Order No.

4470

AGUSTA
®
A119 "KOALA"
Scale fuselage kit for Graupner / JetCat
turbine helicopter mechanics
or UNI-Mechanics 2000

Warning!
The contents of this kit can be assembled to produce a working helicopter, but the model
is by no means a harmless plaything. It is a complex flying machine, and if assembled in-
correctly or handled incompetently or carelessly it can cause serious injury to persons
and damage to property.
The turbine-powered model helicopter which is based on this fuselage kit requires con-
siderable experience in the operation of model helicopters, and this applies in particular
to the areas of competent assembly, initial set-up and maintenance. It is fundamentally
essential that the operator of this model should be a highly skilled, experienced model
helicopter pilot, capable of reacting correctly when unforeseen flight situations occur,
and able to recover from all manner of emergency situations, including auto-rotation
landings.
We wish to point out expressly that any model helicopter based on this
mechanical system is unsuitable for beginners.
You alone are responsible for completing the model correctly and operating it safely. The
kit also includes information sheets which contain safety notes and warnings. Please be
sure to read them and keep to our recommendations, as they are an essential part of
these instructions.
®
A119 "KOALA" is a registered trademark of AGUSTA S.P.A.

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY

ID# 53616
 AGUSTA A119 "KOALA"®

Foreword
The AGUSTA A119 “Koala”® is a single-engined turbine-powered helicopter designed for all ty-
pes of operation. Developed on the basis of the well-known twin-engined A109, the machine is
powered by only one Pratt & Whitney PT6B-37A turbine with a take-off power of 1002 BHP, a
continuous output of 872 BHP, and a robust skid landing gear as befits its role as a “workhorse”
helicopter. In the EMS (air rescue) version the cabin offers space for two stretchers. The full-size
aircraft on which our model is based is an Australian rescue machine operated by “CareFlight”,
and stationed in Orange, New South Wales. This machine was the first EMS version of the “Ko-
ala” helicopter.
Our model is drawn up to a scale of 1 : 5.8, and features a rotor diameter of 186 cm when fitted
with the scale four-blade rotor. The model is designed for the proven Graupner / JetCat heli-
copter mechanical system; the turbine exhaust gases exit the right-hand side of the fuselage via
a short, angled duct. Alternatively the model can be fitted with Graupner/Heim UNI-Mechanics
2000.
The white pigmented GRP fuselage is supplied with many machine-cut window openings and
other apertures, while excellent access to the mechanical systems and installed equipment is
provided by the large, two-part upper fuselage fairing and the removable side-doors. The doors
conceal the fittings for filling the fueltank and the gas container prior to starting the turbine. The
mechanical system, complete with installed servos and ancillary equipment, can be installed in
the fuselage from above as a single sub-assembly; it is attached to the fuselage by means of
two profiled aluminium rails.
The tail rotor drive system takes the form of a 2 mm Ø spring steel shaft, running in Teflon bea-
rings inside a 10 mm Ø aluminium tube. The shaft is connected to the tail rotor gearbox by
means of the coupling sleeve supplied in the set. The tail rotor gearbox and drive shaft therefore
form a single assembly which can be withdrawn from the rear of the fuselage as a unit for
maintenance purposes. The tail rotor control system is based on a cantilever CFRP pushrod.
The main fuselage, the upper fuselage fairing, the tail cone, the horizontal stabilisers and the
side-doors are moulded in white GRP with a high-quality glossy surface finish. If you intend to
decorate the model using the self-adhesive decals provided, there is no need to paint the model.
The sliding doors fit in recesses moulded into the fuselage. The vacuum-moulded glazing panels
feature recessed flanges which allow them to be fitted in the pre-cut window openings in the fu-
selage shell from the inside. This method of installation may require slight trimming of the aper-
tures, but does result in a model with an impressive scale appearance.

Specification
Fuselage length (excl. rotor) approx. 1920 mm
Fuselage width (excl. rotor) approx. 465 mm
Overall height approx. 570 mm
Model scale 5.8 : 1
All-up weight min. approx. 10,000 g

This kit has been produced with the kind approval and support of:
AGUSTA S.P.A. and NRMA Care Flight

2
 AGUSTA A119 "KOALA"®

Warning notes
• The contents of this kit can be assembled to produce a working model helicopter, but
the aircraft is by no means a harmless plaything. If assembled incorrectly or handled
incompetently or carelessly it can cause serious personal injury and damage to pro-
perty.
• When the model helicopter’s engine is running, the two rotors spin at high speed and
contain an enormous quantity of rotational energy. Anything and everything that gets
into the rotational plane of the rotors is either damaged or destroyed - and that inclu-
des parts of your body. Please take extreme care at all times with this machine.
• If any object obstructs the rotational plane of the revolving rotors, severe damage will
probably be caused to the rotor blades as well as the object. Broken parts may fly off
and result in enormous imbalance; the whole helicopter then falls into sympathetic
vibration, you lose control and have no way of predicting what the model will do next.
• You may also lose control if a problem arises in the radio control system, perhaps as a
result of outside interference, component failure or flat or faulty batteries, but in any
case the result is the same: the model helicopter’s response is entirely unpredictable.
Without prior warning it may move off in any direction.
• Helicopters have many parts which are naturally subject to wear, including gearbox
components, motor, ball-links etc., and as a result it is absolutely essential to check
and maintain the model regularly. It is standard practice with full-size aircraft to give
the machine a thorough “pre-flight check” before every flight, and this is equally im-
portant with your model helicopter. Constant checking gives you the opportunity to
detect and correct any faults which may develop before they are serious enough to
cause a crash.
• The kit also includes additional information sheets which include safety notes and
warnings. Please be sure to read them and keep to our recommendations, as they are
an essential part of these instructions.
• This helicopter is designed to be constructed and operated by adults, although young
people of 16 years or over may do so under the instruction and supervision of compe-
tent adults.
• The model features sharp points and edges which may cause injury.
• Flying model aircraft is subject to certain legal restrictions, and these must be obser-
ved at all times. For example, it is essential to take out third party insurance, you must
obtain permission to use the flying site, and you may have to obtain a licence to use
your radio control system (regulations vary from country to country).
• It is important to transport your model helicopter (e.g. to the flying site) in such a way
that there is no danger of damaging the machine. Particularly vulnerable areas are the
rotor head linkages and the tail rotor generally.

3
 AGUSTA A119 "KOALA"®

• Controlling a model helicopter successfully is not easy; you will need persistence and
determination to learn the skills, and good hand-eye co-ordination is a basic require-
ment.
• Before you attempt to fly the model you should study the subject of helicopters in
depth, so that you have a basic understanding of how the machines work. Read
everything you can find on the theory of helicopters, and spend as much time as
possible watching other model helicopter pilots flying. Talk to chopper pilots, ask
their advice, and enrol at a specialist model flying school if you need to. Many model
shops will also be prepared to help you.
• Please be sure to read right through these instructions before you start work on the
model. It is important that you clearly understand each individual stage of assembly
and the correct sequence of events before you begin building.
• Don’t make modifications to the model’s construction by using parts other than those
specifically recommended, unless you are certain of the quality and suitability of these
other components for the task.
• We have made every effort to point out to you the dangers inherent in operating this
model helicopter. Since neither we, the manufacturer, nor the model shop that sold
you the kit have any influence over the way you build and operate your model, we are
obliged to disclaim any liability in connection with it.

Liability exclusion / Compensation

As manufacturers, we at GRAUPNER are not in a position to influence the way you build
and set up the model, nor how you install, operate and maintain the radio control system
components. For this reason we are obliged to deny all liability for loss, damage or costs
which are incurred due to the incompetent or incorrect use and operation of our
products, or which are connected with such operation in any way.
Unless otherwise prescribed by binding law, the obligation of the GRAUPNER company
to pay compensation, regardless of the legal argument employed, is limited to the invoice
value of that quantity of GRAUPNER products which was immediately and directly
involved in the event which caused the damage. This does not apply if GRAUPNER is
found to be subject to unlimited liability according to binding legal regulation on account
of deliberate or gross negligence.

