aw139 mgb o/h training course

MAIN TRANSMISSION GEARBOX

(MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING

THIS TRAINING PUBLICATION IS ISSUED TO TRAINEES OF AGUSTAWESTLAND TRAINING ACADEMY “A.MARCHETTI” FOR TRAINING PURPOSE ONLY. THE INFORMATION CONTAINED IN THIS TRAINING PUBLICATION IS NOT INTENDED TO SUBSTITUTE OR REPLACE ANY RELEVANT TECHNICAL PUBLICATION/ORDER/INSTRUCTION ISSUED BY ANY COMPETENT DESIGN AUTHORITY IN RELATION TO THE SUBJECT MATTER HEREIN AND THE TRAINEES SHALL ALWAYS REFER TO THESE OFFICIAL DOCUMENTS WHILE PERFORMING ACTIVITIES ON THE HELICOPTER. THE INFORMATION HEREIN ARE UPDATED AT THE DATE OF RELEASE OF THIS TRAINING PUBLICATION AND AGUSTAWESTLAND DOES NOT TAKE ANY COMMITMENT TO UPDATE THE SAME UNLESS AGUSTAWESTLAND DETERMINES AT ITS SOLE DISCRETION TO RELEASE AN UPDATE OF THIS DOCUMENT. MOREOVER AGUSTAWESTLAND REPRESENTS THAT NO FURTHER DOCUMENT WILL BE PROVIDED TO THE TRAINEE IN ADDITION TO THE TRAINING PUBLICATION HEREIN. INFORMATION AND DRAWINGS CONTAINED IN THIS TRAINING PUBLICATION ARE CONFIDENTIAL AND PROPERTY OF AGUSTAWESTLAND S.P.A.. TRAINEE SHALL USE SUCH INFORMATION FOR THE TRAINING PURPOSE ONLY AND KEEP THE INFORMATION HEREIN CONFIDENTIAL AND NOT MAKE AVAILABLE OR OTHERWISE DISCLOSE SUCH INFORMATION TO ANY THIRD PARTY WITHOUT THE PRIOR WRITTEN CONSENT OF AGUSTAWESTLAND S.P.A.. ANY UNAUTHORISED USE DISCLOSURE REPRODUCTION IN WHOLE OR IN PART OF THE INFORMATION CONTAINED IN THIS TRAINING PUBLICATION IS FORBIDDEN AND PROSECUTED IN ACCORDANCE WITH THE APPLICABLE LAW.

DOCUMENT No.: 39-A0126-MG001-00 ISSUE: 002 ISSUE DATE: 16 April 2014

Document Name: 39-A0126-MG001-00 ISSUE

DATE

REMARKS

001

2013.07.25

1st Issue

002

2014.04.16

2st Issue

NOTE All information reported in this Manual must be considered for Training purpose only

For Training purpose only

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MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 1 - Introduction

1 - Introduction

The information reported in this training manual are relevant to the Repair & Overhaul procedures described on AW139 IETP data modules for MGB P/Ns: 3G6320A00132, 3G6320A00133, 3G6320A00134, 3G6320A00135 Hereinafter is shown the Table of Contents of this manual.


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1 – Introduction Table of Contents Chapter 1 - Introduction Chapter 2 - Documentation 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12

A/C Publication IETP – Interactive Electronic Technical Publication AMP – A/C Maintenance Publication DMC – Data Module Code Descriptive Data Module AMPI – A/C Maintenance Planning Information CR&OP – Component Repair & Overhaul Publication IPD – Illustrated Part Data ITEP – Illustrated Tolls & Equipment Publication RFM – Rotorcraft Flight Manual QRH – Quick Reference and Handbook MGB Log card


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1 – Introduction (continued) Chapter 3 - General information 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.5 3.6 3.7 3.8

General description MGB description Mechanical assembly description Left and Right Input Shaft Module description Upper Module description Hydraulic Pumps drive quills description ECS compressor drive quill description FAN drive quill description Tail-rotor drive quill description Lubrication system description General Chip detection operation Pumps Pressure regulation Oil Filter Oil Cooler Sensors and Jets Leading Particulars Controls and Indicators Warning, Caution Messages Components that must be removed from the MGB before its overhaul


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1 – Introduction (continued) Chapter 4 – General Procedures

4.1 4.2 4.3 4.4

Introduction A/C Publications AMPI – A/C Maintenance Publication Information Limits

Chapter 5 – Pre-Disassembly Procedures 5.1 5.2 5.3 5.4 5.5

Safety Information Pre-disassembly requirements MGB Drain oil and Draining Pipe removal procedures Anti-Torque Beam & Bottom Cover, removal procedures Installation of the Main Case on the Support Trolley

Chapter 6 – Disassembly Procedures 6.1 6.2

6.3 6.4 6.5

Left and Right Input Shaft Module and Cross Shaft, removal and disassembly procedures Main Case Assembly - External components (Plugs, Covers, Sensors, Filter element, Servo Supports, Chip Detectors, Oil Level gauge, Borescope Port, Lubrication Pumps, Check Valves, PRV,), removal procedures. Main Case Oil Jets, removal procedures. Upper Module, Oil Unions and Planetary Crown (fixed ring gear), removal procedures. Main Case, Backlash Check .


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1 – Introduction (continued) 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24

Drive Quills (LH/RH/Front Hyd. Pumps, ECS-Compressor and Fan drive quill), removal procedures. LH and RH Input Pinion Assembly (II° stage of reduction), removal procedures. LH and RH Input Pinion Assy (II° stage of reduction), disassembly procedures. Tail Rotor Drive Quill Assembly, removal procedures. Tail Rotor Drive Quill Assembly, disassembly procedures. Diaphragm, Oil Jets and Roller Bearing, removal procedures. Collector Gear and Collector Bearing, removal procedures. Main Case Assembly - Internal components (Roller Bearings, Shims and Outer Race of the Roller bearing), removal procedures. Left and Right Input Shaft Module, disassembly procedures – Ref. doc. Freewheel Group Assembly, removal and disassembly procedures. Input Shaft Module, Backlash Check. Input Shaft Module – Input Drive Quill Group, removal procedures Input Drive Quill Group, disassembly procedures. Input Shaft Module – Gear (I° Stage of reduction), removal and disassembly procedures Upper Module, disassembly procedures Mast-Planetary Assembly – Disassembly procedures. Planetary Gears Assembly – Disassembly procedures. LH & RH Lubrication Pumps – Disassembly procedures. ECS Compressor Drive Quill – Disassembly procedures.


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1 – Introduction (continued) 6.25 6.26 6.27

FAN Drive Quill – Disassembly procedures. Front Hyd. Pump Drive Quill – Disassembly procedures. LH & RH Hyd. Pump Drive Quill (No.1 and No. 2) – Disassembly procedures.

Chapter 7 - Components Cleaning, Paint removal, Protection and Inspection

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19

Introduction Cleaning procedures Paint removal Protection procedures Detailed Visual Examination Defects definition Surface finish protection restoration (Main Case) Surface finish protection restoration (Upper Module) Surface finish protection restoration (LH/RH Input Shaft Module) Damages code list Example of damages Detailed visual examination, applicable Data Modules list Main gearbox – Detailed Visual Examination Chip detectors – Detailed Visual Examination LH/RH Right Input Shaft Module – Detailed Visual Examination Freewheel – Detailed Visual Examination Upper Module – Detailed Visual Examination Mast-Planetary Assembly – Detailed Visual Examination Planetary Gears Assembly – Detailed Visual Examination


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1 – Introduction (continued) 7.20 7.21 7.22 7.23 7.24 7.25 7.26 7.27 7.28 7.29 7.30 7.31 7.32 7.33 7.34 7.35 7.36 7.37 7.38 7.39

LH/RH Hyd. Pump Drive Quill – Detailed Visual Examination Front Hyd. Pump Drive Quill – Detailed Visual Examination ECS Compressor Drive Quill – Detailed Visual Examination Fan Drive Quill – Detailed Visual Examination LH/RH Lubrication Pump – Detailed Visual Examination Tail Rotor Drive Quill – Detailed Visual Examination Dimensions Check Main gearbox – Dimensions check LH/RH Input Shaft Module – Dimensions check Upper Module – Dimensions Check Mast-Planetary Assembly – Dimensions check Planetary Gears – Dimensions check LH/RH Hyd. Pump Drive Quill – Dimensions check Front Hyd. Pump Drive Quill – Dimensions check ECS Compressor Drive Quill – Dimensions check Fan Drive Quill – Dimension check LH/RH Lubrication Pump – Dimensions check Tail Rotor Drive Quill – Dimensions check Dye Penetrant Examination General guidelines for Dye Penetrant Examination


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1 – Introduction (continued) 7.40 7.41 7.42 7.43 7.44 7.45 7.46 7.47 7.48 7.49 7.50 7.51 7.52 7.53 7.54 7.55 7.56 7.57 7.58 7.59

Main gearbox – Dye Penetrant Examination LH/RH Input Shaft Module – Dye penetrant Examination Upper Module – Dye Penetrant Examination Front Hyd. Pump Drive Quill – Dye Penetrant Examination ECS Compressor Drive Quill – Dye Penetrant Examination LH/RH Hyd. Pump Drive Quill – Dye Penetrant Examination Tail Rotor Drive Quill – Dye Penetrant Examination Magnetic Particles Examination General guidelines for Magnetic Particles Examination Main gearbox – Magnetic Particles Examination LH/RH Input Shaft Module – Magnetic Particles Examination Upper Module – Magnetic Particles Examination Front Hyd. Pump Drive Quill – Magnetic Particles Examination ECS Compressor Drive Quill – Magnetic Particles Examination LH/RH Lubrication Pump – Magnetic Particles Examination Fan Drive Quill – Magnetic Particles Examination Mast-Planetary Assembly – Magnetic Particles Examination Planetary Gears Assembly – Magnetic Particles Examination LH/RH Hyd. Pump Drive Quill – Magnetic Particles Examination Tail Rotor Drive Quill – Magnetic Particles Examination


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1 – Introduction (continued) Chapter 8 – Assembly Procedures 8.1 8.2 8.2.1

Pre-Assembly Requirements MGB, Assembly procedures Main Case, Assembly procedures 8.2.1.1 Shims, installation. 8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing, installation. 8.2.1.3 Diaphragm Assy, assembly. 8.2.1.4 Collector Gear Assy, assembly. 8.2.1.5 RH / LH Input Pinion Assy (II° stage of reduction), assembly. 8.2.1.6 Tail Rotor Drive Quill Assy, assembly. 8.2.1.7 Left and Right Hyd. Pump Drive Quill, assembly. 8.2.1.8 Front Hyd. Pump Drive Quill, assembly. 8.2.1.9 ECS-Compressor Drive Quill, assembly. 8.2.1.10 Fan Drive Quill, assembly. 8.2.1.11 Collector Gear Assy, installation. 8.2.1.12 Diaphragm Assy, installation. 8.2.1.13 Tail Rotor Drive Quill Assy, installation. 8.2.1.14 RH / LH Input Pinion Assy (II° stage of reduction), installation. 8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation. 8.2.1.16 Front Hyd. Pump Drive Quill Assy, installation. 8.2.1.17 ECS-Compressor Drive Quill Assy and Seal Cover, installation. 8.2.1.18 Fan Drive Quill Assy, installation.


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1 – Introduction (continued) 8.2.1.19 Main Case, Backlash check 8.2.1.20 Fan Seal Cover, installation. 8.2.1.21 Left / Right Lubrication Pump, assembly. 8.2.1.22 Left / Right lubrication Pump, installation. 8.2.1.23 Bottom Cover, assembly. 8.2.1.24 Bottom Cover, installation. 8.2.1.25 AC Generators drive cover and plug, installation 8.2.2 Upper Module, Assembly procedure 8.2.2.1 Planetary gears assembly (mast planetary assembly), assembly. 8.2.2.2 Mast-planetary assembly (upper module), assembly. 8.2.2.3 Upper Fittings, Brackets, installation. 8.2.2.4 Mast-planetary assembly, installation. 8.2.2.5 Planetary Crown (Fixed Ring Gear), installation. 8.2.2.6 Roller Bearing and Cover seal, Installation. 8.2.2.7 Upper Cooler Adapter, installation 8.2.2.8 Four Oil jets, installation. 8.2.2.9 Oil Filler plug, Mast Chip detector, Mast Cover and Ident. Plate installation 8.2.2.10 Unions, installation procedures 8.2.2.11 Upper Module Assy, installation procedures


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1 – Introduction (continued) 8.2.3

Main Case, External components installation procedures 8.2.3.1 Oil draining Pipe, Oil Level Gauge and low Oil Level sensor, installation. 8.2.3.2 Oil Filter Head, Oil Temperature sensor, Oil Pressure sensor and Oil Temperature SW, installation. 8.2.3.3 Rotor Speed Sensor, installation. 8.2.3.4 Check valves and Pressure Relief Valve, installation. 8.2.3.5 Borescope Port, Two Chip Detectors, Washers, Plugs and Flange, installation 8.2.3.6 Fifteen (from No. 1 to No. 13) Oil Jets, installation. 8.2.4 LH / RH Input Shaft Module, assembly procedures 8.2.4.1 Shims, installation. 8.2.4.2 Bearings, installation. 8.2.4.3 Diaphragm Assy, assembly. 8.2.4.4 Gear (I° stage of reduction), assembly. 8.2.4.5 Gear Assy and Diaphragm Assy, installation. 8.2.4.6 Input Drive Quill group, assembly. 8.2.4.7 Input Drive Quill group and Gimbal Assy, installation. 8.2.4.8 Input Shaft Module, Backlash check. 8.2.4.9 Freewheel Group, assembly. 8.2.4.10 Freewheel Group and Oil Jet Cover, installation. 8.2.4.11 Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation 8.2.4.12 LH/RH Input Shaft Module, installation. 8.2.5 Anti-Torque Beam, Installation procedures For Training purpose only

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1 – Introduction (continued) Chapter 9 – Functional Check 9.1 Preliminary Actions 9.1.1 Introduction 9.1.2 Description of operations of flushing 9.2 Functional Check (Test A) 9.2.1 Procedures Chapter 10 – Disassembly procedure after functional check 10.1 Introduction 10.2 MGB - Disassembly procedures, initial phase 10.3 Main Case, Backlash check 10.4 MGB - Disassembly procedure, final phase 10.5 Left / Right Input Shaft Module - Disassembly procedures, initial phase 10.6 Input Shaft Modules, Backlash check 10.7 Left / Right Input Shaft Module - Disassembly procedures, final phase 10.8 Upper module, disassembly procedures 10.9 Mast-Planetary Assy, disassembly procedures 10.10 Front Hyd. Pump drive quill, disassembly procedures 10.11 LH/RH Hyd. Pump drive quills, disassembly procedures


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1 – Introduction (continued) Chapter 11 - Inspection Criteria after Functional check 11.1 General guideline for visual examination of components after functional check 11.2 Main gearbox – Detailed Visual Examination 11.2.1 Collector gear – Wear Pattern Check 11.2.2 Input pinion (II° stage of reduction) – Wear Pattern Check 11.2.3 Gear (Hyd. Pump drive quill) – Wear Pattern Check 11.3 LH/RH Right Input Shaft Module – Detailed Visual Examination 11.3.1 Freewheel – Detailed Visual Examination 11.4 Upper Module – Detailed Visual Examination 11.4.1 Ring Gear – Wear Pattern Check 11.5 Mast-Planetary Assembly – Detailed Visual Examination 11.5.1 Planetary Gear Assembly – Wear Pattern Check 11.6 LH/RH Hyd. Pump Drive Quill – Detailed Visual Examination 11.6.1 LH/RH Hyd. Pump Drive Quill – Wear Pattern Check 11.7 Front Hyd. Pump Drive Quill – Detailed Visual Examination 11.7.1 Front Hyd. Pump Drive Quill – Wear Pattern Check 11.8 ECS Compressor Drive Quill – Detailed Visual Examination 11.8.1 ECS Compressor Drive Quill – Wear Pattern Check 11.9 LH/RH Lubrication Pump – Detailed Visual Examination 11.9.1 LH/RH Lubrication Pump – Wear Pattern Check 11.10 Fan Drive Quill – Detailed Visual Examination 11.10.1 Fan Drive Quill – Wear Pattern Check 11.11 Tail Rotor Drive Quill – Detailed Visual Examination & Wear Pattern Check For Training purpose only

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1 – Introduction (continued) Chapter 12 – Assembly procedures after Functional Check 12.1 Introduction 12.2 MGB - Assembly procedures, initial phase 12.3 Main Case, Backlash check 12.4 MGB - Assembly procedures, intermediate phase 12.5 Mast-Planetary Assy, Assembly procedures 12.6 Upper Module, Assembly procedures 12.7 Upper Module, Installation procedures 12.8 MGB - External components installation 12.9 MGB - Oil jets installation 12.10 Left / Right Input Shaft Module - Assembly procedures, initial phase 12.11 Input Shaft Modules, Backlash check 12.12 Left / Right Input Shaft Module - Assembly procedures, final phase 12.13 Left / Right Input Shaft Module, Installation procedures 12.14 MGB – Assembly procedures, final phase Chapter 13 - Leak Check 13.1 Leak Check (Test B) Chapter 14 - Finish after leak check 14.1 Oil Filter Element installation 14.2 Nylon setscrews installation Chapter 15 - Painting procedures Chapter 16 - Final Acceptance


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Chapter 1 - Introduction

THE END

RETURN TO LESSON SUMMARY For Training purpose only 18 of 18

RETURN TO COURSE MENU

MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 2 - Documentation

2 - Documentation

INDEX 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12

A/C Publication IETP – Interactive Electronic Technical Publication AMP – A/C Maintenance Publication DMC – Data Module Code Descriptive Data Module AMPI – A/C Maintenance Planning Information CR&OP – Component Repair & Overhaul Publication IPD – Illustrated Part Data ITEP – Illustrated Tolls & Equipment Publication RFM – Rotorcraft Flight Manual QRH – Quick Reference and Handbook MGB Log card

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2.1 - Aircraft Publications • IETP Interactive Electronic Technical Publication – – – –

Maintenance Publication (AMP) Maintenance Planning Information (AMPI) Master Minimum Equipment List (MMEL) Component Repair & Overhaul Publication (CR&OP)

• RFM Rotorcraft Flight Manual – – – – –

Limitations Normal and Emergency Procedures Performance Data Weight and Balance Data Handling, Servicing and Maintenance Data

• QRH Quick Reference Handbook – –

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Limitations Normal and Emergency Procedures

2.2 - IETP — Interactive Electronic Technical Publication

The AgustaWestland AW139

Interactive Electronic Technical Publication is distributed on CD-ROM

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2.3 - AMP – A/C Maintenance Publication

Maintenance Publication (AMP)

The Technical Publications are arranged in CHAPTERS and Sections. Each chapter is composed of

DATA MODULES.

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2.4 - DMC — Data Module Code

Each Data Module is identified by a unique Data

Module Code (DMC)

having the following structure:

1

3

2

4

5

6

39-A-XX-XX-XX-YXA-XXXA-A

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2.4.1 — Model Identification Code 1

2

3

4

5

6

39 - A - XX-XX-XX - XYA - XXXA - A The Model

Identification Code for the AW139 is 39.

1

3

2

4

5

6

39-A-XX-XX-XX-YXA-XXXA-A

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2.4.2 — System Difference Code 1

2

3

4

5

6

39 - A - XX-XX-XX - XYA - XXXA - A The System Difference Code is a letter (letters I and O are not used). It is used when two or more subsystems can be installed in the A/C as alternatives to do the same function (hereinafter is reported an example relevant to differents MGB group that can be installed on A/C). (AMP) 39-A-63-20-00-00A-041A-A Main gearbox group - Description of how it is made (P/N 3G6320A00132 and subsequents P/N) with different last two digits)

See AMP: 39-A-63-00-00-00A-000A-C Main rotor drive - General

(AMP) 39-B-63-20-00-00A-041A-K Main gearbox group - Description of how it is made (P/N 4G6320A00132 and subsequents P/N) with different last two digits) Documentation

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2.4.3 — Standard Numbering System (SNS) Code 1

2

3

4

5

6

39 - A - XX-XX-XX - XYA - XXXA - A The Standard

Numbering System Code includes three pairs of digits which show:

• SYSTEM

eg: IPD – 39-A-29-00-00-010-941A-A Hydraulic system Fuselage Section

• SUBSYSTEM

eg: AMP – 39-A-29-10-00-00A-231A-A Main hydraulic system - Bleed

and SUB-SUBSYSTEM • COMPONENT

Documentation

eg: AMP – 39-A-29-11-00-00A-041A-A Number 1 main hydraulic system - Description of how it is made eg: IPD – 39-A-29-11-01-010-941A-A Number 1 Power Control Module Assy

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2.4.4 — Disassembly Code & Disassembly Code Variant 1

2

3

4

1/2

5

6

39 - A - XX-XX-XX - XYA - XXXA - A The Disassembly

Code has two digits The Disassembly Code Variant has one letter The Disassembly Code in AMP shows the breakdown of a component, as follows: -

00 - Data module for all of the helicopter, system, subsystem or component 01 - Data module for the first assembly that you remove from the component 02 - Data module for the second assembly that you remove from the component 03 and subsequent codes refer to the third, fourth, etc. assembly that you remove from the component

The disassembly code is also used to identify the data modules in sequence.

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2.4.4 — Disassembly Code & Disassembly Code Variant 1

2

3

4

5

2/2

6

39 - A - XX-XX-XX - XYA - XXXA - A

The Disassembly Code Variant is a letter which identifies alternative items (letters I and O are not used)

eg:

These items are different, but the difference is too small to cause a change in the System Difference Code.

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A

B

2.4.5 — Information Code & Information Code Variant 1

2

3

4

5

6

39 - A - XX-XX-XX - XYA - XXXA - A The Information

Code has three digits and

identifies the types of information you can find in that data module. The Information

Code Variant has one letter and

is used for different data modules that are applicable to the same component and type of operation.

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Code 0XX 1XX 2XX 3XX 4XX 5XX

6XX 7XX 8XX 9XX

Definition Function, data for plans and description Operation Servicing Examination, tests and checks Fault reports and isolation procedures Disconnect, remove and disassemble procedures Repairs and locally make procedures and data Assemble, install and connect procedures Storage procedures and data Miscellaneous

2.4.6 — Item location code 1

2

3

4

5

6

39 - A - XX-XX-XX - XYA - XXXA - A The Item

Location Code is a letter which shows where you must do the maintenance task.

Examples of location codes: A - on the helicopter. B - on the removed assembly/component. C - R&O shop D - applicable to all the locations.

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2.5 - Descriptive Data Module

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1/8


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2/8


3/8

List of Data Modules and Technical Publications associated to the procedure

References

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List of Tasks to be performed before starting the procedure

Required conditions

List of Special Tools and Support Equipment required to do the procedure Support Equipment

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Preliminary requirements


5/8

Supplies

Spares

List of Consumables and Expendables

necessary to do the procedure

List of Spares

required to complete the job

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General Warnings and Cautions

Safety Conditions

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Sequence of Steps and Illustrations

necessary to do the procedure

Procedure

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Instructions necessary to return the helicopter back to operation

Requirement After Job Completion

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2.6 - AMPI - Maintenance Planning Information

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Each one of these publications gives you all the data necessary for the maintenance planning of the AgustaWestland AW139 helicopter as approved by the relevant Authority.

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AMPI : Chapter 00 HELICOPTER GENERAL Chapter 04 AIRWORTHINESS LIMITATIONS Chapter 05 SCHEDULED/ UNSCHEDULED MAINTENANCE

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AMPI : Chapter 04 AIRWORTHINESS LIMITATIONS 04-00 AIRWORTHINESS LIMITATIONS 04-10 RETIREMENT LIVES 04-20 MANDATORY INSPECTIONS 04-30 CERTIFICATION MAINTENANCE REQUIREMENTS

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2.6 - AMPI - Maintenance Planning Information 04-00

AIRWORTHINESS LIMITATIONS

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RETIREMENT LIVES

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MANDATORY INSPECTIONS

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CERTIFICATION MAINTENANCE REQUIREMENTS

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AMPI : Chapter 05 SCHEDULED/UNSCHEDULED MAINTENANCE 05-00

SCHEDULED/UNSCHEDULED MAINTENANCE

05-10

TIME LIMITS

05-20

COMMON SCHEDULED MAINTENANCE CHECKS

05-30

PHASED and PROGRESSIVE SCHEDULED MAINTENANCE CHECKS

05-40

STANDARD SCHEDULED MAINTENANCE CHECKS

05-50

UNSCHEDULED MAINTENANCE CHECKS

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SCHEDULED/UNSCHEDULED MAINTENANCE

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SCHEDULED/UNSCHEDULED MAINTENANCE (example)

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2.6 - AMPI - Maintenance Planning Information 05-10 TIME LIMITS

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Section 39-A-05-12-00-00A-000A-A (Component overhaul schedule – General) Components overhaul schedule: This sub-section gives the overhaul intervals for the components of the helicopter. List of components: Refer to the following Table (see Note) Ref

Component

Part number

CO63-01 CO63-05 CO63-07 CO63-09

Main gearbox assembly Lubricating pump Main gearbox assembly Lubricating pump

3G6320A00132 3G6320V04252 4G6320A00132 3G6320A18731

Overhaul interval (FH) 5000 (*) 2500 5000 2500

(*) The overhaul interval is extended to 6000 FH if the retro-mod. P/N 3G6306P01511 is applied to the MGB, independently from the date of its application.

Note: Refer to AMPI for further and more detailed information

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COMMON SCHEDULED MAINTENANCE CHECKS LIST

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PHASED and PROGRESSIVE SCHEDULED MAINTENANCE CHECKS

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STANDARD SCHEDULED MAINTENANCE CHECKS

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UNSCHEDULED MAINTENANCE CHECKS

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2.7 CR&OP – Component Repair & Overhaul Publication

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39-A-CR&OP-00-X Section 00-00 Helicopter general This section includes: SECTION 39-A-00-00-00-00A-011E-C Component repair and overhaul publication - List of effectivity codes SECTION 39-A-00-00-00-00A-018E-C Component repair and overhaul publication – Introduction SECTION 39-A-00-00-00-00A-943B-C Illustrated parts data - List of NATO supply codes for manufacturers SECTION 39-A-00-00-00-00A-944B-C Illustrated parts data - List of unit of issue codes SECTION 39-A-00-00-00-00A-945B-C Illustrated parts data - List of abbreviations

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Sec. 39-A-00-00-00-00A-011E-C : List of effectivity codes The meaning of the effectivity codes used is as follows: All : Helicopters AW139:

-

S/N 31005 and subsequent S/N 41001 and subsequent

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Sec. 39-A-00-00-00-00A-018E-C : Introduction  General This publication gives you all the data necessary for the repair and the overhaul of the components of the Agusta Westland AW139. It includes the data that are necessary for the requisition and identification of the spare parts at the repair/overhaul level. • Publication contents The publication gives repair and overhaul data for: System Title 60 Standard practices - rotors 62 Main rotor 63 Main rotor drive 64 Tail rotor 65 Tail rotor drive 67 Rotors flight control Documentation

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Sec. 39-A-00-00-00-00A-018E-C : Introduction (Cont.s) • Publication layout This publication contains: – This introduction and the general data modules (39-A-63-....) – The repair/overhaul data modules (39-A-63-......) – The illustrated parts data modules (IPD: ZG-.....Main gearbox)

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Sec. 39-A-00-00-00-00A-018E-C : Introduction (Cont.s) • Illustrated parts data modules (IPD) General Each Illustrated Parts Data (IPD) module includes a figure and the related text (detailed parts list). A code identifies each IPD module as required. Hereinafter is reported an example.

