TASK 72-60-40-440-001 Angle Gearbox Assembly - Assemble The Angle Gearbox, Assembly-001

DMC:V2500-A0-72-60-4000-00A-710A-B|Issue No:009.00|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 72-60-40-440-001 Angle Gearbox Assembly - Assemble The Angle Gearbox, 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 SPM TASK 70-41-00-400-501, SPM TASK 70-41-00-400-501 and SPM TASK 70-41-01-400-501.

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

Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-039 ENGINE OIL, unless other lubricants are referred to in the procedure.

To identify, lubricate and install seal rings refer to 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 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.

Make sure that the outer race has the same serial number of the related bearing.

Lubricate the cages of the roller bearings with CoMat 10-039 ENGINE OIL before the installation.

Operate by hand the installed gearshafts to make easier subsequent installations.

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
Swivel viseLOCALSwivel vise
Arbor PressLOCALArbor press
Hot Air GunLOCALHot Air Gun
IAE 1F10026 Hydraulic hand pump0AM53IAE 1F100261
IAE 1F10082 Guide Pin0AM53IAE 1F100822
IAE 1F10087 Base0AM53IAE 1F100871
IAE 1F10098 Pusher0AM53IAE 1F100981
IAE 1F10100 Base holder0AM53IAE 1F101001
IAE 1F10102 Pusher0AM53IAE 1F101021
IAE 1F10104 Hand wrench0AM53IAE 1F101041
IAE 1F10105 Pusher0AM531F10105
IAE 1F10110 Stud0AM53IAE 1F101103
IAE 1F10114 Hydraulic cylinder0AM53IAE 1F101141
IAE 1F10122 Pusher0AM53IAE 1F101221
IAE 1F10123 Puller0AM53IAE 1F101231
IAE 1F10128 Pusher0AM53IAE 1F101281
IAE 1F10129 Pusher0AM53IAE 1F101291
IAE 1F10130 Guide pins0AM53IAE 1F101302
IAE 1F10131 Base0AM53IAE 1F101311
IAE 1F10133 Pusher0AM53IAE 1F101331
IAE 1F10134 Ring0AM53IAE 1F101341
IAE 1F10135 Base0AM53IAE 1F101351
IAE 1F10136 Pusher0AM53IAE 1F101361
IAE 1F10201 Base0AM53IAE 1F102011
IAE 2F10132 Backlash fixture0AM53IAE 2F101321
IAE 2F10137 Clamping fixture0AM53IAE 2F101371
IAE 2F10138 Loading fixture0AM53IAE 2F101381
IAE 2F10139 Backlash fixture0AM53IAE 2F101391
IAE 2F10140 Loading fixture0AM53IAE 2F101401
IAE 2F10141 Clearance gage0AM53IAE 2F101411
IAE 2F10143 Clamping fixture0AM53IAE 2F101431
IAE 2F10144 Clamping fixture0AM53IAE 2F101441
IAE 2F10145 Rotating fixture0AM53IAE 2F101451
IAE 2F10147 Rotating fixture0AM53IAE 2F101471
IAE 2F10148 Clamping adapter0AM53IAE 2F101481
IAE 2F10217 Rotating handwheel0AM53IAE 2F102171

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-179 COMPOUND, GEAR MARKINGLOCALCoMat 02-179
CoMat 07-012 AIR DRYING ENAMEL0AM53CoMat 07-012
CoMat 10-039 ENGINE OILLOCALCoMat 10-039

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
PackingAR

72-60-40, 01-260

PackingAR

72-60-40, 01-080

PackingAR

72-60-40, 01-255

PackingAR

72-60-40, 01-415

PackingAR

72-60-40, 01-420

PackingAR

72-60-42, 01-080

PackingAR

72-60-41, 01-220

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-60-40-440-051 Install the Angle Gearbox Casing on the Base Holder

    1. Refer to Figure.

    2. Align the guide pin and the studs in front face of the angle gearbox casing with the holes on IAE 1F10100 Base holder 1 off. Install the angle gearbox casing on the base holder.

    3. Install the eight slave nuts which attach the angle gearbox casing to the base holder.

    4. Attach the base holder to the swivel vice. Put the lower flange of the angle gearbox casing horizontally.

    2. SUBTASK 72-60-40-440-052 Calculate the Thickness of the Shims

      NOTE

      It is only required to calculate the thickness of the shims if any of the following statements are true,
      1. The shim thickness for Dimension X or Dimension Y are not recorded during disassembly of the Angle Gearbox.
      2. One or more of the following parts have been replaced since disassembly of the Angle Gearbox: Driving Bevel Gearshaft, Driven Bevel Gearshaft, Angle Gearbox Casing, Roller Bearing (Driven Bevel Gearshaft), Roller Bearing (Driving Bevel Gearshaft), Ball Bearing (Driving Bevel Gearshaft).

