TASK 72-00-60-020-003-001 External Gearbox Module - Remove The External Gearbox Module - Method 1, Removal-003

DMC:V2500-A0-72-00-6000-03A-520A-B|Issue No:004.00|Issue Date:2020-05-01

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 72-00-60-020-003-001 External Gearbox Module - Remove The External Gearbox Module - Method 1, Removal-003

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.

Apply the approved CoMat 10-058 PENETRATING OIL before the removal of the threaded parts and parts with an interference fit. Let the parts soak before removal.

Remove and discard the lockwire before parts are disconnected or removed.

Discard all rubber seal rings, cotter pins and seal washers removed in this procedure.

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 1F10021 Storage stand0AM53IAE 1F100211
IAE 1F10022 Hydraulic jack0AM53IAE 1F100221
IAE 1F10023 Gearbox adapter0AM53IAE 1F100231
IAE 1F10026 Hydraulic hand pump0AM53IAE 1F100261
IAE 1F10292 Puller0AM53IAE 1F102921
IAE 1F10293 Puller0AM53IAE 1F102931
IAE 1F10294 Puller0AM53IAE 1F102941
IAE 1F10412 Puller0AM53IAE 1F104121
IAE 1J12082 Holding CapLOCALIAE 1J120821
Container - Minimum capacity of about 10 USgal (38 l)LOCAL

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-147 LOCKWIRELOCALCoMat 02-147
CoMat 10-058 PENETRATING OILLOCALCoMat 10-058

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-60-020-051 Drain 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 IN TO YOUR BODY.
        TO LET THE TANK PRESSURE BLEED OFF, DO NOT REMOVE THE OIL TANK CAP FOR FIVE MINUTES AFTER THE ENGINE STOPS. THE HOT OIL IS DANGEROUS.

        CAUTION

        DO NOT LET THE ENGINE MOTOR WHEN THE OIL IS DRAINED.

        Drain the oil tank.

      1. Loosen the oil filler cap.

      2. Release and remove the drain oil plug ENGINE-MAIN GEARBOX CASE AND FITTINGS (72-60-21, 01-120) from the front flange of the main gearbox casing, below the oil pressure pump. Discard the packing from the plug.

      3. NOTE

        Let the engine oil drain for a minimum of 10 minutes.

        Drain the oil in to a container.

      2. Drain the external gearbox.

      1. Put a clean container below the external gearbox to catch the drained oil.

      2. Remove the Left-Hand Gearbox magnetic chip detector (MCD). Refer to TASK 72-00-00-050-001 (REMOVAL-001).

      3. Remove the MCD housing OIL-MAGNETIC CHIP DETECTOR (79-22-45, 01-120).

      4. Unscrew and remove the MCD housing. Discard the lockwire. Let the oil drain into a container.

      5. Remove and discard the seal ring OIL-MAGNETIC CHIP DETECTOR (79-22-45, 01-140) from the MCD housing.

      6. Repeat Step thru Step for the Right-Hand Gearbox magnetic chip detector and the Angle Gearbox magnetic chip detector.

      3. Drain the pressure and the scavenge oil filters.

      1. Release and remove the plugs from the bottom of the pressure and the scavenge oil filters. Drain the oil in to a container.

      2. Discard the packings from the plugs.

    2. SUBTASK 72-00-60-020-052 Remove the Gearbox Dressings

    1. Remove the gearbox dressings, refer to TASK 72-00-60-020-001.

    3. SUBTASK 72-00-60-020-053 Install the External Gearbox Support Tooling

    1. Refer to Figure.

    2. Install the IAE 1F10011 Handling fixture 2 off on the ground handling bosses on the bottom of the external gearbox.

    3. If necessary, install the IAE 1F10026 Hydraulic hand pump 1 off on the IAE 1F10022 Hydraulic jack 1 off and connect the hose.

    4. Install IAE 1F10023 Gearbox adapter 1 off on the plate of the hydraulic jack. Make sure the adjustable support of the hydraulic jack is in lowered position.