4
 AGUSTA A119 "KOALA"®

Contents
• Foreword .............................................. P.2
• Warnings .............................................. P.3
• Accessories, extra items required ............................ P.6
• 1. Assembling the model .................................. P.7
• 1.1 Preparation, explanatory notes ......................... P.7
• 1.2 Bulkheads ........................................ P.8
• 1.3 Tail rotor servo mount ............................... P.11
• 1.4 Mechanics mounting system ........................... P.12
• 1.5 Fueltanks ......................................... P.19
• 1.6 Skid landing gear ................................... P.22
• 1.7 Exhaust gas duct ................................... P.25
• 1.8 Tail rotor drive system ............................... P.27
• 1.9 Tail rotor control system .............................. P.30
• 1.10 Horizontal stabilisers ................................ P.30
• 1.11 Completing the upper fuselage fairing and tail cap .......... P.30
• 1.12 Fitting out the cockpit, glazing panels etc. ................ P.31
• 1.13 Doors .......................................... P.33
• 1.14 Exhaust pipes .................................... P.33
• 1.15 Centre of Gravity .................................. P.33
• 1.16 Installing the receiving system components ............... P.34
• 2. Setting up ........................................... P.37
• 3. Final checks before the first flight .......................... P.38
• 4. Maintenance ......................................... P.38

Notes regarding these instructions

We have invested considerable effort in producing these instructions, with the aim of ensuring
that your model helicopter will fly reliably and safely.
Please take the trouble to follow the instructions step by step, exactly as described, as this
guarantees a successful outcome. This applies to you whether you are a relative beginner or an
experienced “old hand”.

• Certain sections of the model are supplied pre-assembled, but they still need to be checked
and adjusted before use. It is entirely up to the modeller to ensure that all screws and other
joints are correctly seated and properly tightened, and that all adjustments and set-up
procedures are completed correctly.

• The comprehensive illustrations show how the model is constructed; be sure to read the
instructions which accompany the drawings.

• All the joints marked with this symbol need to be secured with thread-lock fluid,
e.g. Order No. 952, or bearing retainer fluid, Order No. 951. Remove all traces of grease
from the joint surfaces before applying the fluid.

5
 AGUSTA A119 "KOALA"®

Mechanics and accessories

Suitable mechanical systems:
Order No. 6810 Graupner / JetCat PHT-3 turbine mechanics
or
Order No. 4448.LN UNI-MECHANICS 2000 with OS MAX 91 motor, reduction ratio 10 : 1

Essential accessories
Turbine exhaust gas duct
Order No. 4470.100 Stainless steel exhaust gas duct with ejector sleeve

CFRP main rotor blades

Order No. 1272 Reflex section, 825 mm long, high-quality CFRP rotor blades
with light grey pigmented surface finish

CFRP tail rotor blades

Order No. 1346B Reflex section, 140 mm long, with light grey pigmented surface
finish

Optional accessories

Order No. 4448.400 Four-blade main rotor head

for A119 “Koala” (jet), NH 90® (jet) and similar large-scale model helicopters

Order No. 4448.501 Upgrade tail rotor, left-hand rotation drive shaft
for GRAUPNER / JetCat turbine mechanics
or
Order No. 4448.500 Upgrade tail rotor, right-hand rotation drive shaft
for UNI-Mechanics 2000

Adhesives
UHU plus schnellfest, Order No. 962, fast-setting epoxy
UHU plus endfest 300, Order No. 950, slow-setting epoxy, for gluing GRP to wood
UHU Blitz, thin cyano-acrylate, Order No. 5803
Thick cyano-acrylate, Order No. 1101, for tacking parts together
Filler agent, e.g. Order No. 963, for thickening resin

Tools required:
Minimum set: assortment of files (round, half-round, flat), set of twist drills, light tin-snips,
fretsaw, various screwdrivers, allen keys and general-purpose pliers. Coarse abrasive paper,
e.g. 100-grit, Order No. 1068.1, for roughening joint surfaces and for sanding the GRP
mouldings.

6
 AGUSTA A119 "KOALA"®

1. Construction
1.1 Preparation, notes
The numbers in (brackets) refer to the numbers in the Parts List at the end of these instructions.
These fuselages are hand-moulded and are likely to exhibit minor variations and irregularities on
the inside, especially along the central joint seam. Good access to the important mechanical
system components is provided by the removable side doors. Before finally installing any part,
please check carefully that it fits, trim where necessary and carry out a “dry run” (without glue).
Take your time, and work steadily and patiently. All screwed joints except those involving plastic
and those with self-locking nuts must be secured with thread-lock fluid; this is a basic rule, and is
not mentioned at every stage in the instructions. Where extra items and accessory components
are used they should be prepared and installed as described in the instructions supplied with
them.
The laser-cut wooden parts exhibit dark edges where they have been cut; these are residues
from the adhesive used to laminate the plywood layers. These residues should be removed ca-
refully using abrasive paper to ensure that the glued joints are as strong as possible.

1.1.1 Mechanics
In these instructions we assume that the main mechanical system for the model is already
completely assembled.

Turbine mechanics:
We recommend that you temporarily remove the rotor head before trial-fitting the mechanical
system in the fuselage. The receiver battery and the turbine power supply should be installed in
the fuselage nose, where they help considerably in maintaining the correct Centre of Gravity.
The battery must be connected to the switch harnesses using high-flex cable with a conductor
cross-section of at least 2.5 mm²
The connector box at the top front of the mechanics should be removed and re-installed at a
different position further down and / or to the side.

UNI-Mechanics 2000:
Before trial-fitting the mechanics in the fuselage we recommend that you temporarily remove the
silencer and exhaust manifold together with the rotor head. When the silencer is re-installed we
recommend that you also fit the silencer console (4450.149 - available separately) to attach it to
the mechanics. The hexagon starter cone, Order No. 4448.103, must be fitted to the cooling fan
in the mechanics, so that the motor can subsequently be started using the hexagon starter
adaptor, Order No. 1621.

Note:
The procedure for modifying the “A119 KOALA” for use with the UNI-Mechanics 2000
mechanical system is described in separate supplementary instructions.

1.1.2 Fuselage
Glued joints: the inside of the GRP mouldings must be roughened thoroughly at the joint
positions using coarse abrasive paper, otherwise there is no chance of a durable, permanent
bond. Nearly all the openings for windows, cooling air, undercarriage legs etc. are machine-cut
as standard. Various holes have to be drilled in the course of assembly to accept further
screwed joints, and their positions are described in the instructions. Where parts have to be
glued inside the fuselage, it is best to apply the adhesive on a long wooden stick or similar tool.
The surfaces of all wooden parts to be installed must be sealed to prevent fuel absorption;
applying thin cyano works well.
The upper fuselage fairing and tail cap have to be trimmed carefully to fit on the fuselage. The
machined openings in the fuselage will also need to be cleaned up using fine abrasive paper,
and trimmed where necessary. The window apertures must be large enough to allow the integral
recessed flanges of the glazing panels to rest snugly on the inside of the moulding.

7
 AGUSTA A119 "KOALA"®

1.2 Bulkheads
Locate the clips with M3 inserts, and attach one to each of the two front fore-and-aft bearers
(A2) using two 2.2 x 13 mm self-tapping screws. Fit the screws in the existing holes in such a
way that the clips are opposite each other when installed. Insert the two fore-and-aft bearers in
the nose bulkhead (A1), setting them vertical and parallel to each other, and connect them to the
instrument panel mount (A3). Glue the joints carefully.

Trial-fit the front main bulkhead (A4) in the fuselage; it must engage fully in the channel formed
by the front sliding door frame. The bulkhead should rest against the moulding all round, without
exerting pressure on the fuselage shell, and without bending or curving in any direction.

8
 AGUSTA A119 "KOALA"®

Once you are confident of this, fit the assembly consisting of the two fore-and-aft bearers and
the nose bulkhead through the bulkhead (A4) and into the nose of the fuselage. Trim the parts
so that the rear lugs of the fore-and-aft bearers engage in the two lower notches in the bulkhead
(A4); the lower edge of the bulkhead should rest against the rear edges of the fore-and-aft
bearers above the notches. To position the parts in this way you will need to bend the bulkhead
at the bottom to allow the fore-and-aft bearers to engage from the front.

Check that the bulkhead framework makes contact with the fuselage shell all round, without
forcing the moulding out of shape and causing it to bulge; carry out any further trimming
required. Ensure that the distance between the fore-and-aft bearers and the bottom edge of the
nose windows is the same on both sides; this produces a flange of even width adjacent to the
window apertures, where it forms a support for the glazing panels.

9
 AGUSTA A119 "KOALA"®

When you are sure that everything fits correctly, glue the bulkhead (A4) to the fore-and-aft bea-
rers initially (leaving the bulkheads in the fuselage!) before gluing the whole assembly to the fu-
selage shell. The best method is to tack the parts in place initially using thin cyano, then apply
plenty of thickened epoxy resin and glass fibre tape to all the joints. At the same time the sup-
ports for the front skid mounting (A17), (A18) can be glued in place at the appropriate points, ta-
king care to leave no voids (empty spaces) between them and the fuselage floor.