    1. Refer to Figure.

      2. Calculate the thickness of the shim (01-175), Figure.

      1. Measure the Dimension C and write it.

      2. Read the value of MD1 on the angle gearbox casing and write it.

      3. Read the value of MDX on the bevel gearshaft and write it.

      4. Calculate the value of X with the subsequent formula:

        X = (MDX + C) - MD1.

      5. Find the shim of which thickness is nearest to X.

      3. Calculate the thickness of the shim (01-165), Figure.

      1. Measure the dimension M1 and write it.

      2. Read the value of MD2 on the angle gearbox casing and write it.

      3. Read the value of MD on the bevel radial gearshaft and write it.

      4. Calculate the value of Y with the subsequent formula:

        Y = M1 - (MD + MD2).

      5. Find the shim of which thickness is nearest to Y.

    3. SUBTASK 72-60-40-440-053 Install the Outer Race of the Upper Roller Bearing

    1. Refer to Figure.

    2. WARNING

      DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES.

      WARNING

      HOT PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF THE HANDS ARE NOT PROTECTED.

      WARNING

      IMMERSE THE CONTACTED AREA IN COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. IMMEDIATELY GET MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

      NOTE

      If the subsequent operation is not easy, locally increase the temperature of the angle gearbox casing to 250 °F (121 °C) maximum. Use a hot air gun.

      Install IAE 1F10082 Guide Pin 2 off in to the bolt holes near the seat of the outer race.

    3. Align the holes on the outer race flange with the guide pins. Install the outer race in to the seat in the internal of the angle gearbox casing. Use IAE 1F10098 Pusher 1 off to easy the installation. Remove the two guide pins.

    4. Install the four keywashers and bolts which attach the outer race to the angle gearbox casing. Torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    5. Bend the tabs of the keywashers to lock the bolts.

    4. SUBTASK 72-60-40-440-054 Install the Driving Gear Assembly for the Contact and the Backlash Checks

    1. Refer to Figure.

    2. Install Angle Gearbox Assembly (72-60-40, 01-080) packing 1 off in to the groove on the radial gear support.

    3. Apply CoMat 02-179 COMPOUND, GEAR MARKING on the teeth of the radial gearshaft.

    4. Install the shim on the lower flange of the angle gearbox casing. Align the holes on the shim with the studs on the angle gearbox casing.

    5. Align the holes on the radial gear support with the studs on the base holder and the upper roller bearing with the outer race. Install the driving gear assembly in to the angle gearbox casing.

    6. Install the six washers and nuts on the studs and torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    5. SUBTASK 72-60-40-440-055 Install the Driven Gear Assembly for the Contact and the Backlash Checks

    1. Refer to Figure.

    2. Turn the angle gearbox casing with the front flange horizontally.

    3. Apply CoMat 02-179 COMPOUND, GEAR MARKING on the teeth of the bevel gearshaft.

    4. Install the shim on the internal flange of the angle gearbox casing. Align the holes on the shim with the studs on the angle gearbox casing.

    5. Align the holes on the bearing support with the studs on the angle gearbox casing. Install the driven gear assembly on the internal flange of the angle gearbox casing. Turn the gear by hand to easy the installation.

    6. Install IAE 1F10110 Stud 3 off on the base holder.

    7. Install IAE 1F10122 Pusher 1 off over the bevel gearshaft and put on the bearing support.

    8. Install IAE 1F10114 Hydraulic cylinder 1 off on the three studs. Make sure that the hydraulic cylinder is seated to push.

    9. Attach IAE 1F10026 Hydraulic hand pump 1 off to the hydraulic cylinder. Operate the hydraulic pump until the driven gear assembly is fully installed on the angle gearbox casing.

    10. Disconnect the hydraulic pump from the hydraulic cylinder. Remove the hydraulic cylinder holder, the pusher and the studs from the angle gearbox.

    11. Install the four washers and nuts on the studs and torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    6. SUBTASK 72-60-40-440-056 Install the Tools for the Backlash Check of the Angle Gearbox Gears

      1. Install the outer race of the roller bearing Extension Layshaft Gear And Bearing Assembly (72-60-24, 01-280) on the backlash fixture, Figure.

