DMC:V2500-A5-72-00-6000-02C-520A-B|Issue No:005|Issue Date:2018-11-01

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

V2500-A5

Common Information

TASK 72-00-60-020-002-B00 External Gearbox Module - Remove The Tubes And Electrical Harnesses From The External Gearbox, Removal-002

General

This TASK gives the procedure to remove the necessary dressings to permit removal of the external gearbox. For related data refer to TASK 72-00-60-020-001.

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.

Apply the approved penetrating oil before the removal of threaded parts and parts with an interference fit. Let the parts soak before removal. For the approved oils and procedures, refer to the SPM TASK 70-64-00-640-501.

Seal all openings when tubes are disconnected, to prevent contamination from unwanted material.

Discard all rubber seal rings removed in this procedure.

Remove and discard the lockwire before the tube or connector is disconnected.

When electrical connectors are disconnected special plastic caps must be installed.

All tubes, hoses and ducts removed in this procedure must have their maintenance completed, as given in the Component Maintenance Manual (CMM-THD-V2500-1IA).

NOTE

Consumable materials are given in the related SPM TASK.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NONE

Consumables, Materials and Expendables

NONE

Spares

NONE

Safety Requirements

NONE

Procedure

1. Refer to Figure.
2. Remove the bolt, the nut, the washers and the clips at clip position 1094 at the electrical connectors 4005EV-A and 4005EV-B.
1. Remove the lockwire which safeties the electrical connectors 4005EV-A and 4005EV-B.
1. Refer to Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure and Figure.
2. Disconnect the electrical connectors 4000KC-A, 4000KC-B and 4000KC-C from the Fuel Metering Unit (FMU).
3. Disconnect the electrical connector 4004EN-A from the oil scavenge filter.
4. Disconnect the electrical connector 4002EN-A from the oil tank.
5. Disconnect the electrical connectors 4005EV-A and 4005EV-B from the Dedicated Alternator.
6. Disconnect the electrical connector 4006EN-A from the No.4 bearing scavenge valve.
7. Disconnect the electrical connector 1030GK-A from the hydraulic pump.
8. Disconnect the electrical connectors 4000XU-A, 4000XU-B and 4000XU-C from the Integrated Drive Generator (IDG).
9. 1. Remove the cover from the IDG cable assembly terminals.
    NOTE
    This will make sure each cable is installed on the correct terminal.
  2. Attach a temporary identification tag to each cable.
  3. Remove the four nuts and washers and disconnect the IDG cable assembly from the terminals. Install the four nuts and washers and the cover.
1. Refer to Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure and Figure.
2. 1. Remove the bolts, washers, nuts, the spacers, clipnuts and clips from the clip positions 0257, 0258, 0787, 0788, 0789, 0922, 1043 and 1106.
  2. Remove the bolts, washers, nuts and clips from the clip positions 1123, 1124, 1125, 1126, 1127, 1131, 1133 and 1140.
  3. SBE 71-0118 : Remove the bolts, washers, nuts, the spacer, clipnuts and clips from the clip positions 0787, 0788, 0789 and 1189.
  4. Pre SBE 71-0288 Pre SBE 73-0219 and SBE 73-0235: Remove the bolt EEC Fan Harness (71-51-41,01-870), the washers EEC Fan Harness (71-51-41,01-871) and EEC Fan Harness (71-51-41,01-876), the spacers EEC Fan Harness (71-51-41,01-874) and EEC Fan Harness (71-51-41,01-875), the clips EEC Fan Harness (71-51-41,01-873) and Control Fuel Tubes (73-11-49,26-190) and the nut EEC Fan Harness (71-51-41,01-877) at the clipping point 0789.
  5. Pre SBE 71-0288 and SBE 73-0219: Remove the bolt EEC Fan Harness (71-51-41,01-870), the washers EEC Fan Harness (71-51-41,01-871) and EEC Fan Harness (71-51-41,01-876), the spacers EEC Fan Harness (71-51-41,01-874) and EEC Fan Harness (71-51-41,01-875), the clips EEC Fan Harness (71-51-41,01-873), (73-11-47,04-552) and Control Fuel Tubes (73-11-49,26-190) and the nut EEC Fan Harness (71-51-41,01-877) at the clipping point 0789.