Ensure that the flange around the nose glazing panel remains free of resin, otherwise the
glazing panels will not fit flush when installed.
At this point glue the plate (A12) for the two receiver power supply switches to the bulkhead
(A4), as shown in the illustration.

10
 AGUSTA A119 "KOALA"®

1.3 Tail rotor servo mount

Attach a clip with M3 insert to the front half-bulkhead (A6) using two 2.2 x 13 mm self-tapping
screws, fitting them through the existing holes, and tighten the screws firmly.

Locate the (plain) tongue attached to the servo plate (A7), fit it into the notch in the rear half-
bulkhead (A5) as far as it will go, and screw it to the clip from the front using an M3 x 10 socket-
head screw, as shown in the illustration.

11
 AGUSTA A119 "KOALA"®

Draw a reference mark on the bottom joint seam of the fuselage shell at a point exactly 820 mm
forward of the shoulder of the bottom vertical stabiliser. Drill a 1.5 mm Ø hole at the marked
point, and fit a 2.2 x 13 mm self-tapping screw in it.
Measure off a second point towards the tail, 310 mm from the reference mark, again exactly on
the joint seam, and drill a second 1.5 mm Ø hole. Fit another 2.2 x 13 mm self-tapping screw in
the second hole.

Assemble the tail rotor servo mount and place it in the fuselage; set the servo plate (A7) hori-
zontal when viewed from the front, and check that the front half-bulkhead (A6) butts up against
the rear of the second self-tapping screw.

Glue the servo mount in this position using plenty of thickened slow-setting epoxy (UHU plus
endfest 300). Please note that these parts should not first be tacked in place with cyano; in this
case the self-tapping screw serves as an end-stop while the glue is curing, and can be removed
again easily when the glue has set hard.

1.4 Mechanics mounting system

Glue the parts (A9) to the rear main bulkhead (A8) at right-angles; ensure that the circular
opening in the bulkhead is at bottom left when viewed from the tail, looking forward. The tail
rotor servo lead passes through this opening when the servo is installed, hence the generous
distance between the hole and the turbine exhaust outlet.

12
 AGUSTA A119 "KOALA"®

Insert the parts (A10) in the parts (A9) at right-angles, but do not glue the joints; instead mark
their position on the bulkhead (A8). Remove the parts (A10) again.

Trim the bulkhead to fit in the fuselage in such a way that it ends flush with the rear edge of the
upper fuselage fairing, and rests against the self-tapping screw at the rear reference mark at the
bottom. Transfer the position of the parts (A10) onto the inward-facing edge of the fuselage
shell, and cut corresponding slots for the parts (A10) in this edge, so that the parts can be fitted
into the bulkhead assembly at their intended position.

When you are sure that everything fits, remove the bulkhead from the fuselage shell so that the
parts (A10) can be glued in place permanently.
This requires you to assemble the rear mechanics mounting, consisting of the rear transverse
bearer and the two steel support bolts. Attach these parts to each other and to the parts (A10)
using M4 x 10 socket-head screws, as shown in the illustration.
Glue the parts (A10) to the bulkhead assembly (A8) / (A9) in this position.

13
 AGUSTA A119 "KOALA"®

This assembly can now be moved back to its intended position in the fuselage. Sand back the
underside of the two rear supports (A11) for the skid landing gear so that they make good
contact with the fuselage floor when they engage in the appropriate notches in the bulkhead
(A8), as shown.

The whole rear bulkhead assembly can now be glued permanently to the fuselage shell using
thickened slow-setting epoxy laminating resin or adhesive and strips of woven glass cloth or
tape. Ensure that any trapped air bubbles between the parts (A11) and the fuselage floor are
filled completely with resin.

14
 AGUSTA A119 "KOALA"®

Cut a notch in both sides of the recessed flange in the upper fuselage opening, as shown in the
illustration:

Attach the two steel brackets to the front mechanics bearer using M4 x 10 socket-head screws,
as shown in the illustration. Attach the two wooden parts (A19) from the rear using M3 x 8 so-
cket-head screws, but don’t tighten them fully; tighten them just to the point where the parts can
still be swivelled and their position adjusted.

15
 AGUSTA A119 "KOALA"®

The assembly thus formed should now be trimmed to fit in the notches you previously cut in the
fuselage opening, as shown in the illustration. Note that the steel brackets should rest against
the edges of the openings, but must not force the fuselage shell out of shape; you may need to
adjust the notches to achieve this. It should now be possible to push the wooden parts (A19)
outwards in such a way that they make contact with the fuselage to the maximum possible ex-
tent.

Remove the interface box (IB) from its original position on the turbine mechanics (a) and mount
it in position (b). Bundle together the cables from the pump and the valves as shown, so that
nothing projects forward beyond the bearer plate.

16
 AGUSTA A119 "KOALA"®

Unscrew the front and rear transverse mechanics bearers, which you earlier trimmed to fit
together with the associated bulkheads, and attach them to the mechanics chassis using M4 x
10 socket-head screws and spring washers, as shown in the illustration.

17
 AGUSTA A119 "KOALA"®

Place the mechanics in the fuselage, and screw the rear transverse bearer in place again using
the steel support bolts. At the front re-attach the steel brackets and the wooden parts (A19) to
the front transverse bearer, in exactly the position previously found to be correct, and align them
inside the fuselage. Check also that the main rotor shaft is exactly central and stands vertically in
the fuselage when viewed from the fuselage nose. Since the rear support points are already
practically fixed, it is only possible to shift the mechanics slightly (if necessary) by undoing the
M4 x 10 screws in the rear transverse bearer.

When you are satisfied that the mechanical system is positioned correctly, and the rear screws
have been tightened fully, you can finally glue the front supports to the fuselage shell. This is ac-
complished by initially applying UHU plus endfest 300 between the steel brackets and the woo-
den parts (A19), then tightening the M3 x 8 socket-head screw. Before you leave the epoxy to
cure, check that the wooden parts rest as closely as possible against the fuselage shell, as pre-
viously established.

18
 AGUSTA A119 "KOALA"®

With the mechanical system installed, glue the parts (A19) in place as securely as possible (after
tacking them with cyano). Allow the adhesive to cure completely, then undo the four (outer) M4 x
10 socket-head screws and remove the mechanics again. Now apply plenty of resin and glass
fibres on each side to fix parts (A19) in place, leaving the fuselage resting on the appropriate
side while the epoxy sets hard. These glued joints should be carried out with particular care at
the door profile position: fill the transitional areas with thickened resin and glass fibres. When the
glue has cured, unscrew the rear steel support bolts from the wooden parts once more, apply
UHU plus endfest 300 to the support surfaces, and finally fit M4 x 10 socket-head screws and
washers through the supports (A10) from the underside; tighten the screws firmly.
Allow the epoxy to set to the point where it no longer runs, then install the mechanical system
again, tighten the retaining screws and place the fuselage upright until the glue has cured
completely. The mechanical system can now be removed from the fuselage again.

1.5 Fueltanks
Assemble the fueltank support from the parts (B1), (B2) and (B3), as shown in the illustration.

Attach the two fueltanks to this assembly using cable ties, as shown.

19
 AGUSTA A119 "KOALA"®

Place the whole fueltank assembly in the fuselage with the rear edge of the tank and its support
located 70 mm forward of the bulkhead (A8).

Fit a 2.2 x 9.5 mm self-tapping screw through the fuselage floor from the underside and into
each of the two fore-and-aft bearers (B1) of the fueltank support, in order to fix the tank
assembly to the fuselage.
When the mechanical system is installed again, it should just touch the front part (B2) at the
bottom; however, do not exert pressure which would distort the fuselage.

20
 AGUSTA A119 "KOALA"®

Filler valve and auxiliary gas tank mountings

Glue the spacers B5 to the base plates B4 in such a way that the 15 mm Ø holes line up exactly.
The aluminium valve holder plates should be glued to the spacers using UHU plus endfest 300;
reinforce the joints with four self-tapping screws each.
The holder for the auxiliary gas tank is attached to the left-hand base plate as shown in the
illustration, using an M4 countersunk screw, washer and self-locking nut; apply UHU plus
endfest 300 between the holder and the base plate for additional strength.

Note: if the installed turbine is fitted with a “kerosene start” system, i.e. auxiliary gas is not
required to start it, then the supports for the gas tank and the gas filler valve are not needed.