      2. Install IAE 1F10130 Guide pins 2 off on the top flange of the backlash fixture.

      3. Align the holes on the outer race flange with the guide pins. Install the outer race on the backlash fixture. Use IAE 1F10128 Pusher 1 off to easy the installation.

      4. Remove the guide pins.

      5. Install the three slave bolts and torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    2. Install the backlash fixture on the base holder. Safety with the four lockwashers and special bolts, Figure.

      3. Install the inner race of the roller bearing Extension Layshaft Gear And Bearing Assembly (72-60-24, 01-280) on the IAE 2F10137 Clamping fixture 1 off, Figure.

      1. Put the clamping fixture on the workbench with the threaded diameter down.

      2. 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.

        Put the inner race of the roller bearing in to the oven and increase the temperature to 250 °F (121 °C) maximum.

      3. Install the inner race on the clamping fixture. Use IAE 1F10133 Pusher 1 off and the Arbor Press ram or equivalent.

      4. Install the clamping fixture, Figure.

      1. Install the clamping fixture with the roller bearing on the backlash fixture.

      2. Align the pin with the dowel slot of the backlash fixture.

      3. Put the expander in to the ID of the bevel gearshaft and the inner race of the roller bearing in to the outer race.

      4. Turn the hexagonal nut with a standard wrench until the bevel gearshaft is locked.

    5. Install IAE 2F10138 Loading fixture 1 off on the backlash fixture and attach with the bolts and washers. Attach the ring nut to the clamping fixture, Figure.

      1. Install the support in to the bottom side of the radial gearshaft.

      2. Install the centering bush in to the opposite side of the radial gearshaft.

      3. Install the tie rod through the centering bush and attach to the support.

      1. Align the holes on the loading fixture with the four studs on the radial gear support.

      2. Install the loading fixture on the radial gear support and secure with the slave nuts.

      3. Attach the ring nut of the loading fixture to the support.

    7. SUBTASK 72-60-40-440-057 Do the Backlash Check of the Angle Gearbox Gears

    1. Refer to Figure.

    2. Make sure that the bevel gearshaft is fully locked.

    3. Install IAE 2F10141 Clearance gage 1 off on the base holder. Safety with the two washers and bolts. Make sure that the dial gage points the pin on the plate.

    4. Make sure that the axis of the dial indicator and the axis of the plate are perpendicular.

      5. Do the backlash check at starter condition.

      1. Adjust to zero the dial indicator on both dynamometers.

      2. Operate the adjusting screw to apply on the bevel gearshaft a load of 44.092 lbf (20 Kg) in the direction of the angle gearbox.

      3. Operate the adjusting screw to apply on the radial gearshaft a load of 22.046 lbf (10 Kg) in the direction of the angle gearbox.

      4. Turn clockwise the plate by hand and adjust the dial gage to zero.

        5. Turn counterclockwise the plate by hand and read the value of the backlash on the dial gage. The value of the backlash must be:

        1. 0.0177 in. (0.45 mm) Minimum.

        2. 0.0334 in. (0.85 mm) Maximum.

        3. Refer to Step if the backlash is out of these limits.

      6. Operate the adjusting screws to release the load on the two gearshafts.

      6. Do the backlash check at run condition.

      1. Adjust to zero the dial indicator on both dynamometers.

      2. Operate the adjusting screw to apply on the bevel gearshaft a load of 44.092 lbf (20 Kg) in the direction opposite the angle gearbox.

      3. Operate the adjusting screw to apply on the radial gearshaft a load of 22.046 lbf (10 Kg) in the direction opposite the angle gearbox.

      4. Turn clockwise the plate by hand and adjust the dial gage to zero.

        5. Turn counterclockwise the plate by hand and read the value of the backlash on the dial gage. The value of the backlash must be:

        1. 0.0177 in. (0.45 mm) Minimum.

        2. 0.0334 in. (0.85 mm) Maximum.

        3. Refer to Step if the backlash is out of these limits.

      6. Operate the adjusting screws to release the load on the two gearshafts.

      7. Remove the clearance gage from the base holder.

    8. SUBTASK 72-60-40-440-058 Remove the Tools used for the Backlash Check of the Angle Gearbox Gears

      1. Remove the loading fixture from the angle gearbox, Figure.

      1. Disconnect the ring nut from the support.

      2. Remove the slave nuts which attach the loading fixture to the radial gear support.

      3. Remove the loading fixture from the angle gearbox.

      2. Remove the backlash fixture from the radial gearshaft.

      1. Release and remove the mandrel from the support and the centering bush.

      2. Remove the support and the centering bush from the radial gearshaft.

      3. Remove the loading fixture from the slave support, Figure.

      1. Disconnect the ring nut from the clamping fixture.

      2. Remove the bolts and the washers which attach the loading fixture to the backlash fixture.

      3. Remove the loading fixture.

    4. NOTE

      Do not remove the backlash fixture with the outer race of the roller bearing from the angle gearbox.

