TASK 72-60-42-440-001 Angle Gearbox Driving Gearshaft Assembly - Assemble The Gearshaft, Assembly-001

DMC:V2500-A0-72-60-4200-00A-710A-B|Issue No:001.00|Issue Date:2013-11-01

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 72-60-42-440-001 Angle Gearbox Driving Gearshaft Assembly - Assemble The Gearshaft, 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 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 10-039 ENGINE OIL, unless other lubricants are referred to in the procedure.

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

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

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

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
ViseLOCALVise
Arbor PressLOCALArbor press
Hot air gunLOCALHot air gun
OvenLOCALOven
Standard wrenchLOCALStandard wrench
IAE 1F10087 Base0AM53IAE 1F100871
IAE 1F10088 Bush0AM53IAE 1F100881
IAE 1F10086 Pusher0AM53IAE 1F100861
IAE 1F10092 Pusher0AM53IAE 1F100921
IAE 1F10095 Wrench0AM53IAE 1F100951
IAE 1F10096 Pusher0AM53IAE 1F100961
IAE 1F10099 Base0AM53IAE 1F100991
IAE 1F10098 Pusher0AM53IAE 1F100981

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-039 ENGINE OILLOCALCoMat 10-039
CoMat 07-012 AIR DRYING ENAMEL0AM53CoMat 07-012

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-60-42-220-053 Calculate the Shim Thickness

    1. Refer to Figure.

    2. Measure the distance between the internal face of the top flange and the external face of the bottom flange of the bearing housing. Write this value as dimension A.

    3. Measure the thickness of the ball bearing. Write this value as dimension B.

    4. Measure the distance between the external face of the top flange and the top face of the mounting flange of the outer race of the roller bearing. Write this value as dimension C.

    5. Calculate the shim thickness (dimension H) as follows:

      Shim thickness = C + B - A.

    2. SUBTASK 72-60-42-440-051 Install the Inner Race of the Roller Bearing on the Bevel Radial Gearshaft

    1. Refer to Figure.

    2. Install IAE 1F10087 Base 1 off on Vise.

    3. Install IAE 1F10088 Bush 1 off on the base.

      4. Install the bevel radial gearshaft on the base.

      1. Align the spline of the bevel radial gearshaft with the spline of the adapter in the base.

      2. Install the bevel radial gearshaft on the base with the short hub of the bevel radial gearshaft to the top.

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

    6. 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 THE MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

      Put the inner race of the roller bearing on the bevel radial gearshaft.

    7. Put IAE 1F10086 Pusher 1 off on the inner race of the roller bearing with the guide pusher in to the ID of the bevel radial gearshaft.

    8. Apply a load of 4496 lbf (20000 N) to the pusher until the inner race of the roller bearing touches the shoulder of the gearshaft. Use arbor press or equivalent.

    9. Remove the pusher from the bevel radial gearshaft.

    10. Let the inner race of the roller bearing get to the room temperature. Make sure the inner race of the roller bearing is correctly installed on the bevel radial gearshaft.

    11. Remove the bevel radial gearshaft from the base.

    12. Remove the bush from the base.

    3. SUBTASK 72-60-42-440-052 Install the Bearing Housing and the Ball Bearing on the Bevel Radial Gearshaft

    1. Refer to Figure and Figure

      2. Install the bevel radial gearshaft on IAE 1F10087 Base 1 off.

      1. Turn the bevel radial gearshaft with the short hub of the gearshaft to the bottom.

      2. Align the spline of the bevel radial gearshaft with the spline of the adapter in the base.

      3. Install the bevel radial gearshaft on the base.

      4. Make sure that the inner race of the roller bearing is correctly installed in to the bush on the base.

    3. Install the bearing housing on the bevel radial gearshaft with the mounting flange to the top. Move by hand the bearing housing against the gear teeth.

      4. Measure the dimensions A, B and C before the installation of the ball bearing on the bevel radial gearshaft, refer to Figure.

      1. Measure the thicknesses of the two half inner races of the ball bearing. Write these values as dimensions A and B.

      2. Measure the distance between the top face of the shoulder and the top face of the hub of the bevel radial gearshaft. Write this value as dimension C.