The two plates can now be glued to the bottom, non-machined part of the door openings using
UHU plus endfest 300, from the inside in each case, with the top edges located about 3 mm
below the door openings. Note that the assembly which includes the gas tank support should be
fitted on the left-hand fuselage side, with the gas tank at the front.
When the epoxy has set hard, mark the position of the 15 mm Ø holes on the fuselage shell and
cut them out. This procedure forms recessed mountings for the filler valves, and the edges
should be sanded smooth and neat. Chamfer or round off the edges so that the catches of the
valves which are housed in them can easily be operated, without being hindered at any point in
the recess.
The FESTO quick-release connections used as filler valves can be unscrewed in the middle
(spanner size 7 / 8 mm A/F), and then re-assembled with the support plates in the middle of the
sandwich. Please note that the kerosene filler valve should be fitted on the right of the aluminium
support plate, and the gas filler valve on the left. Apply a little UHU plus endfest 300 to the joints
for security - but take care to keep the adhesive out of the interior of the valves!
The gas tank should be mounted in the holder with the outlet facing up, and secured using a
cable tie. Connect the Y-shaped distributor piece to it using a short length of hose (single nipple
facing up, two parallel nipples facing down). Connect the second, lower nipple to the filler valve
using as short a piece of hose as possible. The single nipple of the Y-piece(facing up) is
connected to the turbine gas nipple. A filter should be installed in this hose in order to prevent
the gas flow being blocked as a result of icing when ambient temperatures are low.

21
 AGUSTA A119 "KOALA"®

1.6 Skid landing gear

Drill 3 mm Ø holes on the underside of the fuselage for the skid landing gear retaining clips, as
shown in the illustration, then drill them out to 4 mm Ø on the inside to a depth of 3 mm. Glue an
M3 captive nut in each hole.

The skid landing gear consists of two skid bars made of stainless steel tubing and two skids
made of aluminium tube. The skid bars are attached to the skid tubes using the following
procedure: appropriate holes are drilled in the skid tubes, and carbon fibre connecting dowels
are glued in them at the correct angle using epoxy. The skid bars are then fitted onto these
dowels and glued in place. The joints are finally covered by gluing ABS caps over them; the
latter are based loosely on the full-size connecting pieces.

We recommend that you prepare a simple jig for assembling the landing gear, e.g. from cheap
scraps of hardwood sheet from your local DIY store. The component parts can then be attached
temporarily to the jig in the correct position prior to applying the glue, leaving an accurately
made, exactly fitting distortion-free landing gear to be removed from the jig once the epoxy has
cured. A jig is also very useful if repairs to the landing gear ever become necessary. The
illustrations show a suitable jig which we have tried and tested ourselves.

22
 AGUSTA A119 "KOALA"®

The holes in the skid tubes should be bored out to around 16 mm Ø. Take care - don’t drill right
through the skids! Form a set of four sealing plugs from rolled-up paper, and push them into the
skid tubes so that they are located about 3 cm in front of and behind each hole. This produces
four chambers which can be filled completely with thickened epoxy resin surrounding the 14 mm
Ø CFRP dowels. The slightly oversized holes provide sufficient play to enable you to align the
dowels correctly together with the skid bars when pushed down onto them. The bars should be
at right-angles to the skid tubes when viewed from above, and inclined 10° to the rear when
viewed from the side. The skid tubes must be parallel to each other, with the front up-turned
ends aligned exactly vertically.

Please remember to slip the vacuum-moulded skid joint fairings onto the skid bars before they
are glued to the connecting dowels. The fairings are handed (different left and right), and they
should be fitted high enough up on the bars to be out of the way when the landing gear joints are
made.
Once you have glued the landing gear joints using thickened epoxy laminating resin (or a slow-
setting epoxy-based adhesive), the ABS fairings can be slid down over the joint areas and glued
in place using plenty of Stabilit Express (polyester-based resin adhesive). Wipe away excess
glue immediately, and the final surface should be suitable for painting immediately the epoxy has
cured; all you have to do is “key” the surfaces with fine abrasive paper to ensure that the paint
adheres properly.

23
 AGUSTA A119 "KOALA"®

Fit a 2.9 x 13 mm self-tapping screw into the round shoulder projecting from the centre of each
of the four plastic sealing plugs, leaving a gap of about 2 mm under the screw-heads. Press the
plugs into the skid ends with the screws projecting out of the skids, leaving about 2 mm of the
plastic parts exposed. The vacuum-moulded cover caps can now be glued onto these using
Stabilit Express; it is best to fill the recesses in the sealing plugs and the caps completely with
glue, and join them in such a way that the caps engage over the edge of the plugs, and line up
flush with the ends of the skid tubes. Glue the caps in place in pairs: both front then both rear,
one after the other. The screws previously fitted in the sealing plugs form a stable anchor when
they are embedded in adhesive. Stand the landing gear up on the glued ends after joining the
parts.

The completed skid landing gear is attached to the underside of the fuselage using four plastic
clips, each secured with two M3 x 16 socket-head screws. Note that an ABS spacer plate is
inserted between the skid bars and the fuselage shell at each clip position; if the landing gear is
not aligned correctly, you can fit additional spacer plates to compensate for the inaccuracy.

24
 AGUSTA A119 "KOALA"®

1.7 Exhaust outlet

The turbine’s exhaust outlet is located on the right-hand side of the fuselage only, just aft of the
turbine, and runs through an appropriately shaped exhaust duct (not included in the kit). A
single-sided exhaust was selected in order to compensate for a particular problem: the thrust of
the tail rotor usually has to be corrected by tilting the helicopter to the left. However, the residual
thrust of the turbine exhaust compensates for this, with the result that the helicopter sits almost
completely level relative to its longitudinal axis when hovering.
The first task is to cut a circular opening in the right-hand side of the fuselage for the turbine
exhaust gas outlet. The exhaust gas duct is fitted with an ejector ring which has to be attached
permanently to the fuselage; the exhaust pipe is then held in it by sprung metal strips. The
arrangement of the exhaust pipe in the ejector sleeve helps to suck air out of the fuselage via
the exhaust pipe; this in turn cools the fuselage interior, and also keeps the ejector pipe so cold
that it can be allowed to rest against the painted fuselage shell without causing damage. The
position of the opening is marked on the fuselage shell as shown in the illustration; cut it out as
carefully as you can.

25
 AGUSTA A119 "KOALA"®

The wooden parts A20 should be attached to the ejector ring using 2.2 x 6.5 mm self-tapping
screws as shown. You will find that the screw tips project out of the wood on the reverse side of
parts A20; file the ends back flush.

Trim the hole in the fuselage if necessary, and insert the ejector ring in the opening from the in-
side. Rotate it so that the curved outside edge of the ring lies as closely parallel as possible to
the surface of the fuselage, i.e. with an even spacing all round. Glue the wooden parts A20 to
the fuselage shell in this position using thickened resin. The ejector ring should not be glued in
place; you can remove it at any time by undoing the three self-tapping screws, e.g. if you wish to
paint the fuselage.
At a later stage the exhaust pipe will fit inside the ejector sleeve, located by the sprung metal
strips. It is only actually attached to the turbine outlet, onto which it is pushed as far as possible
and held with a single M3 x 8 mm socket-head screw. A threaded hole must therefore be cut in
the turbine’s outlet stub (caution: take every care to avoid any drilling swarf falling into the tur-
bine!). You will need to install and assemble everything in order to define the position of this
screw-hole: place the mechanics in the fuselage and set the assembly at an angle so that the
exhaust pipe can be pushed on to the turbine as far as it will go, then fit the other end of the ex-
haust pipe into the ejector sleeve before moving the mechanical assembly back into its final po-
sition. Tighten the mechanics retaining screws. Rotate the exhaust pipe on the outlet stub of the
turbine so that it stays “put” by itself, and at the same time rests inside the ejector sleeve without
placing anything under stress. When you are confident that all is well, locate the 3 mm Ø hole in
the exhaust pipe and transfer its position to the turbine outlet located inside it, then dismantle
everything and drill and tap the threaded hole at the marked point. At a later stage you will fit an
M3 x 8 socket-head screw and spring washer through the two parts to prevent the exhaust pipe
slipping off the turbine outlet.

26
 AGUSTA A119 "KOALA"®

1.8 Tail rotor drive system

Assemble the tail rotor drive shaft brace from the parts (A13), (A14) and (A15), but take care not
to glue part (A15) at this stage.

