TASK 72-00-60-420-001-001 External Gearbox Module - Install The External Gearbox Module - Method 1, Installation-001

DMC:V2500-A0-72-00-6000-01A-720A-B|Issue No:002.00|Issue Date:2020-02-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 72-00-60-420-001-001 External Gearbox Module - Install The External Gearbox Module - Method 1, Installation-001

General

Fig/item numbers in parentheses in the procedure agree with those used in the IPC. Only the primary Fig/item numbers are used. For the service bulletin alpha variants refer to the IPC.

For all parts identified in a different Chapter/Section/Subject, the applicable Chapter/Section/Subject comes before the Fig/item number.

For standard torque data and procedures, refer to the SPM TASK 70-41-00-400-501 and SPM TASK 70-41-02-400-501.

Special torque data and assembly tolerances are included in the procedure.

Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-077 APPROVED ENGINE OILS, unless other lubricants are referred to in the procedure.

To identify, lubricate and install seal rings, refer to the SPM TASK 70-44-01-400-501.

After assembly apply CoMat 07-012 AIR DRYING ENAMEL to any damaged surface protection, joint flanges and attach parts. Use the correct color of the air drying enamel. Refer to the SPM TASK 70-38-06-380-501 .

The number for each radial location must be identified in a clockwise direction. These start at the engine top position when you look from the rear of the engine, unless stated differently in the procedure.

Transportation covers/blank must be removed immediately before the installation of the components.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 1F10011 Handling fixture0AM53IAE 1F100112
IAE 1F10012 Pusher (installation)0AM53IAE 1F100121
IAE 1F10021 Storage stand0AM53IAE 1F100211
IAE 1F10022 Hydraulic jack0AM53IAE 1F100221
IAE 1F10023 Gearbox adapter0AM53IAE 1F100231
IAE 1F10026 Hydraulic hand pump0AM53IAE 1F100261
IAE 1F10044 Driver (installation)0AM53IAE 1F100441

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 07-012 AIR DRYING ENAMEL0AM53CoMat 07-012
CoMat 10-077 APPROVED ENGINE OILSX333XCoMat 10-077

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
RING - SEAL TRAPEZOIDAL0AM535A21381

72-32-00, 01-154

PACKING - PREFORMEDU1653AS3209-1221

72-60-21, 01-280

PACKING - PREFORMEDU1653AS3209-2261

79-11-41, 01-760

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-60-210-051 Examine the Module Interfaces

    1. Examine the LP compressor/intermediate case module at interface G-32. Refer to TASK 72-00-32-220-005 (INSPECTION-005).

    2. Examine the External gearbox module at interface G-60. Refer to TASK 72-00-60-220-001 (INSPECTION-001).

    2. SUBTASK 72-00-60-420-051 Install the Support Link Assemblies to the External Gearbox

    1. Refer to Figure.

      2. Install the three front links to the gearbox.

      1. WARNING

        DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES.
        HOT PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF THE HANDS ARE NOT PROTECTED.
        IMMERSE THE CONTACTED AREA IN COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. IMMEDIATELY GET MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

        Increase the temperature of one end of the right hand link to 250 deg F (121 deg C) maximum. Use a hot gun.

      2. Put the hot end of the link between the lugs on the right hand of the gearbox. Align the hole of the spherical bearing of the link with the hole of the lugs.

      3. Lubricate the pin (01-160) with CoMat 10-077 APPROVED ENGINE OILS. Install the pin into the hole on the front lug and push through the spherical bearing and the rear lug.

        4. Do the subsequent operations if the installation of the pin is not easy by hand.

        1. Align the hole on the pin flange with the hole on the front lug.

        2. Put IAE 1F10044 Driver (installation) 1 off through the hole on the pin flange and install into the hole on the front lug.

        3. Install the hexagonal head screw of IAE 1F10012 Pusher (installation) 1 off through the pin and the rear lug.

        4. Install the nut on the free end of the hexagonal head screw. Turn the nut until it touches the rear lug.

        5. Hold the hexagonal head screw. Turn clockwise the hexagonal nut until the pin is fully installed. Use a standard wrench.

        6. Let the link get to room temperature. Remove the pusher and the driver from the pin.

      5. Do the Step thru Step for the left hand link and for the center link.

      6. Install the bolts which attach the pins of the right hand link and the left hand link. Tighten by hand.

      7. Install the bolt which attaches the pin of the center link. Torque the bolt to 85 to 95 lbfin (9.604 to 10.734Nm).

      3. Install the rear link to the gearbox.

      1. WARNING

        DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES.
        HOT PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF THE HANDS ARE NOT PROTECTED.
        IMMERSE THE CONTACTED AREA IN COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. IMMEDIATELY GET MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

        Increase the temperature of one end of the rear link to 250 deg F (121 deg C) maximum. Use a hot gun.