      Release the clamping fixture from the bevel gearshaft. Remove the clamping fixture with the inner race of the roller bearing, Figure.

      5. Remove the inner race of the roller bearing from the clamping fixture, Figure.

      1. Adjust the two half of IAE 1F10134 Ring 1 off under the lower flange of the inner race. Install the clamping fixture and the ring on IAE 1F10135 Base 1 off with the inner race to the top.

      2. Install IAE 1F10136 Pusher 1 off on the clamping fixture.

      3. Remove the inner race from the clamping fixture. Use the Arbor Press ram or equivalent.

    9. SUBTASK 72-60-40-440-059 Install the Tools for the Contact Check at Run Condition of the Angle Gearbox Gears

      1. Install the inner race of the roller bearing Extension Layshaft Gear And Bearing Assembly (72-60-24, 01-280) on IAE 2F10144 Clamping fixture 1 off, Figure.

      1. Install the clamping fixture on IAE 1F10201 Base 1 off. Put the small diameter of the clamping fixture in to the smaller hole of the base.

      2. 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.

        Put the inner race of the roller bearing in to the oven and increase the temperature to 250 °F (121 °C) maximum.

      3. Install the inner race on the clamping fixture. Use IAE 1F10133 Pusher 1 off and the Arbor Press ram or equivalent.

    2. Install the clamping fixture over the splined end of the bevel gearshaft. Put the inner race of the roller bearing in to the outer race installed on the backlash fixture, Figure.

    3. Align the square end of the clutch with the square hole on the clamping fixture. Install IAE 2F10143 Clamping fixture 1 off on the backlash fixture and attach with the bolts, Figure.

    4. Turn the angle gearbox with the radial gearshaft vertically.

      5. Install IAE 2F10145 Rotating fixture 1 off on the radial gearshaft, Figure.

      1. Put the splined end of the mandrel in to the splined end of the radial gearshaft.

      2. Put the tie rod in to the radial gearshaft and attach to the mandrel.

    10. SUBTASK 72-60-40-440-060 Do the Contact Check of the Angle Gearbox Gears at Run Condition

    1. Refer to Figure.

    2. Install IAE 2F10217 Rotating handwheel 1 off on the mandrel.

    3. Calibrate the clutch on the clamping fixture to 177 lbfin to 265.5 lbfin (20 Nm to 30 Nm).

    4. Turn the rotating handwheel clockwise for three turns at least.

    5. Remove the rotating handwheel and the rotating fixture from the radial gearshaft.

    6. Remove the clamping fixture from the backlash fixture.

    11. SUBTASK 72-60-40-440-061 Install the Tools for the Contact Check at Starter Condition

    1. Refer to Figure.

    2. Install IAE 2F10148 Clamping adapter 1 off on the radial gear support. Attach with the slave nuts.

    3. Install IAE 2F10143 Clamping fixture 1 off on the clamping adapter and secure with the bolts.

    4. Install IAE 2F10147 Rotating fixture 1 off through the radial gearshaft and attach to the clutch.

    12. SUBTASK 72-60-40-440-062 Do the Contact Check of the Angle Gearbox Gears at Starter Condition

    1. Refer to Figure.

    2. Install IAE 2F10217 Rotating handwheel 1 off on the clamping fixture.

    3. Calibrate the clutch to 177 lbfin to 265.5 lbfin (20 Nm to 30 Nm).

    4. Turn the rotating handwheel counterclockwise for three turns at least.

    5. Remove the rotating handwheel from the clamping fixture.

    13. SUBTASK 72-60-40-440-063 Remove the Tools used for the Contact Check of the Angle Gearbox Gears

    1. Refer to Figure.

    2. Remove the rotating fixture from the radial gearshaft.

    3. Remove the clamping fixture from the clamping adapter.

    4. Remove the clamping adapter from the radial gear support.

    5. Remove the clamping fixture with the inner race of the roller bearing from the bevel gearshaft.

    6. Remove the backlash fixture from the angle gearbox.

      7. Remove the outer race of the roller bearing from the backlash fixture.

      1. Remove the three slave bolts which attach the outer race to the backlash fixture.

      2. Put the backlash fixture with the outer race to the bottom on IAE 1F10131 Base 1 off.

      3. Remove the outer race from the backlash fixture. Use IAE 1F10129 Pusher 1 off.

      8. Remove the inner race of the roller bearing from the clamping fixture, Figure.

      1. Install the clamping fixture on the smaller diameter of IAE 1F10201 Base 1 off with inner race of the roller bearing to the top.