Place this assembly on the recessed fuselage flange 70 mm aft of the bulkhead (A8), set it
parallel to the bulkhead, and mark the position of the holes in the parts (A14) on the recessed
flange. Remove the loose components, and drill the holes 3 mm Ø.

Reinforce the underside of the recessed flange with scrap pieces of plywood under the hole po-
sitions, then drill them out to 4 mm Ø and press four captive nuts into them from the underside;
glue the nuts in place. The tail rotor drive shaft brace can now be temporarily fixed in place using

27
 AGUSTA A119 "KOALA"®

four M3 x 10 mm socket-head screws. Check that everything fits correctly, then remove the
shaft brace again.

Glue together the two tail rotor bulkheads (A16) with their edges flush; slip the aluminium joiner
sleeve and drive shaft for the tail rotor housing through the round holes in order to ensure cor-
rect alignment.
Cut the 10 mm Ø aluminium tube to a length of 890 mm. Locate the stainless steel tube with
Teflon insert, and cut it down to the same length: 890 mm. The ends of the tube should be cur-
led over on the inside in such a way that the Teflon sleeve cannot slip out of it. The best way to
achieve this is to cut the tube to length at both ends using a small tubing cutter (rolling blades),
as this tool automatically forms the cut ends to the desired shape. Slip the five nylon bushes
onto the stainless steel tube, and distribute them equally along its length; glue them to the tube
using cyano. Slide this complete assembly into the aluminium tube, position the stainless steel
tube with the Teflon bushes so that it ends about 1 mm inside the aluminium tube, then secure it
with cyano.
The kit is supplied with two aluminium joiner sleeves with different internal diameters; these are
used to connect the guide tube to the tail rotor housing. Select the appropriate sleeve to suit the
tail rotor you intend to install (normal or upgrade version).
Slide the guide tube into the joiner sleeve from the front until it ends flush with the step on the in-
side. Secure it in this position with two M3 x 3 grubscrews, which are fitted in the joiner sleeve
from the outside.
The quick-release coupling sleeve 4618.58 should now be pushed onto the tail rotor drive shaft
in such a way that its front, pre-formed end rests inside the sleeve; fit the retaining collet 56.0
(with grubscrew fitted) after this, but leave it loose for the moment. Slide the shaft forward into
the guide tube.

Push the drive shaft right back so that it can be inserted as far as it will go into the shaft
coupling, and secure it with the M4 grubscrew. Now slide the tail rotor housing into the joiner
sleeve to its full depth; at a later stage it is secured using two M3 x 3 grubscrews, but they
should not be tightened yet.
The drive shaft must run in a gentle, even curve to ensure that it does not vibrate when running.
A further problem is that the tail rotor would be located very close to the fuselage side if installed
in the conventional manner (parallel to the model’s longitudinal axis), and this can generate an
unpleasant siren-like noise depending on the pitch angle of the blades. The tail rotor should the-
refore be installed in such a way that it runs almost parallel to the outside face of the fuselage,
i.e. at an angle relative to the fuselage centreline. This can be accomplished by curving the
guide tube in a gentle S-shape, evenly over its whole length; however, it is very important to
ensure that the shaft exits the front coupling straight and accurately centred, and enters the rear
tail rotor shaft coupling equally straight; this is actually defined by the design of the connecting
sleeve. This means that the curvature must be positioned in the area of the guide tube only. It is
very important not to allow the shaft to exit the quick-release sleeve at an angle!
Trim the double tail rotor bulkhead (A16) to fit in the tail end of the fuselage, but do not glue it in
place at this stage. It should be located about 20 mm forward of the rear edge of the fuselage
shell. Push the tail rotor assembly into part (A16) from the rear, coupling sleeve first, until the
mounting lugs of the gearbox housing rest squarely on the bulkhead; you will need to cut away
the fuselage shell in the area of the tail rotor to obtain adequate clearance. Set the tail rotor shaft
exactly horizontal, and fix the gearbox to the bulkhead using two 2.9 x 16 mm self-tapping
screws; the third, external mounting lug is not used.
The next step is to adjust the fitting of the tail rotor assembly, which involves unscrewing the unit
from the bulkhead, removing it from the fuselage and then re-installing it - possibly several ti-

28
 AGUSTA A119 "KOALA"®

mes: keep the curvature of the guide tube as broad an S-shape as possible, so that the tail rotor
runs as closely parallel to the outside edge of the tail boom as possible when viewed from
above, even though the drive shaft at the front remains centred on the longitudinal axis of the fu-
selage. The shaft must be routed to the mechanics, resting in the rectangular opening of part
(A13) at the bottom, together with the wooden part (A15) (which is not yet glued in place). Tem-
porarily attach it at that point using a cable tie.
When you have succeeded to this point, temporarily secure the tail rotor and the tail rotor bulk-
head (A16) (which is now permanently attached to it) to the fuselage. Check alignment once
more - tail rotor shaft horizontal, tail rotor as close to parallel to the outside edge of the fuselage
as possible - then glue the bulkhead to the fuselage: start by applying epoxy to the joint from the
rear, and allow it to cure fully. Later, when you have unscrewed the tail rotor assembly again,
apply plenty of thickened epoxy resin to the front face of the bulkhead joint. This is a good mo-
ment to bend the tailskid to shape from 3 mm Ø steel rod; glue it in the bottom of the vertical
stabiliser, as shown in the kit box illustration.
Allow the resin to cure fully, then carefully withdraw the tail rotor from the connecting sleeve, as
far as the quick-release sleeve and the loose collet at the front end of the drive shaft permit.
Replace the mechanics in the fuselage and slide the front end of the drive shaft into the quick-
release coupling of the mechanics. Push the shaft into the coupling sleeve whilst pushing the tail
rotor forward again.
Position the shaft in the yoke of the quick-release coupling, and push it forward so that it strikes
the end at the front; now measure the distance between the tail rotor gearbox and the bulkhead.
Add 1 mm (for clearance) to the measured dimension, then shorten the rear end of the drive
shaft by the calculated amount. Withdraw the shaft from the tail rotor gearbox, and carefully de-
burr the cut end. Push the shaft right into the tail rotor gearbox, and mark the point on the shaft
where the M4 grubscrew engages on it. Grind a small flat area in the steel rod over a length of
about 6 mm, using a grinding stone or a small cut-off disc. The shaft should then be slid right
into the tail rotor gearbox and locked using the two grubscrews. Slide the tail rotor forward and
screw it to the bulkhead, closing the quick-release coupling at the front at the same time. The
shaft should now have about 1 - 2 mm axial play in the quick-release coupling; check this care-
fully.

With the tail rotor and drive system completed and installed, locate the wooden retaining plate,
part (A15) (it is loose on the guide tube), set it exactly horizontal, and attach it to the tube using
two cable ties. Now check the full route of the shaft one last time, starting from the quick-release
sleeve: rotate the drive system several times and ensure that the shaft does not bind at any
point. When you are satisfied, glue part (A15) to the shaft brace (A13) in the appropriate
position. Two cable ties are used to pull the guide tube upwards against this support. This
method of fixing means that the tube is removable at any time: simply cut through the cable ties,
and fit new ones when you re-install it.
When you are confident that everything fits correctly, the tail rotor drive system can be installed
permanently: apply bearing adhesive / retainer fluid to the joints, then carefully clamp the drive
shaft in place at the tail rotor gearbox using the two grubscrews, (one of the grubscrews must
engage fully on the flat section ground into the shaft); allow the adhesive to run between the
spring steel shaft and the hollow shaft. Now carefully secure the tail rotor housing in the
connecting sleeve using the grubscrews. Introduce this assembly into the tail end of the fuselage
from the rear once more, at the same time inserting the shaft into the quick-release coupling at
the front; now secure the tail rotor gearbox by tightening the self-tapping screws. The guide tube
should also be secured against the brace at the front end using two cable ties. Tighten the
retaining collet 56.0 at a point about 1 - 2 mm from the union sleeve, as shown in the drawing.

29
 AGUSTA A119 "KOALA"®

1.9 Tail rotor control system

The tail rotor servo is installed in the removable servo mount (A7): undo the M3 screw at the
front and withdraw the servo plate from the bulkhead (A5). Install the servo with the cable exit
grommet facing forward, then re-install the servo plate complete with the servo. The linkage
takes the form of a cantilever CFRP pushrod. The tail rotor bulkhead (A16) features an opening
through which the pushrod runs; check that the pushrod is free to move the tail rotor from one
end-point to the other without fouling the bulkhead.