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Sec. 39-A-00-00-00-00A-018E-C : Introduction (Cont.s) •

Data Module Code (DMC)

The IPD at the repair/overhaul level refers to components of the helicopter not to systems. Thus, data is “not-chapterized”. The DMC structure is as follows: ZG-W5-.... Z - identifies that the data module is non-chapterized. G - is the code that identifies Agusta as responsible company. W5- .... followed by a sequential number (assigned by Agusta) identifies the project number; see the example reported hereinafter: – 01 - for the main gearbox. – 02 - for the intermediate gearbox. – 03 - for the tail gearbox. For P/N : 3G…

For P/N : 4G…

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Sec. 39-A-00-00-00-00A-018E-C : Introduction (Cont.s) • Detailed parts list The detailed parts list is a table. Each column of the table has a heading that gives the contents. The columns include the information that follows:

Usable on code assembly and model version and effectivity column (UOCA MVEFFECT) Interchangeability column (ICY) Quantity per next higher assembly and unit of issue column (QNHA UI)

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Source, maintenance and recoverability code column (SMR)


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Repair/Overhaul data modules: 39-A-63-20-05-00A-000A-C Main gearbox - General

Documentation

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Repair/Overhaul data modules: 39-A-63-20-05-00A-000A-C Main gearbox – General (cont.s)

Effectivity codes:  39-A-63-20-05-00A-000A-C: The meaning of the effectivity codes used is as follows: All : Main Gearboxes (MGB) P/N 3G6320A00132 and subsequents P/N with different last two digits A01 : MGB P/N 3G6320A00132 and P/N 3G6320A00133 A02 : MGB P/N 3G6320A00134 and subsequents P/N with different last two digits A03 : MGB P/N 3G6320A00135 and subsequents P/N with different last two digits A04 : MGB P/N 3G6320A00132, P/N 3G6320A00133 and P/N 3G6320A00134 B01 : Input shaft module P/N 3K6320A00133 (installed on MGB P/N 3G6320A00132 and 3G6320A00133) B02 : Input shaft module P/N 3K6320A00135 (installed on MGB P/N 3G6320A00134 and 3G6320A00135) B03 : Input shaft module P/N 3K6320A00136 (installed on MGB P/N 3G6320A00134, 3G6320A00135, 3G6320A00132 and 3G6320A00133)  39-B-63-20-05-00A-000A-C: The meaning of the effectivity codes used is as follows: - All : Main Gearboxes (MGB) P/N 4G6320A00132 and subsequents P/N with different last two digits Documentation

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Illustrated parts data modules IPD : 39-A-ZG-W5-01-010-941A-C MAIN GEARBOX ASSY

Documentation

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2.8 - IPD — Illustrated Part Data IPD: Section 63-20 Main gearbox group

Documentation

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2.9 - ITEP – Illustrated Tools & Equipment Publication

Documentation

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2.10 -RFM — Rotorcraft Flight Manual

Documentation

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2.11 - QRH — Quick Reference Handbook

Documentation

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2.12 - MGB LOG CARD (Section 1)

Mxxx

XX-XXX XXXXX

XXXXX

XXXXX

XX-XXX XXXXX

Documentation

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2.12 - MGB LOGCARD (Section 2)

Mxxx

Documentation

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2.12 - MGB LOGCARD (Section 2, Cont.s)

Mxxx

Documentation

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Documentation

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Documentation

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Chapter 2 - Documentation

THE END

RETURN TO LESSON SUMMARY Documentation

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MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 3 – MGB General information

3 – MGB General information INDEX 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.5 3.6 3.7 3.8

General description MGB description Mechanical assembly description Left and Right Input Shaft Module description Upper Module description Hydraulic Pumps drive quills description ECS compressor drive quill description FAN drive quill description Tail-rotor drive quill description Lubrication system description General Chip detection operation Pumps Pressure regulation Oil Filter Oil Cooler Sensors and Jets Leading Particulars Controls and Indicators Warning, Caution Messages Components that must be removed from the MGB before its overhaul


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3.1 – General description The Main Gearbox has the primary functions to transmit the Power/Torque coming from the two Engines to the Main Rotor Shaft (Mast), to the Tail Rotor Mast and to the Accessories installed on the MGB. The MR and the TR rotate CCW, see Figure 1. Tail Rotor Shaft (Mast)

Main Gearbox

Main Rotor Shaft (Mast) Tail Gearbox

Engine No. 2

Lub. Pump

FAN, Oil Cooler Unit Rotor Brake Intermediate Gearbox

RH Hyd. Pump (Hyd. Sys. No. 2)

Tail Rotor Drive System (3 shafts) AC Generator (Optional)

Lub. Pump

ECS Compressor

Engine No.1

LH Hyd. Pump (Hyd. Sys. No. 1) Front Hyd. Pump (Hyd. Sys. No. 2)

AC Generator (Optional)

Fig. 1 - Drive system For Training purpose only

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3.1 – General description (Continued) The Main Gearbox Group includes the following primary components (see Figure 2): -

The Main Gearbox (that includes a mechanical assembly and a lubrication system) The Oil Cooler The Oil Cooler Fan

Figure 2 – Main Gearbox Group For Training purpose only

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Continued

3.2 – MGB description Hereinafter is described the MGB, type “3G”. As already mentioned before, the Main Gearbox has the primary functions to transmit the Power/Torque coming from the two Engines to the Main Rotor Shaft (Mast), to the Tail Rotor Mast and to the Accessories installed on the MGB. The Power / Torque produced by each Engine is transmitted to the MGB by means of specific Engine Drive Shaft (EDS) equipped with Flexible couplings connected to the MGB Input drive quills. Each engine rotate clockwise at 21000 RPM (see Figure 1). The EDS and the Torque Tube is built in Steel Alloy. The MGB that is 5° tilted forward, drives the Main Rotor Shaft (MAST) at 296.4 RPM (CCW), the Tail Rotor Shaft (Mast) at 1435.7 (CCW) by means of the Tail Rotor Drive System (TRDS) that includes: 3 Shafts, the Intermediate Gearbox (IGB) and the Tail Gearbox (TGB). Furthermore, the MGB drives some accessories at the required speeds (see from Figure 1 to Figure 5).

The MGB reduces the engine output speed to the main rotor speed by means of three reduction stages (see Figure 1): • First and Second stage of reduction is carried out by means of spiral bevel gears • Third stage of reduction is carried out by means of an epicyclical planetary gear Each MGB input is provided with a freewheel unit, to override each engine drive in case of engine shut-down or failure, allowing the rotor to be continuously driven by the remaining engine. The MGB includes a Tail Rotor Take-OFF Pinion for the Tail Rotor Drive System (TRDS). The Housing of the Tail Rotor Take-Off Pinion also provides the support for the Rotor Brake Actuator. The Brake Calliper is attached to the Flange that is bolted to the Main Case assembly of the MGB. The drive Flange for the Tail Rotor Drive Shaft also permits the attachment of the Rotor Brake Disc (see Figure 2). For Training purpose only

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3.2 – MGB description

(Continued)

The MGB can drive the following components (see Figure 3):  The Front Hydraulic Pump drive pinion, driven by the Collector Gear,  The ECS Compressor drive pinion, driven by the Collector Gear,  Left and Right Lubrication Pump drive pinion, driven by the Collector Gear,  Two AC Generators (optional) drive pinions, driven by the relevant Input Pinion 2^ stage of reduction,  The Fan Cooling drive pinion, driven by the Tail Rotor Take-Off Pinion,  Left and Right Hydraulic Pump drive pinion, driven by the relevant Input Pinion 2^ stage of reduction. The MGB is pressure lubricated and includes a lubrication and cooling system; all the oil ducts are cored in the MGB housings. The lubrication and cooling system is composed by (see Figures 4a, 4b and 4c):  Two Positive Displacement Pumps (Gerotor type).  Two Pressure Relief Valves (PRV).  Two Check Valves.  An Oil Filter provided of a Disposable Filter, a By-pass Valve, an Impending bypass indicator (Pop-out) with the relevant caution alarm switch.  An Oil Cooler and Cooling Fan.  29 oil Jets (17 located in the Main Case, 4 located in the Upper Module and 4 on each Input Shaft Module).  An oil Level Gauge and a Low Level Sensor located on the Main Case.  An oil Filler Plug.  An oil Pressure Senor, oil Temperature Sensor and an oil Temperature Switch located on the Filter Housing .  Two Low Pressure Switch (one located on each Input Shaft Module).  Three Chip detectors (2 located in lower side of the Main Case and 1 located on the Upper Module). For Training purpose only

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(Continued)

Furthermore, the MGB is provided of (see Figures 4a, 5):     

One Rotor Speed Sensor (NR) located on the Main Case. Two Bearing Temperature Sensors (one thermocouple located on each Input Shaft Module). Three Servo-Actuator Brackets (Front, Left and Right) located on the Main Case. The Swashplate support. Four Attachments points (four upper fittings, located on the MGB Upper Module) and of an Anti-Torque Beam (located on the MGB bottom side). The transmission is locked to the helicopter upper central fuselage structure by means 4 Rods / Supports and by means 4 bolts connected to the Anti-torque beam.


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(Continued)

1435.7 rpm (CCW) 296.4 rpm (CCW)

Mast-Planetary Assy

Gimbal

Crosshead

Torque Tube

TGB

3^ stage of reduction Engine No. 2

T.R. Drive Quill Assy

IGB

RB TRDS

Engine Drive Shaft Input Shaft Module

Engine No.1

2^ stage of reduction Collector Gear + Input Pinion

1^ stage of reduction Input Pinion + Gear + Freewheel unit (Input Shaft Module)

Fig. 1 - Drive system For Training purpose only

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Crosshead connected to the Gimbal

Flexible Coupling MGB Input Drive Quill Connection

Torque Tube

Engine Drive Shaft (EDS)


(Continued)

Rotor Brake Case

Fig. 2 – Rotor Brake Assy For Training purpose only

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Flange


(Continued)

Collector Gear (1355 rpm) Fan Drive Quill (16014 rpm)

Front Hyd. Pump Drive Quill (7732 rpm)

Tail Rotor Take-Off Pinion (4532 rpm) ECS Compressor Drive Quill (4868 rpm)

LH / RH Hyd. Pump Drive Quills (9111 rpm)

AC Gen. Drive Quill (12050 rpm)

LH / RH Lubrication Pump (7302 rpm)

Input Pinion 2^ stage of reduction (6917.6 rpm) Fig. 3 – Components driven by the MGB For Training purpose only

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(Continued)

Fig. 4.a – Lubrication System - Components and Sensors location

OIL TEMPERATURE SWITCH OIL TEMPERATURE SENSOR OIL PRESSURE SENSOR

RH HYD. PUMP drive quill UPPER FITTING TAIL ROTOR DRIVE QUILL Assy LH HYD. PUMP drive quill LH INPUT SHAFT MODULE SUMP CHIP DETECTORS

AC GENERATOR drive quill OIL LOW LEVEL SWITCH UPPER MODULE

ECS COMP. drive quill FRONT HYD. PUMP Drive quill

OIL LEVEL GAUGE


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AC GENERATOR drive quill

MAIN CASE ANTI-TORQUE BEAM


(Continued)

Oil Filter

PRV

CHECK VALVES

LUB. PUMPS

SUMP CHIP DETECTORS

Fig. 4.b – Lubrication System - Components and Sensors location For Training purpose only

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N°10

N°6

(Continued)

N°11

N°12

N°7 N°9

N°3

N°3

N° 16 N°16

N°5 N°8

N°4 N°4 N°13 N°15

N°14

Notes

In the MGB are installed 29 Oil Jets: - 17 oil jets in the Main Case - 4 oil jets in the Upper Module - 3 oil jets in each Input Shaft Module (6 total) - 1 oil jet in each Cover of each Input Shaft Module (2 total)

Fig. 4.c – Lubrication System - Components and Sensors location For Training purpose only

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(Continued)

FWD

Fig. 5 – Mounts and Attachments For Training purpose only

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3.3 Mechanical assembly description The Main Gearbox is a set of Cases which are the housings of the gears of the reduction / transmission stages, the accessories and the other components of the main gearbox. It is a three stages reduction gearbox. The Main Gearbox drives the Main rotor mast, the accessories and the Tail rotor mast (and the rotor brake) through the Tail Rotor drive quill, 3 drive shafts, an IGB and a TGB. The Cases (made of Aluminium Alloy) of the MGB are (see Figure 1): • The two Input Shaft Modules (left input shaft module and right input shaft module) • The Main Case (*) • The Upper Module. (*) A Bottom Cover (Al. Alloy) and an Anti-Torque Beam (Al. Alloy) are connected to the lower side of the Main Case by means of Studs. The Primary Internal Assy of the main gearbox are: • The Input Pinion and the Bevel Gear of the Left and Right Input Shaft Modules (first stage of reduction) • The Input Pinions and the Collector Gear of the Main Case (second stage of reduction) and the Diaphragm. • The Mast-Planetary Gear and the Fixed Ring Gear located in the Upper module (third stage of reduction). Through 3 reduction stages , the Main Rotor Mast will rotates (CCW) at about 296 rpm. For Training purpose only

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3.3 - Mechanical assembly description (continued) The drive quills installed in the Main Case are (see figure 1): – the Front Hyd. Pump drive quill – the Left / Right Hyd. Pumps drive quills – the ECS Compressor drive quill – the Fan drive quill – the Tail Rotor drive quill. – the A/C Generators drive quills (optional)

Besides, LH and RH Lubrication Pumps installed on the Main Case, that are components of the Transmission lubrication system, are driven by the Collector Gear.


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3.3 - Mechanical assembly description (continued)

A/C GENERATORS drive quills

Collector Gear (Sun gear, in view) Planetary

MAIN CASE

Input Pinion

Bottom Cover

Fig. 1 – MGB Cases and Drive Quills For Training purpose only

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3.3.1 - Left and Right Input Shaft Module description There are two Input Shaft Modules installed on the main gearbox, the left input shaft module and the right input shaft module. The two input shaft modules are interchangeable, because they have the same shape, configuration and components. The left and the right input shaft modules are installed on the related side of the main gearbox (studs). The primary components of each module are (see Figure 2 and 3): – the Housing and the Cover – the Gimbal – the Input Flange – the Input Pinion Assy, – the Bevel Gear, I° Stage of reduction – the Freewheel Unit . The Housing is made of Aluminium alloy and contains the components that turn (first reduction stage). The Gimbal has the function to hold the crosshead and the torque tube connected to the engine and is attached to the housing with eight washers and nuts. The Input Flange receives the torque from the Engine Drive Shaft and transmits it to the Input Pinion. The input flange has internal splines and is installed on the splined end of the input pinion. Between the Input Pinion and the Bevel Gear there is the first stage of reduction. A duplex ball bearing and a roller bearing hold the input pinion and let it turn, the input pinion engages the gear that is held in position by a ball bearing and a roller bearing. Three oil jets are installed in each housing of the Input Shaft Module. They lubricates the pinion, the gear and the related bearings. Furthermore, another Oil jet is installed in each Cover of each Input Shaft Module. The freewheel unit is of the "sprag" type and the centrifugal force operates it. It is installed between the gear and the input shaft. The freewheel has two ball bearings that hold it and let it turn. The freewheel is lubricated through an oil jet part of the cover. (see Figure 3). A Low Pressure switch and a Bearing Thermocouple is installed on each Input Shaft Module. For Training purpose only

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3.3.1 - Left and Right Input Shaft Module description

(Continued)

Left Input Shaft Module Oil Jet Cover

Housing

Housing Low Oil Pressure Switch

Oil Jet Cover Gear, I° Stage of reduction

Input Flange Bearing Thermocouple

Freewheel Unit

Input Pinion Assy

Gimbal

Figure 2 - Input Shaft Module For Training purpose only

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3.3.1 - Left and Right Input Shaft Module description

(Continued)

Input Pinion (II° Stage of reduction), part of the Main Case.

(I° Stage of reduction)

EDS

Input shaft

Figure 3 – Freewheel unit For Training purpose only

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3.3.2 - Upper Module description The Upper Module of the main gearbox holds the Mast-Planetary Assy and the Fixed Ring Gear . This module is installed above the Main Case by means of washers and nuts locked to the studs of the main case as required. The primary components of the upper module are (see Figure 4) : – – – –

the Top case, the Mast-Planetary Assy, 5 Planetary Gears Assy, the Fixed Ring Gear (Planetary crown).

The case is a light alloy (AL. Alloy) casting and is machined. In the walls of the case there are the oil ducts for the lubrication of the components. The collector gear (in the main case) engages, by means of the sun gear, the five planetary gears that rotates around the planetary crown (third stage of reduction) that drive the main rotor mast. A ball bearing an a roller bearing hold the mast in position and permits it to turn. Four fittings are installed on the upper module, they are the attachments of the four rods of the main gearbox and of the four Lightning conductor jumpers (see Figure 5).

These sensors / components are installed on the Upper Module (see Figure 5): – the mast chip detector, – the oil cooler adapter, – the oil temperature switch, the oil temperature sensor, the oil pressure sensor, the Pop-out and oil filter caution alarm switch, – four oil jets, – the oil filler cap. For Training purpose only

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3.3.2 - Upper Module description (Continued)

Top Case

Upper Module Assembly

Mast-Planetary assembly

5 Planetary Gears Assy

Packing Planetary Crown (Fixed Ring Gear)

Figure 4 – Upper module For Training purpose only

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3.3.2 - Upper Module description (Continued)

Tsw

Lightning Conductor Jumper

Pop-Out + Caution alarm Switch

Ts

Ps

Oil Filter Head

Upper Fittings (4) 2 Oil Jets No. 1

A

B

C

D

2 Oil Jets No. 2 Mast Chip detector

Oil Filler cap

Oil jet filter O-ring

Screw + washer

Oil Jets No. 1 and No. 2

Oil Cooler adapter (Oil Filter case)

O-ring O-ring

Figure 5 – Upper module (sensors /components ) For Training purpose only

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3.3.3 - Hydraulic Pumps drive quills description Three Hyd. pump drive quills are installed in the main gearbox. One is installed in the left side of the main case, the second is installed in the right side, in symmetrical position while the third drive quill is installed in the front of the main case. Each of them drives one (hydraulic) pump. The Front pump is driven by the Collector gear while, the LH and RH pumps are driven by the relevant Input Pinion II° stage of reduction. The drive quills are shown on Figure attached.


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3.3.3 - Hydraulic Pumps drive quills description

(continued)

A

A Screw (2)

Nylon Screw (2) LH/ RH Hyd. Pump Drive Quill

A

Screw (3)

B

Shim Screw (3)

O-ring B

Shim Setscrew (2)

O-ring

Screw (2)

Figure 6 – Hyd. Pump drive quills For Training purpose only

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FRONT Hyd. Pump Drive Quill

3.3.4 - ECS compressor drive quill description The ECS compressor drive quill is installed in the front of the main case of the gearbox and is driven by the Collector Gear. The ECS compressor drive quill is shown on the Figure attached.

C Screw (3)

O-ring C Shim ECS Compressor Drive Quill Screw (2) Setscrew (3)

Figure 7 – ECS Compressor drive quill For Training purpose only

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3.3.5 - FAN drive quill description The Fan drive quill is installed in the rear of the of the main gearbox, just before and in the upper position of the tail-rotor drive quill. The fan drive quill is driven the Gear installed on the Tail Rotor Take-Off Pinion. The drive quill is shown on the Figure attached.

V Nut, Washer (3) Seal-Cover O-ring Lip-Seal V Screw Shim

Figure 8 – Fan drive quill For Training purpose only

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Fan Drive Quill

3.3.6 - Tail-rotor drive quill description The Tail-rotor drive quill is installed in the rear of the of the main gearbox. The primary components of the tail-rotor drive quill are shown on the Figure attached. The pinion (Tail Rotor Take-Off Pinion) engages the collector gear (second stage of reduction) and drives the tail rotor shaft. A gear installed on the pinion, drives the fan drive quill. The flanged bearing, housed in the rotor-brake case, and the roller bearing, housed in the main case, hold the pinion. The flanged, internal splined, engages the external spline of the pinion. The flange is the connection point of the rotor brake disc. The internal spline of the pinion engages the sliding adaptor that drives the tail rotor shaft. The Retaining rings, the Locking washer and the Locking ring hold in position the pinion and the gear.


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3.3.6 - Tail-rotor drive quill description

(continued)

Gear Pinion (tail rotor take Off pinion)

Retaining ring Locking washer Locking ring Ring Flange Retaining ring Seal case

Nut + Washer Seal

Rotor brake case O-ring

Flanged bearing

Shim Screw

Nipple

Retaining ring Locking washer Locking ring Gear Shim Retaining ring Locking washer Locking ring

Bearing inner race (roller) Pinion

Plug

O-ring

Bearing cage

Figure 9 – Tail-Rotor drive quill For Training purpose only

Figure 1 – Tail-Rotor drive quill Pinion 29 of 51

Plug

3.4 - Lubrication system description 3.4.1 - General

-

The AB/AW139 MGB lubrication system is based on the wet sump concept. With this concept, the lower part of the MGB perform also the function of oil tank whereby the pressure pumps suck the oil for feeding the delivery circuit. Note: • The "dry sump" concept where the gearbox sump is maintained virtually dry by means of a scavenge pump(s) sending all the oil to a separate oil tank, normally placed upward from which the pressure pump(s) suck the oil for feeding the distribution system. • The "wet sump" concept where the scavenge pump(s) and the external tank is eliminated leaving only the pressure pump(s) and the gearbox housing serves also as a tank.

Another important characteristics of the MGB lubrication system design is the absence of remote components and consequently of external pipes and fittings. The lubrication system schematic can be seen on the attached Figure 1. The lubrication System includes:             

Two Lubrication pumps (positive displacement, Gerotor type) installed in the rear side of the Main Case. Two Pressure Relief Valves (PRV). Two Check Valves. An Oil Filter Assy that includes: a Disposable Filter (10 micron), an Anti-Spill Valve, a By-Pass Valve, an Impending bypass indicator (Pop-out) provided of a caution alarm switch (the By-pass valve, the Pop-out and the alarm switch are located on the Oil Filter Head). A Cooling Fan and an Oil Cooler provided of a By-pass Valve. An Oil Pressure sensor installed on the Oil Filter Case. An Oil Temperature sensor and an Oil Temperature switch installed on the Oil Filter Case. 29 oil Jets (17 located in the Main Case, 4 located in the Upper Module and 4 on each Input Shaft Module). A Low Oil Pressure switch located on each Input Shaft Module. A Low Oil Level switch located on the front side and in bottom area of the Main Case. 3 Chip Detectors (One located on the Upper Module “MAST” and two located in the Main Case “SUMP”). A Bearing Thermocouple located on each Upper Module. A Sight glass on the front side of the Main Case; it shows two marks: MAX and MIN.


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3.4.1 – General (continued) The sump is obtained in the bottom of the MGB and is designed to contain about 18 litres of oil (MIL-PRF23699 if the ambient temperature is above -30°C or MIL-PRF-7808L if the ambient temperature is above -40°C, the two oil types are not mixable). From the sump the oil is sucked through the sintered mesh steel screens of the full flow Chip detectors. These screens have the purpose of aiding the trapping or wear particles and the consequent capture by means of the magnetic chip detectors. The screen serves also the purpose of preventing wear or abrasive particles of significant magnitude to enter the lubrication system and therefore causing damage to important components such as the pumps. The overall pressure loss through the screen and the ducts will be minimized by proper sizing of flow areas such that the pressure at the pump inlet shall be not less than about 90kPa.


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3.4.1 – General (continued)

MAST CHIP DETECTOR

T> 109°C

Oil cooler By-pass Valve (Therm. / Diff. Pressure)

P < 3.1 Bar

P < 3.1 Bar T> 140°C T> 140°C

Anti-Spill Valve ΔP = 1.7 Bar ΔP = 1.25 Bar

SUMP CHIP DETECTOR

SUMP CHIP DETECTOR

Figure 1 – Lubrication system schematic For Training purpose only

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• The By-Pass opens at Δp = 190 kPa (1.9 Bar) • The By-Pass opens at T ≤ +80 °C

3.4.2 - Chip Detection Operation

The chip detector senses the unwanted ferrous particles contained in the lubricating oil of the gearbox. The sensor is a magnet with a coil around it, this coil is electrically connected to the circuit in the sensor. The magnetic force of the magnet pulls the ferrous particles to the magnet. When the particles go through the magnetic field, they change the properties of the signal of the coil. The electronic circuit of the sensor amplifies this signal and sends it to the MAU 1 and MAU 2 (Modular Avionics Units) of the vehicle monitoring system. If the metallic particles have a diameter lower than 0.05 mm (0.0019685 in), they can be burned by pressing the CHIP BURNER switch on the miscellaneous control panel. See Figure 2.


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3.4.2 - Chip Detection Operation (continued)

Figure 2 – Chip Detection Operation For Training purpose only

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3.4.3 - Pumps After the chip detectors the oil reaches the oil pumps. The system is based on a dual pump design with features allowing to continue safely with only one pump operating. The pumps are of the positive displacement, GEROTOR (see Fig. 3) type pumps with multiple elements to optimise the rotors tip speed to avoid the risk of cavitations even under the most critical flight conditions.

Figure 3 – Gerotor pump The basic pump characteristics are as follows :

• Inlet pressure pi =47.5 kPa (approximately). • Flow Q=40.1 litre/min (NOMINAL). • Nominal driving speed n=7302 RPM (NOMINAL). • Outlet pressure p0 =700 kPa (NOMINAL)


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3.4.4 - Pressure Regulation Each pump delivery duct is provided with its own Pressure Relief Valve (PRV) which maintain the required constant pressure inside the circuit. These valves are of the spring actuated poppet type and can easily be adjusted at MGB acceptance testing in order to provide a gearbox with the most appropriate system pressure. The pressure relief valve, also called pressure regulating valve, is set at: • Outlet pressure =700 kPa (7 Bar) However the valve is capable of being adjusted over a range allowing correct pressure regulation of the system. After the pressure relief valves, the Check Valves are placed. Their purpose is to exclude the oil backflow in case of pump malfunction or blockage. In fact if one pump fails, the other pump will provide more flow to the system and the flow will be prevented to go back to the sump through the failed pump by means of the check valves. The check valves are of the full flow poppet type giving very little flow resistance (about 1 kPa) during normal operation. After the check valves the two branches of the oil system are joined together before entering the Oil Filter. At this stage the total system flow should have been reduced (by means of the pressure relief valves) to about:

• Flow Q=70 liters/min (NOMINAL) Giving ample regulation margins during development and testing.


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3.4.5 - Oil Filter The oil filter is provided with a bypass valve excluding the filter in case of clogging of the filter element. Before opening the bypass, an electrical sensor will provide advance information that the filter is being clogged and that will be bypassed. • The by-pass opens at Δp=170±28 kPa (1.7 Bar) • The impending bypass alarm switch actuates at Δp=125±14 kPa (1.25 Bar) • Clean filter assembly pressure drop Δp=38 kPa (0.38 bar)

The filtration capacity of the filter is 10 µm and the filter element is disposable. The filter is fitted into a special housing bolted directly to the upper housing and giving interface and support to the oil cooler.


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3.4.6 - Oil Cooler After having been filtered, the oil is delivered to the oil-air heat exchanger also called the oil cooler. The oil cooler is simply connected to the above filter housing assembly avoiding the need of external pipes or fittings as normally required by different, more conventional designs. The oil cooler is provided with a by-pass valves which actuates in case of both high differential pressure and low oil temperature : • The by-pass opens at Δp=190 kPa (NOMINAL) (1.9 Bar) • The by-pass opens at T < +80°± 2°C. The air stream to cool the oil in the heat exchanger is provided by the cooling fan. The fan is mechanically driven at about 16014 RPM by a set of bevel gears directly connected to the MGB providing a high degree of integrity to this assembly as compared to external units driven by shafts. The cooling fan is of the mixed (axial/centrifugal) type delivering approximately an air flow of about 1.14 m3/sec and is provided with aluminium cast impeller and aluminium scroll housing. The impeller is supported on independent self lubricated (grease) bearings avoiding the risk of MGB oil loss or contamination. The fan drive shaft is also provided with a shear section which will prevent damage to the MGB in case of failure of the fan due to FOD or malfunction.


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3.4.7 - Sensors and Jets At the outlet of the fan the following sensors are fitted : • Oil pressure sensor • Oil temperature sensor • Oil temperature switch (actuation point T > 109°C) • Oil low pressure switch (actuation point P < 3.1 Bar) The oil is subsequently delivered to the several points of the MGB, where, by means of dedicated nozzles, it is directed to all the lubrication points. The oil nozzles (total: 29 Oil Jets) are of peculiar design having the following important characteristics (see Figure 4): • Aluminum alloy construction • Removable screen filter • Each and every nozzle can be removed from the outside Furthermore, in the system, on each Input Shaft Module a Bearing Thermocouple is installed near to duplex ball bearing of the Input Drive Quill.


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3.4.7 - Sensors and Jets (continued)

N°10

N°6

N°11

N°12

Oil Jet Screen Filter

N°7 N°9

N°3

N°3 Example of Oil Jet

N° 16 N°16

N°5 N°8

N°4 N°4 N°13 N°15

N°14

Notes

In the MGB are installed 29 Oil Jets: - 17 oil jets in the Main Case - 4 oil jets in the Upper Module - 3 oil jets in each Input Shaft Module (6 total) - 1 oil jet in each Cover of each Input Shaft Module (2 total)

Figure 4 – Oil Jets For Training purpose only

40 of 51

3.5 - Leading Particulars

(LH/RH) (FRONT)

(TQ: 100% +100%) (TQ: 110% +110%)

(TQ: 140%)

(18 Liters)

(TQ: 160%)

Note: - in AEO condition the Maximum Transient (5 sec) TQ is 121% - in OEI condition the Maximum transient (5 sec) TO is 176%


41 of 51

3.6 - Controls and Indicators The main gearbox (MGB) controls are located on the Miscellaneous Panel and on the Test Control Panel both installed in the cockpit console (see Figure attached). The MFD (Main and Cruise Page) displays the MGB OIL TEMP/PRESS parameters. The MFD also provides the malfunction condition in the CAS message window No.1. The Miscellaneous Panel provides the following function: CHIP BURNER: ........................

when pressed a burning attempt for the MGB CHIP MAST or MGB CHIP SUMP is performed. NOTE

If the MGB CHIP MAST or MGB CHIP SUMP cautions illuminate when MGB OIL PRESS warning is illuminated the CHIP BURNER must not be activated. The Test Control Panel provides the following function: MGB OIL LEVEL • Push button test switch: ..... when pressed the caution MGB OIL LOW in inverse video is displayed in the CAS window. NOTE

This test is operative with the A/C on ground and NR < 2%. For Training purpose only

42 of 51

3.6 - Controls and Indications (continued)


43 of 51

3.7 - Warning, Caution Messages and Indications MGB OIL PRESS

Oil pressure below limits at one or both MGB inputs and in MGB oil system (less than 3.1 Bar)

MGB OIL TEMP

MGB Oil temp is above 109°C. Reset below 97°C

Audio Warning: (No Tone) + “Warning – Warning”

1 (2) MGB OIL PRESS

Associated MGB engine Input Oil Pressure low (Less than 3.1 Bar. Reset above 3.4 bar)

Note: With both 1 and 2 Input oil press low, the warning MGB OIL PRESS will suppresses the caution message 1-2 MGB OIL PRESS MGB CHIP MAST

Debris is detected on the Mast Chip Detector

MGB CHIP SUMP

Debris is detected in one of the two Sump Chip Detectors

CHIP MAST FAIL CHIP SUMP FAIL For Training purpose only

Sensing channel of Mast Chip Detector is faulty Sensing channel of Sump Chip Detector is faulty 44 of 51

3.7 - Warning, Caution Messages and Indications (continued) MGB OIL FILTER

Differential pressure exceeds 1.25 bar

MGB OIL LOW

MGB Oil level is at minimum (only active on ground)

1 (2) BRG TEMP

MGB - Engine 1 (2) Input stage bearing temp is above 140°C. Resets below 135 °C.