      2. Remove the inner race from the clamping fixture. Use IAE 1F10136 Pusher 1 off and the Arbor Press ram or equivalent.

    14. SUBTASK 72-60-40-440-064 Remove the Drive Gear Assembly from the Angle Gearbox Casing

    1. Refer to Figure.

    2. Remove the four nuts and washers which attach the driven gear assembly to the angle gearbox casing. Refer to Figure.

      3. Install IAE 1F10123 Puller 1 off on the driving gear assembly.

      1. Make sure that the two L-shaped bolts are not in locked position.

      2. Align the two L-shaped bolts with the free slots on the bearing support. Install the puller over the bevel gearshaft and put on the base holder. Safety the puller with the three washers and bolts.

      3. Move the L-shaped bolts in locked position and safety with the knobs. Make sure the locking leg of the L-shaped bolts engage correctly with the bottom flange of the bearing support.

    4. Install IAE 1F10110 Stud 3 off on the base holder.

      1. Remove the bolt and the washer from the tie rod.

      2. Align the hole of the hydraulic cylinder with the tie rod.

      3. Install the hydraulic cylinder holder over the three studs and secure. Make sure the hydraulic cylinder is seated to pull.

      4. Install the washer and the bolt on the end of the tie rod. Tighten the bolt.

    6. Deleted.

    7. Attach IAE 1F10026 Hydraulic hand pump 1 off to the hydraulic cylinder. Operate the hydraulic pump until the driving gear assembly is disengaged from the angle gearbox casing.

    8. Disconnect the hydraulic pump from the hydraulic cylinder. Remove the bolt and washer from the end of the tie rod. Remove the hydraulic cylinder holder.

    9. Release and remove the three studs from the base holder.

    10. Remove the three bolts and washers which attach the puller to the base holder. Remove the puller and the driven gear assembly from the angle gearbox.

    11. Release the knobs and move the L-shaped bolts from the locked position. Remove the puller from the driven gear assembly.

    12. Examine the contact on the teeth of the bevel gearshaft. Refer to Step.

    15. SUBTASK 72-60-40-440-065 Remove the Driving Gear Assembly from the Angle Gearbox Casing

    1. Refer to Figure.

    2. Remove the six nuts and washers which attach the driving gear assembly to the angle gearbox casing.

    3. Disengage the driving gear assembly from the angle gearbox casing. Use the extraction bolts.

    4. Remove the driving gear assembly with the shim from the angle gearbox casing. Discard the packing.

    5. Examine the contact on the teeth of the radial gearshaft. Refer to Step.

    16. SUBTASK 72-60-40-220-051 Examine the Radial Gearshaft and the Bevel Gearshaft for the Correct Installation

      NOTE

      Go to step C. if the backlash is in the limits specified in the Step.

      1. Do the subsequent steps if the backlash is more than the maximum limits specified in the Step.

      1. Reject the shim of the driving gear assembly and the shim of the driven gear assembly.

      2. Find a new shim (01-065) of the driving gear assembly of which thickness is larger than the thickness of the rejected shim.

      3. Find a new shim (01-175) of the driven gear assembly of which thickness is smaller than the thickness of the rejected shim.

      4. Remove the marking compound from the teeth of the two gears. Use a soft brush.

      5. NOTE

        Go to step C. only if the backlash is in the limits specified in the Step.

        Do again the procedure from the Step.

      2. Do the subsequent steps if the backlash is less than the minimum limits specified in the Step.

      1. Reject the shim of the driving gear assembly and the shim of the driven gear assembly.

      2. Find a new shim (01-065) of the driving gear assembly of which thickness is smaller than the thickness of the rejected shim.

      3. Find a new shim (01-175) of the driven gear assembly of which thickness is larger than the thickness of the rejected shim.

      4. Remove the marking compound from the teeth of the two gears. Use a soft brush.

      5. NOTE

        Go to step C. only if the backlash is in the limits specified in the Step.

        Do again the procedure from the Step.

      3. Examine the contact bearing pattern on the convex side of the teeth of the driving gear assembly and on the concave side of the driven gear assembly (Run condition). The bearing pattern must be as much as possible on the center of the tooth side. Do the subsequent steps if this condition is not satisfactory.