Screw a ball-link onto each of the 75 mm threaded rods to a depth of about 7 mm. Cut the
CFRP tube to a length of 605 mm, and glue one of the threaded rods in each end using UHU
plus endfest 300. At the front end the ball-link should butt up against the end of the CFRP tube;
at the rear end the threaded rod should be positioned to produce an overall pushrod length
(between ball-link centres) of 668 mm, as shown in the illustration. Attach linkage balls to the
servo output arm and the bellcrank using M2 x 8 screws and nuts; the ball on the bellcrank
should be as far outboard as possible. Press the ball-links on the pushrod onto these balls to
connect the output arm to the bellcrank. Check that the tail rotor control system works smoothly,
without fouling or binding at any point.

1.10 Horizontal stabilisers

The horizontal stabiliser panels are mounted on a carbon fibre rod which passes through holes
in both sides of the fuselage tail boom. Start by drilling 2 mm Ø holes in the tail boom at the
marked points. Fit a length of steel rod through the two holes and check that it is horizontal, and
at right-angles to the fuselage centreline when viewed from above. Manufacturing tolerances in
the fuselage moulding process may produce a slight misalignment; if this is the case, the error
can be corrected during the next stage, when the holes are gradually opened up to the final
diameter of 6 mm.
Fit the 6 mm Ø CFRP rod through these two holes, set it central and carefully glue it to the
fuselage shell, applying the glue on the inside of the tail boom only: lay the fuselage first on one
side, then on the other, and apply plenty of thickened resin to the joint on each side in turn.
Drill a 6 mm Ø hole in the root face of each horizontal stabiliser panel, located 30 mm from the
leading edge. The stabiliser panels can now be slid onto the CFRP rod - note that the convex
face of the stabiliser airfoil should face down! Set the panels horizontal and parallel to each
other, then glue them to the CFRP rod and the fuselage shell.

1.11 Completing the upper fuselage fairing and tail cap

The two halves of the upper fuselage fairing are joined using three 2.2 x 6.5 mm self-tapping
screws on each side; the fairing itself is then attached to the fuselage using 25 more 2.2 x 6.5
mm self-tapping screws, spaced out along the peripheral flange; trim the fairing slightly if neces-
sary so that it rests snugly on the shell all round, with the very minimum of gaps. Glue small pie-
ces of scrap plywood on the inside of the screw-holes to prevent the screw threads stripping the
holes.
When you are sure that everything fits properly, seal the rectangular openings in the fairing by
gluing fly grille material behind them. At the bottom, where the fairing rests in the recessed fu-
selage flange, you may need to sand depressions for the grille in the recess to avoid the fairing
standing proud of the surface. The central oval opening at the front of the upper fuselage fairing
should also be sealed by gluing the same grille material behind it.

The tail cap is next trimmed to fit; this is easiest to do initially if you remove the tail rotor, so that
you can ensure that the cone continues the straight run of the fuselage, and fits snugly all round
with the minimum of gaps. The tail cap can then be attached using four 2.2 x 6.5 mm self-tap-
ping screws spaced out all round the periphery, as described for the upper fuselage fairing. Cut
a clearance opening for the tail rotor gearbox and its lever on the left-hand side of the tail cone.

30
 AGUSTA A119 "KOALA"®

1.12 Fitting out the cockpit, installing the glazing panels, etc.
Cut out the vacuum-moulded cockpit back panel as shown in the illustration, and fit it in the
fuselage in such a way that its full area rests against the bulkhead (A4); the two cut-outs at the
bottom should engage over the bulkheads (A2). Cut a tongue from scrap ABS sheet material
and glue it to the top of the bulkhead, so that it secures the cockpit back panel at the top.

Cut out the vacuum-moulded cockpit floor as shown in the illustration, and drill 3 mm Ø holes at
the two marked points. The floor should be positioned pressing against the cockpit back panel at
the rear, resting against the bulkheads (A2). Fix the floor in place using two M3 x 8 socket-head
screws fitted into the previously installed clips.

The vacuum-moulded squabs of the pilots’ seats can now be glued to the consoles which are
moulded into the cockpit floor as shown in the illustration; at the rear they should butt up against
the backrests moulded into the cockpit back panel, and line up with them at the sides.

31
 AGUSTA A119 "KOALA"®

Cut the front cockpit panel to shape and trim it so that it rests against the outside edges of the
supports which are an integral part of the bulkheads (A2). Glue a piece of scrap hardwood in the
centre of part (A3) and sand it back to the point where the front panel can be held in place with a
single 2.2 x 6.5 mm self-tapping screw, without being pushed out of shape.

Trim the instrument panel to fit in the instrument binnacle, and glue it in place; this assembly can
then be glued to the front panel slightly offset to the right, resting on the centre console. The
instrument panel should start directly aft of the angled surface of the console.

Cut out the individual glazing panels, leaving a generous gluing flange all round each one. The
side glazing panels and the lower nose glazing should be trimmed to fit so that they end flush
with the outside surface of the fuselage; glue them in place permanently using UHU plus endfest
300.

32
 AGUSTA A119 "KOALA"®

Carefully trim the front glazing to fit in such a way that it rests evenly in the recessed flange all
round, and is flush with the outside surface of the fuselage. The front screen includes a moul-
ded-in vertical central strut, which should be reinforced by gluing the wooden part (A21) on the
inside. The front glazing should not be glued in place permanently; attach it using six 2.2 x 6.5
mm self-tapping screws so that it can be removed at any time. Glue pieces of scrap material
(glazing panel offcuts) over the inside of the holes for the front screen retaining screws to rein-
force those areas.

1.13 Doors
The side-mounted doors slide open on the full-size machine, and this can be emulated on the
model if you wish; the actual method of actuation is left up to the builder. Naturally the peripheral
flange must first be removed in this case.
However, a much simpler and very practical solution is to make the doors completely removable,
as this option gives optimum access to the interior space whilst making the whole system more
robust mechanically.
Cut two pins from 2 mm Ø mild steel rod and glue them in the top of the door as shown. Drill
matching holes in the upper part of the door recess, so that the pins engage in them and retain
the door at the top when it is pressed against the flange. The door is then retained at the bottom
by a central latch consisting of steel braided cable, fitted with a soldered brass linkage ball at the
outside end which acts as a handle; this is the only part of the concealed latch which is exposed.
The flexible “snake” outer sleeve should be deployed in a loop inside the fuselage and positio-
ned in such a way that the braided cable inside it can be pushed from the underside into another
small piece of snake outer sleeve glued in the bottom of the door (tin the end of the braided
cable to stiffen it). To open the door simply withdraw the braided cable using the ball as a
handle; when the other end no longer engages in the door, the panel can be swung out of the
recess and removed.

1.14 Exhaust pipes

The kit contains dummy turbine exhausts moulded in smoked-tint plastic. They should be
trimmed to fit in the machine-cut circular openings in the upper fuselage fairings, and simply
glued in place.
A highly realistic impression of a discoloured exhaust can be obtained by painting the inside of
the exhaust pipes using an airbrush or spray can: first a very thin (non-covering) coat of copper
colour, then silver, and finally matt black.

1.15 Centre of Gravity

The Centre of Gravity should be located 0 - 5 mm forward of the front edge of the main rotor
shaft; you may need to install lead ballast to achieve this.

33
 AGUSTA A119 "KOALA"®

1.16 Installing the receiving system components

When installing the electronic components it is important to keep strictly to the following recom-
mendations, in order to ensure that the model is as safe and secure as possible when in the air.
The turbine is controlled by a micro-controller, i.e. a small computer with its own power supply,
and a data bus connecting the ECU, turbine interface and GSU circuit board. This type of sys-
tem inevitably generates radio frequency interference, and to counter this it is essential to make
every effort to keep it spatially separated from the components of the receiving system. You
must also avoid routing the associated cables parallel to each other, and even allowing the leads
of the two systems to cross over should be avoided.
In the case of the A119 “KOALA” the systems are separated spatially in a virtually ideal manner,
as the receiving system is installed in the right-hand side of the fuselage nose section, and the
turbine control system on the left-hand side. These two areas are also separated physically by
the space between the two fore-and-aft bulkheads below the cockpit.

