TASK 72-60-00-430-001 External Gearbox Module - Assemble The Module, Assembly-001

DMC:V2500-A0-72-60-0000-00A-710A-B|Issue No:002.00|Issue Date:2019-05-01

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 72-60-00-430-001 External Gearbox Module - Assemble The Module, Assembly-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 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.

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

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 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.

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 1F10023 Gearbox adapter0AM53IAE 1F100231
IAE 5F10048 Gearbox handling adapter0AM53IAE 5F100481
IAE 1F10154 Build stand0AM53IAE 1F101541

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
Packing1
Packing1

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-60-00-430-051 Install the Angle Gearbox to the Main Gearbox

    1. Refer to Figure.

    2. WARNING

      MAKE SURE THAT IAE 1F10154 BUILD STAND 1 OFF, WITH THE MAIN GEARBOX INSTALLED, IS SAFETIED TO THE WORK BENCH. THE WEIGHT OF THE ANGLE GEARBOX CAN TURN OVER THE BUILD STAND.

      Install External Gearbox Module (72-60-00, 01-240) packing 1 off in to the groove on the flange of the angle gearbox support.

    3. Apply CoMat 10-077 APPROVED ENGINE OILS on the flange of the angle gearbox support.

    4. Make sure that the retaining ring is correctly installed in to the groove on the splined end of the bevel gearshaft.

    5. Align the guide pin and the studs on the angle gearbox with the holes on the flange of the angle gearbox support.

    6. Remove the two nuts and washers which attach the crank cover to the front flange of the gearbox. Remove the crank cover and discard the packing.

    7. Install a standard wrench on the starter idler gear and manually turn the gear train to make easier the subsequent operation.

    8. Install the angle gearbox to the angle gearbox support. Engage the spline of the bevel gearshaft with the spline of the layshaft extension gear.

    9. Install the three brackets on the rear flange of the angle gearbox support and align with the studs.

    10. Install the two washers and the eight nuts which attach the brackets angle gearbox to the angle gearbox support. Torque to 85 to 95 lbfin (9.604 to 10.734 Nm).

    2. SUBTASK 72-60-00-430-062 Install Identification Plate

    1. Refer to Figure.

    2. Use two bolts ENGINE-EXTERNAL GEARBOX MODULE (72-60-00, 01-280) to secure the identification plate ENGINE-EXTERNAL GEARBOX MODULE (72-60-00, 01-260) to the bottom of the gearbox casing.

    3. Torque the bolts to 20 lbfin to 26 lbfin (2.26 to 2.94 Nm). Orientation of the bolt head or special alignment with the identification plate is not necessary.

    4. Bend the ends of the identification plate against the bolt head to prevent the bolt from rotating.

    3. SUBTASK 72-60-00-430-063 Install Module Identification Plate

    1. Refer to Figure.

    2. Remove two fasteners ENGINE-ANGLE GEARBOX ASSEMBLY (72-60-40, 01-055) and washers that secure the radial gear support ENGINE-ANGLE GEARBOX DRIVING BEVEL GEAR ASSEMBLY (72-60-42, 01-230) to the bottom of the angle gearbox.

    3. Install the module identification plate External Gearbox Module (72-60-00, 01-222) to the bottom of the angle gearbox using the removed fasteners and washers.

    4. Torque the fasteners to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    4. SUBTASK 72-60-00-430-060 Remove the External Gearbox from the Build Stand

    1. Refer to Figure.

      2. Install the IAE 5F10048 Gearbox handling adapter 1 off on the external gearbox.

      1. Remove the two hexagon nuts from the eyebolt. Remove the eyebolt from the storage hole for shipment.

      2. Install the eyebolt in to the hole for gearbox lifting. Attach with the two hexagon nuts.

      3. Attach a hoist to the top of the eyebolt. Lift the ship/handling adapter from the shipping container and move it on the gearbox.

      4. Lower the shipping adapter until the two links and the bracket of the adapter are in position on the gearbox casing.

      5. Put the bracket between the front lugs in position A. Put the link between the front lugs in position B and the other link between the rear lugs in position C.