        1. If the bearing pattern is to the toe of the teeth of the driven gear and to the heel of the teeth of the driving gear:

        1. Reject the shim of the driving gear assembly and the shim of the driven gear assembly.

        2. Find two new shims, (01-065) and (01-175), of which thickness is smaller than the thickness of the rejected shims.

        2. If the bearing pattern is to the heel of the teeth of the driven gear and to the toe of the teeth of the driving gear:

        1. Reject the shim of the driving gear assembly and the shim of the driven gear assembly.

        2. Find two new shims, (01-065) and (01-175), of which thickness is larger than the thickness of the rejected shims.

      3. Remove the marking compound from the teeth of the gears. Use a soft brush.

      4. Do the procedure from the Step again until the contact bearing patter is satisfactory.

    4. Examine the contact bearing pattern on the concave side of the teeth of the driving gear assembly and on the convex side of the driven gear assembly (Starter condition). The bearing pattern must be as much as possible on the center of the tooth side. No corrective action is necessary.

    17. SUBTASK 72-60-40-440-066 Assemble the Driving Gear Assembly Before the Installation

    1. Refer to Figure.

    2. Put the driving gear assembly in to IAE 1F10087 Base 1 off with the radial gear support to the top.

    3. Install the oil duct in to the radial gearshaft. Use IAE 1F10102 Pusher 1 off.

    4. Install the nut which attach the oil duct to the radial gearshaft. Torque to 619.560 lbfin to 796.577 lbfin (70 Nm to 90 Nm). Use IAE 1F10104 Hand wrench 1 off.

    5. Install the lock washer and the segment to lock the nut. Use IAE 1F10105 Pusher 1 off.

    6. Remove the driving gear assembly from the base. Put the driving gear assembly on the work surface with the radial gear support to the bottom.

    7. Install the radial coupling shaft in to the radial gearshaft. Engage the splined OD of the radial coupling shaft with the splined end of the radial gearshaft.

    8. Install the retaining ring in to the groove on the end of the radial gearshaft.

    9. If not installed, install Angle Gearbox Assembly (72-60-40, 01-080) packing 1 off in to the groove of the radial gear support.

    18. SUBTASK 72-60-40-440-067 Install the Driving Gear Assembly on the Angle Gearbox Casing

    1. Refer to Figure.

    2. Turn the angle gearbox casing with the lower flange horizontally.

    3. Install the shim with the thickness calculated after the contact and the backlash checks (Refer to Step), on the lower flange of the angle gearbox casing. Align the holes on the shim with the studs on the angle gearbox casing.

    4. Align the holes on the radial gear support with the studs on the angle gearbox casing and the upper roller bearing with the outer race. Install the driving gear assembly in to the angle gearbox casing.

    5. Install the six washers and nuts which attach the driving gear assembly, on the angle gearbox casing. Torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    19. SUBTASK 72-60-40-440-068 Install the Driven Gear Assembly on the Angle Gearbox Casing

    1. Refer to Figure.

    2. Turn the angle gearbox casing with the front flange horizontally.

    3. Install the shim, with the thickness calculated after the contact and the backlash checks (Refer to Step), on the internal flange of the angle gearbox casing. Align the holes on the shim with the studs on the angle gearbox casing.

    4. Align the holes on the bearing support with the studs on the angle gearbox casing. Install the driven gear assembly on the internal flange of the angle gearbox casing. Turn the gear by hand to easy the installation.

    5. Install IAE 1F10110 Stud 3 off on the base holder.

    6. Install IAE 1F10122 Pusher 1 off over the bevel gearshaft and put on the bearing support.

    7. Install IAE 1F10114 Hydraulic cylinder 1 off on the three studs. Make sure that the hydraulic cylinder is seated to push.

    8. Attach IAE 1F10026 Hydraulic hand pump 1 off to the hydraulic cylinder. Operate the hydraulic pump until the driven gear assembly is fully installed on the angle gearbox casing.

    9. Disconnect the hydraulic pump from the hydraulic cylinder. Remove the hydraulic cylinder holder, the pusher and the studs from the angle gearbox casing.

    10. Install the four washers and nuts which attach the driven gear assembly to the angle gearbox casing. Torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    11. Turn the gears by hand to make sure the free rotation.

    12. Install the retaining ring in to the groove on the threaded end of the bevel gearshaft.

    20. SUBTASK 72-60-40-440-069 Install the Oil Nozzles on the Angle Gearbox

    1. Refer to Figure.

      2. Install the oil nozzle of the driving gear assembly.

      1. Install Angle Gearbox Assembly (72-60-40, 01-420) packing 1 off and Angle Gearbox Assembly (72-60-40, 01-415) packing 1 off in to the grooves of the oil nozzle.