    5. Move the hydraulic jack with the gearbox adapter below the engine. Operate the hydraulic pump to lift the hydraulic jack until the gearbox adapter is at about 2.75 in. (70 mm) from the gearbox.

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

    7. Align the holes on the shock absorber of the gearbox adapter with the two handling pin. Align the angle gearbox support with the angle gearbox.

    8. Turn clockwise the handwheel of the adjustable support of the hydraulic jack. Lift the gearbox adapter until the handling pin are fully in to the holes of the shock absorbers. Make sure the angle gearbox support touches the angle gearbox.

    9. Install the two safety pins in to the hole of the handling pin.

    10. Put the two locking rods in position on the bosses of the angle gearbox. Safety with the knobs.

    11. Turn clockwise the handwheel of the adjustable support to remove the weight of the external gearbox from the link.

    4. SUBTASK 72-00-60-020-054 Disconnect the External Gearbox from the Intermediate Case

    1. Refer to Figure.

      2. Disconnect the right hand link on the front of the gearbox.

      1. Remove the two bolts that safety the bonding strap and the pins. Remove the bonding strap. Install again the bolts and tighten by hand.

      2. Remove the two nuts, washers and bolts which attach the two brackets to the intermediate case flange.

    3. Disconnect the left hand link on the front of the gearbox. Do the Step and Step.

    4. Remove the two nuts, washers and bolts which attach the brackets of the rear link to the intermediate case flange.

      5. NOTE

        Do the subsequent operation to easy the access at the front link of the gearbox.

        Disconnect the front center link.

      1. CAUTION

        DO NOT PUT LOAD ON THE FRONT LINK AND BRACKETS WITH THE WEIGHT OF THE GEARBOX DURING THE SUBSEQUENT OPERATION.

        Turn counterclockwise the handwheel of the adjustable support to move the external gearbox away from the engine until the link is in vertical position.

      2. Remove the two nuts, washers and bolts which attach the brackets to the intermediate case flange.

    5. SUBTASK 72-00-60-020-055 Remove the External Gearbox from the Intermediate Case

    1. Turn counterclockwise the knob on the front of the hydraulic jack base than lower the hydraulic jack. Move the external gearbox from the engine.

    2. Remove and discard the trapezoidal seal ring from the PTO shaft seal tube on the engine.

      3. Put the assemblies adapter gearbox/external gearbox on the IAE 1F10021 Storage stand 1 off.

      1. Move the hydraulic jack to the front of the opened side of the storage stand.

      2. If necessary, lift the hydraulic jack until the gearbox adapter is higher than the storage stand.

      3. Move the hydraulic jack and align the gearbox adapter with the support of the storage stand.

      4. Slowly lower the hydraulic jack until the gearbox adapter touch the support of the storage stand. Safety with the quick release pins. Remove the hydraulic jack from the storage stand.

    6. SUBTASK 72-00-60-020-138 Install Holding Cap on to the Oil Seal Tube to Hold the PTO Shaft

    1. Refer to Figure.

    2. Remove two of the four bolts (01-160) to replace them with the two bolts of the holding cap. Refer to Figure for the positions of the bolts to be replaced.

    3. Turn the cap screw (part of IAE 1J12082 Holding Cap 1 off) counterclockwise fully to move it out of the cap.

    4. Align the four boltholes in the cap (part of the holding cap) with the two bolts and the two holes in the oil seal tube.

    5. Attach the cap to the oil seal tube and safety with the two washers, spring washers and bolts (part of the holding cap). Tighten the bolts.

    6. Turn the cap screw clockwise until the sheet touches the PTO shaft.

    7. Safety the cap screw with CoMat 02-147 LOCKWIRE. Refer to SPM TASK 70-42-05-400-501.

    8. Install the two nuts (part of the holding cap) on to the two bolts (01-160) that were removed before. Install the bolts in to the threaded holes in the cap and tighten the nuts.

      NOTE

      The holding cap is removed from the oil seal. The two bolts (01-160) are moved from the cap to the oil seal tube in TASKS which install the external gearbox to the fan case.

