TASK 72-00-60-420-001-002 External Gearbox Module - Install The External Gearbox Module - Method 2, Installation-002

DMC:V2500-A0-72-00-6000-01A-720B-B|Issue No:004.00|Issue Date:2021-02-01

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 72-00-60-420-001-002 External Gearbox Module - Install The External Gearbox Module - Method 2, Installation-002

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.

Lightly lubricate the threads and abutment faces of the hydraulic system tube/hose nuts, unions and couplings with the hydraulic fluid used in the aircraft hydraulic system.

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/blanks 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 1F10412 Puller0AM53IAE 1F10412
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
Removal/Installation ToolLOCALS888IDG

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-126 LOCKWIREK6835CoMat 02-126
CoMat 02-147 LOCKWIRELOCALCoMat 02-147
CoMat 07-012 AIR DRYING ENAMEL0AM53CoMat 07-012
CoMat 10-077 APPROVED ENGINE OILSX333XCoMat 10-077
CoMat 10-094 ANTI-SEIZE COMPOUND, PURE Ni-SPECIALK2147CoMat 10-094

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Gasket1
Packing1
Packing1
Packing1
Packing1
Packing1
Packing1
Packing1
Gasket1
Toroidal seal ring1
Sealing ring1
Packing1
Packing1
Packing1
Packing1
Packing1
Packing1
Sealing ring1
Packing1
Seal1

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-60-210-052 Examine the Module Interfaces

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

    2. Examine the external gearbox module at interface G-60. Refer to TASK 72-00-60-220-001.

    2. SUBTASK 72-00-60-420-057 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 an 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.

          Refer to Figure.

        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 to get the 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 10.734 Nm).

      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 an 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 lugs 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. Fully install the bolt of IAE 1F10412 Puller 1 off into the threaded bolt hole of the pin.

        2. Lightly tap the head of the bolt with a hammer until the pin is in position.

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

      6. 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 on 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 the room temperature.

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

        1. Put IAE 1F10044 Driver (installation) 1 off through the hole of the pin flange and install it in the hole of the front lug.

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

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

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

        5. Let the link to get 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 on 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 (01-260) 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 in equal measures 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 to get the room temperature. Remove the two bolts, washers and nuts from the brackets.

    3. SUBTASK 72-00-60-420-098 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 a new LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 01-154) ring 1 off. Install the ring on the PTO shaft seal tube. Refer to Figure.

    4. SUBTASK 72-00-60-420-058 Move the External Gearbox Below the Intermediate Case

      NOTE

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

    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 handling adapter.

    3. Operate the hydraulic pump to lift the hydraulic jack. Remove the external gearbox from the IAE 1F10021 Storage stand 1 off.

    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 72-00-60-420-059 Attach the External Gearbox to the Intermediate Case

    1. Refer to Figure.

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

        Refer to Figure.

      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 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.

        Refer to Figure.

      1. Align the holes on the brackets with the holes on the intermediate case flange. Install the two bolts, washers and nuts which attach the brackets 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.

      Refer to Figure.

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

        Refer to Figure.

      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 72-00-60-420-060 Remove the External Gearbox Support Tooling

    1. Refer to Figure.

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

      Refer to Figure.

    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 72-00-60-450-051 Install the Oil Scavenge Pump Assembly

    1. Refer to Figure.

    2. Install the oil scavenge pump assembly, Refer to TASK 72-00-60-450-007.

    8. SUBTASK 72-00-60-450-052 Install the Oil Tank

    1. Refer to Figure.

    2. Install OIL-OIL TANK (79-11-41, 01-058) packing1 off into the groove on the oil tank flange.

    3. Lubricate with CoMat 10-077 APPROVED ENGINE OILS the oil tank seat on the gearbox casing.

    4. Install the oil tank on the LH flange of the gearbox casing. Align the holes on the oil tank flange with the studs on the gearbox casing flange.

    5. Install the two brackets on the oil tank flange and align with the studs.

    6. Install the two washers on the studs free from the bracket. Install the six nuts which attach the oil tank and the bracket to the gearbox casing. Torque the nuts to 180 to 200 lbfin (20.3 to 22.5 Nm).

    9. SUBTASK 72-00-60-450-053 Install the Oil Scavenge Filter Housing Assembly and the Oil Feed Tubes (180 and 179)

    1. Refer to Figure.

      2. Install the oil tubes 179 and 180 on the scavenge oil filter.

      1. Install the new Gearbox Scavenge Oil Tubes (79-22-48, 05-530 andV2500-A5-79-22-48-22A-941A-D 79-22-489, 05-560)Gearbox Scavenge Oil Tubes packings 1 off on the oil feed tube 180.