      2. Install the oil nozzle in to the seat on the angle gearbox casing. Align the hole in the nozzle flange with the adjacent stud.

      3. Install the washer and the nut and torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

      3. Install the oil nozzle of the driven gear assembly.

      1. Install Angle Gearbox Assembly (72-60-40, 01-260) packing 1 off and Angle Gearbox Assembly (72-60-40, 01-255) packing 1 off in to the grooves of the oil nozzle.

      2. Install the oil nozzle in to the seat on the angle gearbox casing. Align the hole in the nozzle flange with the adjacent stud.

      3. Install the washer and the nut and torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    21. SUBTASK 72-60-40-440-072 Remove the Angle Gearbox Casing from the Base Holder

    1. Refer to Figure.

    2. Remove the eight slave nuts which attach the angle gearbox casing to the base holder.

    3. Remove the angle gearbox casing from the base holder.

    22. SUBTASK 72-60-40-440-070 Install the Plug on the Lower Flange of the Angle Gearbox

    1. Refer to Figure.

    2. Install Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-080) packing 1 off in to the groove of the plug.

    3. Align the holes on the plug with the studs on the radial gear support. Install the plug on the radial gear support.

    4. Install the three washers and nuts which attach the plug to the radial gear support. Torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    23. SUBTASK 72-60-40-440-073 Install the Suction Strainer Assembly on the Angle Gearbox

    1. Refer to Figure.

    2. Install ENGINE-ANGLE GEARBOX CASE (72-60-41, 01-146) packing 1 off to the groove of the suction strainer assembly ENGINE-ANGLE GEARBOX CASE (72-60-41, 01-140).

    3. Install the suction strainer assembly to the seat on the angle gearbox casing. Align the hole on the strainer flange with the adjacent stud.

    4. Install the nut/bolt and torque to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    24. SUBTASK 72-60-40-440-071 Install the Oil Input Adapter on the Angle Gearbox

    1. Refer to Figure.

    2. Install ENGINE-ANGLE GEARBOX CASE (72-60-41, 01-220) packing 1 off to the groove of the oil input adapter ENGINE-ANGLE GEARBOX CASE (72-60-41, 01-200).

    3. Install the oil input adapter to the seat on the angle gearbox casing. Align the holes in the adapter flange with the adjacent studs.

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

    25. Figure: Installation of the Angle Gearbox on the Base Holder

    Installation of the Angle Gearbox on the Base Holder

    Figure: Installation of the Outer Race of the Upper Roller Bearing

    Installation of the Outer Race of the Upper Roller Bearing

    Figure: Installation of the Driving Gear Assembly

    Installation of the Driving Gear Assembly

    Figure: Installation of the Driven Gear Assembly

    Installation of the Driven Gear Assembly

    Figure: Installation of the Driven Gear Assembly

    Installation of the Driven Gear Assembly

    Figure: Installation of the Roller Bearing on the Tools

    Installation of the Roller Bearing on the Tools

    Figure: Installation of the Backlash Fixture and the Clamping Fixture on the Angle Gearbox

    Installation of the Backlash Fixture and the Clamping Fixture on the Angle Gearbox

    Figure: Installation of the Loading Fixture on the Backlash Fixture

    Installation of the Loading Fixture on the Backlash Fixture

    Figure: Installation of the Backlash Fixture and the Loading Fixture on the Radial Gearshaft

    Installation of the Backlash Fixture and the Loading Fixture on the Radial Gearshaft

    Figure: Backlash Check

    Backlash Check

    Figure: Removal of the Inner Race from the Clamping Fixture

    Removal of the Inner Race from the Clamping Fixture

    Figure: Installation of the Inner Race of the Roller Bearing on the Clamping Fixture