  6. SBE 71-0288 Pre SBE 73-0219 and SBE 73-0235: Remove the bolt EEC Fan Harness (71-51-41,01-870), the spacers EEC Fan Harness (71-51-41,01-874) and EEC Fan Harness (71-51-41,01-875), the clips EEC Fan Harness (71-51-41,01-873) and Control Fuel Tubes (73-11-49,26-190), the washer EEC Fan Harness (71-51-41,01-876) and the nut EEC Fan Harness (71-51-41,01-877) at the clipping point 0789.
  7. SBE 71-0288 and SBE 73-0219: Remove the bolt EEC Fan Harness (71-51-41,01-870), the spacers EEC Fan Harness (71-51-41,01-874) and EEC Fan Harness (71-51-41,01-875), the clips EEC Fan Harness (71-51-41,01-873), (73-11-47,04-552) and Control Fuel Tubes (73-11-49,26-190), the washer EEC Fan Harness (71-51-41,01-876) and the nut EEC Fan Harness (71-51-41,01-877) at the clipping point 0789.
3. Disconnect the electrical connector 4000 EL-A from the fuel filter differential pressure switch.
4. Temporarily attach the electrical harness clear of the gearbox.
1. Refer to Figure.
2. Remove the three bolts that attach the breather duct ENGINE-GEARBOX BREATHER OUTLET DUCT (72-61-49,01-010) to the deoiler, remove the breather duct and remove the packing.
1. Refer to Figure.
2. Remove the coupling STARTING-STARTER DUCT (80-13-49,01-510) from the interface of the lower duct STARTING-STARTER DUCT (80-13-49,01-500) and the pneumatic starter STARTING-PNEUMATIC STARTER (80-13-41,01-200).
3. Hold the lower duct and remove the coupling STARTING-PNEUMATIC STARTER VALVE (80-13-51,01-210) from the interface at the lower duct and the starter valve STARTING-PNEUMATIC STARTER VALVE (80-13-51,01-200).
4. Remove the lower duct and remove the seals STARTING-STARTER DUCT (80-13-49, 01-520 and STARTING-PNEUMATIC STARTER VALVE80-13-51, 01-220).
1. Refer to Figure, Figure and Figure.
2. Remove the bolts, washers, nut, clipnuts and clips from the clip positions 1041, 1042 and 0946.
3. Disconnect the tube 187 from the tubes 188 and 89 and remove the tube 187.
1. Refer to Figure, Figure and Figure.
2. Remove the three bolts that attach the tube 89 to the FMU and remove the packing.
3. Disconnect the tube 91 and from the tube 89.
4. Disconnect the tube 89 from the tube 93.
5. Remove the bolts, washers, nut and clipnut and clips from the clip positions 0253 and 1136. Remove the tube 89.
6. Pre SBE 79-0088 Pre SBE 73-0219 and SBE 73-0235: Remove the bolt Control Fuel Tubes (73-11-49,10-141), the washers Control Fuel Tubes (73-11-49,10-142), the clips EEC Fan Harness (71-51-41,01-129) and (71-51-41,10-144), the spacer Control Fuel Tubes (73-11-49,10-146) and Control Fuel Tubes (73-11-49,10-148) at the clipping point 1040.
7. SBE 79-0088 Pre SBE 73-0219 and SBE 73-0235: Remove the bolt Control Fuel Tubes (73-11-49,10-165), the washer Control Fuel Tubes (73-11-49,10-166), the clip Control Fuel Tubes (73-11-49,10-168) and the nut Control Fuel Tubes (73-11-49,10-172) at the clipping point 1461.
8. Pre SBE 79-0088 and SBE 73-0219: Remove the bolt Control Fuel Tubes (73-11-49,10-165), the washers Control Fuel Tubes (73-11-49,10-166), the clips Control Fuel Tubes (73-11-49,10-168) and (73-11-47,04-144), the spacer Control Fuel Tubes (73-11-49,10-170) and the nut Control Fuel Tubes (73-11-49,10-172) at the clipping point 1461.
9. SBE 79-0088 and SBE 73-0219: Remove the bolt Control Fuel Tubes (73-11-49,10-165), the washers Control Fuel Tubes (73-11-49,10-166), the clips Control Fuel Tubes (73-11-49,10-168) and (73-11-47,04-144), the spacer Control Fuel Tubes (73-11-49,10-170) and the nut Control Fuel Tubes (73-11-49,10-172) at the clipping point 1461.
1. Refer to: Figure
2. Disconnect the tube 90 from the LP pump and from the FMU. Remove the tube 90.
1. Refer to Figure, Figure and Figure.