      2. Put the hot end of the link between the lugs on the angle gearbox support. Align the hole of the spherical bearing of the link with the hole of the lugs.

      3. Lubricate the pin (01-280) with CoMat 10-077 APPROVED ENGINE OILS. Install the pin into the hole on the front lug and push through the spherical bearing and the rear lug.

      4. Install the washer and bolt into the hole on the boss adjacent to the front lug.

      5. Make sure that the bolt engages with the groove of the pin. Torque the bolt to 85 to 95 lbfin (9.604 to 10.734 Nm).

      4. Install the brackets to the three front links.

      1. WARNING

        DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES.
        HOT PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF THE HANDS ARE NOT PROTECTED.
        IMMERSE THE CONTACTED AREA IN COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. IMMEDIATELY GET MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

        Increase the temperature of the free end of the right hand link to 250 deg F (121 deg C) maximum. Use a hot gun.

      2. Lubricate the pin (01-140) with CoMat 10-077 APPROVED ENGINE OILS. Install the pin into the hole of the front bracket. Align the hole on the pin flange with the hole of the bracket. Safety the pin with the bolt.

      3. Put the pin with the bracket through the hole of the spherical bearing of the link.

      4. Install the rear bracket on the free end of the pin.

      5. Keep all parts together until the link gets to room temperature.

        6. Do the subsequent operations if the installation of the pin is not easy by hand.

        1. Install the hexagonal head screw of IAE 1F10012 Pusher (installation) 1 off through the pin and the rear bracket.

        2. Install the nut on the free end of the hexagonal head screw. Turn the nut until it touches the rear bracket.

        3. Hold the hexagonal head screw. Turn clockwise the hexagonal nut until the pin is fully installed. Use a standard wrench.

        4. Let the link get to room temperature. Remove the pusher from the pin.

      7. Do the Step thru Step for the installation of the brackets on the left hand link and on the center link.

      5. Install the brackets to the rear link.

      1. WARNING

        DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES.
        HOT PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF THE HANDS ARE NOT PROTECTED.
        IMMERSE THE CONTACTED AREA IN COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. IMMEDIATELY GET MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

        Increase the temperature of the free end of the rear link to 250 deg F (121 deg C) maximum. Use a hot gun.

      2. Lubricate the pin (01-160) with CoMat 10-077 APPROVED ENGINE OILS. Install the pin through the hole of the spherical bearing of the link. Push until the pin protrudes an equal measure from both sides of the spherical bearing.

      3. Install the two brackets on the two ends of the pin. Safety the brackets with the two bolts, washers and nuts. Tighten the bolts by hand.

      4. Let the link get to room temperature. Remove the two bolts, washers and nut from the brackets.

    3. SUBTASK 72-00-60-420-097 Prepare for the External Gearbox Module Installation

    1. Remove the two nuts and washers from the crank cover. Remove the crank cover from the front of the external gearbox. Discard the packing. Refer to Figure.

    2. Lubricate with CoMat 10-077 APPROVED ENGINE OILS the mating diameter of the angle gearbox casing.

    3. Lubricate with CoMat 10-077 APPROVED ENGINE OILS the LP Compressor (LPC) - Intermediate Structure Module(72-32-00,01-154) toroidal seal ring 1 off. Install the seal ring on the PTO shaft seal tube.

    4. SUBTASK 72-00-60-420-052 Move the External Gearbox Below the Intermediate Case

      NOTE

      The external gearbox is installed on IAE 1F10021 Storage stand 1 off with IAE 1F10023 Gearbox adapter 1 off and IAE 1F10011 Handling fixture 2 off.

    1. Install, if necessary, IAE 1F10026 Hydraulic hand pump 1 off on IAE 1F10022 Hydraulic jack 1 off and connect the hose.

    2. Move the hydraulic jack below the external gearbox. Align the pin on the hydraulic jack plate with the bore on the gearbox adapter.

    3. Operate the hydraulic pump to lift the hydraulic jack. Remove the external gearbox from the storage stand.

    4. Make sure the adjustable support of the hydraulic jack is in lowered position.

    5. Carefully move the external gearbox below the engine. Lift the hydraulic jack until the external gearbox is at about 2.75 in. (70 mm) from the intermediate case.