In case double bearing temp caution, AVIONICS FAULT

XMNS OVTQ

1-2 BRG TEMP

will be displayed.

Loss of communication to single MAU is detected for the Chip Detector Power Unit. During AEO TQ1>110% or TQ2>110%. During OEI TQ >160%

CHIP DET UNIT

Chip Detector Power Unit does not respond on Power-up Test and Continuous BIT

CHIP DET TEST

Chip Detector Power Unit responds on manual test. Caution will be displayed when test switch on CDPU is pressed and all is normal.


45 of 51

3.7 - Warning, Caution Messages and Indications (continued)

Note


46 of 51



47 of 51


COMPOSITE FORMAT For Training purpose only

48 of 51

3.8 - Components that must be removed from the MGB before its overhaul In order to remove the Main Gearbox group from the helicopter it is necessary to follow the instructions reported on AMP 39-A-63-20-00-00A-520A-A. In particular, the following preliminary actions are required: -

Observe all Warning, Caution and Note reported in the Specifics Data Module. The Helicopter must be safe for maintenance. The specific access doors and covers must be removed as required. The Main Rotor Head must be removed as required. The ECS Compressor pack must be removed as required. The AC Generators (1 and 2), if installed must be removed as required. The Swashplate must be removed as required. The Fan duct must be removed as required. The Rotor brake disc cover must be removed as required.

Then - Disconnect the Hydraulic lines (section, pressure, drain-house and seal drain house) from each Hydraulic Pump (LH, RH and Front). - Disconnect the Hydraulic pressure and return lines from the Servo-actuators (1, 2 and 3). - Remove the specific Control Rod form the relevant Servo-actuator lever (1, 2 and 3). - Remove the all drain hoses from the Main gearbox. - Disconnect the pressure hose from the Rotor brake caliper. - Disconnect the electrical connector from the Rotor brake caliper and actuator. - Disconnect all electrical connectors from the helicopter structure. - Remove the HUMS (health and usage monitoring systems) wring harness from the box (part of the rotor brake guard installation), if installed. - Disconnect the No.1 Engine Drive Shaft and the No. 2 Engine Drive Shaft form their input flanges. For Training purpose only

49 of 51

3.8 - Components that must be removed from the MGB before its overhaul (continued) - Remove the Crossheads from their Gimbals - Disconnect the No. 1 Flexible coupling (part of the Tail Rotor Drive Shaft) from its sliding adapter located on the gearbox. - Install the Sling on the MAST and apply a light tension as required. - Remove the 4 Bolts installed on the Anti-torque beam as required. - Remove the 4 Rods that connect the gearbox to the helicopter as required. - Carefully lift the Main gearbox from the helicopter and install the Transmission on the applicable trolley.

Then these remaining parts from the MGB: -

Remove the Oil Cooler and the Oil Cooler Fan as required. Remove all Hydraulic Pumps as required. Remove all Hydraulic Servo-actuators as required. Remove the Rotor Brake Disc, Actuator and Caliper as required. Drain the Oil as required.


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Chapter 3 – MGB Genaral information

THE END



MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 4 - General Procedures

4 – General Procedures

INDEX 4.1 4.2 4.3 4.4

Introduction A/C Publications AMPI – A/C Maintenance Publication Information Limits


2 of 8

4.1 - Introduction • Before describing the procedure of disassembling of the MGB it is important to know the Retirement lives, the Discard time of the MGB components and the Overhaul intervals of the MGB and where it is possible to find them in the IETP. • In this section will be shown the Publications, the Data Modules and the Limits involved. • The information reported hereafter are relevant to MGB P/N: 3G6320A00132 or 3G6320A00133 or 3G6320A00134 or 3G6320A00135

NOTE All information reported hereinafter must be considered for Training purpose only For Training purpose only

3 of 8

4.2 - Aircraft Publications

• IETP Interactive Electronic Technical Publication – – – –


4 of 8

Maintenance Publication (AMP) Maintenance Planning Information (AMPI) Master Minimum Equipment List (MMEL) Component Repair & Overhaul Publication (CR&OP)


Each one of these publications gives you all the data necessary for the maintenance planning of the AgustaWestland AW139 helicopter as approved by the relevant Authority.


5 of 8

4.4 – Limits (Part 1) Note: The overhaul intervals and the discard times, specified for the AgustaWestland part numbers (e.g.: 3G6310A00531, 3G3350A01811) written in the specific table (see D.M), apply also to all successive part numbers with the same first ten digits and different last two digits, unless specified differently.

MGB Overhaul intervals (EASA) AMPI (EASA), Data Module

Ref

Component

Part number

Overhaul interval

39-A-05-12-00-00A-000A-A Component overhaul schedule – General

CO63-01

Main gearbox assembly

3G6320A00132

5000 FH (*) Note: The overhaul interval is extended to 6000 FH if the retromod P/N 3G6306P01511 is applied to the MGB, independently from the date of its application. (*)


CO63-05

Lubricating pump

3G6320V04252

2500 FH (*)


CO63-09

Lubricating pump

3G6320A18731

2500 FH (*)

MGB Discard time (EASA) AMPI (EASA), Data Module 39-A-05-13-00-00A-000A-A Discard time schedule – General

Ref

Component

Part number

Discard time

DT63-03

MGB Gimbal support assembly

3K6320A01131

46000 FH (*)

(*): Refer to AMPI for further and more detailed information. For Training purpose only

6 of 8

4.4 – Limits (Part 2)

MGB Retirement lives (EASA) AMPI (EASA), Data Module 39-A-04-10-00-00A-000A-A Retirement lives - General

Ref

Part

Part number

Retirement life

RL021

MGB Case, Top Assembly

3G6320A01033

8800 FH or 23000 landings whichever comes first (*)

MGB Case, Top Assembly

3G6320A01035

17000 FH (*)

39-A-04-10-00-00A-000A-A Retirement lives - General

RL022

MGB Shaft, Main Rotor

3G6320A01852



RL023

MGB Case, Main Assembly

3G6320A02734

5000 FH landings comes first

MGB Case, Main Assembly

3G6320A02736


or 27000 whichever (*)


RL024

MGB Upper Fitting

3G6330A00232

95800 landings (*)


RL025

MGB Antitorque Beam

3G6330A00532


(*): Refer to AMPI for further and more detailed information. For Training purpose only

7 of 8

Chapter 4 - General Procedures

THE END



MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 5 - Pre-Disassembly Procedures

5 – Pre-Disassembly Procedures

INDEX 5.1 5.2 5.3 5.4 5.5

Safety Information Pre-disassembly requirements MGB Drain oil and Draining Pipe removal procedures Anti-Torque Beam & Bottom Cover, removal procedures Installation of the Main Case on the Support Trolley


2 of 12

5.1 – Safety Information Dangerous materials Every time you use a dangerous material make sure you know the related safety precautions and first aid instructions. For more data refer to: – The label of the material container – The manufacturer safety data sheet – The local safety regulations. Refer to CR&OP data module 39-A-60-50-00-00A-074A-C. Critical parts Critical parts are those parts the failure of which during ground or flight operations can have catastrophic effects on the helicopter. Refer to AMP data module 39-A-00-60-00-00A-010A-A. Note -

When the disassembly of the MGB has been completed all disassembled components must be cleaned and protected as necessary. Rubber glovers must be used when moving components. Cotton gloves must be used after cleaning to prevent component contamination.

(Cont’s)


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5.2 - Pre-disassembly Requirements 1. 2. 3.

Refer to CR&OP: 39-A-63-20-05-00A-531A-C (Main gearbox – General guidelines for disassemble procedures) Make sure that the work area is clean. Install the main gearbox on the Trolley (main gearbox support). Support equipment:

4.

5. 6. 7.

Nomenclature

Identification No.

Trolley, main gearbox transport

HE-04-00, or 3G6320A00131A188B, or 3G6320A00331A188E, or equivalent

Drain the oil from the main gearbox as required. Refer to CR&OP: 39-A-63-20-05-00A-222A-C (Main gearbox - Drain oil). Remove the beads of sealing compound from the mating edges between the components of the main gearbox and around the nuts. To do this, use a plastic scraper. After then removal of the sealing compound beads, clean the surfaces with the Cloth and the Solvent. Dry the cleaned surfaces with the Cloth and the compressed air until you fully remove all solvent. Supplies:

Nomenclature

Identification No Specification references

Ref. Documents

Cloth, soft lint-free

C011

None

(AMDI) 39-A-00-50-00-10A-078A-D

Cleaning solvent

C010

P-D-680 type II

(AMDI) 39-A-00-50-00-09A-078A-D

(Cont’s)


4 of 12

5.2 - Pre-disassembly Requirements 8.

Always keep the parts of an assembly together. Do not interchange these parts with the same parts of other assemblies. 9. During disassembly, put the parts in applicable containers as you remove them. 10. Remove the internal Oil Draining Pipe from the gearbox. Refer to CR&OP: 39-A-63-20-05-00A-530A-C (Main gearbox - Disassemble procedures). 11. Remove the Anti-Torque Beam, the Bottom Cover and the Slip Ring from the gearbox. Refer to CR&OP: 39-A-63-20-05-00A-530A-C (Main gearbox - Disassemble procedures). 12. At the disassembly, discard the fasteners (nuts, bolts…… ) and seals as required.


5 of 12

5.3 - MGB Drain oil and Draining Pipe removal procedures CR&OP Data Module:

39-A-63-20-05-00A-222A-C Main gearbox - Drain oil

(MGB)

Support Equipments: (Filler Cap + Breather)

(Oil Filler Neck)

A

Nomenclature

Identification No.

Trolley, main gearbox support

3G6320A00131A188B

Adapters kit, helicopter servicing

3G1205G00131

Hose, MGB oil draining

3G1205G00332

Pump, MGB oil draining

E1224/30-40

Container

Local supply

Draining Pipe – removal-

CR&OP Data Module:

(Coupling Half)

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures.

(Drain Cap)


6 of 12

5.4 - Anti-Torque Beam & Bottom Cover, removal procedures CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Support Equipments:

M/R Shaft (MAST)

Nomenclature

Identification No.

Lifting tool, main gearbox

3G6320A00131A181A

Lifting device

Local supply

MGB Assembly

Note: •During this procedure, obey the general guidelines applicable to the disassemble procedures. Refer to 39-A-63-20-05-00A-531A-C. •Before to remove the Anti-torque Beam and the Bottom Cover from the MGB Main case, it is necessary to disconnect the MGB assembly from its Trolley Support .

Anti-Torque Beam


Bottom Cover

HE-04-00, or 3G6320A00131A188B, or 3G6320A00331A188E, or equivalent


7 of 12

5.4.1 - Anti-Torque Beam, removal procedures CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. Support Equipments: Upper Module Nomenclature

Identification No.


3G6320A00131A181A

Lifting device

Local supply

MGB Main Case

Standard Screw Extractors

Anti-Torque Beam removed, Main Case – Stud detail RH

Main Case

RH

Anti-Torque Beam Nylon Screw

LH

Nylon Screw (x 2) Washers + Nut (x 23)

Washers + Nut

LH

Anti-Torque beam, looking from the bottom view


8 of 12

5.4.2 - Bottom Cover , removal procedures CR&OP Data Module: 39-A-63-20-05-00A-530A-C

Support Equipments:

Nomenclature Main Case

Identification No.

Lifting tool, main 3G6320A00131A181A gearbox

O-ring O-ring

Lifting device

Local supply

Extractor, drive quill

3G6320A00331A029G

Bottom Cover

Nylon Screw (x 3)

O-ring Slip ring

Washers + Nut (x 13)

Retaining ring Bottom Cover


9 of 12

Bottom Cover removed

5.4.3 - Retaining ring and Slip ring, removal procedures CR&OP Data Module: 39-A-63-20-05-00A-530A-C

Support Equipments:

Nomenclature

Identification No.

Extractor tool, retaining ring

3G6320A00331A023R

Removal tool, slip ring

3G6320A00331A023Q

O-ring O-ring Bottom Cover

Nylon Screw (x 3)

O-ring Slip ring


Retaining ring


10 of 12

5.5 - Installation of the Main Case on the Support Trolley

CR&OP Data Module: 39-A-63-20-05-00A-530A-C Support Equipments: Main Case Assembly

Nomenclature

Identification No.

Trolley, main case maintenance

3G6320A00131A188C

Main Case Assembly Support

Maintenance Trolley Side View


Front View

11 of 12

Chapter 5 - Pre-Disassembly Procedures

THE END



MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 6 - Disassembly Procedures

6 – MGB Disassembly Procedures

INDEX

6.1 6.2

6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12

Left and Right Input Shaft Module removal and Cross Shaft disassembly procedures Main Case Assembly - External components (Plugs, Covers, Sensors, Filter element, Servo Supports, Chip Detectors, Oil Level gauge, Borescope Port, Lubrication Pumps, Check Valves, PRV,) , removal procedures. Main Case Oil Jets, removal procedures. Upper Module, Oil Unions and Planetary Crown (fixed ring gear), removal procedures. Main Case, Backlash Check. Drive Quills (LH/RH/Front Hyd. Pumps, ECS-Compressor and Fan drive quill), removal procedures. LH and RH Input Pinion Assembly (II° stage of reduction), removal procedures. LH and RH Input Pinion Assy (II° stage of reduction), disassembly procedures. Tail Rotor Drive Quill Assembly, removal procedures. Tail Rotor Drive Quill Assembly, disassembly procedures. Diaphragm, Oil Jets and Roller Bearing, removal procedures. Collector Gear and Collector Bearing, removal procedures. (Cont’s)


2 of 126

6 – MGB, Disassembly procedures 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27

Main Case Assembly - Internal components (Roller Bearings, Shims and Outer Race of the Roller bearing), removal procedures. Left and Right Input Shaft Module, disassembly procedures – Ref. documentations Freewheel Group Assembly, removal and disassembly procedures. Input Shaft Module, Backlash Check. Input Shaft Module – Input Drive Quill Group, removal procedures Input Drive Quill Group, disassembly procedures. Input Shaft Module – Gear (I° Stage of reduction), removal and disassembly procedures Upper Module, disassembly procedures Mast-Planetary Assembly – Disassembly procedures. Planetary Gears Assembly – Disassembly procedures. LH & RH Lubrication Pumps – Disassembly procedures. ECS Compressor Drive Quill – Disassembly procedures. FAN Drive Quill – Disassembly procedures. Front Hyd. Pump Drive Quill – Disassembly procedures. LH & RH Hyd. Pump Drive Quill (No.1 and No. 2) – Disassembly procedures.


3 of 126

6.1 - Left and Right Input Shaft Module Removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Notes:

The removal procedure used for LH Input Module is also applicable for RH Input Module.

Support Equipments: Std Screw Extractors Main Case

O-ring Plug Cross Shaft LH Input Shaft Module Union

Cross Shaft Washers

O-rings

Washers Washers Nuts Bracket

Nuts Bracket

Washers + Nuts Bracket


4 of 126

Washers NutsWashers Set screw (Nylon)

6.1.1 - LH and RH Cross Shaft, disassembly procedures CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Cross Shaft

Support Equipments: Std Tools Plug

Input Shaft Module


Input Shaft Module (inner side)

5 of 126

Plug

6.2 – Main Case , External Components (Plugs, Covers, Sensors, Filter element, Servo Supports, Chip Detectors, Oil level gauge, Lub. Pumps, Check Valves, PRV) removal Engine 2 Inlet (Drive Shaft)

Details

Engine 1 Inlet (Drive Shaft)

Front Side

A – Input Shaft Module (1 & 2) B - Hydraulic Pump (1 & 2) Drive Quills C - ECS Compressor Drive Quill D - Hydraulic Pump (front) Drive Quill E - AC Generator Drive Cover (2 positions) F - Oil Level Gauge G - Oil Filter case H – Low Oil Level Sensor I – Draining Pipe J – Plugs K - Rotor Speed Sensor (NR) L – Front Servo Support M – Left Servo Support N – Right Servo support O – Borescope port P – Check Valves (2 positions) Q – Pressure Relief Valve (PRV) R – Chip Detectors (2 positions) S – Washer and Screw (3 positions) T – Plug (Flange) U – Lubrication Pump (2 positions) V – Fan Drive Quill

CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Rear Side


6 of 126

6.2 Detail B - (No. 1 & No. 2 Hyd. Pump drive quill), external components removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. B

Components removed: B Nylon Screw

- Nylon Screws (2 positions) - Plug

Front Side

Hydraulic Pump Drive Quill

Plug


7 of 126

6.2 Detail C - (ECS Compressor drive quill), external components removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. Seal Lip Cover Seal O-ring Plug

C

ECS Compressor Drive Quill

Retaining Ring

Components removed: - Plug - Retaining Ring - Seal Cover + O-ring - Lip seal - Nipple or Plug (Oil drain) Support Equipments:

Front Side


8 of 126

Nomenclature

Identification No.

Removal tool, seal cover

3G6320A00731A029E

Extractor tool, lip seal

3G6320A00731A029D

6.2 Detail D – (Front Hyd. Pump drive quill), external components removal

CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Components removed: D Hydraulic Pump Drive Quill

Nylon Screw

Plug

Front Side


9 of 126

- Plug - Nylon Screw (2 positions)

6.2 Detail E - AC Generator Drive Cover, Shim and Plug removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Support Equipments: E E

Nomenclature

Identification No.

Extractor tool, generator drive cover

3G6320A00132A029A

Screw Shim O-ring Nut, Washers

AC Generator Drive Cover

O-ring Plug

Front Side


10 of 126

6.2 Detail F - Oil Level gauge removal

CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox – Disassemble procedures.

F Oil level gauge disassembled

Oil level Gauge Nuts + Washers

Front View, LH side


11 of 126

6.2 Detail G - Oil filter head, Oil Filter Element, Anti-spill Valve, Oil press. Sensor, Oil Temp. Sensor and Oil Temp. Switch removal References: Oil Pressure sensor

CR&OP: 39-A-63-20-05-29A-520A-C Oil filter element (main gearbox) - Remove procedures AMP: 39-A-63-41-05-00A-920A-A Oil temperature sensor – Replacement AMP: 39-A-63-41-06-00A-920A-A Oil pressure sensor - Replacement AMP: 39-A-63-41-07-00A-920A-A Oil temperature switch - Replacement

Oil Temp. sensor

Components removed: Oil Filter Head

Anti-Spill Valve

Oil Temp. Sw

Oil Filter element

Oil Filter Case

OUT

Oil

IN Cooler Pop-Out + Caution alarm Switch Tsw

Ts

Ps

Oil Filter Head


12 of 126

- Oil Filter Head - Oil Filter Element - Anti-spill Valve - Oil Temp. Switch (Tsw) - Oil Temp. Sensor (Ts) - Oil Press. Sensor (Ps)

6.2 Detail H - Low Oil Level Sensor removal

CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures

H Low Oil Level Sensor

Front View, RH side


13 of 126

6.2 Detail J - Plugs removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures

J

Plug J

Plug


14 of 126

6.2 Detail K - Rotor Speed Sensor (NR) removal

CR&OP Data Module:

K

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures O-ring

Washer Nut

K Rotor Speed Sensor

Front View, LH side


15 of 126

6.2 Details L, M, N - Front Servo Support, Left Servo Support and Right Servo Support removal CR&OP Data Module: N

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. M

Support Equipments:

L

Nomenclature

Identification No.

Extractor tool, servo support

3G6320A00331A029N

Screw + Washer(4)

Front Servo Support

L

L

L

Setscrew (2)

M

LH Servo Support


RH Servo Support 16 of 126

N

L

6.2 Detail O - Borescope Port removal O

CR&OP Data Module: O-ring Washers

Screws

O

Borescope Port

Rear View, LH side


17 of 126


6.2 Detail P - Check Valves removal CR&OP Data Module:

39-A-63-20-05-00A-530A-C Main gearbox Disassemble procedures.

P P

Check Valve Plug

P

O-ring O-ring Check Valve Retaining ring


18 of 126

Rear View

6.2 Detail Q - Pressure Relief Valves removal CR&OP Data Module:

Q PRV

39-A-63-20-05-00A-530A-C Main gearbox Disassemble procedures. PRV

O-ring O-ring

Q Q

Rear View

Rear View


19 of 126

6.2 Detail R - Chip Detectors removal CR&OP Data Module: R Chip Detector

39-A-63-20-05-00A-530A-C Main gearbox Disassemble procedures.

O-ring Chip Detector Valve O-ring

Chip Detector Valve

Rear View

R

R R


20 of 126

Chip Detector

6.2 Details S, T - Washers, Screws and Flange removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox Disassemble procedures.

S S

Flange

T

S Rear View – LH side

Rear View – RH side Nylon Screw

S

Nut

T

Flange

Flange O-ring

Washer + Screw Washer

S

S

Washer

S

T Rear View – LH side

Rear View


21 of 126

Rear View – RH side

6.2 Detail U - LH and RH Lubrication Pump removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox Disassemble procedures.

U

Support Equipments:

Nomenclature

Identification No.


3G6320A00331A029G

Rear View RH Lubrication Pump removal

Washers + Nut

U Nylon Screw (3) O-rings

Lub. Pump

Rear View – RH Lubrication Pump Extractor tool installation Rear View – LH Lubrication Pump


22 of 126

Rear View – RH Lubrication Pump

6.2 Detail V - (Fan Drive quill), external components removal CR&OP Data Module: V

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. Components removed: - Plug - Seal Cover Support Equipments:

Rear View


23 of 126

Nomenclature

Identification No.

Extractor tool, seal cover

3G6320A00331A029L

6.3 - Fifteen (from No. 1 to No. 13) Oil Jets removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. Components removed: - Filter - Oil Jet - O-ring - Screw + Washer Support Equipments: Top View

Nomenclature

Identification No.

applicable plastic scraper

Local supply

Oil Jets

Oil Jets

Filter O-ring Screw + Washer

Filter O-ring Screw + Washer

Rear View O-ring

O-ring O-ring

O-ring O-ring


24 of 126

6.4 - Upper Module, Oil Unions and Fixed ring Gear Assy removal Oil Union “A” (x4)

Upper Module Assy

D Oil Union “B”

C

CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures.

B

Support Equipments: A / A1 Nylon Screw (x 3)

Side View

Main Case

A / A1

Planetary Crown (Fixed Ring Gear)

Details B Nut Washer Bracket

Nut Washer Bracket

6 pos. 1 pos. C Nut D Nut Washer Bracket

1 pos.

Washers

22 pos.

Top View


25 of 126

Nomenclature

Identification No.


3G6320A00131A181A

Lifting device

Local supply

Trolley, upper module support

3G6320A00231A188B

6.4.1 - Oil Unions removal CR&OP Data Module:

Oil Union “A” (x4)


39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. Support Equipments:

Oil Union “B”

Nomenclature

Identification No.

Extractor tool, oil union 3G6320A00131A029A “A” “A” “A”

Main Case

“A”

“A” “B”

Oil Union (5 positions)


26 of 126

6.4.2 - Planetary Crown (Fixed Ring Gear) removal Planetary Crown (external view)

Planetary Crown (Removal)

Collector Gear

Diaphragm Tool installation

Planetary Crown (inner view)

Support Equipments Nomenclature

Identification No.

Lifting device

Local supply

Disassembly tool, planetary crown

3G6320A00231A029F


27 of 126

6.5 - Main Case, Backlash check

Backlash check required RH Input Pinion II° Stage Collector Gear Hyd. Pump No. 2

Check of the backlash between:

CR&OP Data Module:

Collector Gear and the Input Pinions (LH/RH) II° Stage

39-A-63-20-05-00A-713A-C Main gearbox - Backlash/gear pattern check, Para. 2

Collector Gear and Tail-Rotor Drive Quill


Collector Gear and Compressor Drive Quill

ECS-


Collector Gear and Front Hyd. Pump Drive Quill


Left/Right Input Pinion II° Stage and Left/Right Pump Drive Quill (Hyd. Pump No. 1 & No. 2)


Tail-Rotor Drive Quill and Fan Drive Quill


Main Case Fan Drive Quill Tail-Rotor Drive Quill

Hyd. Pump No. 1 ECS Compressor Drive Quill

Front Hyd. Pump


LH Input Pinion II° Stage

28 of 126

6.5.1 - Main Case, Backlash tool (Collector gear) installation CR&OP Data Module: 39-A-63-20-05-00A-713A-C Main gearbox - Backlash/gear pattern check, Para. 1

Nomenclature

Identification No.

Backlash tool, collector gear

3G6320A00331A676L

Dial gauge

Local supply

Support Equipments:

Legend: Item No.


29 of 126

Nomenclature

1

Dial Gauge Support (3)

2

Tool Top section

3

Knobs (4)

4

Bolt

5

Nylon Split Ring

6

Bolts (4)

7

Registers (2)

8

Retainers

9

Bolts (2)

10

Wrench (Torque application point)

11

Expander

12

Tool Bottom Section

13

Torque application point

14

Collector Gear

6.5.2 - MGB (Collector gear) Top Tool Section installation 7

1

Register Expander, installation 6 Wrench

2

Retainer

Tool Top Section, installation 3

Nylon Split Ring

Bolts 5

4

Collector Gear

Knobs


30 of 126

6.5.3 – MGB, (Collector gear) Tool Bottom Section installation

10

8

9


31 of 126

6.5.4 – MGB, Backlash tool (Collector gear), torque wrench application and Collector Gear levelness check 11

Top Section

13

Bolts

Register (2 positions)

Dial gauges (3 positions)

Bottom Section

Note:

12

Lock the Collector Gear with the Expander as required.

Note: Use the two Registers to adjust the levelness as required. Tighten the Bolts as required.

Note: Push the tool bottom section up as required.


32 of 126

6.5.5 - Backlash check between the Collector Gear and the Input pinions CR&OP Data Module:

Input Pinion

39-A-63-20-05-00A-713A-C Main gearbox Backlash/gear pattern check, Para. 2 Support Equipments: Nomenclature

Identification No.

Backlash tool, input pinions

3G6320A00331A676B

Dial gauge

Local supply Note: - Lock the tool expander. - Pull the input pinion externally as required. - Measure and record the backlash in three positions, 120˚ apart. - Perform this action on both Input pinions.

Input Pinion Backlash Tool installation

LH Input Pinion II° Stage, Backlash Tool installation


RH Input Pinion II° Stage, Backlash Tool installation 33 of 126

6.5.6 - Backlash check between the Collector Gear and the Tail-Rotor Drive Quill Tail Rotor Drive Quill, Backlash Tool installation

CR&OP Data Module: 39-A-63-20-05-00A-713A-C Main gearbox - Backlash/gear pattern check, Para. 3 Support Equipments: Nomenclature

Identification No.

Backlash tool, tail rotor 3G6320A00331A676C drive quill Dial gauge Tail Rotor Drive Quill

Output Pinion

Local supply

Note: - Lock the tool expander. - Push the pinion internally as required. - Measure and record the backlash in three positions, 120˚ apart.


34 of 126

6.5.7 - Backlash check between the Collector Gear and the ECS-Compressor Drive Quill CR&OP Data Module: ECS Compressor Drive Quill

39-A-63-20-05-00A-713A-C Main gearbox - Backlash/gear pattern check, Para. 4 Support Equipments:

ECS Compressor Drive Quill, Backlash Tool installation

Nomenclature

Identification No.

Backlash tool, ECScompressor drive quill

3G6320A00331A676E

Dial gauge

Local supply



35 of 126

6.5.8 - Backlash check between the Collector Gear and the Front Hyd. Pump drive quill CR&OP Data Module: Front Hyd. Pump Drive Quill


Front Hyd. Pump, Backlash Tool installation

Nomenclature

Identification No.