    7. SUBTASK 72-00-60-020-056 Remove the Support Link Assemblies from the External Gearbox

    1. Refer to Figure.

      2. Remove the right hand link with IAE 1F10292 Puller 1 off.

      1. Remove the bolt that safeties the pin to the lug.

      2. Remove the hexagonal head screw from the puller support (if installed).

      3. Put the puller against the gearbox lug. Align and install the rod of the pusher in to the hole on the lug adjacent the pin.

      4. Put the driver bolt through the smaller hole of the puller support and install in to the bolt hole of the pin.

      5. Put the hexagonal head screw through the larger hole of the puller support and through the internal hole of the pin. Install the special nut on the threaded end of the hexagonal head screw and turn against the pin.

      6. Turn the hexagonal head screw with a standard wrench until the pin is removed from the lugs.

      7. Remove the driver bolt and the pusher from the gearbox lug. Remove the special nut and remove the pin from the hexagonal head screw.

    3. Remove the left hand link with IAE 1F10293 Puller 1 off. Do the Step thru Step.

      4. Remove the center link with IAE 1F10294 Puller 1 off.

      1. Remove the bolt that safeties the pin to the lug.

      2. Remove the hexagonal head screw from the puller support (if installed).

      3. Put the puller against the gearbox lug.

      4. Put the driver bolt through the smaller hole of the puller support and install in to the bolt hole of the pin.

      5. Put the hexagonal head screw through the larger hole of the puller support and through the internal hole of the pin. Install the special nut on the threaded end of the hexagonal head screw and turn against the pin.

      6. Turn the hexagonal head screw with a standard wrench until the pin is removed from the lugs.

      7. Remove the driver bolt and the pusher from the gearbox lug. Remove the special nut and remove the pin from the hexagonal head screw.

      5. Remove the rear link from the angle gearbox support.

      1. Remove the bolt and washer which attach the rear pin to the lug.

        2. Prepare the IAE 1F10412 Puller 1 off. Refer to Figure.

        1. Remove the bolt from the puller.

      3. Put the two blocks of IAE 1F10412 Puller 1 off equally spaced between the two lugs of the Angle Gearbox Support.

      4. Install the bolt through the puller into the threaded bolthole in the pin.

      5. Rotate the two screws at the same time until the pin is free.

      6. Remove the pin.

      7. Remove the puller from the lugs.

      6. Remove the brackets and the pins from the three front links.

      1. Remove the brackets from the free ends of the three pins.

      2. Remove the bolts which attach the pins to the brackets.

      3. Remove the pins from the three links. Use a soft drift.

      4. Remove the remaining brackets from the pins.

      7. Remove the brackets and the pin from the rear link.

      1. Remove the two brackets from the ends of the pin.

      2. Remove the pin from the rear link. Use a soft drift.

    8. Figure: External gearbox support tooling

    External gearbox support tooling

    Figure: External gearbox support tooling

    External gearbox support tooling

    Figure: Removal of the external gearbox from the intermediate case

    Removal of the external gearbox from the intermediate case

    Figure: Removal of the external gearbox from the intermediate case

    Removal of the external gearbox from the intermediate case

    Figure: Removal of the external gearbox from the intermediate case

    Removal of the external gearbox from the intermediate case

    Figure: Removal of the support link assembly from the external gearbox

    Removal of the support link assembly from the external gearbox

    Figure: Removal of the support link assembly from the external gearbox

    Removal of the support link assembly from the external gearbox

    Figure: Install The Holding Cap On To The PTO Shaft To Hold The PTO Shaft

    Install The Holding Cap On To The PTO Shaft To Hold The PTO Shaft

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added new subtask and figure. (19VC647)

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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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:X222X
Supply Number:CoMat 10-058
Type:sp01
Supply Short Name:CoMat 10-058 PENETRATING OIL
Supply Name:CoMat 10-058 PENETRATING OIL
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:0AM53
Tool Number:IAE 1F10011
Tool Name:IAE 1F10011 Handling fixture
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 1F10292
Tool Name:IAE 1F10292 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1F10293
Tool Name:IAE 1F10293 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1F10294
Tool Name:IAE 1F10294 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1F10412
Tool Name:IAE 1F10412 Puller
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