    6. Turn clockwise the knob on the front of the hydraulic jack base to prevent any accidental lowering of the hydraulic jack.

    5. SUBTASK 72-00-60-420-053 Attach the External Gearbox to the Intermediate Case

    1. Refer to Figure.

      2. Attach the front center link to the intermediate case flange.

      1. Hold the link in vertical position. Turn clockwise the handwheel adjacent to the adjustable support of the hydraulic jack. Lift the gearbox until the holes on the brackets are aligned with the holes on the intermediate case flange.

      2. Install the two bolts, washers and nuts which attach the brackets to the intermediate case flange. Torque the nuts to 270 to 370 lbfin (33 to 42 Nm).

      3. NOTE

        Operate the two handwheels (one installed on the hydraulic jack base and the other below the hydraulic jack plate) to adjust the position of the external gearbox.

        Move the external gearbox in position.

      1. Lift the external gearbox and move the front center link in horizontal position.

      2. Engage the radial gearshaft of the angle gearbox with the PTO shaft on the intermediate structure. Turn, if necessary, the starter idler gear on the front of the gearbox to make easier this operation. Use a standard wrench.

      3. CAUTION

        DO NOT DAMAGE THE TOROIDAL SEAL RING ON THE PTO SHAFT SEAL TUBE.

        Engage the angle gearbox with the PTO shaft seal tube.

      4. Attach the right hand link to the intermediate case flange.

      1. Align the holes on the brackets with the holes on the intermediate case flange. Install the two bolts, washers and nut which attach the bracket to the intermediate case flange. Torque to 270 to 370 lbfin (33 to 42 Nm).

      2. Remove the bolts which attach the two pins of the link.

      3. Install the bonding strap and align the holes with the holes on the pin flanges.

      4. Install again the bolts and torque to 85 to 95 lbfin (9.604 to 10.734 Nm).

    5. Attach the left hand link to the intermediate case flange. Do the Step thru Step.

      6. Attach the rear link to the intermediate case flange.

      1. Align the holes on the brackets with the holes on the intermediate case flange.

      2. Install the two bolts, washers and nuts which attach the brackets to the intermediate case flange. Torque to 180 to 220 lbfin (20 to 25 Nm).

    6. SUBTASK 72-00-60-420-054 Remove the External Gearbox Support Tooling

    1. Refer to Figure.

    2. Remove the two safety pins from the handling fixtures.

    3. Loosen the rotating block and disconnect the two locking rods from the bosses on the angle gearbox.

    4. Turn counterclockwise the handwheel adjacent to the adjustable support of the hydraulic jack. Lower the hydraulic jack plate and disengage the gearbox adapter from the handling fixtures.

    5. Turn counterclockwise the knob on the front of the hydraulic jack base then lower the hydraulic jack.

    6. Remove the two handling fixtures from the ground handling bosses on the bottom of the external gearbox. Install on the gearbox adapter and safety with the safety pins.

    7. Move the hydraulic jack away from the engine.

    7. SUBTASK 72-00-60-420-055 Install the Crank Cover on the External Gearbox

    1. Refer to Figure.

    2. Install ENGINE-MAIN GEARBOX CASE AND FITTINGS (72-60-21, 01-280) packing 1 off on the crank cover.

    3. Install the crank cover on the front of the external gearbox.

    4. Install the two washers and nuts which attach the crank cover to the gearbox. Torque the nuts to 85 to 95 lbfin (9.604 to 10.734 Nm).

    8. SUBTASK 72-00-60-420-056 Install the Gearbox Dressings

    1. Install the gearbox dressing. Refer to TASK 72-00-60-420-002 (INSTALLATION-004).

    2. Make sure that the oil pressure and oil scavenge filter and MCD's are installed.

    9. SUBTASK 72-00-60-790-051 Do the Oil System Static Leak Check

    1. Refer to TASK 71-00-00-700-004 (TESTING-004).

    10. SUBTASK 72-00-60-610-051 Fill the Oil Tank and the Engine Oil System

    1. WARNING

      DO NOT GET ENGINE OIL ON YOUR SKIN FOR LONG PERIODS. THE OIL IS POISONOUS AND CAN GO THROUGH YOUR SKIN AND into YOUR BODY.

      Make sure that the drain plugs and all the oil system components are installed.