Backlash tool, front pump drive quill

3G6320A00331A676H

Dial gauge

Local supply



36 of 126

6.5.9 - Backlash check between the Left/Right Input Pinion II° Stage and the Left/Right Pump (Hyd. Pump No. 1 & No. 2) Drive Quill CR&OP Data Module: 39-A-63-20-05-00A-713A-C Main gearbox Backlash/gear pattern check, Para. 6 Support Equipments: Left/Right Pump (Hyd. Pump No. 1 and No. 2) Drive Quill, Backlash Tool

Nomenclature

Identification No.

Backlash tool, left and right pump drive quill

3G6320A00331A676D

Dial gauge

Local supply Note: - Lock the tool expander. - Pull the pinion externally as required. - Measure and record the backlash in three positions, 120˚ apart. - Perform this action on both Hyd. Pumps.

Left/Right Pump (Hyd. Pump No. 1 and No. 2) Drive Quill

Left Pump (Hyd. Pump No. 1) Drive Quill


Right Pump (Hyd. Pump No. 2) Drive Quill 37 of 126

6.5.10 - Backlash check between the Tail-Rotor Drive Quill and the Fan Drive Quill CR&OP Data Module: 39-A-63-20-05-00A-713A-C Main gearbox Backlash/gear pattern check, Para. 7 Support Equipments:

Fan Drive Quill, Backlash Tool Fan Drive Quill


38 of 126

Nomenclature

Identification No.

Backlash tool, fan drive quill

3G6320A00331A676F

Dial gauge

Local supply Note: - Lock the tool expander. - Pull the pinion externally as required. - Measure and record the backlash in three positions, 120˚ apart.

6.6 - Drive Quills (Hyd. Pumps, ECS- Compressor and Fan) removal Engine 2 Inlet (Drive Shaft)

Details B - LH/RH Hydraulic Pump Drive Quills C - ECS Compressor Drive Quill D - Front Hydraulic Pump Drive Quill V - Fan Drive Quill Engine 1 Inlet (Drive Shaft)

CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures


39 of 126

6.6.1 - Hydraulic Pump (No. 1 & No. 2) Drive Quill removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures

B

B Screw (2)

B

Screw (3)

Nylon Screw (2)

Support equipment:

Hyd. Pump Drive Quill

Nomenclature

Identification No.


3G6320A00331A029G

3

O-ring Shim

2 1

Extractors installation

Screws removal


40 of 126

Shim

6.6.2 - ECS-Compressor Drive Quill removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. C Screw (3)

Support equipment: O-ring C Shim

Screw (2) Setscrew (3)

ECS- Compressor Drive Quill



41 of 126

Nomenclature

Identification No.


3G6320A00331A029G

6.6.3 - Front Hyd. Pump Drive Quill removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures D

Support equipment: Shim Screw (3) D Setscrew (2) O-ring

Screw (2)

Hyd. Pump Drive Quill



42 of 126

Nomenclature

Identification No.


3G6320A00331A029G

6.6.4 - Fan Drive Quill removal CR&OP Data Module: V

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures

Nut, Washer (3)

Support equipment:

Seal-Cover O-ring Lip-Seal

Nomenclature

Identification No.

V


3G6320A00331A029G

Screw Shim Fan Drive Quill 1


43 of 126

2

6.6.5 - Drive Quills removed

LH Hyd. Pump Drive Quill

RH Hyd. Pump Drive Quill


Front Hyd. Pump Drive Quill

44 of 126

ECS- Compressor Drive Quill

Fan Drive Quill

6.7 - LH & RH Input Pinion Assembly (II° Stage of reduction), removal CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Support equipment:

Bearing Sleeve Main Case

“V” incision

O-ring

Nomenclature

Identification No.

Extractor, input pinions

3G6320A00331A029F

Input Pinion II° Stage 1

Bearings Spacer Nuts, Washers (parts to be removed) Retaining Ring

Pump gear

Retaining Ring Pump gear Locking Ring Locking Washer

Nuts, Washers Input Pinion Assembly installed inside the Main Case (RH Side) 2 LH and RH Input Pinion Assembly removed


45 of 126

6.8 - LH & RH Input Pinion Assembly (II° Stage), Disassembly CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Support equipment:

Bearing Sleeve Main Case

“V” incision

O-ring

Input Pinion II° Stage

Bearings Spacer Nuts, Washers

Retaining Ring

Pump gear

Identification No.

Installation tool, input pinions

3G6320A00331A023W

Removal tool, pump gear

3G6320A00331A029R

Removal tool, pinion

3G6320A00331A029O

Removal tool, bearings

3G6320A00331A029P

Retaining Ring

Locking Ring


Nomenclature

Locking Washer

46 of 126

Note Details of the Input Pinion Assembly disassembled are available on the next page.

6.8.1 - Details of the Input Pinion Assy disassembled Inner side of the Pinion

External side of the Pinion

O-ring


Bearing Sleeve


Bearings

Spacers

Pump gear Retaining Ring


47 of 126

6.9 - Tail-Rotor Drive Quill Assembly, removal CR&OP Data Module:

Nut + Washer (8)

Nylon Screw (3)

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures Support equipment:

Rotor Brake Housing

Main Case

Tail Rotor Drive Quill Assembly

2

Nomenclature

Identification No.


3G6320A00131A188C

Lifting device

Local supply

Extractor, tail rotor drive quill

3G6320A00331A029I

Lifting tool, pinion assembly

3G6320A00331A026M

1 3

Main Case rotated


48 of 126

Tools installation

TRDQ Assembly removed

6.10 - Tail-Rotor Drive Quill Assembly, disassembly procedures CR&OP Data Module: 39-A-63-20-05-28A-530A-C Tail rotor drive quill (main gearbox) Disassemble procedures Retaining ring Locking washer Locking ring Ring Flange Retaining ring O-rings Seal case

Nut + Washer

Seal

Rotor brake case O-ring Shim

Nipple

Retaining ring

Screw

Locking washer Locking ring

Flanged bearing (spherical) O-rings

Nomenclature

Identification No.

Reaction tool, pinion

3G6320A00331A023Z

Extractor tool, locking washer

3G6320A00431A029C

Wrench

3G6320A00331A026F

Removal tool, flange

3G6320A00331A028A

Removal tool, seal cover

3G6320A00331A029Y


3G6320A00331A029W

Gear Shim Retaining ring Locking washer Locking ring

Removal tool, rotor brake 3G6320A00331A029U case

Bearing inner race (roller) Pinion

Support equipment:

Plug

O-ring

Bearing cage

Removal tool, flanged bearing

3G6320A00331A029V

Wrench

3G6320A00331A026B

Removal tool, gear

3G6320A00331A029T

Wrench

3G6320A00331A026A

Removal tool, bearing

3G6320A00331A029S

Plug Pinion


49 of 126

6.10.1 - Tail-Rotor Drive Quill Assembly , disassembly procedures – Step 1

STEP 1 Put the Tail-Rotor Drive Quill on the Reaction Tool attached to an applicable work table.

Support equipment:


50 of 126

Nomenclature

Identification No.


3G6320A00331A023Z

6.10.2 - Tail-Rotor Drive Quill Ass. , disassembly procedures – Steps 2 ÷ 7 Pinion

STEPS 2 ÷ 7

Retaining ring Locking washer Locking ring Ring Flange Retaining ring Seal cover

(3G6320A00331A026F) (3G6320A00431A029C)

Removal Tool (3G6320A00331A028A)

Detail B

Detail A


2 - Remove the Retaining Ring (1) from the pinion. 3 - Remove the Locking Washer (2) from the pinion. Use the Extractor Tool No. 3G6320A00431A029C (see Detail A) 4 - Remove the Locking Ring (3) from the pinion. Use the Wrench No. 3G6320A00331A026F (see Detail B). 5 - Remove the Ring (4) from the pinion. 6 - Remove the Flange (5) from the pinion and from the Seal Cover (7). Use the Removal Tool No. 3G6320A00331A028A (see Detail C). 7 - Remove the assembled pinion from the Reaction Tool No. 3G6320A00331A023Z.

Detail C 51 of 126


STEPS 8 ÷ 13

Retaining ring Seal case O-rings

Nut + Washer

Lip Seal

Rotor brake case O-ring Shim Flanged bearing (spherical)

Nipple

Screw

Extractor Tool (G6320A00331A029W)

8 - Remove the Retaining Ring (6) from the Rotor-Brake Case (11). 9 - Remove the Seal Case (7) from the RotorBrake Case (11). Use the Removal Tool No. G6320A00331A029Y (see Detail D). 10 Remove the O-rings (8) and (9) from the Seal Case (7). 11 - Remove the Lip Seal (10) from the Seal case (7). Use the Extractor Tool No. 3G6320A00331A029W (see Detail E). 12 - Remove the six Nuts (15) and the six Washers (16). 13 - Remove the Rotor-Brake Case (11) from the Flanged bearing (17). Use the Removal Tool No. 3G6320A00331A029U as required (see Detail F). Removal Tool (G6320A00331A029U)

Removal Tool (G6320A00331A029Y)

Detail E

Detail D


52 of 126

Detail F


STEPS 14 ÷ 16 14 - Remove the three Screws (14A) and the Shim (14) from the Rotor Brake Case (11). 15 - Remove the Nipple (13) and the O-ring (12) from the Rotor Brake Case (11). 16 - Remove the Flanged Bearing (17) from the pinion. Use the Removal Tool No. 3G6320A00331A029V with Press (locally supply) as required. See Detail G.

Nut + Washer

Rotor brake case O-ring Shim Flanged bearing (spherical)

Removal Tool (G6320A00331A029V)

Nipple

Screw

Detail G


53 of 126

6.10.5 - Tail-Rotor Drive Quill Ass. , disassembly procedures – Steps 17 ÷ 20 STEPS 17 ÷ 20 Retaining ring Locking washer Locking ring Gear Shim

Pinion

17 - Remove the retaining ring (18) and the locking washer (19) from the Pinion (30) or (30A). Use the Extractor Tool No. 3G6320A00431A029C (see Detail H). 18 - Remove the Locking Ring (20) from the Pinion (30) or (30A). Use the Wrench No. 3G6320A00331A026B (see Detail I). 19 - Remove the Gear (21) from the Pinion (30) or (30A). Use the Removal Tool No. 3G6320A00331A029T (see Detail J). 20 - Remove the Shim (22) from the Pinion (30) or (30A). Removal Tool (3G6320A00331A029T)

Pinion

(3G6320A00431A029C) (3G6320A00331A026B)

Detail H


Detail I 54 of 126

Detail J

6.10.6 -Tail-Rotor Drive Quill Ass., disassembly procedures – Steps 21 ÷ 26 STEPS 21 ÷ 26 21 - (Main gearbox P/N 3G6320A00132). Remove the Bearing Inner Race (28) from the Pinion (30) as follows: 21.1 Remove the Retaining Ring (23) and the Locking Washer (24) from the Pinion (30). Use the Extractor Tool No. 3G6320A00431A029C (see Detail K). 21.2 Remove the Locking Ring (25) from the pinion (30). Use the Wrench No. 3G6320A00331A026A (see Detail L). 21.3 Remove the Bearing Inner Race (28) from the Pinion (30). Use the Removal Tool No. 3G6320A00331A029S (see Detail M). 21.4 Remove the Pinion (30) from the Reaction Tool.

O-rings

Retaining ring Locking washer Locking ring Bearing inner race (roller) Pinion

Plug

O-ring Bearing cage

Plug

Pinion

(3G6320A00431A029C)

24 (Main gearbox P/N 3G6320A00132). Remove the Plug (29) from the Pinion (30). 25 (Main gearboxes P/N 3G6320A00133 and subsequent P/N with different last two digits). Remove the Plug (29A) from the Pinion (30A). 26 (Main gearboxes P/N 3G6320A00133 and subsequent P/N with different last two digits). Remove the O-ring (33) from the Plug (29A).

Tool (G6320A00331A026A)

Detail K


22 (Main gearboxes P/N 3G6320A00133 and subsequent P/N with different last two digits). Remove the Bearing Cage (28A) from the pinion (30A). 23 Remove the O-rings (31) and (32) from the pinion (30) or (30A).

Detail L 55 of 126

Removal Tool (3G6320A00331A029S) Detail M

6.11 - Diaphragm, Oil Jets and Roller Bearing removal Nuts, Washers

CR&OP Data Module:

Screws (14)

Diaphragm


Roller Bearing Bolts Collector Gear

Support equipment:

Oil Jets pre-mod.

Nomenclature

Identification No.

Extractor Tool

3G6320A00331A029I

Extractor tool, roller bearing 3G6320A00331A029A

A

Oil Jets post-mod.


56 of 126

6.11.1 - Diaphragm removal

1a

Screws (14)

Diaphragm

3 Oil Jets pre-mod. Roller Bearing Collector Gear

1b Diaphragm removed from the Main Case

2

Oil Jets post-mod.

Extractor Tool installation


57 of 126

6.11.2 – Oil Jets removal

Diaphragm

Oil Jets pre-mod.

Oil Jets post-mod.


58 of 126

6.11.3 – Roller Bearing removal (A) Diaphragm Roller Bearing

+

Diaphragm

Roller Bearing

(B) Roller bearing removed Nuts, Washers

Upper side

Extractor tool, roller bearing (3G6320A00331A029A)


59 of 126

6.12 - Collector Gear removal CR&OP Data Module:

Collector Gear Bolts

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures

Collector Bearing

Support equipment: Locking Ring Locking Washer

(B) Note:

Identification No.

Removal tool, collector gear

3G6320A00331A029E

Lifting device

Local supply

Retaining Ring

Retaining Ring installed on MGB P/N 3G6320A00135 only

Collector Gear Retaining Ring

Nomenclature

3 2 Main Case

Washers Nuts


1

60 of 126

6.12.1 - Collector Bearing and Retaining Ring removal CR&OP Data Module: Collector Gear

Main Case

Collector Bearing

Bolts

39-A-63-20-05-00A-530A-C Main gearbox Disassemble procedures. Support equipment:

Locking Ring Locking Washer

(B) Note:

Retaining Ring


Nomenclature

Identification No.

Lifting tool, collector gear

3G6320A00331A181C

Lifting device

Local supply

Removal tool, Locking ring

3G6320A00331A023D

Removal tool, collector bearing

3G6320A00331A023C

Hydraulic cylinder

Local supply


Washers Nuts


61 of 126

6.12.2 Retaining ring and Collector Bearing, View of the removal tools

Removal tool, Locking ring

3G6320A00331A023D


62 of 126

Removal tool, collector bearing

3G6320A00331A023C

6.13 - Main Case Ass., Internal Components removal – Step 1

Shim

Nuts + Washers

CR&OP Data Module:

Screws Shim

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. (Roller bearing 188), (Shim 193) and (Shim 187).

Screws

4

Shim (187) Roller Bearing

Support equipment: Identification No.

Extractor tool, roller bearing

3G6320A00331A029C

Note: Record the thickness of the shim

Roller Bearing (188)

1

Nomenclature

2

3

Shim (193)

Input Pinions II° Stage, installation side

Shim (193) Roller Bearing, removal


63 of 126

6.13 - Main Case Ass., Internal Components removal – Step 2 Screws

Main Case

CR&OP Data Module:

Nuts + Washers

Support equipment:


Nomenclature

Identification No.

Extractor tool, outer race roller bearing

3G6320A00331A029D

Shim

Screws

3 2

Outer Race of the roller bearing Tail Rotor Drive Quill location

1

Screws

Nuts + Washers Shim Main Case external view


Screws Main Case internal view


64 of 126

Main Case external view

6.13 - Main Case Ass., Internal Components removal – Step 3 A Screws

Shim

CR&OP Data Module: 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures.

Hyd. Pump (No.1 and No.2) drive quill location



65 of 126

6.13 - Main Case Ass., Internal Components removal – Step 4 Fan drive quill location

Screws

A

CR&OP Data Module: Shim




66 of 126


CR&OP Data Module: Shim


Screws

Note: Record the thickness of the shim ECS drive quill location


67 of 126


CR&OP Data Module: Shim Screws

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. Note: Record the thickness of the shim

AC Generator drive covers location


68 of 126


CR&OP Data Module: Shim Screws

39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures. Note: Record the thickness of the shim

Front drive quill (Hyd. Pump No. 3) location


69 of 126

6.14 - LH and RH Input Shaft Module, disassembly procedures – Ref. documentations Engine 2 Inlet (Drive Shaft)

CR&OP Data Module:

Right input shaft module

39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures (Effectivity Code: B01) Engine 1 Inlet (Drive Shaft)

Or 39-A-63-20-05-01B-530A-C Left input shaft module (main gearbox) - Disassemble procedures (Effectivity Code: B02) Or 39-A-63-20-05-01C-530A-C Left input shaft module (main gearbox) - Disassemble procedures (Effectivity Code: B03)

Left input shaft module

Effectivity Codes: CR&OP Data Module: gearbox – General

39-A-63-20-05-00A-000A-C

- B01 : Input shaft module P/N 3K6320A00133 (installed on P/N 3G6320A00132 and 3G6320A00133) - B02 : Input shaft module P/N 3K6320A00135 (installed on P/N 3G6320A00134 and 3G6320A00135) - B03 : Input shaft module P/N 3K6320A00136 (installed on P/N 3G6320A00134, 3G6320A00135, 3G6320A00132 3G6320A00133)


70 of 126

And Main

MGB

39-A-63-20-05-02A-530A-C Right input shaft module (main gearbox) - Disassemble procedures Note

MGB MGB and

The disassemble procedures given for the leftinput shaft module are applicable to the rightinput shaft module. Refer to: – [B01], – [B02], – [B03] as necessary.

6.15 - Freewheel Group Assy, removal and disassembly procedures – Action No. 1 : Install the Input Module on the applicable Stand LH Input Shaft Module

CR&OP Data Module:

Thermocouple

39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) Disassemble procedures.

Freewheel Group

Support equipment:

Oil Pressure Switch

Nomenclature

Identification No.

Stand, backlash check

3K6320A00131A676A

Plastic Caps/Plugs Cotton gloves Oil Jet

Oil Jet Cover Oil Jet Cover

Oil Pressure Switch

Note Perform this action on both Input Shaft Modules. Use the specific Data Module

Thermocouple

RH Input Shaft Module


71 of 126

6.15 - Freewheel Group Assy, removal and disassembly procedures – Action No. 2 : Remove the Sealant and Clean the mating areas CR&OP Data Module: Oil Pressure Switch

39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures.

Support equipment: Oil Jets

Nomenclature

Identification No.

Plastic scraper

Local supply

Supplies:

Oil Jet Cover



72 of 126

Nomenclature

Identification No.

Cloth, soft lint free

C011

Solvent, cleaning

C010 (P-D-680 type II)


6.15 - Freewheel Group Assy, removal and disassembly procedures – Action No. 3 : Oil Jets, Thermocouple and Oil Pressure Switch removal LH Input Shaft Module

Screw + Washer Thermocouple

CR&OP Data Module: 39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures.

O-ring Screw Oil Pressure Switch

Thermocouple

Washer

Oil Jet O-ring Oil Pressure Switch




73 of 126

6.15 - Freewheel Group Assy, removal and disassembly procedures – Action No. 4 : Oil Jet Cover removal LH Input Shaft Module

CR&OP Data Module:


Freewheel Group

Support equipment: Nomenclature

Identification No.

Jackscrew, MGB

3G6005G00531


O-ring

Oil Jet Cover

1


Nuts + Washers

2

74 of 126

3

6.15 - Freewheel Group Assy, removal and disassembly procedures – Action No. 5 : Freewheel Group removed and disassembled LH Input Shaft Module

Freewheel Group Inner Bearing Oil Vane Input Shaft Freewheel Outer Bearing O-ring Spacer O-ring

CR&OP Data Module:


39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures. Support equipment: Nomenclature

Identification No.

Tool, clutch removal

3K6320A00131A029D

Tool, inner/outer bearing removal

3K6320A00131A029G

Arbor press

Local supply

Retaining ring

Freewheel Group disassembled


75 of 126

6.16 - Input shaft module – Backlash check CR&OP Data Module:

Left Input Shaft Module

39-A-63-20-05-01A-713A-C Left input shaft module (main gearbox) Backlash/gear pattern check Note Perform this action on both Input Shaft Modules. Use the specific Data Module. Record the backlash found between the Input Pinion and the Gear.

Gear, I° Stage of reduction

Support equipment: Flange

Input Pinion


76 of 126

Nomenclature

Identification No.


3K6320A00131A676A

Stopper, gear

3K6320A00131A023L

Backlash tool, input drive quill

3K6320A00131A676B

Dial gauge

Local supply

6.16.1 Input shaft module (main gearbox) – Backlash check, Procedures Left Input Shaft Module (1), Input side

A A

Stand (3K6320A00131A676A)

Stopper, gear (3K6320A00131A023L)

Procedure: 1 - Put the left input module (1) on the Stand. 2 - Install the Gear Stopper on the Stand. 3 - Lock the gear (2) in the left input module (1) with the Stopper. 4 - Install the Backlash Tool on the input side of the left input module (1). 5 - Lock the Backlash Tool to the flange (3). 6 - Do a check of the backlash between the gear (2) and the input pinion (4) as follows as required. Perform in phases, first by pulling and turning the Input pinion and second by pushing and turning the Input pinion. Note

Measure these value in three position at 120˚ to each other. Calculate for each condition the average value and then record these values are required.

Backlash tool, installation (3K6320A00131A676B)

B


Flange (3)

D

C Gear, 1° Stage of reduction (2) Input Pinion (4) Flange (3)


Dial gauge, installation 77 of 126

Backlash check

6.17 - Input shaft module, Input Drive-Quill Group removal CR&OP Data Module:

Input Drive-Quill Group

39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) Disassemble procedures.

Keys

Input Pinion

Bolt

Nut

Washer

Plug


Roller Bearing

Bearing Sleeve

Support equipment:

O-ring Duplex Ball Bearing

+

Plug

Nuts Nuts

Washers Retaining Spring

Gimbal

Nomenclature

Identification No.

Heat gun

Local supply

Jackscrew, MGB

3G6005G00531 Input DriveQuill Group removal

O-ring Carbon Seal

LH Input Shaft Module

O-ring

Locknut Flange Bushings

Ring O-ring Fitting

Carbon Seal

Spacer


78 of 126

Note Use the Heat Gun and increase the temperature (60÷70°C) of the LH Input Module locally in the housing area of the Input Pinion.

6.18 - Input drive-quill group - Disassembly procedures Action No. 1: Locknut, Flange, Gimbal, Bushing, Carbon Seal Assy removal Bushings (already removed)

Locknut

A

Gimbal

Gimbal

Flange

Retaining Spring

Carbon Seal Ring

Retaining Spring

Plug O-ring

O-ring

Locknut Flange

CR&OP Data Module: 39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures.

Bushings

O-ring

Support Equipment:

Nomenclature

Identification No.

Reaction, locknut removal

3K6320A00131A023F

Wrench

3K6320A00131A023P

Tool, pinion support

3K6320A00131A023B

Tool, flange removal

3K6320A00131A029E

Tool, Gimbal removal

3K6320A00131A029F

Tool, carbon seal removal

3K6320A00131A023T

Tool, bushing removal

EA6305G630-041

Puller, mating ring

GJ-06-01

Fitting

Pinion Mating Ring Bearing Sleeve Spacer


B

C D

E

Pinion

Locknut removal

Gimbal removal


79 of 126

Carbon Seal removal

Bearing Sleeve Ring removal

6.18 - Input drive-quill group - Disassembly procedures Action No. 2: Bushings removal CR&OP Data Module: 39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures.

Support Equipment:


80 of 126

Nomenclature

Identification No.

Tool, bushing removal

EA6305G630-041

6.18 - Input drive-quill group - Disassembly procedures Action No. 3: Pinion, Duplex Ball Bearing and Bearing Sleeve disassembly CR&OP Data Module: 39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures. Support Equipment: Duplex Ball

Two Keys Plug Pinion

Bearing Bearing Sleeve O-ring

1

Nomenclature

Identification No.

Tool, bearing sleeve removal

3K6320A00131A029B

Arbor press

Local supply

Bearing race removal

3K6320A00131A029A

Bearing Sleeve + Bearings

2

Procedure

Keys

Disassemble the input drive-quill group. To do this obey the instructions that follow: - Remove the input pinion (60) from the duplex ball bearing (49) and bearing sleeve (47) group. Use the Tool No. 3K6320A00131A029B. - Remove the plug (60A) from the input pinion (60). Remove the duplex ball bearing (49) from the bearing sleeve (47) as required. Use tool P/N 3K6320A00131A029A and the Arbor Press as necessary.

Items disassembled

3


81 of 126


6.18 - Input drive-quill group - Disassembly procedures Action No. 4: Roller Bearing Removal CR&OP Data Module:

Bolt Washer

39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures

Roller Bearing

Nut

Support Equipment: Nomenclature

Identification No.

Tool, roller bearing removal

3K6320A00131A029M



Left Input Shaft Module, Input side


82 of 126

6.18 - Input shaft module Action No. 5 : Shim (input side) removal CR&OP Data Module: Shim

Screw





83 of 126

6.19 - Input Shaft Module – Gear (I° Stage of reduction). Removal and disassembly procedures Bolts + Washers Flanged Roller Bearing

CR&OP Data Module:

Diaphragm

Bolts

Oil dam Nuts + Washers

39-A-63-20-05-01A-530A-C Left input shaft module (main gearbox) - Disassemble procedures

O-ring

Support Equipment: Nomenclature

Gear, 1° Stage of reduction

Diaphragm, standard extractor Locally supply

Nuts + Washers

Shim

Flanged Ball Bearing Bolts Lock ring

Screws

Lock nut


84 of 126

Identification No.

Reaction, lock nut removal (see next page)

3K6320A00131A023H

Wrench (see next page)

3K6320A00131A023I

Pusher

3K6320A00131A029C

Tool, gear support

3K6320A00131A023D

Puller, oil dam

3K6320H02331


6.19.1 Input Shaft Module – Gear (I° Stage of reduction). DWG of the Reaction, Wrench and Pusher tools used


85 of 126

6.19.2 - Input Shaft Module – Gear (I° Stage of reduction). View of the parts removed 1

6

Tools installation, Lock nut removal

Diaphragm Assembly removal 2

Gear, 1° Stage of reduction – looking from the base of the ISM 3

Diaphragm & Bearing removed

Flanged ball Bearing

7

12

Gear Shim

Lock ring & Lock nut removed

Bearing

5

8

Lock ring

Lock nut

Gear, 1° Stage of reduction

9

4

11

Outer Race of the Flanged Bearing 10

Roller Bearing removal Oil dam & O-ring removed from the Gear


86 of 126

6.20 - Upper Module, disassembly procedures (Main Components)

CR&OP Data Module: Top Case

39-A-63-20-05-03A-530A-C Upper module (main gearbox) Disassemble procedures Upper Module Assembly

Mast-Planetary assembly Note Planetary Crown (Fixed Ring Gear) already removed.

Packing Planetary Crown (Fixed Ring Gear)


87 of 126

6.20 - Upper Module, disassembly procedures Action No. 1: Make sure that Upper Module is installed on the Support CR&OP Data Module: 39-A-63-20-05-03A-530A-C Upper module (main gearbox) Disassemble procedures.

Support equipment:


88 of 126

Nomenclature

Identification No.

Support trolley

3G6320A00231A188B

6.20 - Upper Module, disassembly procedures Action No. 2: Ident. Plate, Cond. Jumper, Mast Cover removal CR&OP Data Module: Mast Cover Packing Upper Module

Mast-Planetary assembly

Identification plate

Lightning Conductor Jumper

39-A-63-20-05-03A-530A-C Upper module (main gearbox) Disassemble procedures.


Identification No.

Blade, sharp (for Id. Plate)

Local supply

Extractor (For Mast Cover)

3G6320A00231A029E

Lifting tool (Upper fittings )

3G6320A00231A181B

Lifting tool (Gear Ring)

3G6320A00131A181A

Lifting device

Local supply

Work trolley

3G6320A00231A188A

Supplies: Nomenclature

Cloth, soft lint free C011

Upper Fittings (4)

Solvent, cleaning


Identification No.

89 of 126

C010 (P-D-680 type II)

6.20 - Upper Module, disassembly procedures Action No. 3: Chip Detector Valve and Oil Filler Neck removal CR&OP Data Module: 39-A-63-20-05-03A-530A-C Upper module (main gearbox) Disassemble procedures.

Oil Filler plug

O-ring

Chip Detector O-ring Chip Det. Valve

Oil Filler Neck O-ring

O-ring

Oil drain cup


90 of 126

6.20 - Upper Module, disassembly procedures Action No. 4: Four Oil Jets removal CR&OP Data Module: 39-A-63-20-05-03A-530A-C Upper module (main gearbox) - Disassemble procedures.

2 Oil Jets No. 1

A

B

C

D

2 Oil Jets No. 2 Screw + washer

Oil jet filter O-ring

Oil Jets No. 1 and No. 2 O-ring O-ring Oil Jets No. 1 and No. 2 removed


91 of 126

6.20 - Upper Module, disassembly procedures Action No. 5: Upper Cooler Adapter and Oil Ducts removal C

CR&OP Data Module: 39-A-63-20-05-03A-530A-C Upper module (main gearbox) Disassemble procedures.

