TASK 72-60-43-440-001 Angle Gearbox Driven Gearshaft Assembly - Assemble The Gearshaft Assembly, Assembly-001

DMC:V2500-A0-72-60-4300-00A-710A-B|Issue No:002.00|Issue Date:2018-08-01

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 72-60-43-440-001 Angle Gearbox Driven Gearshaft Assembly - Assemble The Gearshaft Assembly, 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.

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 70-38-21-380-501.

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
Swivel viseLOCALSwivel vise
OvenLOCALOven
Standard wrenchLOCALStandard wrench
IAE 1F10109 Pusher0AM53IAE 1F101091
IAE 1F10111 Base0AM53IAE 1F101111
IAE 1F10112 Base0AM53IAE 1F101121
IAE 1F10113 Pusher0AM53IAE 1F101131
IAE 1F10114 Hydraulic cylinder0AM53IAE 1F101141
IAE 1F10026 Hydraulic hand pump0AM53IAE 1F100261
IAE 1F10119 Wrench0AM53IAE 1F101191
IAE 1F10120 Pusher0AM53IAE 1F101201
IAE 1P16539 Fixture0AM53IAE 1P165391

Consumables, Materials and Expendables

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

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-60-43-440-051 Install the Outer Race of the Roller Bearing on the Bearing Support

    1. Refer to Figure.

      2. Install the bearing support on the base of IAE 1F10109 Pusher 1 off.

      1. Put the bearing support in to oven and increase the temperature to 250 deg F (121 deg C) maximum.

      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.

        Align the two opposite holes on the smaller flange of the bearing support with the two pins on the base of the pusher.

      3. Install the bearing support on the base with the larger flange to the top.

      3. Install the outer race of the roller bearing on the bearing support.

      1. Align the two opposite flange holes of the outer race of the roller bearing with the two pins on the base.

      2. Put the outer race of the roller bearing on the bearing support with the mounting flange to the top.

      3. Put the adapter of the pusher in to the smaller ID of the outer race of the roller bearing.

      4. Push the handle of the pusher until the outer race of the roller bearing is fully installed on the bearing support.

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

    5. Remove the bearing support from the pusher base.

    2. SUBTASK 72-60-43-440-052 Install the Outer Race of the Ball Bearing and the Ball Bearing Housing on the Bearing Support

    1. Refer to Figure.

    2. Install IAE 1F10111 Base 1 off on swivel vise.

      3. Install the bearing support on the base.

      1. Align the four external holes on the bearing support with the holes on the base.

      2. Install the bearing support on the base with the smaller flange to the bottom.

      3. Attach with four hexagon socket head capscrews.

    4. Install the outer race of the ball bearing on the outer race of the roller bearing.

      5. Install the ball bearing housing on the outer race of the roller bearing.

      1. Align the four holes on the mounting flange of the ball bearing housing with the holes on the flange of the outer race of the roller bearing.

      2. Install the ball bearing housing with the mounting flange to the bottom on the outer race of the roller bearing.

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

    6. From the bottom, install the flat washer and the bolt into the hole shown in Figure on the smaller flange of the bearing support.

    7. Install the nut which attach the ball bearing housing to the bearing support. Tighten but do not torque the nut at this stage.

    8. Remove the four hexagon socket head capscrews. Remove the assembled parts from the base.

    3. SUBTASK 72-60-43-440-053 Install the Inner Race of the Roller Bearing on the Bevel Gearshaft

    1. Refer to Figure.

    2. Install the bevel gearshaft on the guide of IAE 1F10112 Base 1 off with the hub to the top.

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

    4. 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 gearshaft.

    5. Install IAE 1F10113 Pusher 1 off on to the bevel gearshaft and put on the inner race of the roller bearing.

    6. Install the plate of IAE 1F10114 Hydraulic cylinder 1 off on to the guide rods on the base. Make sure that the hydraulic cylinder is seated to pull.

    7. Attach IAE 1F10026 Hydraulic hand pump 1 off to the coupler of the hydraulic cylinder.

    8. Operate the hydraulic pump and apply a load of 6744 lbf (30000 N) to the pusher until the inner race of the roller bearing touches the shoulder of the bevel gearshaft.

    9. Release the pressure of the hydraulic pump and remove the plate of the hydraulic cylinder from the guide rods on the base.

    10. Remove the pusher from the bevel gearshaft.

    11. Let the inner race of the roller bearing get to the room temperature.

    12. Make sure that the inner race of the roller bearing is correctly installed against the shoulder of the bevel gearshaft.

    13. Measure the dimension C between the top of the bevel gearshaft and the inner race of the roller bearing (refer to Figure) and write it.