      2. Lubricate the oil feed tube mating faces on the scavenge oil filter housing assembly and the oil tank assembly with CoMat 10-077 APPROVED ENGINE OILS.

      3. Attach the oil feed tube (180) on the scavenge oil filter housing assembly with the three bolts Gearbox Scavenge Oil Tubes (79-22-48, 05-510) and the three washers OIL-SCAVENGE OIL TUBES-ENGINE (79-22-49, 05-520).

      4. Tighten the bolts with your hand.

      5. Install the new Gearbox Scavenge Oil Tubes (79-22-48, 03-130 and Gearbox Scavenge Oil Tubes 79-22-48, 03-160) packings on the oil tube.

      6. Lubricate the oil feed tube mating faces on the scavenge oil filter housing assembly and the oil scavenge pump with CoMat 10-077 APPROVED ENGINE OILS.

      7. Attach the oil tube (179) on the scavenge oil filter assembly with the three bolts Gearbox Scavenge Oil Tubes (79-22-48, 03-140) and the three washers Gearbox Scavenge Oil Tubes (79-22-48, 03-150).

      3. Install the scavenge oil filter assembly on the oil tank.

      1. Put the scavenge oil filter housing assembly with the oil feed tube (180) and the oil tube (179) in position on the oil tank.

      2. Align and engage the flange of the oil feed tube (180) with the flange on the oil tank.

      3. Install the Gearbox Scavenge Oil Tubes (79-22-48, 05-470) bracket, the washer Gearbox Scavenge Oil Tubes (79-22-48, 05-550) and the three Gearbox Scavenge Oil Tubes (79-22-48, 05-540) bolts.

      4. Tighten the bolts with your hand.

      5. Align and engage the flange of the oil tube (179) with the flange on the oil scavenge pump.

      6. Install the washers Gearbox Scavenge Oil Tubes (79-22-48, 03-120) and the bolts Gearbox Scavenge Oil Tubes (79-22-48, 03-110).

      7. Tighten the bolts with your hand.

      8. Install the three washers Scavenge Oil Filter Housing (79-22-43, 01-054) and the three bolts Scavenge Oil Filter Housing (79-22-43, 01-052).

      9. TORQUE the Scavenge Oil Filter Housing (79-22-43, 01-052) bolts to between 85 and 95 lbfin (0.96 to 1.07 mdaN) (Refer to TASK 70-41-01-400-501).

      10. TORQUE the bolts Gearbox Scavenge Oil Tubes (79-22-48, 05-540), Gearbox Scavenge Oil Tubes (79-22-48, 03-110), Gearbox Scavenge Oil Tubes (79-22-48, 03-140) and Gearbox Scavenge Oil Tubes (79-22-48, 05-510) to between 85 and 95 lbfin (0.96 and 1.07 mdaN).

    10. SUBTASK 72-00-60-450-054 Install the Fuel Pump

    1. Refer to Figure.

    2. Lubricate a new Fuel Pumps (73-12-41, 01-135) sealing ring 1 off with clean CoMat 10-077 APPROVED ENGINE OILS and install it on the adapter housing.

    3. Install the adapter housing on the gearbox and attach it with the six bolts and washers.

    4. Install the Fuel Pumps (73-12-41, 01-080) bracket and the four washers and six bolts.

    5. Install the fuel pump. Refer to TASK 72-00-60-450-008.

    11. SUBTASK 72-00-60-450-055 Install the Fuel Metering Unit onto the Fuel Pump

    1. Install the fuel metering unit on the fuel pump. Refer to TASK 72-00-60-450-002.

    12. SUBTASK 72-00-60-450-056 Install the IDG QAD Coupling

    1. Refer to Figure.

    2. Install the new ELECTRICAL POWER-IDG QAD COUPLING (24-21-41, 01-020) gasket 1 off to the gearbox accessory mounting pad.

    3. NOTE

      Make sure that the index pin holes in the pad, gasket and coupling are aligned. The words TOP - V2500 must be in the 12 o'clock position.

      Install the coupling to the gearbox accessory mounting pad.

    4. Apply CoMat 10-094 ANTI-SEIZE COMPOUND, PURE Ni-SPECIAL and install the QAD attaching bolts ELECTRICAL POWER-IDG QAD COUPLING (24-21-41, 01-030) 8 off.

    5. NOTE

      Turn the QAD tension bolt to align a white line (Open position mark) on the QAD ring with the open position mark on the QAD adapter plate.

      Torque the screw to between 348 to 384 lbfin (39.3 to 43.4 Nm) for the QAD Adapter ELECTRICAL POWER-IDG QAD COUPLING (24-21-41, 01-010) and ELECTRICAL POWER-IDG QAD COUPLING (24-21-41, 01-010A). Torque the screw to between 324 and 348 lbfin (36.6 to 39.3 Nm) for QAD Adapter ELECTRICAL POWER-IDG QAD COUPLING (24-21-41, 01-010B).