Upper Cooler Adapter removed A

A Top Oil Duct (q.ty 4)

O-ring

B

Nuts + Washers (q.ty 5)

O-ring

Upper Cooler Adapter O-ring Main Oil Duct (q.ty 1) O-ring Rear View


92 of 126

Side View

6.20 - Upper Module, disassembly procedures Action No. 6: Seal Cover and Lip Seal removal Mast-Planetary assembly

CR&OP Data Module:

A

39-A-63-20-05-03A-530A-C Upper module (main gearbox) - Disassemble procedures. Support equipment:

Nylon Screw (Q.ty 2)

A

Nuts + Washers Seal Cover + Lip Seal O-ring

O-ring Top Case


93 of 126

Nomenclature

Identification No.

Removal tool, lip seal

3G6320A00231A029C

6.20 - Upper Module, disassembly procedures Action No. 7.1: “Ring Gear”, Mast-Planetary Ass., Roller Bearing removal Action A

E

Nuts + Washers

Roller Bearing

CR&OP Data Module: 39-A-63-20-05-03A-530A-C Upper module (main gearbox) Disassemble procedures.

Top Case

O-ring

Support equipment: D

MastPlanetary Assembly Ball Bearing Planetary Gear Assembly B

Packing

Nuts + Washers

C

Ring Gear

Note Ring Gear already removed.


94 of 126

Nomenclature

Identification No.

Work trolley

3G6320A00231A188A

Clamp

3G6320A00231A023M

Lifting tool, gear ring

3G6320A00231A181A

Lifting device

Local supply

Removal tool, mastplanetary assembly

3G6320A00231A029A

Hydraulic jack

Local supply

Lifting tool, mastplanetary assembly

3G6320A00231A181C

Work trolley, mastplanetary assembly

3G6320A07231A188A

Removal tool, roller bearing

3G6320A00231A029B

6.20 - Upper Module, disassembly procedures Action No. 7.2: Details A, B and C A: Temporary install two Nuts and two Washers (33,34) on the Roller Bearing. Note: in this photo the seal cover is yet installed.

View of the Mast-Planetary Assembly (4) installed in the TOP Case

B: Remove the Nuts and the Washers (44, 45, 46) from the Top Case and the flanged Outer race of the Ball Bearing.

C: Packing (42), removal

Detail B


95 of 126

6.20 - Upper Module, disassembly procedures

Action No. 7.3: Detail “D” of the Mast-Planetary Assembly removed from the TOP Case Work trolley

3G6320A00231A188A

MastPlanetary Assembly, installed on the Work trolley

D1

Mast-Planetary Assembly, lifting tool installation. Lifting tool, mastplanetary assembly

TOP Case – inner view

D5

3G6320A00231A181C

D3

D2

D4

Mast-Planetary Assembly, removed from the TOP Case


96 of 126

Work trolley, 3G6320A07231A188A mast-planetary assembly

6.20 - Upper Module, disassembly procedures Action No. 8: Upper Fittings removal

Details A,B,C and D are relevant to the Upper Fittings (Item 49)

CR&OP Data Module: 39-A-63-20-05-03A-530A-C Upper module (main gearbox) Disassemble procedures. Support equipment:

Top Case

Bolts Screw

Washers Brackets

Nomenclature

Identification No.

Lifting device

Local supply

Lifting tool, mast

3G6320A00231A181B

Work trolley

3G6320A00231A188A

Work bench

Local supply

Plastic scraper

Local supply

Adapter, MGB upper fitting removal

3G6305G10931

Grease gun

Local supply

Upper Fitting Note • Install the Adapter in the threaded hole of the upper fitting (49). • Connect the Grease Gun filled with Grease to the Adapter Tool (code C009: Aeroshell 22). • Operate the Grease Gun and slowly remove the upper fitting (49) from the top case. • Do this action on each position.


97 of 126

6.20 - Upper Module, disassembly procedures Action No. 8.1: View of the Upper Fittings removed and the tools used 7 1

6 2

5

3 4


98 of 126

6.21 - Mast-Planetary assembly, disassembly procedures

Action No. 1: Ret. springs removal from the Ring Nuts and inst. of the M-P Ass. on the React. tool Retaining ring

CR&OP Data Module:

1

39-A-63-20-05-13A-530A-C Mast-planetary assembly (upper module) - Disassemble procedures.

Lock washer Ring Nut

Support equipment: Ball bearing

Nomenclature

Identification No.

Work trolley

3G6320A07231A188A

Reaction tool

3G6320A07231A023E

Lifting tool

3G6320A00131A181A

Mast

Lifting device

Local supply

Bolts Lock washers Bushings

Work table

Local supply

Retaining springs removal

Oil collector 2

Retaining springs Ring nuts

Flange Planetary Gear Assy.

Ring nut (upper view)

Pins

Spacers

3

Plate Pins

Bushings Lock washers Bolts


4 99 of 126

6.21 - Mast-Planetary assembly , disassembly procedures Action No. 2: Installation of the M.-P. Assembly on the Reaction tool assembly

1

2

3


100 of 126


Action No. 3: Retaining ring (1) and Lock washer (2) removal from the Ring nut. Retaining ring

CR&OP Data Module: 39-A-63-20-05-13A-530A-C Mast-planetary assembly (upper module) - Disassemble procedures.

Lock washer Ring Nut Ball bearing Oil collector

Retaining ring, removal

Support equipment:

1

Nomenclature

Identification No.

Work table

Local supply

Reaction tool

3G6320A07231A023E

Mast



Lock washer, removal 2


Spacers

Pins

Pins Plate Bushings Lock washers Bolts


101 of 126

Ring Nut

6.21 - Mast-Planetary assembly, disassembly procedures Action No. 4: Ring nut (3) removal from the Mast. Retaining ring Lock washer Ring Nut Ball bearing Oil collector Mast


Bolts Lock washers Bushings Flange

Planetary Gear Assy.

Spacers

Pins



102 of 126

CR&OP Data Module: 39-A-63-20-05-13A-530A-C Mast-planetary assembly (upper module) - Disassemble procedures. Support equipment: Nomenclature

Identification No.

Work table

Local supply

Reaction tool

3G6320A07231A023E

Ring nut, rem./inst. tool

3G6320A07231A023G

Servo-multiplier

Sweeney 8200

Lifting tool

3G6320A00131A181A

Lifting device

Local supply

6.21 - Mast-Planetary assembly, disassembly procedures Action No. 5: Ring nut (3) removal , Tools installation sequence 6

1

Ring nut, rem./inst. tool 2

Ring Nut, location

7 5

8 3

4

Ball bearing

Servo-multiplier


103 of 126

Ring Nut, removed

6.21 - Mast-Planetary assembly, disassembly procedures Action No. 6: Ball bearing (4) and Oil collector (5) removal Retaining ring Lock washer

CR&OP Data Module: 39-A-63-20-05-13A-530A-C Mast-planetary (upper module) - Disassemble procedures.

Ring Nut

Support equipment:

Ball bearing Oil collector


Nomenclature

Identification No.

Work table

Local supply

Lifting tool

3G6320A00131A181A

Mast

Lifting device

Local supply


Reaction tool assembly (adapter, spacer)

3G6320A07231A023D

Removal tool assembly

3G6320A07231A029C


Spacers

Pins



104 of 126

Removal tool 3G6320A07231A023F assembly (plunger) Jack

Enerpack RC-252

assembly


Action No. 7: Ball bearing (4) and Oil collector (5) removal, tools installation

(3G6320A07231A023D) (3G6320A00131A181A)

(3G6320A07231A029C)

(Enerpack RC-252)

(3G6320A07231A023F) Ball bearing

Oil collector

Work Table


(3G6320A07231A023D)

105 of 126

6.21 - Mast-Planetary assembly, disassembly procedures Action No. 8: Ring nuts (20) removal, tools installation Retaining ring Lock washer


assembly

Ring Nut Ball bearing Oil collector Mast


Nomenclature

Identification No.

Work table

Local supply

Reaction tool assembly (Wrench)

3G6320A07231A023D



Spacers

Pins



106 of 126

3

Support equipment:

1

2

Ring nut, removed


Action No. 9: Pins (17), Items 6 and Planetary gear assemblies (19) removal Retaining ring Lock washer


Ring Nut

Support equipment:

Ball bearing Oil collector Mast




Pins

Spacers Plate Pins

Bushings Lock washers Bolts


107 of 126

Nomenclature

Identification No.

Work table

Local supply

Lifting tool

3G6320A00131A181A

Lifting device

Local supply

Work trolley (turn the Mast 180°)

3G6320A07231A188A

Bushing removal tool

3G6320A07131A023B

Planetary gear removal 3G6320A07131A029A tool Jack (planetary gear removal)

RCH-121H

assembly


Action No. 10: Pins (17), Items 6 and Planetary gear assemblies (19), details

Flange (11) disassembled, Planetary gear Assy (19) removed

Planetary Gear Assy. (19)

Pins (17) Plate (13)

E A

B

D Plate (13) removal

C

Items 6, details


108 of 126

Spacers (18) partially removed from the Planetary gear Assy

6.22 - Planetary gears assembly, disassembly procedures CR&OP Data Module: 39-A-63-20-05-14A-530A-C Planetary gear assembly (mast planetary assembly) Disassemble procedures Support equipment:

Planetary Gears Assy.

Top-inner bearing race Roller cage Rollers

Gear (outer bearing race)

Rollers Bottom-inner bearing race


Roller cage

109 of 126

Nomenclature

Identification No.

Rollers removal tool

3G6320A07231A029D

Procedure Put the planetary gear assembly (1) on an applicable work table. Note Identify and record the installation position of the top and bottom-inner bearing race (2) and (8) on the planetary gear assembly (1). This is to put them again in their correct position during the assembly. Disassemble the planetary gear assembly (1). Obey the instructions that follow: - Remove the rollers (4), the top-inner bearing race (2) and the roller cage (3) from the gear (5). Always keep these parts together. Do not interchange the rollers (4) with the rollers (6). - Remove the rollers (6), the bottom-inner bearing race (8) and the roller cage (7) from the gear (5). Always keep these parts together. Do not interchange the rollers (6) with the rollers (4).

6.22.1 - Planetary gears disassembled, details Gear (outer bearing race)

A

Rollers removal tool

3G6320A07231A029D

B C

Bottom-inner bearing race

Top-inner bearing race

Roller cage

Roller cage

Rollers

Bottom-inner bearing race Roller cage Rollers

Rollers

Roller cage Inner Bearing race

F

Bottom side Rollers

Inner Bearing race

E Top side D


110 of 126

Roller cage

6.23 - LH & RH Lubrication Pumps, disassembly procedures Ring nut

Gear Lubrication pump

CR&OP Data Module:

Retaining ring

Key

39-A-63-20-05-06A-530A-C Left lubrication pump (main gearbox)- Disassemble procedures 39-A-63-20-05-24A-530A-C Right lubrication pump (main gearbox) - Disassemble procedures

Lock washer A Shaft

Support equipment:

Retaining ring

B

Nomenclature

Identification No.

Reaction tool

3G6305G00931

Removal tool, lock washer

3G6305G01431

Wrench, ring nut

3G6305G01051

Lubrication pumps, disassembled

Vice

Lock washer

Ring nut

C

D


Key

E 111 of 126

F

Shaft

G

6.24 - ECS Compressor drive quill, disassembly procedures Action No. 1: Retaining ring and Locking washer removal CR&OP Data Module: 39-A-63-20-05-05A-530A-C ECS compressor drive quill (main gearbox) - Disassemble procedures. Locking ring

Support equipment: Pinion ECS-compressor drive quill

Case Flanged bearing Retaining ring

Locking washer

Nuts + Washers

ECS-compressor drive quill Vice Retaining ring, removal


112 of 126

Nomenclature

Identification No.


3G6320A00431A029C

6.24 - ECS Compressor drive quill, disassembly procedures Action No. 2: remove the Locking ring from the Pinion CR&OP Data Module: 39-A-63-20-05-05A-530A-C ECS compressor drive quill (main gearbox) - Disassemble procedures.

Locking ring Pinion

Flanged bearing Retaining ring

Locking washer

Case

Nuts + Washers

Locking ring, removal


113 of 126


Identification No.

Removal/installation tool, locking ring

3G6320A00731A023C

6.24 - ECS Compressor drive quill, disassembly procedures Action No. 3: remove the Pinion from the Case CR&OP Data Module: 39-A-63-20-05-05A-530A-C ECS compressor drive quill (main gearbox) - Disassemble procedures.

Locking ring Pinion

Support equipment: Case Flanged bearing Retaining ring

Locking washer

Nuts + Washers

IN


114 of 126

OUT

Nomenclature

Identification No.


3G6320A00731A029B

Arbor press

Local supply

6.24 - ECS Compressor drive quill, disassembly procedures Action No. 4: remove the Flanged Bearing from the Case CR&OP Data Module: 39-A-63-20-05-05A-530A-C ECS compressor drive quill (main gearbox) - Disassemble procedures.

Locking ring Pinion

Support equipment: Case Flanged bearing Retaining ring

Locking washer

Nuts + Washers

IN

OUT


115 of 126

Nomenclature

Identification No.

Arbor press

Local supply


3G6320A00731A029A

6.25 - Fan drive quill, disassembly procedures

Action No. 1: Retaining ring and Locking Washer removal from the pinion CR&OP Data Module: Fan drive quill

39-A-63-20-05-07A-530A-C Fan drive quill (main gearbox) - Disassemble procedures.


Identification No.

Work table Tightening tool

Pinion

3G6320A00931A023B

Extractor tool, locking 3G6320A00431A029C washer

Flanged bearing Locking ring

Retaining ring

Locking washer

Vice


116 of 126

6.25 - Fan drive quill, disassembly procedures

Act. No. 2: Locking Ring removal from the Pinion and Pinion removal from the Flanged bearing

CR&OP Data Module:

Fan drive quill

39-A-63-20-05-07A-530A-C Fan drive quill (main gearbox) - Disassemble procedures. Pinion

Support equipment:


Retaining ring

Locking washer

Identification No.

Work table

Local supply

Tightening tool, 3G6320A00931A023B

PINION (REF.)

IN


Nomenclature

117 of 126

OUT

Tightening tool (wrench)

3G6320A00931A023B


3G6320A00931A029A

Arbor press

Local supply

6.26 - Front Hyd. Pump Drive Quill, disassembly procedures CR&OP Data Module: Pinion Pump case

39-A-63-20-05-04A-530A-C Front pump drive quill (main gearbox) - Disassemble procedures Support equipment:

Front Hyd. pump drive quill

Plug O-ring

O-ring

Nomenclature

Identification No.

Work table

Local supply

Fitting

Removal tool, lip 3G6320A00431A029E seal cover Flanged bearing Washers + Nuts Locking ring Locking washer Retaining ring Packing Lip seal Seal cover

Extractor tool, lip 3G6320A00431A029D seal Extractor tool, locking washer

3G6320A00431A029C

Removal/installa tion tool, locking ring

3G6320A00531A023B


3G6320A00531A029A

Arbor press

Local supply


3G6320A00431A029A

Retaining ring


118 of 126

6.26 - Front Hyd. Pump Drive Quill, disassembly procedures

Action No.1: Items 15,14,13,12,11,10 and 9 removal from the Pump Case

CR&OP Data Module: Pinion Pump case


39-A-63-20-05-04A-530A-C Front pump drive quill (main gearbox) - Disassemble procedures. Support equipment: Nomenclature

Identification No.

Work table

Local supply

Removal tool, lip seal cover

3G6320A00431A029E


3G6320A00431A029D

Plug O-ring

O-ring Fitting

Flanged bearing Washers + Nuts Locking ring Locking washer Retaining ring

Pump case

Packing Lip seal Seal cover Retaining ring

Seal cover


119 of 126

6.26 - Front Hyd. Pump Drive Quill, disassembly procedures Action No.2: Items 8, 7 and 6 removal from the Pinion


39-A-63-20-05-04A-530A-C Front pump drive quill (main gearbox) - Disassemble procedures. Support equipment:

Front hyd. pump drive quill

Nomenclature

Identification No.

Work table and Vice

Local supply


3G6320A00431A029C

Removal/installation tool, locking ring (wrench)

3G6320A00531A023B

Plug O-ring

O-ring Fitting

Flanged bearing Washers + Nuts Locking ring Locking washer Retaining ring Packing Lip seal Seal cover Retaining ring


120 of 126

6.26 - Front Hyd. Pump Drive Quill, disassembly procedures Action No.3: Items 2, 5, 4 and 3 removal from the Pump Case


39-A-63-20-05-04A-530A-C Front pump drive quill (main gearbox) - Disassemble procedures. Support equipment:

Front hyd. pump drive quill

Nomenclature

Identification No.

Work table

Local supply


3G6320A00531A029A

Arbor press

Local supply


3G6320A00431A029A

Plug O-ring

O-ring Fitting

Flanged bearing Washers + Nuts Locking ring Locking washer Retaining ring Packing Lip seal Seal cover Retaining ring


121 of 126

Pump case

6.27 – LH/RH Hyd. Pump Drive Quill (No.1 and No. 2), disassembly procedures

Retaining ring Seal cover

CR&OP Data Module: 39-A-63-20-05-27A-530A-C Left/right pump drive quill (main gearbox) - Disassemble procedures

Lip seal

Support equipment: Packing Retaining ring

Left/right pump drive quill (Hyd. pump No.1 and N0.2 drive quill)

Locking washer

Nomenclature

Identification No.

Work table

Local supply

Locking ring

Removal tool, lip 3G6320A00431A029E seal cover

Flanged bearing+ Washers and Nuts

Extractor tool, lip 3G6320A00431A029D seal Plug

O-ring Fitting

O-ring Pump case


3G6320A00431A029C

Removal/installa tion tool, locking ring

3G6320A00431A023C


3G6320A00431A029B

Arbor press

Local supply


3G6320A00431A029A

Pinion


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6.27 - LH/RH Hyd. Pump Drive Quill (No.1 and No. 2), disassembly procedures Action No. 1: items 12, 13, 16, 2, 3, 4 and 8 removal from the Pump Case. Retaining ring Seal cover

CR&OP Data Module: 39-A-63-20-05-27A-530A-C Left/right pump drive quill (main gearbox) - Disassemble procedures. Support equipment:

Lip seal

Nomenclature

Identification No.

Work table

Local supply

Removal tool, lip seal cover

3G6320A00431A029E


3G6320A00431A029D

Packing Retaining ring Locking washer Locking ring Flanged bearing+ Washers and Nuts Plug O-ring

O-ring Fitting

Pump case

Seal cover Pinion Pump case


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6.27 - LH/RH Hyd. Pump Drive Quill (No. 1 and No. 2), disassembly procedures Action No. 2: items 5, 6 and 7 removal from the Pinion. Retaining ring Seal cover

Lip seal

Nomenclature

Retaining ring Locking washer Locking ring

Plug O-ring Pump case

Pinion


Identification No.

Work table and Vice Local supply Extractor tool, locking washer

3G6320A00431A029C

Removal/installation 3G6320A00431A023C tool, locking ring (Wrench)


Fitting

39-A-63-20-05-27A-530A-C Left/right pump drive quill (main gearbox) - Disassemble procedures. Support equipment:

Packing

O-ring

CR&OP Data Module:

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6.27 - LH/RH Hyd. Pump Drive Quill (No.1 and No. 2), disassembly procedures Action No. 3: items 15, 9, 10 and 11 removal from the Pump case. Retaining ring Seal cover

Lip seal

CR&OP Data Module: 39-A-63-20-05-27A-530A-C Left/right pump drive quill (main gearbox) - Disassemble procedures. Support equipment:

Packing Retaining ring Locking washer Locking ring Flanged bearing+ Washers and Nuts

Nomenclature

Identification No.

Work table

Local supply


3G6320A00431A029B

Arbor press

Local supply


3G6320A00431A029A

Plug O-ring

O-ring Fitting

Pump case

Pump case

Pinion


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Chapter 6 - Disassembly Procedures

THE END



MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING

Ch. 7: Components Cleaning, Paint removal, Protection and Inspection

7 – Components Cleaning, Paint removal, Protection and Inspection INDEX 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23 7.24 7.25

Introduction Cleaning procedures Paint removal Protection procedures Detailed Visual Examination Defects definition Surface finish protection restoration (Main Case) Surface finish protection restoration (Upper Module) Surface finish protection restoration (LH/RH Input Shaft Module) Damage codes list Example of damage – general information Detailed visual examination, applicable Data Modules list Main gearbox – Detailed Visual Examination Chip detectors – Detailed Visual Examination LH/RH Right Input Shaft Module – Detailed Visual Examination Freewheel – Detailed Visual Examination Upper Module – Detailed Visual Examination Mast-Planetary Assembly – Detailed Visual Examination Planetary Gears Assembly – Detailed Visual Examination LH/RH Hyd. Pump Drive Quill – Detailed Visual Examination Front Hyd. Pump Drive Quill – Detailed Visual Examination ECS Compressor Drive Quill – Detailed Visual Examination Fan Drive Quill – Detailed Visual Examination LH/RH Lubrication Pump – Detailed Visual Examination Tail Rotor Drive Quill – Detailed Visual Examination (Cont’s)


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7 – Components Cleaning, Paint removal, Protection and Inspection

7.26 7.27 7.28 7.29 7.30 7.31 7.32 7.33 7.34 7.35 7.36 7.37 7.38 7.39 7.40 7.41 7.42 7.43 7.44 7.45 7.46

Dimensions Check Main gearbox – Dimensions check LH/RH Input Shaft Module – Dimensions check Upper Module – Dimensions Check Mast-Planetary Assembly – Dimensions check Planetary Gears – Dimensions check LH/RH Hyd. Pump Drive Quill – Dimensions check Front Hyd. Pump Drive Quill – Dimensions check ECS Compressor Drive Quill – Dimensions check Fan Drive Quill – Dimension check LH/RH Lubrication Pump – Dimensions check Tail Rotor Drive Quill – Dimensions check Dye Penetrant Examination General guidelines for Dye Penetrant Examination Main gearbox – Dye Penetrant Examination LH/RH Input Shaft Module – Dye penetrant Examination Upper Module – Dye Penetrant Examination Front Hyd. Pump Drive Quill – Dye Penetrant Examination ECS Compressor Drive Quill – Dye Penetrant Examination LH/RH Hyd. Pump Drive Quill – Dye Penetrant Examination Tail Rotor Drive Quill – Dye Penetrant Examination

(Cont’s)


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7 – Components Cleaning, Paint removal, Protection and Inspection

7.47 7.48 7.49 7.50 7.51 7.52 7.53 7.54 7.55 7.56 7.57 7.58 7.59

Magnetic Particles Examination General guidelines for Magnetic Particles Examination Main gearbox – Magnetic Particles Examination LH/RH Input Shaft Module – Magnetic Particles Examination Upper Module – Magnetic Particles Examination Front Hyd. Pump Drive Quill – Magnetic Particles Examination ECS Compressor Drive Quill – Magnetic Particles Examination LH/RH Lubrication Pump – Magnetic Particles Examination Fan Drive Quill – Magnetic Particles Examination Mast-Planetary Assembly – Magnetic Particles Examination Planetary Gears Assembly – Magnetic Particles Examination LH/RH Hyd. Pump Drive Quill – Magnetic Particles Examination Tail Rotor Drive Quill – Magnetic Particles Examination


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7.1 - Introduction

Hereinafter will be shown: • Cleaning procedures • Paint removal with Abrasive blast and with Paint remover • Surface protection (after cleaning procedures)

• Detailed Visual Examination (damage codes list, example of damages, procedures) • Surface finish protection restoration (on repaired area) • Dimensions Check

• Dye Penetrant Inspection • Magnetic Inspection NOTE All information reported hereinafter must be considered for Training purpose only. Refer to CR&OP as required


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7.2 - Cleaning procedures Clean the disassembled metal components of the MGB as required. Refer to CR&OP: 39-A-60-10-01-00A-251A-C Supplies Nomenclature

Identification No

Specification references

Ref. Documents

Solvent (Trichloroethylene)

C133

ASTM D4080-00

(AMDI) 39-A-00-50-00-24A-078B-D

Safety conditions WARNINGS 1.

The Solvent (C133) is a dangerous material. Before you do this procedure, make sure that you know all the safety precautions and first aid instructions for the solvent. Refer to CR&OP: 39-A-60-50-00-00A-074A-C; in particular refer to: - The label of the material container, - The manufacturer safety data sheet, - The local safety regulations, - Perform the cleaning operations in a well-ventilated area.

2.

You must use rubber gloves when you move the components during cleaning. CAUTION After cleaning, do not touch the metal components with bare hands. Put on clean, lint-free cotton gloves before you touch the metal components. Contamination from your bare hands will cause corrosion of the metal components.


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7.3 - Paint removal - with abrasive blast In order to remove the paint layer from the MGB metal components use the Blasting Equipment (Schlick Stripmaster 4S or equivalent) and the Abrasive plastic (C280) equivalent to MIL-PRF-85891 A. Refer to CR&OP: 39-A-60-10-01-00A-651A-C WARNING Make sure you obey all applicable precautions when you use the blasting equipment. CAUTIONS • The procedure described in this Data Module is not permitted on: – Plated Aluminium surfaces. – Aluminium sheets less than 0.8 mm (0.03 in) thick, without an applicable support. – Composite material surfaces (tell the Manufacturer for an authorization). • Only approved personnel can use the Blasting Equipment and the procedure described in this Data Module. Procedure The procedure described in this Data Module permit to remove all paint, sealing compound and adhesive from the metal components.

When operates the blasting equipment observe the following notes: – Blast pressure: 2.8 bar (41 lbf/in²) – Distance from the surface: 100 mm (4 in) – Angle of impact: 45 to 60˚ – Dwell time: less than 1 second. For Training purpose only

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7.3 - Paint removal - with paint remover As alternative procedure a paint remover can be used. In this case refer to the following CR&OP data module: 39-A-60-10-01-00A-659A-C Disassembled metal components - Paint removal with paint remover - Other processes to remove material Supplies Nomenclature


Ref. Documents

Solvent

C005

TT-M-261

(AMDI) 39-A-00-50-00-04A-078A-D

Paint remover

C348

MIL-PRF-25134

(AMDI) 39-A-00-50-00-10D-078A-D

Paint remover

C349

MIL-R-81294 Type I and II

(AMDI) 39-A-00-50-00-11D-078A-D

Cleaner, alkaline

C255

None

(AMDI) 39-A-00-50-00-23C-078A-D

Oil, protective

C256

None

(AMDI) 39-A-00-50-00-24C-078A-D

Procedure Refer to the instructions reported in the D.M. Note The Paint Removers must not be used on composite parts and adhesive bonded structures.


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7.4 - Protection procedures If it is not possible to examine the components immediately after clean procedure, apply protection to their surfaces. Refer to CR&OP: 39-60-10-01-00A-259A-C. Supplies Nomenclature


Ref. Documents


C011

None

(AMDI) 39-A-00-50-00-10A-078A-D

Cleaning solvent

C010

P-D-680 type II

(AMDI) 39-A-00-50-00-09A-078A-D

Corrosion preventative

C150

MIL-C-15074

(AMDI) 39-A-00-50-00-16B-078A-D

Oil

C008

DOD-L-85734

(AMDI) 39-A-00-50-00-07A-078A-D

For Warning and Procedure refer to the applicable D.M.

Note

Before you examine the component, clean it with the Cloth and the Cleaning Solvent.


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7.5 - Detailed visual examination CR&OP Data Module:

39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination Safety conditions: CAUTION • • •

During this procedure, do not touch the components made of metal with bare hands. Put on applicable cotton gloves before you touch the components. Contamination from your bare hands will cause corrosion of the metals. Procedure

To make an estimate of the damage, use the damage codes on the tables of the detailed visual examination figures and refer to Data Module CR&OP: 39-A-63-20-05-00A-913A-C for the acceptability / rejection criteria. Support equipment: Nomenclature

Identification No.

Magnifying glass, 10 times

Local supply


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7.6 - Defects definition

Refer to CR&OP: 39-A-63-20-05-00A-913A-C

Defects definition :

Small It's a defect that will not have unwanted effects on the component life or on the overhaul period.

Moderate It’s a defect that does not cause the component to become unserviceable. This defect can decrease the component life and overhaul period. Bad It’s a defect that causes the life of the component to decrease. Note

When required, restore the surface finish protection on the repaired area in accordance with CR&OP: 39-A-63-20-05-00A-640A-C (Main gearbox - Disassembled metal components - Change the surface finish of materials)


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7.7 Surface finish protection restoration (MGB - Main Case) CR&OP Data Module:

39-A-63-20-05-00A-640A-C Main gearbox - Disassembled metal components Change the surface finish of materials Procedure Refer to Para. 1 Apply to the components shown in Fig 1 the chromate conversion coating (C237: Alodine1200) Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C Apply to the components shown in Fig 2 the surface finishes that follow: – The chromate conversion coating (C237) . Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C. – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

Apply to the components shown in Fig 3 the cadmium plating finish (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C. On the pages reported hereinafter are shown the fig.1, 2 and 3.