1.16.1 Airborne power supply

The power supply for the receiving system takes the form of a single four-cell NiMH battery (4.8
V / min. 2 Ah capacity) installed in the fuselage nose. Two high-power switch harnesses (Order
No. 3050) are fitted adjacent to each other in the appropriate cut-outs in the switch support
(A12). Their power leads should be soldered together (after removing the G2 plugs), and exten-
ded using high-flex cable with a conductor cross-section of at least 2.5 mm². Run this lead to the
battery in the fuselage nose, routing it along the right-hand fore-and-aft bulkhead. At this point
the battery is connected using G2 gold-contact connectors which have to be soldered on. This
arrangement ensures that current flows to the receiver via two switches and four power cables;
the redundant switches and connecting leads ensure a high level of security in the system.
The turbine battery is also housed in the fuselage nose. Cut down its leads to the minimum pos-
sible length, fit a charge socket and deploy the cable to the ECU, running it along the left-hand
fore-and-aft bearer towards the rear. The ECU should be installed on the left-hand side of the
fuselage below the port seat. It makes sense to install the charge socket low down in the nose
area, where it is out of sight but still easily accessible.

1.16.2 Receiver, gyro system

The receiver and gyro system should be installed on the right-hand side, under the starboard
seat. Connect the gyro electronics to the receiver, pack the receiver in foam and install it at the
rear with the servo sockets facing the tail. Fit the gyro sensor in front of the receiver; it can be
stuck to the fuselage floor using double-sided foam tape.

34
 AGUSTA A119 "KOALA"®

1.16.3 Servo extension leads

Extension leads are required for the servos installed in the mechanics (swashplate, rotor brake);
the leads should be bundled together to form a loom, and connected permanently to the
receiver. With this arrangement it is possible to leave the extension leads connected to the
receiver when the servos in the mechanics have to be disconnected in order to remove the
system.
Another extension lead is used to connect the tail rotor servo to the gyro system, and should be
deployed aft of the fueltank along the bulkhead (A8) from the right side to the left, then through
the appropriate circular opening towards the rear.

1.16.4 Receiver aerial

The receiver aerial should be deployed as follows:
Slip the aerial in a plastic sleeve (Order No. 3593) before installing it in the fuselage. Start at
front right, run it up to the right along the edge of the front screen, then along the front edge of
the roof window to the centre, then aft, through the top of the bulkhead (A4). At this point the
aerial lies along the upper fuselage fairing, and terminates adjacent to the main rotor shaft. The
plastic sleeve can be held in place using cable ties.
The advantage of this method of aerial deployment is as follows: it is well clear of any
mechanical components which could radiate electrical noise, and it forms an efficient receiving
plane regardless of the helicopter’s orientation.

1.16.5 Turbine control electronics (ECU)

As already mentioned, the ECU is installed below the left-hand seat, with the battery socket
facing forward.
Install the LED / socket board on the left-hand base plate of the valve mount from the inside, so
that the LEDs can be observed through the window when the door is closed; the GSU can be
connected when the door is opened.

The mechanical system is supplied complete with factory-made cable looms for connecting the
ECU to the turbine and the LED / socket board:
• One loom (around 50 cm long) connects the ECU to the cut-off valves for gas and fuel, and
also to the fuel pump. These sockets are grouped together on the side of the mechanics in
an interface box mounted above the pump / valve platform, and terminate in a multi-pin
connector. At the other end are the connectors on both sides of the ECU, which are labelled
appropriately. It is particularly important to ensure that each plug is connected with correct
polarity. Note that these connectors remain plugged in even when the mechanical system is
removed from the model; the system is disconnected by withdrawing the (red) multi-pin plug
from the interface box.
• A three-core lead (approx. 30 cm long) fitted with (green) multi-pin plugs is used to connect
the ECU to the glowplug and starter motor sockets on the lower interface box.
• A black cable with RJ45 (“Western”) connectors (around 30 cm long) connects the ECU to
the speed and temperature sensors via a plug and socket in the lower interface box.
• A lead of the same type is used to connect the ECU to the LED / socket board.

The remaining lead is around 1 m long, and is used as required to connect the GSU to the LED /
socket board.

We urgently recommend that you keep to the installation arrangement described here, as it is
very important for the reasons outlined earlier. You may well think that access would be
generally easier and more convenient if the LED / socket board were mounted on the same side
as the receiver switch, but this is definitely not a good idea.

35
 AGUSTA A119 "KOALA"®

1.16.6 Supplementary measures

The basic rule when preparing any turbine-powered helicopter is to ensure that all parts,
including cables and connectors, are securely fixed, and that there are no loose
components in the fuselage which could be sucked into the turbine.

Further precautions can be taken in order to guard against fires inside the fuselage, and to help
you maintain control of the situation and limit the damage if a fire should occur:

• Wrap the hoses which carry starter gas in silicone spiral tubing, which you cut yourself from
suitable fuel tubing or exhaust hose. If a flame occurs briefly, this will help to prevent it
burning through the hose and igniting the starter gas.

• As far as humanly possible, deploy all cables along the bottom of the fuselage, and wrap
them in silicone spiral tubing to avoid fire damage.

• All important servo leads (swashplate) should be grouped together in cable looms, and
wrapped in silicone spiral tubing to prevent fire damage.

• All non-vital servo leads (auxiliary functions, lighting, etc.) should be grouped together in
cable looms and protected with silicone spiral tubing in the usual way. The power supply to
these functions should also be passed through a fuse (approx. 3 A … 6 A); this ensures
that a short-circuit following a cable fire cannot disable the entire receiving system.

• It is important to ensure that inflammable gases cannot collect inside the fuselage when the
model is not in use - particularly in the Summer. Remove both doors at regular intervals to
provide an airflow through the fuselage.

• The liquid gas system must be checked at regular intervals for leaks: a fully charged gas
tank should remain full even after several days.

• Occasionally lubricate the gas filler valve with a little silicone oil, as the rubber seal
becomes brittle in contact with liquid gas, and may then leak. The external installation of the
valve was chosen deliberately to ensure that gas cannot collect inside the fuselage (the gas
used is heavier than air) even if the filler valve should leak.

• Bearing in mind all the points outlined above, an easy means of obtaining a significant
increase in operational safety is to convert the turbine to “kerosene start”, i.e. to remove
the need for liquid gas altogether. Naturally this eliminates all the potential problems and
hazards connected with the gas supply.

36
 AGUSTA A119 "KOALA"®

2. Setting up
The following sections are intended as a supplement to the explanations included in the
assembly manuals supplied with the mechanics.

2.1 Setting up the cyclic control system

The basic settings for the roll-axis and pitch-axis control systems should already be correct if
you have installed the linkages exactly as described in the instructions. Since the instructions
include the lever lengths (correct linkage holes), the final set-up procedure is carried out using
the electronic facilities provided by your transmitter. Note that the servo travels should not be
excessive. Ensure that the swashplate does not strike its end-stops on the main rotor shaft at
either end-point of the transmitter stick travel for roll-axis and pitch-axis movements, as this
would mean that collective pitch control would not be linear, i.e. axial movements would be
restricted.

2.2 Main rotor pitch settings

The main rotor pitch is measured using a pitch gauge (optional accessory, not included in the
kit). The following table shows the recommended basic settings, but the optimum values may
well vary from model to model according to the rotor blades you are using.

Minimum Hover Maximum

Hovering and practice +1° 9°...10° 18°
Cruise +1° 8°... 9° 18°
Auto-rotation +1° 10° 18°

The best way of setting the correct blade pitch on the transmitter is as follows:
1. Measure the hovering pitch and set it to the correct value mechanically.
2. Measure collective pitch maximum and minimum and adjust the values using your
transmitter's collective pitch curve facility.

2.3 Power control system

Power control is automatic through the turbine’s speed governor; all the pilot has to do is select
the desired system rotational speed at the transmitter within the range 1150 … 1260 rpm.

All the functions of the turbine control system are operated using a single radio control channel.
The simplest method of control is to use a slider:

• OFF Bottom end-point

• Stand-by Centre
• Start Top end-point
• Idle Centre again
• Nominal speed Centre … top end-point
• Auto-OFF Bottom end-point

The programming facilities of modern radio control systems such as the mc-22 or mc-24 provide
a much more convenient method of operating the turbine control system:

• The throttle limiter is used to switch from OFF to STAND-BY.

• A separate slider is used to set the system rotational speed between idle (bottom end-point)
and the nominal rotational speed (top end-point), which varies according to the selected
flight phase.
• The turbine is started using a separate momentary switch.
• The throttle limiter is used to stop and cool the turbine.

If you have an mc-24 transmitter, this configuration is programmed as follows:

1. In the Heli mixer set the end-points of the throttle curve to “0” by pressing CLEAR, to
produce a horizontal straight line through the 0-point.
2. In the “Stick mode” menu switch off the trim of the throttle / collective pitch stick.