    4. SUBTASK 72-60-43-440-054 Install the Lower Half-Inner Race of the Ball Bearing (01-400) on the Bevel Gearshaft

    1. Refer to Figure.

    2. Measure the dimension B of the lower half-inner race (refer to Figure) and write it.

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

    4. 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 IS PAIN OR BLISTERING PERSISTS.

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

    5. Install IAE 1F10113 Pusher 1 off on to the bevel gearshaft and put on the half-inner race of the ball bearing.

    6. Install the plate of IAE 1F10114 Hydraulic cylinder 1 off on to the guide rods on the base. Make sure that the hydraulic cylinder is seated to pull.

    7. Operate the IAE 1F10026 Hydraulic hand pump hydraulic pump and apply a load of 2248 lbf (10000 N) to the pusher until the half-inner race of the ball bearing touches the inner race of the roller bearing.

    8. Release the pressure of the hydraulic pump and remove the plate of the hydraulic cylinder from the guide rods on the base.

    9. Remove the pusher from the bevel gearshaft.

    10. Let the half-inner race of the ball bearing get to the room temperature.

    11. Make sure that the half-inner race of the ball bearing is correctly installed against the inner race of the roller bearing.

    5. SUBTASK 72-60-43-440-055 Install the Oil Shroud and the Bearing Support Assembly on the Bevel Gearshaft

    1. Refer to Figure.

    2. Install the three bolts through the flange holes of the oil shroud with the bolt heads in the internal of the shroud.

    3. Install the oil shroud around the spiral bevel gear. In this position the bolt heads are against the crown gear.

      4. NOTE

        The bearing support assembly has the outer race of the roller bearing, the outer race with the ball bearing and the ball bearing housing installed together in the Step and Step.

        Install the bearing support assembly on the bevel gearshaft.

      1. Put the bearing support assembly on the bevel gearshaft with the ball bearing housing to the top. Align the three free holes on the smaller flange of the bearing support with the three bolts of the oil shroud.

        2. Install the bearing support on the three bolts. Make sure that:

        1. The outer race of the roller bearing is correctly installed on the rollers of the bearing inner race.

        2. The bearing outer race and balls are correctly installed on the lower half-inner race of the ball bearing.

      3. Install the three nuts on the bolts which attach together the ball bearing housing, the outer race of the roller bearing, the bearing support and the oil shroud.

      4. Tighten the three nuts by hand.

      5. Make sure that the three bolt heads are correctly installed against the mounting flange of the oil shroud. Examine with an endoscope.

    6. SUBTASK 72-60-43-440-056 Install the Upper Half-Inner Race of the Ball Bearing on the Bevel Gearshaft

    1. Refer to Figure.

    2. Measure the dimension A of the upper half-inner race (refer to Figure) and write it.

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

    4. 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 on the bevel gearshaft with the ball seat to the bottom.

    5. Install IAE 1F10113 Pusher 1 off on to the bevel gearshaft and put on the half-inner race of the ball bearing.

    6. Install the plate of IAE 1F10114 Hydraulic cylinder 1 off on to the guide rods on the base. Make sure that the hydraulic cylinder is seated to pull.

    7. Attach IAE 1F10026 Hydraulic hand pump 1 off to the coupler of the hydraulic cylinder.

    8. Operate the hydraulic pump and apply a load of 2248 lbf (10000 N) to the pusher until the upper half-inner race of the ball bearing touches the lower half-inner race of the ball bearing.

    9. Release the pressure of the hydraulic pump and disconnect from the hydraulic cylinder.

    10. Remove the plate of the hydraulic cylinder from the guide rods on the base. Remove the pusher from the bevel gearshaft.

    11. Let the half-inner race of the ball bearing get to the room temperature.

    7. SUBTASK 72-60-43-220-053 Examine the Correct Installation of the Ball 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 the Step.

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

      Limit: 0.0008 in. (0.02 mm).

    8. SUBTASK 72-60-43-440-057 Install the Diaphragm on the Bevel Gearshaft

    1. Refer to Figure.

    2. If necessary, put the diaphragm 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 diaphragm on the bevel gearshaft with the larger flange to the top.

    4. Install IAE 1F10113 Pusher 1 off on to the bevel gearshaft and put the pusher on the diaphragm.

    5. Install the plate of IAE 1F10114 Hydraulic cylinder 1 off on to the guide rods on the base. Make sure that the hydraulic cylinder is seated to pull.

    6. Attach IAE 1F10026 Hydraulic hand pump 1 off to the coupler of the hydraulic cylinder.

    7. Operate the hydraulic pump and apply a load to the pusher until the diaphragm touches the upper half-inner race of the ball bearing.