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7.7.1 - Main Case components – Surface finishes - Fig. 1

On these components apply the chromate conversion coating (C237: Alodine1200) . Refer to data module CR&OP: 39-A-60-10-0100A-644A-C


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7.7.2 – Main Case components – Surface finishes - Fig. 2

On these components apply the surface finishes that follow: – The chromate conversion coating (C237, Alodine 1200) . Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C. – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.


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7.7.3 – Main Case components – Surface finishes - Fig. 3

On these components apply the cadmium plating finish (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-0100A-647A-C.


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7.8 - Surface finish protection restoration (MGB - Upper Module) CR&OP Data Module:

39-A-63-20-05-00A-640A-C Main gearbox - Disassembled metal components Change the surface finish of materials Procedure Refer to Para. 2

Apply to the components shown in Fig 4 the surface finishes that follow: – The chromate conversion coating (C237: Alodine 1200). Refer to data module CR&OP: 39-A-60-10-0100A-644A-C – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

Apply to the components shown in Fig 5 the surface finishes that follow: – The cadmium plating (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A647A-C – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

On next page are shown the fig. 4 and fig. 5.


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7.8.1 - Upper Module components – Surface finishes, Fig. 4 and Fig. 5

–

The chromate conversion coating (C237: Alodine 1200). Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

Figure 5

Figure 4


– The cadmium plating (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

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7.9 - Surface finish protection restoration (MGB - LH/RH Input Shaft Module) CR&OP Data Module:

39-A-63-20-05-00A-640A-C Main gearbox - Disassembled metal components Change the surface finish of materials Procedure Refer to Para. 3

Apply to the components shown in Fig 6 the surface finishes that follow: – The chromate conversion coating (C237: Alodine 1200). Refer to data module CR&OP: 39-A-60-10-0100A-644A-C – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

Apply to the components shown in Fig 7 the surface finishes that follow: – The cadmium plating (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A647A-C – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

On next page are shown the fig. 6 and fig. 7.


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7.9.1 – LH/RH Input Shaft Module comp. – Surface finishes, Fig. 6 and 7

– The chromate conversion coating (C237: Alodine 1200). Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

Figure 7

Figure 6


– The cadmium plating (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C – The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

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7.10 - Damage codes list Refer to CR&OP: 39-A-63-20-05-00A-913A-C Sheet 1 of 9 Visual examination of Bearings Damage Code

Area of Inspection

Acceptable damage

Not-acceptable damage

T1

Balls and Rollers

Smearing. Accept the part if you find small smearing. Staining. Accept the part if the staining is not related to pitting or overheating. Indentation that you can see only with a light reflection. Accept the part.

Pitting, spalling, corrosion, heat discoloration, continuous circumferential indentation, brinelling, seizure and cracks. Reject the part if you find one of these defects.

T1

Bearing races

Smearing. Accept the part if you find small smearing. Staining. Accept the part if the staining is not related to pitting or overheating. Indentation that you can see only with a light reflection. Accept the part.

Pitting, spalling, heat discoloration, brinelling, seizure, corrosion and cracks. Reject the part if you find one of these defects.

T1

Not active surfaces of the bearings

Staining. Accept the part if the staining is not related to pitting or overheating. Corrosion. Accept the part if you find small corrosion that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Fretting. Accept the part if you find small fretting that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Make sure that the fretting is not more than 10% of the working surface. Moderate and bad fretting areas, usually, have the typical brown colour. Scratches. Accept the part if you find small or moderate scratches.

Bad circumferential scoring, spinning marks, cracks, heat discoloration, bad fretting and seizure. Reject the part if you find one of these defects. Reject the part if you find rusting.

T1

Cages

Polishing. Accept the part if you find polishing. Staining. Accept the part if the staining is not related to pitting or overheating.

Corrosion, heat discoloration, seizure, pocket deformation, peeling of the plated surface and cracks. Reject the part if you find one of these defects.


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7.10 - Damage codes list Refer to CR&OP: 39-A-63-20-05-00A-913A-C Sheet 2 of 9 Visual examination of Gears (sheet 1 of 2) Damage Code

Area of Inspection

Acceptable damage


T2

Teeth

Wear of abrasive type. Accept the part if you find small worn areas caused by small particles that go through the gear mesh. Polishing. Accept the part if you find polishing. Scratches. Accept the part if you find small scratches caused by burrs that go through the gear mesh. Interference wear. Accept the part if you find small interference wear. Corrosion. Accept the part if you find small corrosion that you can repair with a Scotch-brite pad or Number 600 abrasive paper. Staining. Accept the part if the staining is not related to pitting or overheating. Indentation that you can see only with a light reflection. Accept the part.

Scores, flaking, pitting, spalling, peening, heat discoloration and cracks. Reject the part if you find one of these defects. Reject the part if you find rusting.

T3

Bearing races

Polishing. Accept the part if you find polishing. Staining. Accept the part if the staining is not related to pitting or overheating. Scratches. Accept the part if you find small scratches caused by burrs that go through the roller elements. Indentation that you can see only with a light reflection. Accept the part. Corrosion. Accept the part if you find small corrosion that you can repair with a Scotch-brite pad.

Pitting, spalling, heat discoloration, brinelling and seizure. Reject the part if you find one of these defects. Reject the part if you find moderate and bad circumferential marks. Reject the part if you find rusting.


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7.10 - Damage codes list Refer to CR&OP: 39-A-63-20-05-00A-913A-C Sheet 3 of 9

Visual examination of Gears (sheet 2 of 2) Damage Code

Area of Inspection

Acceptable damage


T4

Journals

Staining. Accept the part if the staining is not related to pitting or overheating. Corrosion. Accept the part if you find small corrosion that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Fretting. Accept the part if you find small fretting that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Make sure that the fretting is not more than 10% of the working surface. Usually, the areas that show fretting have a different colour from the surfaces that do not show fretting. Moderate and bad fretting areas, usually, have the typical brown colour.

Bad circumferential scores, spinning marks, flaking, heat discoloration and seizure. Reject the part if you find one of these defects. Reject the part if you find rusting.

T5

Shoulders

Staining. Accept the part if the staining is not related to pitting or overheating. Corrosion. Accept the part if you find small corrosion that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Fretting. Accept the part if you find small fretting that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Make sure that the fretting is not more than 10% of the working surface. Usually, the areas that show fretting have a different colour from the surfaces that do not show fretting. Moderate and bad fretting areas, usually, have the typical brown colour. Scratches. Accept the part if you find small scratches that are not more than 10% of the working surface. Polishing. Accept the part if you find polishing.

Moderate or bad wear, heat discoloration, seizure and cracks. Reject the part if you find one of these defects. Reject the part if you find rusting.

T6

Interface planes

Small fretting. Accept the part if you find small fretting that you can repair with a Scotchbrite pad or Number 600 abrasive paper.

Bad fretting and cracks. Reject the part if you find one of these defects.


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7.10 - Damage code list Refer to CR&OP: 39-A-63-20-05-00A-913A-C Sheet 4 of 9 Visual examination of Splines Damage Code T7

Area of Inspection

Acceptable damage


Teeth

Wear of abrasive type. Accept the part if you find small worn areas caused by small particles that go through the gear mesh. Polishing. Accept the part if you find polishing. Corrosion. Accept the part if you find small corrosion that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Staining. Accept the part if the staining is not related to pitting or overheating. Fretting. Accept the part if you find small fretting that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Usually, the areas that show fretting have a different colour from the surfaces that do not show fretting. Moderate and bad fretting areas, usually, have the typical brown colour.

Pitting, spalling, cracks and bad fretting. Reject the part if you find one of these defects. Reject the part if you find rusting.


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7.10 - Damage codes list Refer to CR&OP: 39-A-63-20-05-00A-913A-C

Sheet 5 of 9 Visual examination of Casting Damage Code

Area of Inspection

Acceptable damage


T8

Interface planes

Fretting. Accept the part if you find small fretting that you can repair with a Scotchbrite pad or Number 600 abrasive paper.

Bad fretting and cracks. Reject the part if you find one of these defects.

T9

Liners

Polishing. Accept the part if you find polishing. Corrosion. Accept the part if you find small corrosion that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Staining. Accept the part if the staining is not related to overheating. Fretting. Accept the part if you find small fretting that you can repair with a Scotchbrite pad or Number 600 abrasive paper. Make sure that the fretting is not more than 10% of the working surface. Usually, the areas that show fretting have a different colour from the surfaces that do not show fretting. Moderate and bad fretting areas, usually, have the typical brown colour.

Heat discoloration, seizure, cracks, moderate and bad circumferential scores, spinning marks and moderate and bad fretting. Reject the part if you find one of these defects. Reject the part if you find rusting.

T10

Sleeve seats

Polishing. Accept the part if you find polishing.

Bad fretting and seizure. Reject the part if you find one of these defects.


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7.10 - Damage codes list Refer to CR&OP: 39-A-63-20-05-00A-913A-C Sheet 6 of 9 Criteria of acceptability for an “indentation” noted on the surface of the Casting (sheet 1 of 3) Damage Code

Area of Inspection

Acceptable damage

T10

Surface of the casting

Indentation (Nick)

Examples of “indentation”

INDENTATION

Accept the part if: The indentation has a dimension of approximately 2.5 x 2.5 mm with a depth of 0.25 mm without paint removal. Refer to photo No. 1.

INDENTATION

Photo No.1


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7.10 - Damage codes list Refer to CR&OP: 39-A-63-20-05-00A-913A-C Sheet 7 of 9 Criteria of acceptability for an “indentation” noted on the surface of the Casting (sheet 2 of 3) Damage Code T10

Area of Inspection

Acceptable damage


Indentation (Nick)


Accept the part if: The indentation has a dimension of approximately 2.5 x 2.5 mm with a depth of 0.25 mm with paint removal. Refer to photos No. 2, 3 and 4.

INDENTATION

INDENTATION

INDENTATION

INDENTATION

INDENTATION

INDENTATION

Photo No.2


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Photo No.3

Photo No.4

7.10 - Damage codes list Refer to CR&OP: 39-A-63-20-05-00A-913A-C Sheet 8 of 9 Criteria of acceptability for an “indentation” noted on the surface of the Casting (sheet 3 of 3) Damage Code

Area of Inspection

Acceptable damage

T10


Indentation (Nick)


INDENTATION

Accept the part if: – The has a depth 5. – The has a depth 6.

indentation is on the corner (high thickness) and dimension of approximately 4.0 x 4.0 mm with a of 0.5 mm with paint removal. Refer to photo No. indentation is on the corner (low thickness) and dimension of approximately 4.0 x 4.0 mm with a of 0.2 mm with paint removal. Refer to photo No. Picture No.5

- Blend the sharp corners. - Apply the paint finish as required.39-A-60-10-0100A-257A-C

INDENTATION

Picture No.6


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7.10 - Damage codes list Refer to CR&OP: 39-A-63-20-05-00A-913A-C Sheet 9 of 9 Visual examination of Threads Damage Code

Area of Inspection

Acceptable damage


T11

Bolt threads, Threaded shafts, Nuts .

Mechanical damage.

Corrosion, seizure, distortion and cracks. Reject the part if you find one of these defects.

Accept the part if the mechanical damage is limited to one thread pitch at the input. Damage must not be more than ¼ of the threaded depth after repair.


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If you find that a stud is damaged, you must replace it. Refer to CR&OP: 39-A-60-30-0200A-921A-C.

7.11 - Example of damage – General information

(Note: Photos reported below are not related to the Transmission of the AW139)

Sheet 1 of 9

Damage Definition Smearing

Example

Smearing is a phenomenon where minute seizure is concentrated on the rolling surface. In smearing, the surface is partially melted by heat of high temperature generated by friction; and on some parts, the surface damaged becomes significantly rough.

Searing on Inner Ring raceway surface

Smearing on roller rolling surface of Cylindrical Roller Bearing

Searing on Outer Ring raceway surface

Smearing on outer ring raceway surface of Cylindrical Roller Bearing


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Smearing on ball surface

7.11 - Example of damage – General information Sheet 2 of 9

Damage Definition Discoloration (Staining)

Example

Discoloration is a phenomenon in which the bearing surface is discoloured by staining or heat generated during operation.

Discoloration on inner ring and roller of Roller Bearing (Staining)

Heat Discoloration

It is a phenomenon in which the bearing surface is heavy discoloured by overheating generated during operation.

Heat Discoloration on inner ring


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Surface overheated


Damage

Definition

Flaking

Flaking is a phenomenon in which the bearing surface turns scaly and peels off due to contact load repeatedly received on the raceway and rolling surface during rotation.

Fretting

Fretting is a phenomenon which occurs when slight sliding is repeatedly caused on the contact surface. On the fitting surface, fretting corrosion occurs, generating a rust like powder


Example

Flaking on inner ring of Deep Groove Ball Bearing

Flaking on inner ring of Cylindrical Roller Bearing

Fretting on inner ring bore surface of Tapered Roller Bearing

Fretting on outer ring O.D. surface of Deep Groove Ball Bearing

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Damage Definition Indentation (Nick)

A depression in a surface, normally having sharp edges and bottom, generally caused by an impact with a sharp object and/or having an hardness higher than the part Hardness (FOD)

Seizure

The seizure described in this section is the kind in which bearing parts are melted and adhere to one another due to abnormal heat or the rolling surface becoming rough; as a result, the bearing can no longer rotate.

Example

Seizure of Tapered Roller Bearing (Heat is generated on roller end face and inner ring rib face)


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Example of seizure on roller bearing

7.11 - Example of damage – General information sheet 5 of 9

Damage Definition Pitting corrosion

Example

Pitting corrosion is a phenomenon in which the bearing surface is partially melted by sparks generated when electric current enters the bearing and passes through an extremely thin oil film at the rolling contact point. Depressions like craters can be observed when pitting is magnified, indicating that the surface has been melted by sparks.

Heavy corrosion on gear

Pitting on Cylindrical Roller Bearing inner ring

Example of pitting corrosion


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Damage

Definition

Example

Crack

Separation of material visible to naked eye. Cracks include slight cracks, splitting and fracture.

Crack very heavy on Cast Housing

Scratch

Crack in outer ring of Roller Bearing

A linear depression with a sharp bottom caused by the contact and/or handling. Or A scratch is a relatively shallow flaw caused by sliding contact.

Scratch Medium – Precision Surface


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Scratch on roller rolling surface of Roller Bearing - Scratch occurring in circumference direction -


Damage

Definition

Example

Brinelling

Brinelling is depressions created on the part of the raceway surface which comes into contact with the rolling element, and is due to plastic deformation. Brinelling is also small depressions on the rolling surface caused by contamination by solid foreign matters. Brinelling on outer ring raceway surface of Ball Bearing

Dent (Brinelling)

Brinelling on inner ring raceway surface of Roller Bearing

A depression in a surface , normally having round edges and bottom, generally caused by an impact with an object of round shape and/or having an hardness lower than the part Hardness Dent Heavy - Gear teeth


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Dent Heavy – Roller Bearing Race


Damage

Definition

Example

Rust

Rust is a film of oxide, hydroxide, or carbonate produced on a metallic surface by chemical action.

Rust on roller rolling surface of Cylindrical Roller Bearing

Rust on outer ring raceway surface of Roller Bearing

Failure of Cage

1) Cracks and Chips If a seriously cracked bearing is used under heavy operating conditions, it will fail. 2) Distortion Since cages are made from soft material, they tend to be damaged or become distorted by external forces or from contact with other parts. 3) Rust / Corrosion If rust or corrosion is found on cages, it can be assumed that it is also occurring on the bearing ring and rolling element.


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Distortion of Cylindrical Roller Bearing cage

Crack of Roller Bearing cage

Rust on Roller bearing cage


Damage

Definition

Spalling

Spalling is similar to destructive pitting except that the pits are usually large diameter and quite shallow. Often the damaged area does not have uniform diameter.


Example

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7.12 - Detailed visual examination, applicable Data Modules list Hereinafter are shown the CR&OP Data Modules required to perform a DV Examination: 7.20) 39-A-63-20-05-27A-311A-C Left/right pump drive quill (main gearbox) - Detailed visual examination

7.13) 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination 7.14) 39-A-63-20-05-00A-311B-C Main gearbox - Chip detectors examination

-

Detailed

visual

7.15) 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) - Detailed visual examination 7.15) 39-A-63-20-05-02A-311A-C Right input shaft module (main gearbox) - Detailed visual examination 7.16) 39-A-63-20-05-01A-311B-C Left input shaft module (main gearbox) - Freewheel Detailed visual examination 7.17) 39-A-63-20-05-03A-311A-C Upper module (main gearbox) examination

-

Detailed

visual

7.18) 39-A-63-20-05-13A-311A-C Mast-planetary assembly (upper module) - Detailed visual examination 7.19) 39-A-63-20-05-14A-311A-C Planetary gear assembly (mast-planetary assembly) Detailed visual examination


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7.21) 39-A-63-20-05-04A-311A-C Front pump drive quill (main gearbox) - Detailed visual examination 7.22) 39-A-63-20-05-05A-311A-C ECS compressor drive quill (main gearbox) - Detailed visual examination 7.23) 39-A-63-20-05-07A-311A-C Fan drive quill (main gearbox) - Detailed visual examination 7.24) 39-A-63-20-05-06A-311A-C Left lubrication pump (main gearbox) - Detailed visual examination 7.24) 39-A-63-20-05-24A-311A-C Right lubrication pump (main gearbox) - Detailed visual examination 7.25) 39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination

7.13 – MGB - Main Case - Detailed visual examination (Sheet 1 of 5) CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 1 and Figure 1 (Sheet 1 of 5) P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................ General Safety conditions: CAUTION • During this procedure, do not touch the components made of metal with bare hands. • Put on applicable cotton gloves before you touch the components. • Contamination from your bare hands will cause corrosion of the metals. Procedure

Fig. 1 - Main case – MGB (sheet 1 of 5)


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To make an estimate of the damage, use the damage codes on the tables of the detailed visual examination figures and refer to CR&OP: 39-A-63-20-05-00A-913A-C for the acceptability / rejection criteria.

7.13 – MGB - Main Case - Detailed visual examination (Sheet 2 of 5) CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 1 and Figure 1 (Sheet 2 of 5). P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................



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7.13 - Main Case - Detailed visual examination (Sheet 3 of 5) CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 1 and Figure 1 (Sheet 3 of 5). P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................



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7.13 - Main Case - Detailed visual examination (Sheet 4 of 5) CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 1 and Figure 1 (Sheet 4 of 5). P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................



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7.13 – MGB - Main Case - Detailed visual examination (Sheet 5 of 5) CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 1 and Figure 1 (Sheet 5 of 5). P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................



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7.13.1 – MGB - Diaphragm - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 2 and Figure 2 P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 2 – Diaphragm (MGB)


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7.13.2 – MGB - Bottom cover - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 3 and Figure 3 P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 3 – Bottom cover (MGB)


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7.13.3 – MGB - Seal Cover of the Fan and ECS compressor drive quills – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 4 and Figure 4 P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 4 – Seal covers (MGB)


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7.13.4 - MGB - Anti-torque beam – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 5 and Figure 5 P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 5 – Anti-torque beam (MGB)


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7.13.5 – MGB - 17 Oil Jets (Main case) – Detailed visual examination

N°10

CR&OP Data Module:

N°11

N°6 N°12

N°7

39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 6 and Figure 6.

N°9

N°3

N°3

N° 16 N°16

N°5 N°8

N°4 N°4 N°13

Oil Jet No. 3 (x2) Oil Jet No. 4 (x2) Oil Jet No. 5… Oil Jet No. 6… Oil Jet No. 7… Oil Jet No. 8… Oil Jet No. 9… Oil Jet No. 10… Oil Jet No. 11… Oil Jet No. 12… Oil Jet No. 13… Oil Jet No. 14… Oil Jet No. 15… Oil Jet No. 16 (x2)

Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet Oil Jet

P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….………… P/N: …….…………

Inspection results: ..............................

N°14

N°15

Notes 1) In the MGB are installed 29 Oil Jets: - 17 oil jets in the Main Case - 4 oil jets in the Upper Module - 3 oil jets in each Input Shaft Module (6 total) - 1 oil jet in each Cover of each Input Shaft Module (2 total) 2) Check with filtered compressed air the possible occlusion of the oil jet holes

Fig. 6 – Oil Jets (MGB) – Sheet 1 of 2


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N°3

N°3

Fig. 6 – Oil Jets (MGB) – Sheet 2 of 2

7.13.6 – MGB - 3 Servo-Actuator Brackets – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 7 and Figure 7 Front servo-actuator Bracket (A) P/N:…………………. S/N:…………………. Left servo-actuator Bracket (B) P/N:…………………. S/N:…………………. Right servo-actuator Bracket (C) P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 7 – Servo-actuator brackets (MGB)


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7.13.7 – MGB - Cross shaft (left and right) - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 8 and Figure 8 Left Cross shaft P/N:…………………. S/N:…………………. Right Cross shaft P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 8 – Cross shaft (MGB)


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7.13.8 – MGB - Ring nuts (Input pinions II° stage) Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 9 and Figure 9 Left ring nut P/N:…………………. S/N:…………………. Right ring nut P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 9 – Ring nuts - Input pinion II° stage (MGB)


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7.13.9 – MGB - Pump gears - (Input pinions II° stage) - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 10 and Figure 10 Left Pump gear P/N:…………………. S/N:…………………. Right Pump gear P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 10 – Pump gears - Input pinion II° stage (MGB)


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7.13.10 – MGB - Bearing sleeves - (Input pinions II° stage) – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 11 and Figure 11 Left Bearing sleeve P/N:…………………. S/N:…………………. Right Bearing sleeve P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 11 – Bearing sleeve - Input pinion II° stage (MGB)


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7.13.11 – MGB - Bearing sleeve Retaining rings (Input pinions II° stage) - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 12 and Figure 12 Left Retaining Ring P/N:…………………. S/N:…………………. Right Retaining Ring P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 12 – Bearing sleeve Retaining Rings - Input pinion II° stage (MGB)


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7.13.12 – MGB - Input pinions II° Stage – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 13 and Figure 13 Left Input Pinion P/N:…………………. S/N:…………………. Right Input Pinion P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 13 – Input pinions II° stage (MGB)


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7.13.13 – MGB - Sliding adapter (Tail rotor drive quill) – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 14 and Figure 14 P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 14 – Sliding adapter (MGB)


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7.13.14 - Collector gear Locking ring - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 15 and Figure 15 P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 15 – Collector gear Locking ring (MGB)


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7.13.15 – MGB - Collector gear - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 16 and Figure 16 P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 16 – Collector gear Locking ring (MGB)


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7.13.16 – MGB - Filter head and the Bypass valve – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 17 and Figure 17 Filter Head P/N:…………………. S/N:…………………. Bypass Valve P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 17 – Filter head and Bypass valve (MGB)


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7.13.17 – MGB - Pressure relief valves - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 18 and Figure 18 LH PRV P/N:…………………. S/N:…………………. RH PRV P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 18 – PRV (MGB)


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7.13.18 – MGB - Input-pinion II ° stage triplex Ball Bearings Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 19 and Figure 19 LH triplex ball bearing P/N:…………………. S/N:…………………. RH triplex ball bearing P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 19 – Triplex ball bearings – Input Pinion II° stage (MGB)


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7.13.19 – MGB - Input pinion II° stage Roller Bearings – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 20 and Figure 20 LH Roller bearing P/N:…………………. S/N:…………………. RH Roller bearing P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 20 – Roller Bearings – Input pinion II° stage (MGB)


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7.13.20 – MGB - Collector-gear Flanged bearing – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 21 and Figure 21 Collector-gear Flanged bearing P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 21 – Collector gear flanged bearing (MGB)


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7.13.21 – MGB - Collector gear Roller bearing – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-00A-311A-C Main gearbox - Detailed visual examination. See Para. 22 and Figure 22 Collector-gear Roller bearing P/N:…………………. S/N:…………………. Inspection results: ................................................................................... ................................................................................... ...................................................................................

Fig. 22 – Collector gear flanged bearing (MGB)


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7.14 - Chip detectors - Detailed visual examination CR&OP Data Module: MGB

39-A-63-20-05-00A-311B-C Main gearbox Chip detectors - Detailed visual examination Support equipment:

Sump Chip Detector (x2)

Nomenclature

Identification No.

Container

Local supply

Magnifying glass, 10-power

Local supply

Paint brush

Local supply

Supplies: Mast Chip Detector Mast Chip Detector (upper module) P/N:…………………. S/N:…………………. LH Chip Detector (sump) P/N:…………………. S/N:…………………. RH Chip Detector (sump) P/N:…………………. S/N:…………………. Inspection results: ............................................................


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Nomenclature

Identification No

Specification references Ref. Documents

Cleaning solvent

C010

P-D-680 type II

(AMDI) 39-A-00-50-00-09A-078A-D

Adhesive tape

C012

DEF1313 or DEF STAN75-3-1.

(AMDI) 39-A-00-50-00-11A-078A-D

Procedure: 1) Examine each of the chip detectors. Use a strong light and the Magnifying Glass. Make sure that there are no metallic particles on these Chip Detectors. 2) If you find metallic particles on the chip detectors obey the instructions reported in this data module.

7.14.1 - Chip Detector Event Report Card Procedure: • As reported on CR&OP 39-A-63-20-05-00A-311B-C apply the tape strip with the relevant metallic particle on the applicable box of the “Drive System Chip detector Event Report Card”. See Card attached. • Compile the Card as required. • Send the form to the laboratory for analysis and inform AgustaWestland Costumer Support.


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7.15 - Left and right Input Shaft Module (main gearbox) - Detailed visual examination CR&OP Data Module:

39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) - Detailed visual examination

39-A-63-20-05-02A-311A-C Right input shaft module (main gearbox) - Detailed visual examination Safety conditions: CAUTION • • •


To make an estimate of the damage, use the damage codes on the tables of the detailed visual examination figures and refer to Data Module CR&OP: 39-A-63-20-05-00A-913A-C for the acceptability / rejection criteria. Support equipment:

General Note:

Nomenclature

Identification No.


Local supply


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The data to the a detailed visual examination of the left-input shaft module is applicable also to the right-input shaft module (see CR&OP 39-A-63-20-05-02A-311A-C).

7.15.1 - Case Assy - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 1 and Figure 1 LH Case Assy P/N:……………………………………… S/N:………………………………………. RH Case Assy P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

T11

T8 T10

Fig. 1 - Case assy (Left input shaft module)


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7.15.2 - Input Pinion- Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 2 and Figure 2 LH Pinion P/N:……………………………………… S/N:………………………………………. RH Pinion P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

T7

Fig. 2 - Pinion (Left input shaft module)


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7.15.3 - Gear, I° stage of reduction - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 3 and Figure 3 LH Gear P/N:……………………………………… S/N:………………………………………. RH Gear P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 3 - Gear (Left input shaft module)


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7.15.4 - Input shaft - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 4 and Figure 4 LH Input Shaft P/N:……………………………………… S/N:………………………………………. RH input Shaft P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

T7

Fig. 4 – Input Shaft (Left input shaft module)


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7.15.5 - Diaphragm - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 5 and Figure 5 LH Diaphragm P/N:……………………………………… S/N:………………………………………. RH Diaphragm P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

T10 T10

T8

Fig. 5 – Diaphragm (Left input shaft module)


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7.15.6 - Sleeve - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 6 and Figure 6 LH Sleeve P/N:……………………………………… S/N:………………………………………. RH Sleeve P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

T8 T9 T9

Fig. 6 –Sleeve (Left input shaft module)


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7.15.7 - Flange - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 7 and Figure 7 LH Flange P/N:……………………………………… S/N:………………………………………. RH Flange P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

T7

T8

Fig. 7 – Flange (Left input shaft module)


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7.15.8 - Gimbal support - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 8 and Figure 8 LH Gimbal support P/N:……………………………………… S/N:………………………………………. RH Gimbal support P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

T10 T10 T8

Fig. 8 – Gimbal (Left input shaft module)


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7.15.9 - Oil jet cover - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 9 and Figure 9 LH Oil Jet cover P/N:……………………………………… S/N:………………………………………. RH Oil Jet cover P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................ Note Using filtered compressed air inspect the oil jet holes for possible blockage. T8

Fig. 9 – Oil jet cover (Left input shaft module)


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7.15.10 - Three oil jets - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 10 and Figure 10 Left Input Shaft module: Oil Jet “A” No…. P/N:……………………………………… Oil Jet “B” No…. P/N:……………………………………… Oil Jet “C” No…. P/N:……………………………………… Inspection results: ........................................................................ Right Input Shaft module: Oil Jet “A” No…. P/N:……………………………………… Oil Jet “B” No…. P/N:………………………………………

Note Check with filtered compressed air the possible occlusion of the oil jet holes Fig. 10 – Oil jets (Left input shaft module)


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Oil Jet “C” No…. P/N:……………………………………… Inspection results: ........................................................................

7.15.11 - Two locking ring nuts - Detailed visual examination B

CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 11 and Figure 11 Left Input Shaft module: Ring nut “A” P/N:……………………………………… S/N:……………………………………….