    2. Lift the handle of the cap and turn to the open position. Remove the cap from the manual filler port of the oil tank.

    3. Fill the oil tank with new CoMat 10-077 APPROVED ENGINE OILS until the tank is full.

      4. Install the oil tank cap.

      1. Replace OIL-OIL TANK (79-11-41, 01-760) packing 1 off of the cap if the cuts or other defects are found.

      2. Make sure that the handle of the cap is in the open position.

      3. Align the locks of the cap with the slots on the filler neck. Install the cap and turn the handle to the closed position.

      4. Lower the handle to lock the oil tank cap.

    5. Prime the engine oil system. Refer to TASK 71-00-00-700-061-A00 (TESTING-000, CONFIG-001) or TASK 71-00-00-700-061-B00 (TESTING-000, CONFIG-002).

    11. SUBTASK 72-00-60-790-053 Do the Dry Motor Leak Check

    1. Refer to TASK 71-00-00-700-001 (TESTING-001).

    12. Figure: Installation of the support link assemblies to the external gearbox

    Sheet 1

    Legend
    Installation of the support link assemblies to the external gearbox

    Sheet 1

    Close

    Figure: Installation of the support link assemblies to the external gearbox

    Sheet 2

    Legend
    Installation of the support link assemblies to the external gearbox

    Sheet 2

    Close

    Figure: Installation of the external gearbox to the intermediate case

    Sheet 1

    Legend
    Installation of the external gearbox to the intermediate case

    Sheet 1

    Close

    Figure: Installation of the external gearbox to the intermediate case

    Sheet 2

    Legend
    Installation of the external gearbox to the intermediate case

    Sheet 2

    Close

    Figure: Installation of the external gearbox to the intermediate case

    Sheet 3

    Legend
    Installation of the external gearbox to the intermediate case

    Sheet 3

    Close

    Figure: External gearbox support tooling

    Sheet 1

    Legend
    External gearbox support tooling

    Sheet 1

    Close

    Figure: External gearbox support tooling

    Sheet 2

    Legend
    External gearbox support tooling

    Sheet 2

    Close

    Figure: Removal/installation of the crank cover

    Removal/installation of the crank cover

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Editorial Update - correct task reference links (CAS-60404-G2Y6X3)

Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:U1653
Enterprise Name:Society Of British Aerospace Companies, LTD.
Manufacturer Code:X333X
Enterprise Name:REFER TO V2500 SB ENG-79-0108
Part Number:5A2138
Part Name:RING - SEAL TRAPEZOIDAL
Manufacturer Code:0AM53
Part Number:AS3209-122
Part Name:PACKING - PREFORMED
Manufacturer Code:U1653
Part Number:AS3209-226
Part Name:PACKING - PREFORMED
Manufacturer Code:U1653
Optional Parts
Part NumberPart NameManufacturer
AS43013-226RINGU1653
Part Number:AS43013-226
Part Name:RING
Manufacturer Code:U1653
Optional Parts
Part NumberPart NameManufacturer
AS3209-226PACKING - PREFORMEDU1653
Manufacturer Code:0AM53
Supply Number:CoMat 07-012
Type:sp01
Supply Short Name:CoMat 07-012 AIR DRYING ENAMEL
Supply Name:CoMat 07-012 AIR DRYING ENAMEL
Specification Groups:
Doc NumberType
USE COMAT 07-038
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:X333X
Supply Number:CoMat 10-077
Type:sp01
Supply Short Name:CoMat 10-077 APPROVED ENGINE OILS
Supply Name:CoMat 10-077 APPROVED ENGINE OILS
Specification Groups:
Doc NumberType
For V2500-A1/A5/D5 models - Refer to V2500 Service Bulletin ENG-79-0108
For V2500-E5 model - Refer to Service Bulletin E5-79-0001
Suppliers:
ManufacturerRemarks
X333X
Manufacturer Code:0AM53
Tool Number:IAE 1F10011
Tool Name:IAE 1F10011 Handling fixture
Manufacturer Code:0AM53
Tool Number:IAE 1F10012
Tool Name:IAE 1F10012 Pusher (installation)
Manufacturer Code:0AM53
Tool Number:IAE 1F10021
Tool Name:IAE 1F10021 Storage stand
Manufacturer Code:0AM53
Tool Number:IAE 1F10022
Tool Name:IAE 1F10022 Hydraulic jack
Manufacturer Code:0AM53
Tool Number:IAE 1F10023
Tool Name:IAE 1F10023 Gearbox adapter
Manufacturer Code:0AM53
Tool Number:IAE 1F10026
Tool Name:IAE 1F10026 Hydraulic hand pump
Manufacturer Code:0AM53
Tool Number:IAE 1F10044
Tool Name:IAE 1F10044 Driver (installation)