2. Remove the bolt, the washer, the spacer, the clipnut and the clip from the clip position 1397.
3. Remove the bolt, the washer, the spacer, the clipnut and the clips from the clip positions 1130 and 1134. Remove the raceway (71-51-50, 02-100).
4. Disconnect the tube 103 from the tube 106.
5. Remove the three bolts that attach the tube 103 to the FMU and remove the tube 103. Remove the packing.
1. Refer to Figure, Figure, Figure, and Figure.
2. Remove the bolt, the washer, the two spacers, the clipnut and the four clips from the clip position 0795.
3. Remove the four bolts that attach the tube 102 to the fuel pump and remove the sealing ring.
4. Remove the three bolts and the two washers that attach the tube 102 to the fuel filter and remove the sealing ring. Remove the tube 102.
1. Refer to Figure, Figure and Figure.
2. Remove the bolts, washers, nuts and the clips from the clip positions 1050, 1137, 1138, 1139 and 1188.
3. Disconnect the tube 254 from the fuel diverter and the tube 117 adapter. Remove the tube 254.
4. Disconnect the tube 255 from the fuel diverter and the tube 91. Remove the tube 255.
5. Disconnect the tube 91 from the tube 89 and remove the tube 91.
1. Refer to Figure, Figure, Figure, and Figure.
2. Remove the bolts, washers, nuts and clips from the clip position 0922.
3. Pre SBE 73-0219 and SBE 73-0235: Remove the bolt Control Fuel Tubes (73-11-49,26-157), the washer Control Fuel Tubes (73-11-49,26-158), the clip Control Fuel Tubes (73-11-49,26-160) and the nut Control Fuel Tubes (73-11-49,26-164) at the clipping point 0921.
4. SBE 73-0219: Remove the bolt Control Fuel Tubes (73-11-49,26-157), the washers Control Fuel Tubes (73-11-49,26-158), the clips Control Fuel Tubes (73-11-49,26-160) and (73-11-47,04-544) and the nut Control Fuel Tubes (73-11-49,26-164) at the clipping point 0921.
5. Pre SBE 73-0219 and SBE 73-0235: Remove the bolt Control Fuel Tubes (73-11-49,26-173), the clips OIL-PRESSURE OIL TUBES-ENGINE (79-21-49,05-184) and Control Fuel Tubes (73-11-49,26-176), the spacer Control Fuel Tubes (73-11-49,26-178) and the clip nut Control Fuel Tubes (73-11-49,26-180) at the clipping point 1072.
6. SBE 73-0219: Remove the bolt Control Fuel Tubes (73-11-49,26-173), the washers Control Fuel Tubes (73-11-49,26-174), the clips (73-11-47,04-560), OIL-PRESSURE OIL TUBES-ENGINE (79-21-49,05-100) and Control Fuel Tubes (73-11-49,26-176), the spacers Control Fuel Tubes (73-11-49, 26-179) and Control Fuel Tubes (73-11-49,26-178) and the clip nut Control Fuel Tubes (73-11-49,26-180) at the clipping point 1072.
7. Remove the three bolts that attach the tube 116 and the bracket Control Fuel Tubes (73-11-49, 26-090) to the FMU and remove the sealing ring.
8. Remove the two bolts that attach the tube 116 to the diverter valve and remove the three sealing rings and the seal housing. Remove the tube 116.
1. Refer to Figure, Figure and Figure.
2. Remove the three bolts that attach the tube 108 to the LP compressor/intermediate case and remove the sealing ring.
3. Remove the three bolts that attach the tube 107 to the scavenge pump and remove the sealing ring.
4. Remove the scavenge tube assembly.
5. Remove the four bolts that attach the two flanges of the filter housing and remove the filter. Also remove the two sealing rings.
  NOTE
  The parts of the magnetic chip detector assembly must have their maintenance completed, as given in Component Maintenance Manual (CMM-MECH-V2500-1IA).
6. Remove the magnetic probe, body unit and three preformed packings from the tube 107.
1. Refer to Figure.
2. Disconnect the tube 112 from the tube 111 and remove the restrictor and the retaining ring.
1. Refer to Figure.
2. Disconnect the tube 123 from the tube 124.
1. Refer to Figure, Figure and Figure.
2. Disconnect the tube 115 from the oil tank.
3. Remove the bolts, the washers, the nutclips and the clips from the clip positions 0755 and 1093.