A

Ring nut “B” P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ Right Input Shaft module: Ring nut “A” P/N:……………………………………… S/N:………………………………………. Ring nut “B” P/N:……………………………………… S/N:……………………………………….

Fig. 11 – Ring nuts (Left input shaft module)


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Inspection results: ........................................................................

7.15.12 - Carbon seal and Ring - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 12 and Figure 12 Left Input Shaft module: Carbon Seal P/N:……………………………………… S/N:………………………………………. Ring P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ Right Input Shaft module: Carbon Seal P/N:……………………………………… S/N:………………………………………. Ring P/N:……………………………………… S/N:……………………………………….

Fig. 12 – Carbon Seal and Ring (Left input shaft module)


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Inspection results: ........................................................................

7.15.13 - Inner Bearing - Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 13 and Figure 13 LH Inner Bearing P/N:……………………………………… S/N:………………………………………. RH Inner Bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 13 Inner Bearing (Left input shaft module)


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7.15.14 - Outer Bearing – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 14 and Figure 14 LH Outer Bearing P/N:……………………………………… S/N:………………………………………. RH Outer Bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 14 Outer Bearing (Left input shaft module)


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7.15.15 - Ball bearing (gear 1° stage of reduction) – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 15 and Figure 15 LH Ball Bearing P/N:……………………………………… S/N:………………………………………. RH Ball Bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 15 – Ball Bearing of the Input gear 1° stage of reduction - (Left input shaft module)


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7.15.16 - Roller bearing (gear 1° stage of reduction) – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 16 and Figure 16 LH Roller Bearing P/N:……………………………………… S/N:………………………………………. RH Roller Bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 16 – Roller Bearing of the Input gear 1° stage of reduction - (Left input shaft module)


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7.15.17 - Roller bearing (Input pinion) – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 17 and Figure 17 LH Roller Bearing P/N:……………………………………… S/N:………………………………………. RH Roller Bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 17 – Roller Bearing of the Input pinion - (Left input shaft module)


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7.15.18 - Duplex ball bearing (input pinion) – Detailed visual examination CR&OP Data Module: 39-A-63-20-05-01A-311A-C Left input shaft module (main gearbox) Detailed visual examination. See Para. 18 and Figure 18 LH Duplex Ball Bearing P/N:……………………………………… S/N:………………………………………. RH Duplex Ball Bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 18 – Duplex Ball Bearing of the Input pinion - (Left input shaft module)


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7.16 - Freewheel – Detailed visual examination Procedure

CR&OP Data Module:

1) Do the detailed visual examination with the aid of the Magnifying Glass, the Mirror and a strong light. Refer to Fig. 1 reported on the next page. 2) Examine the freewheel for corrosion and distress caused by the heat. Reject it if you find one of these defects. 3) Examine the sprags, the inner cage, the outer cage and the inner springs and the outer springs for cracks and breaks. Reject the freewheel if you find one of these defects. 4) Make sure that the sprags move freely in their pockets and stay in position. Reject the freewheel if the sprags do not move freely or do not stay in position. 5) Examine each sprag for discoloration caused by the heat, chips and spalling and pitting. Reject the freewheel if you find one of these defects. Accept the freewheel if you find small polished areas. 6) Examine the position of the wear patterns on the inner and outer faces of each sprags. The wear pattern must be at a minimum distance of 1.0 mm (0.04 in) from the high load corner. Reject the freewheel if you do not find these conditions. 7) Examine each sprag for wear on the outer and inner faces. Make sure that the wear width on the inner face is not more than 0.30 mm (0.012 in) (see Detail A). Reject the freewheel if you find one of these defects. 8) Examine the inner springs for wear. Reject the freewheel if the inner springs show important wear (approximately 30% of the original thickness). 9) Examine the outer springs for fretting. Refer to Detail B for an example of permitted fretting. 10) Examine the cross bars of the inner and outer cages for straightness and uniformity. The cross bars must not be bent from the initial shape and there must be no distortion. Reject the freewheel if you find one of these defects.


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39-A-63-20-05-01A-311B-C

Left input shaft module (main gearbox) - Freewheel Detailed visual examination. LH Freewheel P/N:……………………………………… S/N:………………………………………. RH Freewheel P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................


Identification No.

Magnifying glass, 10-power

Local supply

Mirror

Local supply

Note: The procedure reported in this D.M. is applicable for both (LH, RH) freewheels.

7.16.1 - Freewheel – Detailed visual examination

Fig. 1 – Freewheel – Detailed visual examination


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7.17 - Upper Module (main gearbox) - Detailed visual examination CR&OP Data Module:

39-A-63-20-05-03A-311A-C Upper module (main gearbox) Detailed visual examination

Safety conditions: CAUTION • • •




Nomenclature

Identification No.


Local supply

88 of 313

7.17.1 Top case – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-03A-311A-C module (main gearbox) visual examination. See Para. 1 and Figure 1.

Upper Detailed

Top case P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 1 – Top Case (Upper Module)


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7.17.2 - Cooler adapter – Detailed visual examination CR&OP Data Module:


Upper Detailed

Cooler adapter P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 2 – Cooler adapter (Upper Module)


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7.17.3 - Seal cover – Detailed visual examination CR&OP Data Module:


Upper Detailed

Seal cover P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 3 – Cooler adapter (Upper Module)


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7.17.4 - Four Upper Fittings – Detailed visual examination CR&OP Data Module:


Upper Detailed

Upper Fitting P/N:……………………………………… S/N:………………………………………. Upper Fitting P/N:……………………………………… S/N:………………………………………. Upper Fitting P/N:……………………………………… S/N:………………………………………. Upper Fitting P/N:……………………………………… S/N:……………………………………….

Inspection results: ........................................................................ ........................................................................ ........................................................................ Fig. 4 – Upper Fittings (Upper Module)


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7.17.5 - Four oil jets – Detailed visual examination CR&OP Data Module: C

D

A

B


Upper Detailed

Oil Jet (A) No. 1 P/N:……………………………………… Oil Jet (B) No. 1 P/N:……………………………………… Oil Jet (C) No. 2 P/N:……………………………………… Oil Jet (D) No. 2 P/N:……………………………………… Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 5 – Oil Jets (Upper Module)


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7.17.6 - Ring gear – Detailed visual examination CR&OP Data Module:


Upper Detailed

Ring gear P/N:……………………………………… S/N:……………………………………… Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 6 – Ring Gear (Upper Module)


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7.17.7 -Roller bearing – Detailed visual examination CR&OP Data Module:


Upper Detailed

Roller Bearing P/N:……………………………………… S/N:……………………………………… Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 7 – Roller bearing (Upper Module)


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7.17.8 - Components – Detailed visual inspection CR&OP Data Module:


Upper Detailed

Mast cover P/N:…………………………… Chip detector P/N:……………………….. Oil filler neck P/N:………………………… Oil scupper P/N:…………………………... Union P/N:………………………………….. Unions P/N:………………………………… Washers P/N:………………………………. Brackets P/N:………………………………. Inspection results: .......................................................................

Procedure

Fig. 8 – Components (Upper Module)


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Do the detailed visual examination of the following components for corrosion, wear and damage: – The mast cover (1) – The chip detector (2) – The oil filler neck (3) – The oil scupper (4) – The unions (5) (five items) – The washers (6) (four items) – The brackets (7) (two items).

7.18 - Mast-planetary assembly (upper module) – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mast-planetary assembly (upper module) - Detailed visual examination Safety conditions: CAUTION • • •


To make an estimate of the damage, use the damage codes on the tables of the detailed visual examination figures and refer to Data Module CR&OP: 39-A-63-20-05-00A-913A-C for the acceptability / rejection criteria.

Support equipment:


Nomenclature

Identification No.


Local supply

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7.18.1 - Main rotor shaft (MAST) – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 1 and Figure 1. Main rotor shaft (Mast) P/N:…………………………… S/N:……………………….. Inspection results: .......................................................................

Fig. 1 – Main rotor shaft (Mast-Planetary Assembly)


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7.18.2 – Spider plate – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 2 and Figure 2. Spider plate P/N:…………………………… S/N:……………………….. Inspection results: .......................................................................

Fig. 2 – Spider plate (Mast-Planetary Assembly)


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7.18.3 - Ring nut – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 3 and Figure 3. Ring nut P/N:…………………………… S/N:……………………….. Inspection results: .......................................................................

Fig. 3 – Ring nut (Mast-Planetary Assembly)


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7.18.4 - Ball bearing – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 4 and Figure 4. Ball bearing P/N:…………………………… S/N:……………………….. Inspection results: .......................................................................

Fig. 4 – Ball bearing (Mast-Planetary Assembly)


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7.18.5 - Five planetary gear ring nuts – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 5 and Figure 5. Planetary gear ring nut P/N:…………………………… S/N:……………………….. Planetary gear ring nut P/N:…………………………… S/N:……………………….. Planetary gear ring nut P/N:…………………………… S/N:……………………….. Planetary gear ring nut P/N:…………………………… S/N:………………………..

Planetary gear ring nut P/N:…………………………… S/N:……………………….. Fig. 5 – Planetary gear ring nut (Mast-Planetary Assembly)


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Inspection results: .......................................................................

7.18.6 - Five planetary pins – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 6 and Figure 6. Planetary pin P/N:…………………………… S/N:……………………….. Planetary pin P/N:…………………………… S/N:……………………….. Planetary pin P/N:…………………………… S/N:……………………….. Planetary pin P/N:…………………………… S/N:………………………..

Planetary pin P/N:…………………………… S/N:………………………..

Fig. 6 – Planetary pin (Mast-Planetary Assembly)


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7.18.7 - Five planetary gear spacers – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 7 and Figure 7. Planetary gear spacer P/N:…………………………… S/N:……………………….. Planetary gear spacer P/N:…………………………… S/N:……………………….. Planetary gear spacer P/N:…………………………… S/N:……………………….. Planetary gear spacer P/N:…………………………… S/N:………………………..

Planetary gear spacer P/N:…………………………… S/N:……………………….. Fig. 7 – Planetary gear spacer (Mast-Planetary Assembly)


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7.18.8 - Five spider plate spacers – Detail visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 8 and Figure 8. Spider plate spacer P/N:…………………………… Spider plate spacer P/N:…………………………… Spider plate spacer P/N:…………………………… Spider plate spacer P/N:…………………………… Spider plate spacer P/N:……………………………

Inspection results: ....................................................................... Fig. 8 – Spider plate spacer “pin” (Mast-Planetary Assembly)


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7.18.9 - Components – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mastplanetary assembly (upper module) Detailed visual examination. See Para. 9 and Figure 9. Retaining ring P/N:…………………………… Oil Collector P/N:…………………………… Nut springs P/N:…………………………… Spider bolts P/N:…………………………… Spacer bush P/N:…………………………… Inspection results: ....................................................................... Procedure

Fig. 9 – Components (Mast-Planetary Assembly)


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Do the detailed visual examination of the following components for corrosion, wear and damage: – The retaining ring (1) – The oil collector (2) – The nut spring (3) (five items) – The spider bolts (4) (ten items) – The spacer bush (5) (ten items).

7.19 - Planetary gear assembly (mast-planetary assembly) Detailed visual examination CR&OP Data Module:

39-A-63-20-05-14A-311A-C Planetary gear assembly (mast-planetary examination

assembly)

-

Detailed

visual




Support equipment:


Nomenclature

Identification No.


Local supply

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7.19.1 - Gear – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-14A-311A-C Planetary gear assembly (mast-planetary assembly) Detailed visual examination. See Para.1 and Figure 1 Planetary Gear Assy P/N:…………………………… S/N:…………………………… Planetary Gear Assy P/N:…………………………… S/N:…………………………… Planetary Gear Assy P/N:…………………………… S/N:…………………………… Planetary Gear Assy P/N:…………………………… S/N:……………………………

Planetary Gear Assy P/N:…………………………… S/N:…………………………… Fig. 1 – Gear (Planetary-Gear Assembly)


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7.19.2 - Inner bearing race – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-14A-311A-C Planetary gear assembly (mast-planetary assembly) Detailed visual examination. See Para.2 and Figure 2

Fig. 2 – inner bearing race (Planetary-Gear Assembly)

Inner bearing race Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Inner bearing race Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Inner bearing race Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Inner bearing race Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Inner bearing race Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Inspection results: .......................................................................


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7.19.3 - Rollers and Cages – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-14A-311A-C Planetary gear assembly (mast-planetary assembly) Detailed visual examination. See Para.3 and Figure 3

Fig. 3 – Rollers and Cages (Planetary-Gear Assembly)

Rollers and Cages Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Rollers and Cages Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Rollers and Cages Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Rollers and Cages Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Rollers and Cages Relevant to Planetary gear assy P/N:…………………………… S/N:…………………………… Inspection results: .......................................................................


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7.20 - Left/Right hyd. pump drive quill (main gearbox) – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right pump drive quill (main gearbox) - Detailed visual examination Safety conditions: CAUTION • • •



Support equipment:


Nomenclature

Identification No.


Local supply

111 of 313

7.20.1 - Pinion – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right pump drive quill (main gearbox) Detailed visual examination. See Para.1 and Figure 1. Left pinion P/N:…………………………… S/N:…………………………… Right pinion P/N:…………………………… S/N:…………………………… Inspection results: .......................................................................

Fig. 1 – Pinion (left/right pump drive quill)


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7.20.2 - Locking ring and Seal cover – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right pump drive quill (main gearbox) Detailed visual examination. See Para.2, 3 and Figure 2. Left pump drive quill Locking ring P/N:…………………………… Seal Cover P/N:…………………………… S/N:…………………………… Right pump drive quill Locking ring P/N:…………………………… Seal Cover P/N:…………………………… S/N:……………………………

Fig. 2 – Locking ring and Seal cover (left/right pump drive quill)


113 of 313


7.20.3 - Pump case – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right pump drive quill (main gearbox) Detailed visual examination. See Para.4 and Figure 3. Left Pump case P/N:…………………………… S/N:…………………………… Right Pump case P/N:…………………………… S/N:…………………………… Inspection results: .......................................................................

T8

Fig. 3 – Pump case (left/right pump drive quill)


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7.20.4 - Flanged bearing – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right pump drive quill (main gearbox) Detailed visual examination. See Para.5 and Figure 4. Left Flanged bearing P/N:…………………………… S/N:…………………………… Right Flanged bearing P/N:…………………………… S/N:…………………………… Inspection results: .......................................................................

Fig. 4 – Flanged bearing (left/right pump drive quill)


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39-A-63-20-05-27A-311A-C Left/right pump drive quill (main gearbox) Detailed visual examination. See Para.6 Left pump drive quill

Procedure

Do the detailed visual examination of the following components for corrosion, wear and damage: – The plug – The fitting – The locking washer

Plug P/N:…………………………… Fitting P/N:....................................... Locking washer P/N:.......................................

Right pump drive quill Plug P/N:…………………………… Fitting P/N:....................................... Locking washer P/N:....................................... Inspection results: ......................................................................


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7.21 - Front hyd. pump drive quill (main gearbox) – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-04A-311A-C Front pump drive quill (main gearbox) - Detailed visual examination Safety conditions: CAUTION • • •



Support equipment:


Nomenclature

Identification No.


Local supply

117 of 313


39-A-63-20-05-04A-311A-C Front pump drive quill (main gearbox) - Detailed visual examination. See Para. 1 and Figure1. Pinion P/N:…………………………… S/N:....................................... Inspection results: ......................................................................

Fig. 1 – Pinion (Front pump drive quill)


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7.21.2 - Locking ring and Seal cover – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-04A-311A-C Front pump drive quill (main gearbox) - Detailed visual examination. See Para. 2, 3 and Figure 2. Locking ring P/N:…………………………… Seal Cover P/N:…………………………… S/N:…………………………… Inspection results: ......................................................................

Fig. 2 – Locking ring and Seal cover (Front pump drive quill)


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7.21.3 - Pump case – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-04A-311A-C Front pump drive quill (main gearbox) - Detailed visual examination. See Para. 4 and Figure 3. Pump case P/N:…………………………… S/N:…………………………… Inspection results: ......................................................................

Fig. 3 – Pump Case (Front pump drive quill)


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39-A-63-20-05-04A-311A-C Front pump drive quill (main gearbox) - Detailed visual examination. See Para. 5 and Figure 4. Flanged bearing P/N:…………………………… S/N:…………………………… Inspection results: ......................................................................

Fig. 4 – Flanged bearing (Front pump drive quill)


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39-A-63-20-05-04A-311A-C Front pump drive quill (main gearbox) - Detailed visual examination. See Para. 6.

Procedure

Plug P/N:……………………………

Do the detailed visual examination of the following components for corrosion, wear and damage:

Locking washer P/N:.......................................

– The plug – The locking washer

Inspection results: ......................................................................


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7.22 - ECS compressor drive quill (main gearbox) – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-05A-311A-C ECS compressor drive quill (main gearbox) - Detailed visual examination Safety conditions: CAUTION • • •



Support equipment:


Nomenclature

Identification No.


Local supply

123 of 313


39-A-63-20-05-05A-311A-C ECS compressor drive quill (main gearbox) Detailed visual examination. See Para.1 and Figure 1. Pinion P/N:…………………………… S/N:....................................... Inspection results: ......................................................................

Fig. 1 – Pinion (ECS compressor drive quill)


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7.22.2 - Locking ring – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-05A-311A-C ECS compressor drive quill (main gearbox) Detailed visual examination. See Para.2 and Figure 2. Locking ring P/N:…………………………… Inspection results: ......................................................................

Fig. 2 – Locking ring (ECS compressor drive quill)


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7.22.3 - Case – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-05A-311A-C ECS compressor drive quill (main gearbox) Detailed visual examination. See Para.3 and Figure 3. Case P/N:…………………………… S/N:.......................................


Fig. 3 – Case (ECS compressor drive quill)


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39-A-63-20-05-05A-311A-C ECS compressor drive quill (main gearbox) Detailed visual examination. See Para.4 and Figure 4. Flanged bearing P/N:…………………………… S/N:.......................................


Fig. 4 – Flanged bearing (ECS compressor drive quill)


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7.22.5 - Locking washer – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-05A-311A-C ECS compressor drive quill (main gearbox) Detailed visual examination. See Para.5. Locking washer P/N:……………………………


Procedure Do the detailed visual examination of the locking washer for corrosion, wear and damage.


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7.23 - Fan drive quill (main gearbox) – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-07A-311A-C Fan drive quill (main gearbox) - Detailed visual examination Safety conditions: CAUTION • • •



Support equipment:


Nomenclature

Identification No.


Local supply

129 of 313


39-A-63-20-05-07A-311A-C Fan drive quill (main gearbox) - Detailed visual examination. See Para.1 and Figure 1. Pinion P/N:…………………………… S/N:....................................... Inspection results: ......................................................................

Fig. 1 – Pinion (Fan drive quill)


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39-A-63-20-05-07A-311A-C Fan drive quill (main gearbox) - Detailed visual examination. See Para.2 and Figure 2. Locking ring P/N:…………………………… Inspection results: ......................................................................

Fig. 2 – Locking ring (Fan drive quill)


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39-A-63-20-05-07A-311A-C Fan drive quill (main gearbox) - Detailed visual examination. See Para.3 and Figure 3. Flanged bearing P/N:…………………………… S/N:…………………………… Inspection results: ......................................................................

Fig. 3 – Flanged bearing (Fan drive quill)


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7.23.4 - Locking washer – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-07A-311A-C Fan drive quill (main gearbox) - Detailed visual examination. See Para.4. Locking washer P/N:……………………………




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7.24 - Left/Right lubrication pump (main gearbox) – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-06A-311A-C Left lubrication pump (main gearbox) - Detailed visual examination

39-A-63-20-05-24A-311A-C Right lubrication pump (main gearbox) - Detailed visual examination Safety conditions: CAUTION • • •



Note:

Nomenclature

Identification No.


Local supply


134 of 313

The data to do a detailed visual examination of the left lubrication pump is applicable also to the right lubrication pump. Refer to 39-A-63-20-05-24A-311A-C.

7.24.1 - Gear – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-06A-311A-C Left lubrication pump (main gearbox) Detailed visual examination. See Para. 1 and Figure 1. Left Gear P/N:…………………………… S/N:…………………………… Right Gear P/N:…………………………… S/N:……………………………


Fig. 1 – Gear (Left lubrication pump)


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39-A-63-20-05-06A-311A-C Left lubrication pump (main gearbox) Detailed visual examination. See Para. 2 and Figure 2. Left Locking ring P/N:…………………………… S/N:…………………………… Right Locking ring P/N:…………………………… S/N:……………………………


Fig. 2 – Locking ring (Left lubrication pump)


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7.24.3 -Locking washer – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-06A-311A-C Left lubrication pump (main gearbox) Detailed visual examination. See Para. 3. Left Locking washer P/N:……………………………

Right Locking washer P/N:……………………………




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7.25 - Tail rotor drive quill (main gearbox) – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination





Nomenclature

Identification No.


Local supply

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7.25.1 - Rotor brake case – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination. See Para.1 and Figure 1 Rotor Brake Case P/N:…………………………… S/N:....................................... Inspection results: ......................................................................

Fig. 1 – case (Tail rotor drive quill)


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39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination. See Para.2 and Figure 2 Pinion P/N:…………………………… S/N:....................................... Inspection results: ......................................................................

T4

Fig. 2 – Pinion (Tail rotor drive quill)


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7.25.3 - Fan gear – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination. See Para.3 and Figure 3 Fan gear P/N:…………………………… S/N:....................................... Inspection results: ......................................................................

Fig. 3 – Fan gear (Tail rotor drive quill)


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7.25.4 - Flange – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination. See Para.4 and Figure 4 Flange P/N:…………………………… S/N:....................................... Inspection results: ......................................................................

Fig. 4 – Flange (Tail rotor drive quill)


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7.25.5 - Three locking rings – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination. See Para.5 and Figure 5 Locking ring P/N:…………………………… S/N:....................................... Locking ring P/N:…………………………… S/N:.......................................

Locking ring P/N:…………………………… S/N:.......................................


Fig. 5 – Locking rings (Tail rotor drive quill)


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7.25.6 - Roller bearing – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination. See Para.6 and Figure 6 Roller bearing P/N:…………………………… S/N:.......................................


Fig. 6 – Roller bearing (Tail rotor drive quill)


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7.25.7 - Flanged ball bearing – Detailed visual examination CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination. See Para.7 and Figure 7 Flanged ball bearing P/N:…………………………… S/N:.......................................


Fig. 7 – Flanged ball bearing (Tail rotor drive quill)


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39-A-63-20-05-28A-311A-C Tail rotor drive quill (main gearbox) - Detailed visual examination. See Para. 8 Retaining ring (flange) P/N:…………………………… Spacer (flange) P/N:…………………………… Shim (case) P/N:…………………………… Retaining ring (gear) P/N:…………………………… Shim (gear) P/N:…………………………… Nipple P/N:…………………………… Retaining ring (roller bearing) P/N:…………………………… Inspection results: ......................................................................

Procedure: Check the components reported above for corrosion, wear and damage. For Training purpose only

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7.26 - Dimensions check Hereinafter are shown the CR&OP Data Modules required to perform the Dimensions check: 7.27) 39-A-63-20-05-00A-361A-C Main gearbox - Dimensions check

7.33) 39-A-63-20-05-04A-361A-C Front pump drive quill (main gearbox) - Dimensions check

7.28) 39-A-63-20-05-01A-361A-C Left input shaft module (main Dimensions check

gearbox)

-

7.34) 39-A-63-20-05-05A-361A-C ECS compressor drive quill (main gearbox) Dimensions check

7.28) 39-A-63-20-05-02A-361A-C Right input shaft module (main Dimensions check

gearbox)

-

7.35) 39-A-63-20-05-07A-361A-C Fan drive quill (main gearbox) - Dimensions check

7.29) 39-A-63-20-05-03A-361A-C Upper module (main gearbox) - Dimensions check 7.30) 39-A-63-20-05-13A-361A-C Mast-planetary assembly (upper Dimensions check

7.31) 39-A-63-20-05-14A-361A-C Planetary gear (mast-planetary Dimensions check

7.36) 39-A-63-20-05-24A-361A-C Right lubrication pump (main gearbox) - Dimensions check

module)

-

7.36) 39-A-63-20-05-06A-361A-C Left lubrication pump (main gearbox) - Dimensions check

assembly)

-

7.37) 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check

7.32) 39-A-63-20-05-27A-361A-C Left/right pump drive quill (main gearbox) – Dimensions check


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7.27 - Main gearbox (Main case) – Dimensions check CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox - Dimensions check


During this procedure, do not touch the components made of metal with bare hands. Put on applicable cotton gloves before you touch the components. Contamination from your bare hands will cause corrosion of the metals.


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7.27.1 - Collector gear – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 1 and Figure 1

(MGB A04)

Collector gear P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ (MGB A03)

Fig. 1 – Collector gear (Main gearbox)


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7.27.2 - Diaphragm – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 2 and Figure 2

Diaphragm P/N:……………………………………… S/N:……………………………………….

Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 2 – Diaphragm (Main gearbox)


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7.27.3 - Housing of the collector-gear ball bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 3 and Figure 3

Housing of the collector-gear ball bearing, Main Case P/N:……………………………………… S/N:……………………………………….


Fig. 3 – Housing of the collector gear ball bearing (Main gearbox)


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7.27.4 - Collector-gear ball bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 4 and Figure 4

Collector-gear ball bearing P/N:……………………………………… S/N:……………………………………….


Fig. 4 – Collector gear ball bearing (Main gearbox)


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7.27.5 - Collector-gear roller bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 5 and Figure 5

Collector-gear roller bearing P/N:……………………………………… S/N:……………………………………….


Fig. 5 – Collector gear roller bearing (Main gearbox)


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7.27.6 Housing of the tail rotor drive quill – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 6 and Figure 6 Housing of the tail rotor drive quill, Main Case P/N:……………………………………… S/N:……………………………………….


178.030 / 7.0090

Fig. 6 – Housing of the tail rotor drive quill (Main gearbox)


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7.27.7 - Housing of the fan drive quill – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 7 and Figure 7 Housing of the fan drive quill, Main Case P/N:……………………………………… S/N:……………………………………….


Fig. 7 – Housing of the fan drive quill (Main gearbox)


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7.27.8 - Sliding adaptor – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 8 and Figure 8 Sliding adaptor P/N:……………………………………… S/N:……………………………………….


Fig. 8 – Sliding adaptor (Main gearbox)


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7.27.9 - Cross shafts (left and right input pinion shaft module) – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 9 and Figure 9 Left Cross shaft P/N:……………………………………… S/N:………………………………………. Right Cross shaft P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 9 – Cross shaft (left and right input pinion)


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7.27.10 - Left and right input pinion (II° stage) – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 10 and Figure 10 Left input pinion P/N:……………………………………… S/N:………………………………………. Right input pinion P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 10 – Input pinion (left and right)


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7.27.11 - Left and right pump gear – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 11 and Figure 11 Left pump gear P/N:……………………………………… S/N:………………………………………. Right pump gear P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 11 – Pump gear (left and right Input pinion)


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7.27.12 - Left and right bearing sleeve – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 12 and Figure 12 Left bearing sleeve P/N:……………………………………… S/N:………………………………………. Right bearing sleeve P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 12 – Bearing sleeve (left and right Input pinion)


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7.27.13 - Housing of the left and right input pinion bearings (main case) – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 13 and Figure 13 Housing of the left and right input pinion bearings, Main case: P/N:……………………………………… S/N:……………………………………….


Fig. 13 – Housing of the left and right input pinion bearings (main case)


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7.27.14 - Triplex bearing (left and right input pinion) – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 14 and Figure 14 Left triplex ball bearing P/N:……………………………………… S/N:………………………………………. Right triplex ball bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 14 – Ttriplex bearing (left and right input pinion)


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7.27.15 - Roller bearing (left and right input pinion) – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 15 and Figure 15 Left roller bearing P/N:……………………………………… S/N:………………………………………. Right roller bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 15 – Roller bearing (left and right input pinion)


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7.27.16 - Housing of the diaphragm – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 16 and Figure 16 Housing of the diaphragm, Main case: P/N:……………………………………… S/N:……………………………………….


Fig. 16 – Housing of the diaphragm (main case)


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7.27.17 - Housing of the left and right pump drive quill – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 17 and Figure 17 Housings of the left and right pump drive quill, Main case: P/N:……………………………………… S/N:……………………………………….


Fig. 17 – Housings of the left and right pump drive quill (Main case)


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7.27.18 - Housing of the front pump drive quill – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 18 and Figure 18 Housing of the front pump drive quill, Main case: P/N:……………………………………… S/N:……………………………………….


Fig. 18 – Housing of the front pump drive quill (Main case)


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7.27.19 - Housing of the ECS drive quill – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 19 and Figure 19 Housing of the ECS drive quill, Main case: P/N:……………………………………… S/N:……………………………………….


Fig. 19 – Housing of the ECS drive quill (Main case)


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7.27.20 - Housings of the left and right lubrication pump – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 20 and Figure 20 Housings of the left and right lubrication pimp, Main case: P/N:……………………………………… S/N:……………………………………….