      6. Align the hole of the bracket and the holes of the two links with the holes of the lugs.

        7. Install the two pins to the front lugs in positions A and B.

        1. Put the pin in to the front gearbox lug.

        2. Push fully the pin through the lugs and the spherical bearing.

        3. Align the hole on the pin flange with the hole on the front gearbox lug. Install the bolt and torque to 85 to 95 lbfin (9.604 to 10.734 Nm).

        4. Do the Step to Step again for the outer pin.

        8. Install the pin to the rear gearbox lugs in position C.

        1. Put the pin in to the rear gearbox lug.

        2. Push fully the pin through the lugs and the spherical bearing of the link.

        3. Install the washer and the pin securing bolt in to the hole on the boss adjacent to the lug.

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

    3. Release the six knobs of IAE 1F10154 Build stand build stand 1 off and lift the external gearbox from the supports of the build stand.

    5. SUBTASK 72-60-00-430-061 Install the External Gearbox on the Storage Stand

    1. Refer to Figure.

    2. Move the external gearbox on IAE 1F10021 Storage stand 1 off.

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

    4. Slowly lower the external gearbox on the storage stand.

    5. Align the two handling pins with the holes of IAE 1F10023 Gearbox adapter 1 off on the storage stand. Align the angle gearbox with the angle gearbox support of the gearbox adapter.

    6. Continue to lower the external gearbox until the two handling fixtures are fully in to the holes of the gearbox adapter.

    7. Make sure that the angle gearbox is correctly installed on the angle gearbox support between the two locking rods.

    8. Install the two safety pins to the handling fixtures.

    9. Put the two locking rods in position on the bosses of the angle gearbox. Tighten the rotating blocks.

      10. Remove the IAE 5F10048 Gearbox handling adapter 1 off from the external gearbox, refer to Figure.

        1. Disconnect the bracket at position A and the link at position B from the front lugs.

        1. Remove the bolts which attach the two pins to the front lugs.

        2. Remove the two pins from the bushings and the spherical bearings by hand.

        2. Disconnect the link from the rear lugs in position C.

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

        2. Remove the pin from the bushings of the lugs and from the spherical bearing of the link by hand.

      3. Lift the shipping adapter from the external gearbox.

      4. Put again the shipping adapter into the shipping container.

    6. SUBTASK 72-60-00-430-057 Install the Crank Cover

    1. Refer to Figure.

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

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

    4. Align the holes with the stud and install the crank cover on the gearbox.

    5. Safety the crack cover with the two washers and nuts. Torque the nuts to 85 to 95 lbfin (9.604 to 10.734 Nm).

    7. Figure: Install the angle gearbox

    Install the angle gearbox

    Figure: Install the oil tank

    Install the oil tank

    Figure: Install the oil scavenge filter assembly

    Install the oil scavenge filter assembly

    Figure: Remove and install the cover crank

    Remove and install the cover crank

    Figure: Install the oil scavenge pump assembly

    Install the oil scavenge pump assembly

    Figure: Install the oil pressure pump assembly

    Install the oil pressure pump assembly

    Figure: Install/Remove the shipping adapter on/from the external gearbox

    Install/Remove the shipping adapter on/from the external gearbox

    Figure: Install/Remove the shipping adapter on/from the external gearbox

    Install/Remove the shipping adapter on/from the external gearbox

    Figure: Install the external gearbox to the storage stand

    Install the external gearbox to the storage stand

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Updated installation procedure and figure. (18VC232)

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:X333X
Enterprise Name:REFER TO V2500 SB ENG-79-0108
Link not Found
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 1F10021
Tool Name:IAE 1F10021 Storage stand
Manufacturer Code:0AM53
Tool Number:IAE 1F10023
Tool Name:IAE 1F10023 Gearbox adapter
Manufacturer Code:0AM53
Tool Number:IAE 1F10154
Tool Name:IAE 1F10154 Build stand
Manufacturer Code:0AM53
Tool Number:IAE 5F10048
Tool Name:IAE 5F10048 Gearbox handling adapter