1. Refer to Figure, Figure and Figure.
2. Remove the bolt, washer, nut, the spacer and clips from the clip position 0905.
3. Disconnect the tube 118 from the tube 120 adjacent to the oil tank and the tube 119 adjacent to the deoiler.
4. Disconnect the tube 121 from the tube 122 adjacent to the deoiler.
1. Refer to Figure.
2. Remove the three bolts that attach the tube 110 to the fuel pump and remove the sealing ring and the bracket Main Fuel Supply Fuel Tubes (73-11-47,01-070).
3. Remove the three bolts that attach the tube 117 to the fuel pump and remove the sealing ring.
1. Refer to Figure.
2. Remove the three bolts that attach the tube 109 to the FMU and remove the sealing ring.
1. Refer to Figure.
2. Disconnect the tube 248 from the dedicated alternator stator. Refer to TASK 72-00-60-050-001-B00 (REMOVAL-005, CONFIG-002).
3. Disconnect the tube 248 from the tube 247 and remove the tube 248, refer to TASK 72-00-32-020-003-B00 (REMOVAL-003, CONFIG-002).
4. Remove the clip positions 0779, 0845, 0847, 0893 and 0849 which attach the harnesses to the tube 247. Refer to TASK 72-00-32-020-002-B00 (REMOVAL-002, CONFIG-002).
5. Disconnect tube 247 from the tube 246 remove tube 247.
6. Refer to TASK 72-00-32-020-003-B00 (REMOVAL-003, CONFIG-002) for the procedure to remove the remaining cooling air tubes.
1. Refer to Figure, Figure and Figure.
2. Remove the bolts, washers, spacers, the nut and clips from the clip positions 0966 and 0967.
3. Disconnect the tubes 100 and 101 from the IDG and from the tubes 96 and 97. Remove the tubes 100 and 101.
1. Refer to Figure.
2. Remove the bolt, washer, clipnut and the clip from the clip position 0556.
3. Disconnect the tube 126 from the No. 4 bearing scavenge valve.
4. Disconnect the tube 128 from the No. 4 bearing scavenge valve.
1. Refer to Figure.
2. Remove the bolt, the washer, the nut and the clip from the clip position 0594.
3. Remove the three bolts that attach the tube 125 to the deoiler and remove the bracket 79-22-49, 10-470. Remove the sealing ring.
1. Refer to Figure and Figure.
2. Disconnect the tubes 208 and 209 from the scavenge filter.
1. Refer to Figure.
2. Put an applicable container below the hydraulic pump.
3. Disconnect the hydraulic pressure hose 210 and let the hydraulic fluid drain into the container until the flow of fluid stops.
4. Disconnect the hydraulic suction hose 212 and let the hydraulic fluid drain into the container until the flow of fluid stops.
5. Disconnect the hydraulic case drain hose 214 and let the hydraulic fluid drain into the container until the flow of fluid stops.
1. Refer to TASK 72-00-60-020-003-001 or TASK 72-00-60-020-003-002.
1. SBE 79-0069: Introduction of re-routed oil tubes and revised clipping above the external gearbox.
2. Refer to Figure, Figure, Figure, Figure, Figure and Figure.
3. Remove the bolts, the washers, the clipnuts and the clips from the clip positions 1108 and 1117.
4. SBE 79-0069: Remove the bolts, the washer, the clipnut, the nut and the clips from the clip positions 1108 and 1401.
5. Remove the bolt and the clipnut from the clip position 1111.
6. SBE 79-0069: Remove the bolt and the nut from the clip position 1402.
7. Remove the bolt, the washer, the clip and the nut from the clip position 1105.
8. Remove the tube 118.
9. Remove the bolt, the washer, the clip and the nut from the clip position 1109.
10. Remove the bolts, the washers, the clipnuts, and the clips from the clip positions 1110 and 1116.
11. SBE 79-0069: Remove the bolts, the washer, the clipnut, the nut and the clips from the clip positions 1110 and 1400.
12. Remove the bolt, the spacers, the washer, the clipnut and the clips from the clip position 0200.
13. Remove the three bolts that attach the tube 121 to the oil pump, remove the tube 121 and remove the preformed packing.
1. Refer to Figure and Figure.