    Installation of the Inner Race of the Roller Bearing on the Clamping Fixture

    Figure: Installation of the Clamping Fixture and the Clutch

    Installation of the Clamping Fixture and the Clutch

    Figure: Contact Check at Run Condition

    Contact Check at Run Condition

    Figure: Contact Check at Starter Condition

    Contact Check at Starter Condition

    Figure: Removal of the Roller Bearing from the Clamping Fixture

    Removal of the Roller Bearing from the Clamping Fixture

    Figure: Removal of the Driven Gear Assembly

    Removal of the Driven Gear Assembly

    Figure: Installation of the Oil Duct on the Driving Gear Assembly

    Installation of the Oil Duct on the Driving Gear Assembly

    Figure: Installation of the Radial Coupling Shaft on the Driving Gear Assembly

    Installation of the Radial Coupling Shaft on the Driving Gear Assembly

    Figure: Oil Nozzles on the Angle Gearbox

    Oil Nozzles on the Angle Gearbox

    Figure: Installation of the Plug on the Lower Flange of the Angle Gearbox

    Installation of the Plug on the Lower Flange of the Angle Gearbox

    Figure: Calculate The Value Of X To Find The Shim Thickness

    Calculate The Value Of X To Find The Shim Thickness

    Figure: Calculate The Value Of Y To Find The Shim Thickness

    Calculate The Value Of Y To Find The Shim Thickness

    Figure: Installation of the Oil Input Adapter

    Installation of the Oil Input Adapter

    Figure: Installation of the Suction Strainer Assembly

    Installation of the Suction Strainer Assembly

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedural steps and figures. (20VC319)

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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Manufacturer Code:LOCAL
Supply Number:CoMat 02-179
Type:sp01
Supply Short Name:CoMat 02-179 COMPOUND, GEAR MARKING
Supply Name:CoMat 02-179 COMPOUND, GEAR MARKING
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:LOCAL
Supply Number:CoMat 10-039
Type:sp01
Supply Short Name:
Supply Name:CoMat 10-039 ENGINE OIL
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:0AM53
Tool Number:1F10105
Tool Name:IAE 1F10105 Pusher
Manufacturer Code:LOCAL
Tool Number:Arbor press
Tool Name:Arbor Press
Manufacturer Code:LOCAL
Tool Number:Hot Air Gun
Tool Name:Hot Air Gun
Manufacturer Code:0AM53
Tool Number:IAE 1F10026
Tool Name:IAE 1F10026 Hydraulic hand pump
Manufacturer Code:0AM53
Tool Number:IAE 1F10082
Tool Name:IAE 1F10082 Guide Pin
Manufacturer Code:0AM53
Tool Number:IAE 1F10087
Tool Name:IAE 1F10087 Base
Manufacturer Code:0AM53
Tool Number:IAE 1F10098
Tool Name:IAE 1F10098 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10100
Tool Name:IAE 1F10100 Base holder
Manufacturer Code:0AM53
Tool Number:IAE 1F10102
Tool Name:IAE 1F10102 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10104
Tool Name:IAE 1F10104 Hand wrench
Manufacturer Code:0AM53
Tool Number:IAE 1F10110
Tool Name:IAE 1F10110 Stud
Manufacturer Code:0AM53
Tool Number:IAE 1F10114
Tool Name:IAE 1F10114 Hydraulic cylinder
Manufacturer Code:0AM53
Tool Number:IAE 1F10122
Tool Name:IAE 1F10122 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10123
Tool Name:IAE 1F10123 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1F10128
Tool Name:IAE 1F10128 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10129
Tool Name:IAE 1F10129 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10130
Tool Name:IAE 1F10130 Guide pins
Manufacturer Code:0AM53
Tool Number:IAE 1F10131
Tool Name:IAE 1F10131 Base
Manufacturer Code:0AM53
Tool Number:IAE 1F10133
Tool Name:IAE 1F10133 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10134
Tool Name:IAE 1F10134 Ring
Manufacturer Code:0AM53
Tool Number:IAE 1F10135
Tool Name:IAE 1F10135 Base
Manufacturer Code:0AM53
Tool Number:IAE 1F10136
Tool Name:IAE 1F10136 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10201
Tool Name:IAE 1F10201 Base
Manufacturer Code:0AM53
Tool Number:IAE 2F10132
Tool Name:IAE 2F10132 Backlash fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10137
Tool Name:IAE 2F10137 Clamping fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10138
Tool Name:IAE 2F10138 Loading fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10139
Tool Name:IAE 2F10139 Backlash fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10140
Tool Name:IAE 2F10140 Loading fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10141
Tool Name:IAE 2F10141 Clearance gage
Manufacturer Code:0AM53
Tool Number:IAE 2F10143
Tool Name:IAE 2F10143 Clamping fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10144
Tool Name:IAE 2F10144 Clamping fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10145
Tool Name:IAE 2F10145 Rotating fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10147
Tool Name:IAE 2F10147 Rotating fixture
Manufacturer Code:0AM53
Tool Number:IAE 2F10148
Tool Name:IAE 2F10148 Clamping adapter
Manufacturer Code:0AM53
Tool Number:IAE 2F10217
Tool Name:IAE 2F10217 Rotating handwheel
Manufacturer Code:LOCAL
Tool Number:Swivel vise
Tool Name:Swivel vise