37
 AGUSTA A119 "KOALA"®

3. In the “Transmitter controls” menu assign the physical control (slider or switch) for the
throttle limiter.
4. In the “Transmitter controls” menu assign the slider for rotational speed setting to “Throttle
(Ch 6)”, and reduce travel to +50% symmetrically. Offset the centre point to +50% in the “up”
direction, and set a transition time of 5 seconds for both directions.
5. Program a free linear mixer which is operated by the momentary switch (for starting the
turbine): “S -> 6”; mixer input asymmetrical: switch operated: -100%, switch idle: 0%.

If you wish to use a different system rotational speed for each flight phase, this can be set in
each phase in the “Transmitter controls” menu by changing the travel of the throttle (6)
asymmetrically for the top position of the slider.

Further adjustments
For the swashplate servos (collective pitch function) it is important to check that servo travels
are symmetrical, i.e. with the same values for both directions. The collective pitch function of the
swashplate servos should produce a range of blade pitch angles covering +1° to +18°, also with
symmetrical travels; you may find it necessary to remove the servo output arm, move it round by
one spline and fit the retaining screw again.

The mechanics should now be set up virtually perfectly. When the collective stick is at centre
(hover point), collective pitch should be about 9.5°.

Note:
The collective pitch curve can be adjusted later to meet your exact personal requirements.
However, if you have already allowed differential travels to creep in during the basic set-up
procedure, any fine adjustments required subsequently will be more difficult!

3. Final checks before the first flight

When you have completed the model, run through the final checks listed below before flying the
helicopter for the first time:
• Study the manual once more and ensure that all the stages of assembly have been
completed correctly.
• Check that all the screws in the ball-links and brackets are tightened fully after you have
adjusted gear meshing clearance.
• Can all the servos move freely, without mechanical obstruction at any point? Do they all
rotate in the correct direction relative to the stick movements? Are the servo output arm
retaining screws in place and tight?
• Check the direction of effect of the gyro system.
• Ensure that the transmitter and receiver batteries are fully charged. We recommend using a
voltage monitor module (e.g. Order No. 3157) to check the state of charge of the receiver
battery.

Don’t attempt to start the turbine and fly the helicopter until you have successfully checked
everything as described above.
Be sure to read the instructions on operating the turbine.

4. Maintenance
Helicopters, whether large or small, place substantial demands on maintenance. Whenever you
notice vibration in your model, take immediate steps to reduce or eliminate it. Rotating parts,
important screwed joints, control linkages and linkage junctions should be checked before every
flight. If repairs become necessary, be sure to use original replacement parts exclusively. Never
attempt to repair damaged rotor blades; replace them with new ones.

38
 AGUSTA A119 "KOALA"®

AGUSTA
®
A119 "KOALA"

Summary of
replacement parts
Date of issue 9/07

39
 AGUSTA A119 "KOALA"®

Graupner Part Description Dimensions No. off

Order No. No. [mm] reqd. / pack
4470.01 GRP fuselage 1
4470.02 Upper fuselage fairing, front / rear 1 each
Tail cone 1
4470.03 Plywood parts, laser-cut:
A1 Nose bulkhead 4 1
A2 Fore-and-aft nose bulkhead 4 2
A3 Transverse joiner 4 1
A4 Front main bulkhead 4 1
A5 Rear half-bulkhead for tail rotor servo 4 1
A6 Front half-bulkhead for tail rotor servo 4 1
A7 Tail rotor servo plate 4 1
A8 Rear main bulkhead 4 1
A9 Console 4 2
A10 Support 4 2
A11 Rear skid bar support 4 2
A12 Switch plate 4 1
A13 Tail rotor drive shaft brace 4 1
A14 Mounting plate 4 2
A15 Retaining plate 4 1
A16 Tail rotor bulkhead 4 2
A17 Front skid bar support 4 2
A18 Central skid bar support 4 1
A19 Front mechanics mounting 4 2
A20 Ejector ring mount 4 3
A21 Front screen glazing bar 4 1
B1 Fueltank support fore-and-aft bearer 3 2
B2 Fueltank support transverse bearer 3 2
B3 Fueltank support 3 2
B4 Valve holder base plate 3 2
B5 Valve holder spacer 10 2
4470.04 Mechanics mounting system, consisting
of: 1
Aluminium rear transverse bearer 1
Aluminium front transverse bearer 2
Steel support bolt 2
Steel support bracket
4470.05 GRP door, R / L 1 each
4470.06 Stainless steel skid bar 2/1
4470.07 Aluminium skid tube 2
CFRP joiner dowel 14 Ø x 70 4
ABS spacer plate 1 mm 8
Plastic mounting clip 4
ABS joiner fairing, R / L 2 each
1292.10A Plastic end-plug 4
ABS end-cap 4
746.13 Self-tapping screw 2.9 x 13 4
565.16 Socket-head screw M3x16 8

40
 AGUSTA A119 "KOALA"®

Graupner Part Description Dimensions No. off

Order No. No. [mm] reqd. / pack
4470.08 Set of ABS vacuum-moulded parts,
consisting of: 1
Cockpit back panel 1
Cockpit floor 2
Seat squab 1
Front panel 1
Instrument binnacle 1
Instrument panel 2 each
ABS joiner fairing R / L 4
ABS skid end-cap
4470.09 Set of glazing panels and dummy exhausts 1
4470.10 Tail rotor drive shaft joiner sleeve 1
4470.11 Tail rotor shaft joiner sleeve, upgrade rotor 1
4470.12 GRP horizontal stabiliser, R / L 1 each
Hard aluminium sleeve 10 Ø x 900 1
4470.13 Stainless steel / Teflon tail rotor shaft guide 5 / 2.2Ø x 900 1
tube 5
Plastic bushes for guide tube
4618.64 Tail rotor drive shaft 2 Ø x ~ 1000 1
5221.2 CFRP tube 5 / 3 Ø x 850 1/1m
1291.10 Steel pushrod end 2.5 Ø x 75 2
519.3,0 Spring steel tailskid 3 Ø x 300 1/1m
Aluminium valve holder 2
607 Gas tank holder 1
5221.3 CFRP tube (horizontal stabiliser joiner) 6 / 4 Ø x 250 1/1m
1291.21A Clip with M3 insert 3
1004.2,0 Plated mild steel rod / door latch 2 Ø x 100 1/1m

273 Fueltank 1000 ml 2/1

Metal fly grille 150 x 150 1
3592 Plastic tube / door latch 3.2/2.2Øx250 1
732 Braided steel cable / door latch 1.9 Ø x 300 1
4618.155 M2.5 ball-link 2 / 10
fr. 4618.55 Linkage ball 4 / 10

704.8 Cheesehead screw M2 x 8 2

710 Nut M2 2
2995.10 Countersunk screw M4 x 10 1
747.7 Self-tapping screw 2.2 x 6.5 45
747.10 Self-tapping screw 2.2 x 9.5 10
747.13 Self-tapping screw 2.2 x 13 8
746.13 Self-tapping screw 2.9 x 13 4
746.16 Self-tapping screw 2.9 x 16 2
107 Grubscrew M3 x 3 4
565.8 Socket-head screw M3 x 8 5
565.10 Socket-head screw M3 x 10 5
565.16 Socket-head screw M3 x 16 8
566.10 Socket-head screw M4 x 10 10
Spring washer 3Ø 1
Spring washer 4Ø 8
560.6 Plain washer 3.2/6.0Ø x 0.5 4
560.7 Plain washer 4.3/9.0Ø x 0.8 3
617 Self-locking nut M4 1
728.3 Captive nut M3 12

4470.99 Decal sheet 1

41
 AGUSTA A119 "KOALA"®

Suitable accessories
1272 CFRP main rotor blades 1 Set
1346B CFRP tail rotor blades 1 Set
4448.400 Four-blade main rotor head 1

Suitable accessories (for turbine mechanics)

4470.100 Exhaust gas duct 1
4448.501 Upgrade tail rotor, left-hand rotation 1

Suitable accessories (for UNI-Mechanics 2000)

4448.103 Hexagon starter cone 1
1621 Hexagon starter adaptor with freewheel 1
2239A Stainless steel exhaust manifold (rear- 1
exhaust)
2238A Stainless steel exhaust manifold (side- 1
exhaust)
2258 Universal stainless steel compact silencer 1
2253 Stainless steel compact silencer 1
4448.500 Upgrade tail rotor, right-hand rotation 1

42