2. Remove the bolt, washer, clipnut, spacer and clip from the clip positions 0286 and 1192.
3. Remove the three bolts that attach the tube 123 to the oil scavenge pump. Remove the tube 123 and remove the sealing ring.
  NOTE
  The parts of the magnetic chip detector assembly must have their maintenance completed, as given in the Component Maintenance Manual (CMM-MECH-V2500-1IA).
4. Remove the magnetic probe, the body unit and the three preformed packings from the tube 123.
1. Refer to Figure and Figure.
2. Remove the bolt, washer, clipnut and clip from clip position 0287.
3. With an applicable tool, hold the oil distributor OIL-PRESSURE OIL TUBES-GEARBOX (79-21-48,01-700) to prevent movement, disconnect the tube 112 from the oil distributor on the gearbox and remove the tube 112.
1. Refer to Figure, Figure and Figure.
2. Remove the three bolts and washers that attach the tube 173 to the deoiler.
3. Remove the three bolts and washers that attach the tube 173 to the oil tank. Remove the tube 173 from the gearbox. Remove the preformed packing from the deoiler tube connection and remove the bracket OIL-OIL TANK (79-11-41,01-247).
  NOTE
  The parts of the tank pressurization valve must have their maintenance completed, as given in the Component Maintenance Manual (CMM-MECH-V2500-1IA).
4. Disengage and remove the tank pressurization valve OIL-OIL TANK VALVE (79-11-51,01-001) from the tube 173.
1. Refer to Figure and Figure.
2. 1. Disconnect the tube 181 at the angle gearbox and at the oil distributor OIL-PRESSURE OIL TUBES-GEARBOX (79-21-48,01-700) and remove the tube 181.
  2. Disconnect the tube 182 at the gearbox and at the distributor, and remove the tube 182.
  3. Disconnect the tube 183 at the gearbox and at the distributor and remove the tube 183.
    NOTE
    The gearbox oil distributor must have its maintenance completed, as given in the Component Maintenance Manual (CMM-MECH-V2500-1IA).
  4. Remove the nut that attaches the distributor to the gearbox and remove the distributor.
3. Disconnect the tube 184 at the gearbox and at the Dedicated Alternator and remove the tube 184.
1. Refer to Figure.
  NOTE
  The two magnetic chip detectors removed from the scavenge tubes (107 and 123) were positions 2 and 3.
2. 1. Remove the magnetic probe, the body unit and the three preformed packings from the positions that follow:
    Position 1 - Scavenge oil filter.
    Position 4 - Gearbox (adjacent to the IDG).
    Position 5 - Angle gearbox.
    Position 6 - Scavenge pump.
    NOTE
    The parts of the magnetic chip detector assemblies must have their maintenance completed, as given in the Component Maintenance Manual (CMM-MECH-V2500-1IA).
    Position 7 - Deoiler.
1. Refer to Figure and Figure.
2. Remove the two bolts and washers that attach the bracket Gearbox Scavenge Oil Tubes (79-22-48,05-470) to the oil inlet manifold (tube 180). Remove the bracket and install the two bolts and washers again. Tighten by hand.
3. Remove the two nuts that attach the bracket Fuel Pumps (73-12-41,01-080) to the fuel pump mount. Remove the bracket and install the two nuts again. Tighten by hand.
4. Remove the four nuts that attach the brackets Angle Gearbox Assembly (72-60-40, 01-057 and Angle Gearbox Assembly72-60-40, 01-056) to the angle gearbox. Remove the bracket ELECTRICAL POWER-IDG OIL COOLING TUBES (24-21-49,02-900) and install the bracket Angle Gearbox Assembly (72-60-40,01-056) and the four nuts again. Tighten by hand.
1. Refer to Figure.
2. Remove the four bolts that attach the oil quantity transmitter to the oil tank.
3. SBE 71-0118 : Remove the clip bracket OIL-OIL QUANTITY TRANSMITTER (79-31-15,01-015).
  NOTE
  The oil quantity transmitter must have its maintenance completed, as given in the Ragen Data Component Maintenance Manual (79-31-15).
4. Remove the oil quantity transmitter and remove and discard the sealing ring.