    13. SUBTASK 72-00-60-450-157 Install the IDG Cooling Tubes Overflow, Pressure Couplings, Overflow Drain Valves and Pressure-Fill Valve

    1. Refer to Figure.

    2. Install the IDG Cooling Tubes Overflow and Pressure Couplings.

    3. Lightly lubricate the new packing ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-114) with CoMat 10-077 APPROVED ENGINE OILS and install it on the coupling ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-110). Install the coupling in the IDG and torque to 500 to 600 lbfin. (56.5 to 67.8 Nm).

    4. Lightly lubricate the new packing ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-506) with CoMat 10-077 APPROVED ENGINE OILS and install it on the coupling ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-502). Install the coupling in the IDG and torque to 320 to 380 lbfin. (36.2 to 42.9 Nm).

    5. Safety the couplings ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-110) and ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 02-502) with CoMat 02-126 LOCKWIRE. Refer to the SPM TASK 70-42-05-400-501.

    6. Lightly lubricate the new packing ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-045) with CoMat 10-077 APPROVED ENGINE OILS and put it on the overflow drain valve ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-050). Install the overflow drain valve on the IDG and torque 280 to 305 lbfin (31.6 to 34.5 Nm). Put the dust cap ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-040) on the overflow drain valve.

    7. Lightly lubricate the new packing ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-058) with CoMat 10-077 APPROVED ENGINE OILS and put it on the pressure-fill valve ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-060). Install the pressure-fill valve on the IDG and torque 120 to 150 lbfin (13.6 to 16.9 Nm). Put the dust cap ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-055) on the overflow drain valve.

    8. Safety the overflow drain valve and the pressure-fill valve with CoMat 02-147 LOCKWIRE. Refer to the SPM TASK 70-42-05-400-501.

    14. SUBTASK 72-00-60-450-057 Install the Integrated Drive Generator

    1. Refer to Figure.

      2. Install the IDG removal/installation tool.

      1. Attach the IDG to the IDG removal/installation tool, S888IDG.

    3. Install new ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-020 and ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR 24-21-51, 01-030) packings left onto the IDG.

    4. Lubricate these components with CoMat 10-077 APPROVED ENGINE OILS:

      - the packing ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-020)

      - the packing ELECTRICAL POWER-INTEGRATED DRIVE GENERATOR (24-21-51, 01-030)

      - the IDG drive shaft

      - the Qad coupling

      5. CAUTION

        INSTALL THE IDG IN A STRAIGHT LINE. THE INPUT SHAFT CAN CATCH AND CAUSE DAMAGE TO THE INPUT SHAFT SEAL.

        CAUTION

        DO NOT USE EXTERNAL PARTS OR TOOLS TO ALIGN THE IDG ON THE GEARBOX. THEY CAN CAUSE DAMAGE TO THE IDG AND THE GEARBOX.

        CAUTION

        MAKE SURE THAT THE IDG INPUT SHAFT DOES NOT HANG ON THE GEARBOX OUTPUT SHAFT. DAMAGE TO THE SHAFTS AND THE SEALS CAN OCCUR.

        Install the IDG as follows:

      1. Put the IDG into position on the gearbox.

      2. Carefully align the IDG drive shaft and the gearbox output shaft.

      3. Push the IDG forward onto the gearbox.

      4. Make sure that the mounting flanges are correctly aligned.

      5. Make sure that the two open marks are aligned.

      6. Make sure that the IDG is correctly engaged in the QAD coupling.

      7. Tighten the QAD coupling until the IDG flange lugs are fully engaged in the QAD coupling lugs.

      8. Make sure that the QAD coupling turns easily and does not catch.

      9. TORQUE the QAD coupling to between 265 and 310 lbfin (30 and 35 Nm).

      10. Lightly hit the QAD coupling circumference to center it and make sure that the torque values are correct.

      11. Do a check of the torque value on the QAD coupling.

      12. Make sure that the torque has not decreased by more than 24 lbfin (0.31 mdaN) from that in Step.

      13. If necessary do Step thru Step again.

      14. Make sure that the torque value of the QAD coupling is between the limits given in Step.

      15. Safety the QAD coupling with CoMat 02-147 LOCKWIRE.

    6. Remove the Removal/Installation Tool 1 off.

    15. SUBTASK 72-00-60-450-058 Install the Oil Pressure Pump and Filter Assembly

    1. Install the oil pressure pump and filter assembly. Refer to TASK 72-00-60-450-003.

    16. SUBTASK 72-00-60-450-059 Install the Hydraulic Pump

    1. Please refer to TASK 71-00-02-400-009, SUBTASK 71-00-02-450-011 .

    17. SUBTASK 72-00-60-450-060 Install the Dedicated Alternator Stator

    1. V2500-A1 Install the dedicated alternator stator, refer to TASK 72-00-60-450-001-A00.

      V2500-A5 Install the dedicated alternator stator, refer to TASK 72-00-60-450-001-B00.