    5. Put the lower half inner race of the ball bearing in to oven and increase the temperature to 250 deg F (121 deg C) maximum.

    6. 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 THE MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

      Put the lower half inner race of the ball bearing on the bevel radial gearshaft with the ball seat to the top.

    7. Put IAE 1F10092 Pusher 1 off on the half inner race of the ball bearing.

    8. Apply a load of 2248 lbf (10000 N) to the pusher until the half inner race of the ball bearing touches the shoulder of the gearshaft. Use arbor press or equivalent.

    9. Remove the pusher from the bevel radial gearshaft.

    10. Let the half inner race of the ball bearing get to the room temperature. Make sure the half inner race of the ball bearing is correctly installed on the bevel radial gearshaft.

    11. Install the outer race of the ball bearing on the half inner race of the ball bearing.

    12. Put the upper half inner race of the ball bearing in to the oven and increase the temperature to 250 deg F (121 deg C) maximum.

    13. 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 THE MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

      Put the half inner race of the ball bearing with the ball seat to the bottom on the bevel radial gearshaft.

    14. Put the pusher on the half inner race of the ball bearing.

    15. Apply a load of 2248 lbf (10000 N) to the pusher until the half inner race of the ball bearing touches the other half inner race. Use the arbor press or equivalent.

    16. Remove the pusher from the bevel radial gearshaft.

    17. Let the half inner race of the ball bearing get to the room temperature. Measure the dimension T after the installation of the ball bearing.

    4. SUBTASK 72-60-42-220-054 Examine the Correct Installation of the Bearing

    1. Refer to Figure.

    2. Calculate the dimension T by the subsequent formula from the value measured, refer to Figure and write it.

      T = C - (A + B).

    3. Measure the four dimensions of T1. Calculate the average and write it.

    4. NOTE

      If the difference is not in the limit, repeat from Step.

      Make sure that the difference between the dimension T1 (measured) and the dimension T (calculated) is in the subsequent limit.

      Limit: 0,0008 in. (0.02 mm).

    5. SUBTASK 72-60-42-440-053 Install the Inner Race of the Roller Bearing (01-340) on the Bevel Radial Gearshaft

    1. Refer to Figure.

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

    3. 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 THE MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

      Put the inner race of the roller bearing on the bevel radial gearshaft.

    4. Put IAE 1F10086 Pusher 1 off on the inner race of the roller bearing.

    5. Apply a load of 4496 lbf (20000 N) to the pusher until the inner race of the roller bearing touches the inner race of the ball bearing. Use arbor press or equivalent.

    6. Remove the pusher from the bevel radial gearshaft.

    7. Let the inner race of the roller bearing get to the room temperature. Make sure the inner race of the roller bearing is correctly installed on the bevel radial gearshaft.

    6. SUBTASK 72-60-42-440-054 Install the Bearing Nut Washer on the Bevel Radial Gearshaft

    1. Refer to Figure.

    2. Put the nut washer on the bevel radial gearshaft. Tighten the nut washer as far as it can be tightened by hand.

    3. Align the lugs of IAE 1F10095 Wrench 1 off with the slots of the nut. Install the wrench on the nut washer.

    4. Torque the nut washer to 222 to 258 lbfft (300 to 350 Nm). Use standard wrench.

    5. Remove the wrench from the bevel radial gearshaft.

    7. SUBTASK 72-60-42-440-055 Install the Lock Washer and the Segment on the Nut Washer

    1. Refer to Figure.

    2. Install the slide of IAE 1F10096 Pusher 1 off on the nut washer.

    3. Put the segment in to the groove of the lock washer.

    4. Put the lock washer and the segment in to the ID of the slide with the lugs of the lock washer to the bottom.

    5. Put the pusher on the lock washer. Push the pusher until the lock washer and the segment are fully installed in to the slots of the nut washer.

    6. Remove the pusher and the slide from the nut washer.

    7. Hold by hand the bearing housing and remove the bevel radial gearshaft from the base.

    8. SUBTASK 72-60-42-440-056 Install the Outer Race of the Roller Bearing on the Radial Gear Support

    1. Install IAE 1F10099 Base 1 off on vise.

    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 THE MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

      NOTE

      If the subsequent operation is not easy, locally increase the temperature of the housing of the bearing to 250 deg F (121 deg C) maximum. Use hot air gun.

