 of 17 Pilot control box assy P/N 109- 0010

- 81 -103

Co -pilot control box assy P/N 109-0010- 81

- 107



# FIGURE 1

Open the cover act ing on the four fixing screws

Open the cover acting on the four fixing screw sB.T. 119

- 39

Page 12 of 1 7 Pilot control box assy P/N 109

- 0010

- 81

- 103

Co -pilot control box assy P/N 109-0010- 81

- 107



# FIGURE 2 Verify that the gear l ocking pin is correctly installed in its seat

Verify that the gear l ocking pin is correctly installed in its seatB.T. 119

- 39

Page 13 of 17 N. 4 FOAM CUBES P/N 68172

- 1 TO PROTECT THE BOX ASSY INTERIOR



# FIGURE 3B.T. 119

- 39

Page 14 of 1 7

THREADED STUD P/N 68169

- 1 USED FOR CLAMP ASSY KIT

P/N 109G7606R01

- 101 INSTALLATION



# FIGURE 4B.T. 119

- 39

Page 15 of 17 CLAMP ASSY KIT P/N 109G7606R01

- 101 INSTALLED AND LOCKWIRED



# FIGURE 5B.T. 119

- 39

Page 16 of 1 7 109G7606R01

- 101 CLAMP ASSY KIT



# FIGU RE 6

68167

- 1 LOWER HALF CLAMP 68165

- 1 UPPER HALF CLAMP NAS135 2C04H8 SCREW (2 OFF)

TAB MUST INSERT IN A GEAR HOLEB.T. 119

- 39

Page 17 of 17 

# FIGURE 7 IDENTIFICATION AREA MARK: BT 119

- 39 REV. A WITH ETCH PEN

IDENTIFICATION AREA MARK: BT 119

- 39 REV.A WITH ETCH PEN 109

- 0010

- 81

- 107 COPILOT CONTROL BOX ASSY

109

- 0010

- 81

- 10 3 PILOT C ONTROL BOX ASSYNote: 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.