    18. SUBTASK 72-00-60-450-061 Install the Pneumatic Starter

    1. Refer to Figure.

    2. Install the pneumatic starter, refer to TASK 72-00-60-450-009.

    19. SUBTASK 72-00-60-420-099 Install the Gearbox Dressing

    1. V2500-A1 Install the remaining tubes and electrical harnesses to the external gearbox, refer to TASK 72-00-60-420-002-A00.

    2. V2500-A5 Install the remaining tubes and electrical harnesses to the external gearbox, refer to TASK 72-00-60-420-002-B00.

    20. SUBTASK 72-00-60-790-054 Do the Oil System Static Leak Check

    1. Do the oil static leak check, refer to TASK 71-00-00-700-004.

    21. SUBTASK 72-00-60-610-052 Fill the Oil Tank and the Engine Oil System

    1. WARNING

      DO NOT GET APPROVED 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 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. V2500-A1 Prime the engine oil system. Refer to TASK 71-00-00-700-061 .

      V2500-A5 Prime the engine oil system. Refer to TASK 71-00-00-700-061 .

    22. SUBTASK 72-00-60-790-052 Do the Dry Motor Leak Check

    23. 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

    Figure: Installation of the Oil Scavenge Pump

    Installation of the Oil Scavenge Pump

    Figure: Installation of the Oil Tank

    Installation of the Oil Tank

    Figure: Installation to the Scavenge Filter

    Installation to the Scavenge Filter

    Figure: Installation of the Fuel Pump

    Installation of the Fuel Pump

    Figure: Installation of the IDG QAD Coupling

    Installation of the IDG QAD Coupling

    Figure: Installation of the Integrated Drive Generator

    Installation of the Integrated Drive Generator

    Figure: Installation of the Starter

    Installation of the Starter

    Figure: Installation of the Hydraulic Pump

    Installation of the Hydraulic Pump

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Corrected the ATA reference for bracket. (19VC627)

Link not Found
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:K2147
Enterprise Name:BOSTIC FINDLEY
BU Name:BOSTIC FINDLEY
Street:COMMON ROAD
City:STAFFORD
Zip Code:ST16 3EH
Country:UNITED KINGDOM
Phone Number:44-1785-272727
Fax Number:44-1162-689283
Manufacturer Code:K6835
Enterprise Name:MED-LAB LTD
BU Name:MED-LAB LTD
Street:COPELAND ST
City:DERBY
Zip Code:DE1 2PU
Country:GREAT BRITAIN
Phone Number:44-1332-349094
Fax Number:44-1332-371237
Email:sales@med-lab.co.uk
Internet:www.med-lab.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X333X
Enterprise Name:REFER TO V2500 SB ENG-79-0108
Link not Found
Manufacturer Code:K6835
Supply Number:CoMat 02-126
Type:sp01
Supply Short Name:CoMat 02-126 LOCKWIRE
Supply Name:CoMat 02-126 LOCKWIRE
Specification Groups:
Doc NumberType
DTD 189A, 0.028 TO 0.032 IN DIA
Suppliers:
ManufacturerRemarks
K6835
KB362
LOCAL
U06C8
Manufacturer Code:LOCAL
Supply Number:CoMat 02-147
Type:sp01
Supply Short Name:CoMat 02-147 LOCKWIRE
Supply Name:CoMat 02-147 LOCKWIRE
Specification Groups:
Doc NumberType
AIA/NAS NASM20995 Part Number MS20995C32 (0,8 MM)
Suppliers:
ManufacturerRemarks
LOCAL
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:K2147
Supply Number:CoMat 10-094
Type:sp01
Supply Short Name:CoMat 10-094 ANTI-SEIZE COMPOUND, PURE Ni-SPECIAL
Supply Name:CoMat 10-094 ANTI-SEIZE COMPOUND, PURE Ni-SPECIAL
Specification Groups:
Doc NumberType
BOSTIK NEVER-SEEZ PURE NICKEL SPECIAL
Suppliers:
ManufacturerRemarks
K2147
K6835
5W425
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)
Manufacturer Code:0AM53
Tool Number:IAE 1F10412
Tool Name:IAE 1F10412 Puller
Manufacturer Code:LOCAL
Tool Number:S888IDG
Tool Name:Removal/Installation Tool