    8. Release the pressure of the hydraulic pump and disconnect from the hydraulic cylinder.

    9. Remove the plate of the hydraulic cylinder from the guide rods on the base. Remove the pusher from the bevel gearshaft.

    10. Let the diaphragm get to the room temperature.

    11. Make sure that the diaphragm is correctly installed against the upper half-inner race of the ball bearing.

    12. Remove the bevel gearshaft from the base.

    9. SUBTASK 72-60-43-440-058 Install the Nut Washer on the Bevel Gearshaft

    1. Refer to Figure and Figure.

      2. Install the bevel gearshaft on IAE 1P16539 Fixture 1 off with the hub to the top.

      1. Open the four hook clamps of the fixture outboard.

      2. Position the angle gearbox driven gear and layshaft assembly on the fixture over the post and align it on the two dowel pins.

      3. Close the four hook clamps on the fixture inboard. Tighten the bolts to secure the clamps in position.

    3. Put the nut washer on the bevel gearshaft. Tighten the retaining nut as far as it can be tightened by hand. Install IAE 1F10119 Wrench 1 off over the bevel gearshaft.

    4. Align the lugs of the wrench with the slots of the nut washer. Install the wrench on the nut washer.

    5. Torque the nut washer to 310 lbfft to 354 lbfft (420 Nm to 480 Nm). Use standard wrench.

    6. Remove the wrench from the bevel gearshaft.

    10. SUBTASK 72-60-43-440-059 Install the Lock Washer and the Segment on the Nut Washer

    1. Refer to Figure.

    2. Install the slide of IAE 1F10120 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 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.

    11. SUBTASK 72-60-43-440-060 Torque the Four Nuts (01-285) on the Ball Bearing Housing

    1. Refer to Figure.

    2. Torque the four nuts on the ball bearing housing to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    3. CAUTION

      BE CAREFUL NOT TO CAUSE DAMAGE TO THE OIL SHROUD DURING THE MOVEMENT OF THE DRIVEN GEAR AND LAYSHAFT ASSEMBLY.

      Remove the driven gear and layshaft assembly from the base.

    12. SUBTASK 72-60-43-220-054 Examine the Driven Gear and Layshaft Assembly

    1. CAUTION

      BE CAREFUL NOT TO CAUSE DAMAGE TO THE OIL SHROUD DURING THE MOVEMENT OF THE DRIVEN GEAR AND LAYSHAFT ASSEMBLY.

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

    13. Figure: Install the Outer Race of the Roller Bearing on the Bearing Support

    Install the Outer Race of the Roller Bearing on the Bearing Support

    Figure: Install the Outer Race of the Ball Bearing and the Ball Bearing Housing on the Bearing Support

    Install the Outer Race of the Ball Bearing and the Ball Bearing Housing on the Bearing Support

    Figure: Install the Inner Races of the Bearings on the Bevel Gearshaft

    Install the Inner Races of the Bearings on the Bevel Gearshaft

    Figure: Do the Dimension Inspection

    Do the Dimension Inspection

    Figure: Install the Bearing, Support and the Diaphragm on the Bevel Gearshaft

    Install the Bearing, Support and the Diaphragm on the Bevel Gearshaft

    Figure: Install the Nut Washer on the Bevel Gearshaft

    Install the Nut Washer on the Bevel 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 Gearshaft on the Fixture

    Install the Bevel Gearshaft on the Fixture

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to update the installation of outer race of the ball bearing and Figure 2. (17VC575)

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:0AM53
Tool Number:IAE 1F10026
Tool Name:IAE 1F10026 Hydraulic hand pump
Manufacturer Code:0AM53
Tool Number:IAE 1F10109
Tool Name:IAE 1F10109 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10111
Tool Name:IAE 1F10111 Base
Manufacturer Code:0AM53
Tool Number:IAE 1F10112
Tool Name:IAE 1F10112 Base
Manufacturer Code:0AM53
Tool Number:IAE 1F10113
Tool Name:IAE 1F10113 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1F10114
Tool Name:IAE 1F10114 Hydraulic cylinder
Manufacturer Code:0AM53
Tool Number:IAE 1F10119
Tool Name:IAE 1F10119 Wrench
Manufacturer Code:0AM53
Tool Number:IAE 1F10120
Tool Name:IAE 1F10120 Pusher
Manufacturer Code:0AM53
Tool Number:IAE 1P16539
Tool Name:IAE 1P16539 Fixture
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:Swivel vise
Tool Name:Swivel vise