      Install the radial gear support on the base. Attach with the hexagon head capscrews.

    3. Install the outer race of the roller bearing on the radial gear support. Use IAE 1F10098 Pusher 1 off.

    4. Let the parts get to the room temperature. Make sure the outer race of the roller bearing is correctly installed on the radial gear support.

    9. SUBTASK 72-60-42-440-057 Install the Bevel Radial Gearshaft on the Radial Gear Support

    1. Refer to Figure.

      2. Install the shim on the radial gear support.

      1. Select the shim (01-360) in the available set with the value of the thickness nearest to the value calculated in Step.

      2. Align the holes on the shim with the studs on the radial gear support. Install the shim on the radial gear support.

      3. Install the bevel radial gearshaft on the radial gear support.

      1. Hold by hand the bearing housing.

      2. Install the bevel radial gearshaft with the short hub of the gearshaft to the top on the radial gear support.

      3. Put the bearing inner race and rollers in to the outer race.

      4. Install the bearing housing on the radial gear support.

      1. Align the four holes on the mounting flange of the bearing housing with the studs on the radial gear support.

      2. Install the bearing housing on the radial gear support.

      3. Make sure that the two anti rotation pins in the internal flange of the bearing housing are correctly installed in to the grooves on the outer race of the ball bearing.

    5. Install the four self locking nuts which attach the bearing housing and the outer race of the roller bearing to the radial gear support. Torque the nuts to 85 to 95 lbfin (9.604 to 10.734 Nm).

    10. SUBTASK 72-60-42-220-055 Examine the Driving Radial Gear Assembly

    1. Refer to Figure.

    2. Measure the dimension X between the roller bearing and the internal face of the bearing housing.

    3. Make sure that this value is between 0.0008 and 0.0028 in. (0.02 and 0.07 mm).

      4. If the value of X is not in the limits, proceed as follows:

      1. Remove the bevel radial gearshaft from the radial gear housing.

      2. Remove the shim.

      3. Select a new shim in the available set.

      4. Install the shim and the bevel radial gearshaft on the radial gear housing. Refer to Step.

    5. Turn the bevel radial gearshaft by hand to make sure the free rotation.

    6. Remove the driving radial gear assembly from the base.

    11. Figure: Calculate the shim thickness

    Calculate the shim thickness

    Figure: Install the inner race of the roller bearing on the bevel radial gearshaft

    Install the inner race of the roller bearing on the bevel radial gearshaft

    Figure: Install the bearing housing, the ball bearing and the inner race of the roller bearing on the bevel radial gearshaft

    Install the bearing housing, the ball bearing and the inner race of the roller bearing on the bevel radial gearshaft

    Figure: Do the dimension inspection

    Do the dimension inspection

    Figure: Install the nut washer on the bevel radial gearshaft

    Install the nut washer on the bevel radial gearshaft

    Figure: Install the lock washer and the segment on the nut washer

    Install the lock washer and the segment on the nut washer

    Figure: Install the bevel radial gearshaft on the radial gear support

    Install the bevel radial gearshaft on the radial gear support

    Figure: Examine the driving gear assembly

    Examine the driving gear assembly

Requirements After Job Completion

Follow-On Conditions

NONE
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: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:LOCAL
Tool Number:Arbor press
Tool Name:Arbor Press
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 1F10086
Tool Name:IAE 1F10086 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10087
Tool Name:IAE 1F10087 Base
Manufacturer Code:0AM53
Tool Number:IAE 1F10088
Tool Name:IAE 1F10088 Bush
Manufacturer Code:0AM53
Tool Number:IAE 1F10092
Tool Name:IAE 1F10092 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10095
Tool Name:IAE 1F10095 Wrench
Manufacturer Code:0AM53
Tool Number:IAE 1F10096
Tool Name:IAE 1F10096 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10098
Tool Name:IAE 1F10098 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10099
Tool Name:IAE 1F10099 Base
Manufacturer Code:LOCAL
Tool Number:Oven
Tool Name:Oven
Manufacturer Code:LOCAL
Tool Number:Standard wrench
Tool Name:Standard wrench
Manufacturer Code:LOCAL
Tool Number:Vise
Tool Name:Vise