Fig. 20 – Housings of the left and right lubrication pump (Main case)


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7.27.21 - Housing of the servo actuators brackets – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 21 and Figure 21 Housing of the servo actuators brackets, Main case: P/N:……………………………………… S/N:……………………………………….


Fig. 21 – Housings of the servo actuators brackets (Main case)


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7.27.22 - Anti-torque beam – Dimensions check CR&OP Data Module: 39-A-63-20-05-00A-361A-C Main gearbox Dimensions check. See Para. 22 and Figure 22 Anti-torque beam P/N:……………………………………… S/N:……………………………………….


Note:

Fig. 22 – Anti-torque beam


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If the internal diameter of one of the four bushings of the anti-torque beam does not obey the permitted dimension written in Fig 22, you must replace the bushing (or the bushings). Refer to CR&OP 39-A-63-20-05-40A-921A-C. (This task is not part of this course). Contact the Manufacturer.

7.28 - Left and Right input shaft module (main gearbox) Dimensions check CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft module Dimensions check

(main

gearbox)

-

39-A-63-20-05-02A-361A-C Right input shaft module (main gearbox) Dimensions check Safety conditions: CAUTION • • •


General note The data to do a dimension check of the left-input shaft module is applicable also to the right-input shaft module (see CR&OP 39-A-63-20-05-02A-361A-C)


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7.28.1 - Case assy – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 1 and Figure 1 LH Case Assy P/N:……………………………………… S/N:………………………………………. RH Case Assy P/N:……………………………………… S/N:……………………………………….


Fig. 1 – Case Assy (left input shaft module)


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7.28.2 - Input Pinion – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check. See Para. 2 and Figure 2

(MGB A01)

(MGB A02)

LH Pinion P/N:………………………… S/N:………………………… RH Pinion P/N:………………………… S/N:………………………… Inspection results: ....................................................

Fig. 2 – Input pinion (left input shaft module)


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7.28.3 - Gear, I° stage of reduction – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 3 and Figure 3 LH Gear P/N:……………………………………… S/N:………………………………………. RH Gear P/N:……………………………………… S/N:……………………………………….


Fig. 3 – Gear (left input shaft module)


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7.28.4 - Input shaft – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 4 and Figure 4 LH Input shaft P/N:……………………………………… S/N:………………………………………. D

RH Input shaft P/N:……………………………………… S/N:……………………………………….


D

Fig. 4 – Input shaft (left input shaft module)


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7.28.5 - Diaphragm – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 5 and Figure 5 LH Diaphragm P/N:……………………………………… S/N:………………………………………. RH Diaphragm P/N:……………………………………… S/N:……………………………………….


Fig. 5 – Diaphragm (left input shaft module)


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7.28.6 - Sleeve – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 6 and Figure 6 LH Sleeve P/N:……………………………………… S/N:………………………………………. RH Sleeve P/N:……………………………………… S/N:……………………………………….


Fig. 6 – Sleeve (left input shaft module)


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7.28.7 - Flange – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 7 and Figure 7 LH Flange P/N:……………………………………… S/N:……………………………………….

D

RH Flange P/N:……………………………………… S/N:………………………………………. D


Fig. 7 – Flange (left input shaft module)


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7.28.8 Gimbal support – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 8 and Figure 8 LH Gimbal support P/N:……………………………………… S/N:………………………………………. RH Gimbal support P/N:……………………………………… S/N:……………………………………….


Fig. 8 – Gimbal support (left input shaft module)


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7.28.9 - Inner bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 9 and Figure 9 LH Inner bearing P/N:……………………………………… S/N:………………………………………. RH Inner bearing P/N:……………………………………… S/N:……………………………………….


Fig. 9 – Inner bearing (left input shaft module)


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7.28.10 - Outer bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 10 and Figure 10 LH Outer bearing P/N:……………………………………… S/N:………………………………………. RH Outer bearing P/N:……………………………………… S/N:……………………………………….


Fig. 10 – Outer bearing (left input shaft module)


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7.28.11 - Ball bearing (gear, I° stage of reduction) – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 11 and Figure 11 LH Ball bearing P/N:……………………………………… S/N:………………………………………. RH Ball bearing P/N:……………………………………… S/N:……………………………………….


Fig. 11 – Ball bearing (left input shaft module)


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7.28.12 - Roller bearing (gear, I° stage of reduction) – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 12 and Figure 12 LH Roller bearing P/N:……………………………………… S/N:………………………………………. RH Roller bearing P/N:……………………………………… S/N:……………………………………….


Roller bearing OD

Fig. 12 – Roller bearing (left input shaft module)


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7.28.13 - Roller bearing (Input pinion) – Dimensions check CR&OP Data Module: 39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check See Para. 13 and Figure 13 LH Roller bearing P/N:……………………………………… S/N:………………………………………. RH Roller bearing P/N:……………………………………… S/N:……………………………………….


Fig. 13 – Roller bearing (left input shaft module)


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7.28.14 - Duplex ball bearing (Input pinion) – Dimensions check CR&OP Data Module: (MGB A01)

39-A-63-20-05-01A-361A-C Left input shaft module (main gearbox) - Dimensions check. See Para. 14 and Figure 14 LH Duplex ball bearing (MGB A02)

P/N:…………………………… S/N:…………………………… RH Duplex ball bearing P/N:…………………………… S/N:……………………………

Inspection results: ...............................................

Fig. 14 – Duplex ball bearing (left input shaft module)


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7.29 - Upper module (main gearbox) – Dimensions check CR&OP Data Module:

39-A-63-20-05-03A-361A-C Upper module (main gearbox) Dimensions check Safety conditions: CAUTION • • •



186 of 313

7.29.1 - Top Case – Dimensions check CR&OP Data Module: 39-A-63-20-05-03A-361A-C Upper (main gearbox) - Dimensions check See Para. 1 and Figure 1 Top Case P/N:……………………………………… S/N:………………………………………. Inspection results: ........................................................................ ........................................................................ ........................................................................

Fig. 1 – Top case (Upper module)


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module

7.29.2 - Top-case strut attachments – Dimensions check CR&OP Data Module: 39-A-63-20-05-03A-361A-C Upper (main gearbox) - Dimensions check See Para. 2 and Figure 2 Top-case strut attachment of the upper fittings, Top case: P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 2 – Top case strut attachments (Upper module)


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module

7.29.3 - Ring gear – Dimensions check CR&OP Data Module: 39-A-63-20-05-03A-361A-C Upper (main gearbox) - Dimensions check See Para. 3 and Figure 3 Ring gear P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 3 – Ring gear (Upper module)


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module

7.29.4 - Roller bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-03A-361A-C Upper (main gearbox) - Dimensions check See Para. 4 and Figure 4 Roller bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 4 – Roller bearing (Upper module)


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module

7.29.5 - Four Upper Fittings – Dimensions check CR&OP Data Module: 39-A-63-20-05-03A-361A-C Upper (main gearbox) - Dimensions check See Para. 5 and Figure 5

module

Upper Fitting P/N:……………………………………… S/N:………………………………………. Upper Fitting P/N:……………………………………… S/N:………………………………………. Upper Fitting P/N:……………………………………… S/N:………………………………………. Upper Fitting P/N:……………………………………… S/N:……………………………………….

Inspection results: .................................................................

Note: If required, replace the Spherical Bearing i.a.w. CR&OP 39-A-63-20-05-00A-921A-C. (This task is not part of this course). Contact the Manufacturer. Fig. 5 – Upper Fitting (Upper module)


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7.30 - Mast-planetary assembly (upper module) – Dimensions check CR&OP Data Module:

39-A-63-20-05-13A-361A-C Mast-planetary assembly (upper module) - Dimensions check Safety conditions: CAUTION • • •



192 of 313

7.30.1 - Main rotor shaft (MAST) – Dimensions check CR&OP Data Module: 39-A-63-20-05-13A-361A-C Mast-planetary assembly (upper module) Dimensions check See Para. 1 and Figure 1 Main rotor shaft (mast) P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 1 – Main rotor shaft (Mast planetary assembly)


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7.30.2 - Spider plate – Dimension check CR&OP Data Module: 39-A-63-20-05-13A-361A-C Mast-planetary assembly (upper module) Dimensions check See Para. 2 and Figure 2 Spider plate P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 2 – Spider plate (Mast planetary assembly)


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7.30.3 - Planetary pin – Dimension check CR&OP Data Module: 39-A-63-20-05-13A-361A-C Mast-planetary assembly (upper module) Dimensions check See Para. 3 and Figure 3 Planetary Pin P/N:……………………………………… S/N:………………………………………. Planetary Pin P/N:……………………………………… S/N:………………………………………. Planetary Pin P/N:……………………………………… S/N:………………………………………. Planetary Pin P/N:……………………………………… S/N:………………………………………. Planetary Pin P/N:……………………………………… S/N:……………………………………….

Fig. 3 – Planetary pin (Mast planetary assembly)


195 of 313

Inspection results: ......................................................................... ......................................................................... ......................................................................

7.30.4 - Ball bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-13A-361A-C Mast-planetary assembly (upper module) Dimensions check See Para. 4 and Figure 4 Ball bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 4 – Ball bearing (Mast planetary assembly)


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7.31 - Planetary gear (mast–planetary assembly) Dimensions check CR&OP Data Module:

39-A-63-20-05-14A-361A-C Planetary gear (mast-planetary assembly) - Dimensions check Safety conditions: CAUTION • • •



197 of 313

7.31.1 - Inner bearing race – Dimensions check CR&OP Data Module: 39-A-63-20-05-14A-361A-C Planetary gear (mast-planetary assembly) Dimensions check See Para. 1 and Figure 1 Inner bearing race, part of the Planetary gear assy P/N:……………………………………… S/N:………………………………………. Inner bearing race, part of the Planetary gear assy P/N:……………………………………… S/N:………………………………………. Inner bearing race, part of the Planetary gear assy P/N:……………………………………… S/N:………………………………………. Inner bearing race, part of the Planetary gear assy P/N:……………………………………… S/N:………………………………………. Inner bearing race, part of the Planetary gear assy P/N:……………………………………… S/N:………………………………………. Fig. 1 – Planetary gear (Mast planetary assembly)


198 of 313

Inspection results: ......................................................................... .........................................................................

7.32 - Left/right hyd. pump drive quill (main gearbox) – Dimensions check CR&OP Data Module:

39-A-63-20-05-27A-361A-C Left/right pump drive quill (main gearbox) - Dimensions check Safety conditions: CAUTION • • •



199 of 313

7.32.1 - Pinion – Dimensions check CR&OP Data Module: 39-A-63-20-05-27A-361A-C Left/right pump drive quill (main gearbox) - Dimensions check See Para. 1 and Figure 1 Left pinion P/N:……………………………………… S/N:………………………………………. Right pinion P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 1 – Pinion (left/right pump drive quill)


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7.32.2 - Pump case – Dimensions check CR&OP Data Module: 39-A-63-20-05-27A-361A-C Left/right pump drive quill (main gearbox) - Dimensions check See Para. 2 and Figure 2 Left pump case P/N:……………………………………… S/N:………………………………………. Right pump case P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 2 – Pump case (left/right pump drive quill)


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7.32.3 - Flanged bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-27A-361A-C Left/right pump drive quill (main gearbox) - Dimensions check See Para. 3 and Figure 3 Left Flanged bearing P/N:……………………………………… S/N:………………………………………. Right Flanged bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 3 – Flanged bearing (left/right pump drive quill)


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7.33 - Front hyd. pump drive quill (main gearbox) – Dimensions check CR&OP Data Module:

39-A-63-20-05-04A-361A-C Front pump drive quill (main gearbox) - Dimensions check Safety conditions: CAUTION • • •



203 of 313

7.33.1 - Pinion – Dimensions check CR&OP Data Module: 39-A-63-20-05-04A-361A-C Front pump drive quill (main gearbox) - Dimensions check See Para. 1 and Figure 1

Pinion P/N:……………………………………… S/N:……………………………………….


Fig. 1 – Pinion (Front pump drive quill)


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7.33.2 - Pump Case – Dimensions check CR&OP Data Module: 39-A-63-20-05-04A-361A-C Front pump drive quill (main gearbox) - Dimensions check See Para. 2 and Figure 2

Pump Case P/N:……………………………………… S/N:……………………………………….


Fig. 2 – Pump Case (Front pump drive quill)


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7.33.3 - Flanged bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-04A-361A-C Front pump drive quill (main gearbox) - Dimensions check See Para. 3 and Figure 3

Flanged bearing P/N:……………………………………… S/N:……………………………………….


Fig. 3 – Flanged bearing (Front pump drive quill)


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7.34 - ECS compressor drive quill (main gearbox) – Dimensions check CR&OP Data Module:

39-A-63-20-05-05A-361A-C ECS compressor drive quill (main gearbox) - Dimensions check Safety conditions: CAUTION • • •



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7.34.1 - Pinion – Dimensions check CR&OP Data Module: 39-A-63-20-05-05A-361A-C ECS compressor drive quill (main gearbox) Dimensions check. See Para. 1 and Figure 1 Pinion P/N:……………………………………… S/N:……………………………………….


Fig. 1 – Pinion (ECS compressor drive quill)


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7.34.2 - Case – Dimensions check CR&OP Data Module: 39-A-63-20-05-05A-361A-C ECS compressor drive quill (main gearbox) Dimensions check. See Para. 2 and Figure 2 Case P/N:……………………………………… S/N:……………………………………….


Fig. 2 – Case (ECS compressor drive quill)


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7.34.3 - Flanged bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-05A-361A-C ECS compressor drive quill (main gearbox) Dimensions check. See Para. 3 and Figure 3 Flanged bearing P/N:……………………………………… S/N:……………………………………….


Fig. 3 – Flanged bearing (ECS compressor drive quill)


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7.35 - Fan drive quill (main gearbox) – Dimensions check CR&OP Data Module:

39-A-63-20-05-07A-361A-C Fan drive quill (main gearbox) Dimensions check Safety conditions: CAUTION • • •



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7.35.1 - Pinion – Dimensions check CR&OP Data Module: 39-A-63-20-05-07A-361A-C Fan drive quill (main gearbox) - Dimensions check. See Para. 1 and Figure 1

Pinion P/N:……………………………………… S/N:……………………………………….


Fig. 1 – Pinion (Fan drive quill)


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7.35.2 - Flanged bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-07A-361A-C Fan drive quill (main gearbox) - Dimensions check. See Para. 2 and Figure 2

Flanged bearing P/N:……………………………………… S/N:……………………………………….


Fig. 2 – Flanged bearing (Fan drive quill)


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7.36 - Left /Right lubrication pump (main gearbox) – Dimensions check CR&OP Data Module:

39-A-63-20-05-06A-361A-C Left lubrication pump (main gearbox) - Dimensions check 39-A-63-20-05-24A-361A-C Right lubrication pump (main gearbox) - Dimensions check Safety conditions: CAUTION • • •

During this procedure, do not touch the components made of metal with bare hands. Put on applicable cotton gloves before you touch the components. Contamination from your bare hands will cause corrosion of the metals. Note: The data to do the dimensions check of the left lubrication pump is applicable also to the right lubrication pump. See 39-A-63-20-05-24A-361A-C.


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7.36.1 - Gear – Dimensions check CR&OP Data Module: 39-A-63-20-05-06A-361A-C Left lubrication pump (main gearbox) Dimensions check. See Para. 1 and Figure 1

Left Gear P/N:……………………………………… S/N:………………………………………. Right Gear P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 1 – Gear (Left Lubrication Pump)


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7.36.2 - Pump shaft – Dimensions check CR&OP Data Module: 39-A-63-20-05-06A-361A-C Left lubrication pump (main gearbox) Dimensions check. See Para. 2 and Figure 2

Left Pump P/N:……………………………………… S/N:………………………………………. Right Pump P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 2 – Pump shaft (Left Lubrication Pump)


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7.37 - Tail rotor drive quill (main gearbox) – Dimensions check CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) Dimensions check




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7.37.1 - Pinion – Dimensions check (sheet 1 of 2) CR&OP Data Module: 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check See Para. 1 and Figure 1

Pinion (for MGB P/N 3G6320A00132) P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 1 – Pinion (Tail rotor drive quill) – Sheet 1 of 2


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7.37.1 - Pinion – Dimensions check (sheet 2 of 2) CR&OP Data Module: 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check See Para. 1 and Figure 1

Pinion (for MGB P/N 3G6320A00133 and subsequent P/N with different two last digits) P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 1 – Pinion (Tail rotor drive quill) – Sheet 2 of 2


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7.37.2 - Fan gear – Dimensions check CR&OP Data Module: 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check See Para. 2 and Figure 2

Fan gear P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 2 – Fan gear (Tail rotor drive quill)


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7.37.3 - Flange – Dimensions check CR&OP Data Module: 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check See Para. 3 and Figure 3

Flange P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 3 – Flange (Tail rotor drive quill)


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7.37.4 - Rotor brake case – Dimensions check CR&OP Data Module: 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check See Para. 4 and Figure 4

Rotor brake case P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 4 – Rotor brake case (Tail rotor drive quill)


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7.37.5 - Flanged bearing – Dimensions check CR&OP Data Module: 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check See Para. 5 and Figure 5

Flanged bearing P/N:……………………………………… S/N:………………………………………. Inspection results: ......................................................................... ......................................................................... ......................................................................

Fig. 5 –Flanged bearing (Tail rotor drive quill)


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7.37.6 - Roller bearing – Dimensions check (sheet 1 of 2) CR&OP Data Module: 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check See Para. 6 and Figure 6

Roller bearing (for MGB P/N 3G6320A00132) P/N:……………………………………… S/N:………………………………………. Inspection results: .................................................................................. .................................................................................. ....................................................

Fig. 6 – Roller bearing (Tail rotor drive quill) – sheet 1 of 2


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7.37.6 - Roller bearing – Dimensions check (sheet 2 of 2) CR&OP Data Module: 39-A-63-20-05-28A-361A-C Tail rotor drive quill (main gearbox) - Dimensions check See Para. 6 and Figure 6

Roller bearing (for MGB P/N 3G6320A00133 and subsequent P/N with different two last digits) P/N:……………………………………… S/N:………………………………………. Inspection results: .................................................................................. .................................................................................. ....................................................

Fig. 6 – Roller bearing (Tail rotor drive quill) – sheet 2 of 2


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7.38 - Dye penetrant Examination Hereinafter are shown the CR&OP Data Modules required to perform the dye penetrant examination on the MGB components:

7.39) 39-A-60-20-01-00A-351A-C Disassembled metal components – Tests for surface cracks with dye penetrant (General guidelines for Dye Penetrant Examination) 7.40) 39-A-63-20-05-00A-351A-C Main gearbox – Tests for surface cracks with dye penetrant 7.41) 39-A-63-20-05-01A-351A-C Left input shaft module (main gearbox) – Tests for surface cracks with dye penetrant 7.41) 39-A-63-20-05-02A-351A-C Right input shaft module (main gearbox) – Tests for surface cracks with dye penetrant 7.42) 39-A-63-20-05-03A-351A-C Upper module (main gearbox) – Tests for surface cracks with dye penetrant


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7.43) 39-A-63-20-05-04A-351A-C Front pump drive quill (main gearbox) – Tests for surface cracks with dye penetrant 7.44) 39-A-63-20-05-05A-351A-C ECS compressor drive quill (main gearbox) – Tests for surface cracks with dye penetrant 7.45) 39-A-63-20-05-27A-351A-C Left/right pump drive quill (main gearbox) – Tests for surface cracks with dye penetrant 7.46) 39-A-63-20-05-28A-351A-C Tail rotor drive quill (main gearbox) – Tests for surface cracks with dye penetrant

7.39 – General guidelines for Dye Penetrant Examination CR&OP Data Module:

39-A-60-20-01-00A-351A-C Disassembled metal components - Tests for surface cracks with dye penetrant Safety conditions: WARNINGS You must be careful when you do the penetrant inspection. Make sure you know the safety precaution given in standard practices for liquid penetrant examination (ASTM-E1417). Wear protective goggles when you use the compressed air. Dust and particles can cause injury to your eyes.

CAUTION Only approved personnel are permitted to do this procedure.

Procedure 1 ) Unpainted component. Clean the component. Refer to CR&OP 39-A-60-10-01-00A-251A-C. 2) Painted component. Remove the paint finish from the component as applicable, refer to: CR&OP: 39-A-60-10-01-00A-651A-C or to 659A-C or to -659B-C as necessary. 3) Do a penetrant inspection of the component to find cracks. Obey the standard practices for liquid penetrant examination (ASTME1417).

Note Refer to QPL-AMS-2644-1 for a list of the qualified products for the liquid penetrant examination.

“NDT” Type Type I, Method D, Sensitivity Level 2 or Level 3 penetrant (refer to the data module of the applicable component).


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7.40 - Main gearbox – Tests for surface cracks with dye penetrant CR&OP Data Module:

39-A-63-20-05-00A-351A-C Main gearbox - Tests for surface cracks with dye penetrant

Procedure

To do the test of metal components for surface cracks with dye penetrant. Refer to CR&OP: 39-A-60-20-01-00A-351A-C for general guideline.


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7.40.1 - Main case, Bottom cover, Anti-torque beam, Diaphragm – Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-00A-351A-C Main gearbox - Tests for surface cracks with dye penetrant. See form Para. 1 to Para. 4 and Figure 1 (sheet 1 of 4)

Diaphragm

1) Main case P/N:……………………………………… S/N:……………………………………….

Main Case

2) Bottom cover P/N:……………………………………… S/N:………………………………………. 3) Anti-torque beam P/N:……………………………………… S/N:……………………………………….

Bottom Cover

4) Diaphragm P/N:……………………………………… S/N:………………………………………. Dye Penetrant Classification :

Anti-torque beam

Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 2 (Sensitivity level: Medium). Fig. 1 – Main gearbox (sheet 1 of 4)


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Inspection results: ..................................

7.40.2 - Seal cover of the Fan & ECS compressor drive quills – Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-00A-351A-C Main gearbox - Tests for surface cracks with dye penetrant. See Paragraphs 5,6 and Figure 1 (sheet 2 of 4) 5) Seal cover of the Fan drive quill Seal cover (Fan drive quill)

P/N:……………………………………… S/N:………………………………………. 6) Seal cover of the ECS compressor drive quill

Seal cover (ECS compressor)

P/N:……………………………………… S/N:……………………………………….

Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 2 (Sensitivity level: Medium).

Inspection results: .................................. Fig. 1 – Main gearbox (sheet 2 of 4)


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7.40.3 - Servo-actuator brackets - Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-00A-351A-C Main gearbox - Tests for surface cracks with dye penetrant. See Para. 7 and Figure 1 (sheet 3 of 4) 7) Front servo-actuator Bracket (A) P/N:……………………………………… S/N:………………………………………. 8) Left servo-actuator Bracket (B) P/N:……………………………………… S/N:………………………………………. Servo-actuators Brackets

9) Right servo-actuator Bracket (C) P/N:……………………………………… S/N:……………………………………….

Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 3 (Sensitivity level: High). Inspection results: .................................. Fig. 1 – Main gearbox (sheet 3 of 4)


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7.40.4 - Left and Right input pinions locking rings, collector-gear locking ring - Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-00A-351A-C Main gearbox - Tests for surface cracks with dye penetrant. See Para. 8 and Figure 1 (sheet 4 of 4) 10) Left ring nut P/N:……………………………………… S/N:………………………………………. 10) Right ring nut P/N:……………………………………… S/N:………………………………………. 11) Collector-gear locking ring P/N:……………………………………… S/N:……………………………………….

Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 3 (Sensitivity level: High).

Collector-gear Locking ring

Ring nut Inspection results: ..................................

Fig. 1 – Main gearbox (sheet 4 of 4)


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7.41 - Left and right input shaft module (main gearbox) – Tests for surface cracks with dye penetrant CR&OP Data Module:

39-A-63-20-05-01A-351A-C Left input shaft module (main gearbox) - Tests for surface cracks with dye penetrant 39-A-63-20-05-02A-351A-C Right input shaft module (main gearbox) - Tests for surface cracks with dye penetrant Procedure


Nota The data to do a test for surface cracks with dye penetrant of the left-input shaft module are applicable also to the right-input shaft module (see CR&OP 39-A-63-20-05-02A-351A-C). For Training purpose only

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7.41.1 - Case assy, Oil jet cover, Diaphragm – Tests for surface cracks with dye penetrant CR&OP Data Module:

Diaphragm Case Assy

39-A-63-20-05-01A-351A-C Left input shaft module (main gearbox) Tests for surface cracks with dye penetrant See Paragraphs 1, 2, 3 and Figure 1

Oil Jet Cover

1) LH Case Assy P/N:……………………………………… S/N:……………………………………….

1) RH Case Assy P/N:……………………………………… S/N:………………………………………. 2) LH Oil jet cover P/N:……………………………………… S/N:……………………………………….

Fig. 1 – left input shaft module (MGB)

Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 2 (Sensitivity level: Medium), Time: 30’. Inspection results: ..................................


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2) RH Oil jet cover P/N:……………………………………… S/N:………………………………………. 3) LH Diaphragm P/N:……………………………………… S/N:……………………………………….

3) RH Diaphragm P/N:……………………………………… S/N:……………………………………….

7.42 - Upper module (main gearbox) – Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-03A-351A-C Upper module (main gearbox) - Tests for surface cracks with dye penetrant Procedure



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7.42.1 - Top case, Cooler adapter and Seal cover Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-03A-351A-C Upper module (main gearbox) - Tests for surface cracks with dye penetrant. See Para. 1, 2, 4 and Figure 1 (sheet 1 of 2)

Seal cover

1) Top Case P/N:……………………………………… S/N:……………………………………….

2) Cooler adapter P/N:……………………………………… S/N:………………………………………. 3) Seal cover P/N:……………………………………… S/N:……………………………………….

Top case Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 2 (Sensitivity level: Medium).

Cooler adapter

Inspection results: .................................. Fig. 1 – Upper module (MGB) – sheet 1 of 2


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7.42.2 - Four Upper Fittings Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-03A-351A-C Upper module (main gearbox) - Tests for surface cracks with dye penetrant. See Para. 3 and Figure 1 (sheet 2 of 2) Upper Fitting (A) P/N:……………………………………… S/N:……………………………………….

Upper Fitting (B) P/N:……………………………………… S/N:………………………………………. Upper Fitting (C) P/N:……………………………………… S/N:……………………………………….

Upper Fitting (D) P/N:……………………………………… S/N:……………………………………….

Upper Fitting

Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 3 (Sensitivity level: High). Inspection results: .................................. Fig. 1 – Upper module (MGB) – sheet 2 of 2


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7.43 - Front hyd. pump drive quill (main gearbox) – Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-04A-351A-C Front pump drive quill (main gearbox) - Tests for surface cracks with dye penetrant Procedure



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7.43.1 - Pump Case, Seal Cover – Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-04A-351A-C Front pump drive quill (main gearbox) - Tests for surface cracks with dye penetrant. See Para. 1 and 2, Figure 1 Pump Case P/N:……………………………………… S/N:………………………………………. Seal Cover P/N:……………………………………… S/N:………………………………………. Pump case Seal Cover

Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 2 (Sensitivity level: Medium). Inspection results: ..................................

Fig. 1 – Front pump drive quill (MGB)


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7.44 - ECS compressor drive quill (main gearbox) – Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-05A-351A-C ECS compressor drive quill (main gearbox) Tests for surface cracks with dye penetrant Procedure



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7.44.1 - Case - Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-05A-351A-C ECS compressor drive quill (main gearbox) Tests for surface cracks with dye penetrant See Para. 1 and Figure 1 Case P/N:……………………………………… S/N:………………………………………. Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 2 (Sensitivity level: Medium). Inspection results: ..................................

Case

Fig. 1 – ECS compressor drive quill (MGB)


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7.45 - Left/right hyd. pump drive quill (main gearbox) – Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-27A-351A-C Left/right pump drive quill (main gearbox) Tests for surface cracks with dye penetrant

Procedure To do the test of metal components for surface cracks with dye penetrant. Refer to CR&OP: 39-A-60-20-01-00A-351A-C for general guideline.


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7.45. 1 - Pump Case and Seal Cover – Tests for surface cracks with dye penetrant CR&OP Data Module: 39-A-63-20-05-27A-351A-C Left/right pump drive quill (main gearbox) Tests for surface cracks with dye penetrant. See Para. 1 and 2, Figure 1 Left Pump Case P/N:……………………………………… S/N:………………………………………. Left Seal Cover P/N:……………………………………… S/N:……………………………………….

Pump Case

Seal Cover

Right Pump Case P/N:……………………………………… S/N:………………………………………. Right Seal Cover P/N:……………………………………… S/N:……………………………………….

Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 2 (Sensitivity level: Medium).

Fig. 1 – Left/right pump drive quill (MGB)


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Inspection results: ..................................

7.46 - Tail rotor drive quill (main gearbox) – Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-28A-351A-C Tail rotor drive quill (main gearbox) - Tests for surface cracks with dye penetrant

Procedure To do the test of metal components for surface cracks with dye penetrant. Refer to CR&OP: 39-A-60-20-01-00A-351A-C for general guideline.


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7.46.1 - Rotor brake case, Seal case and Locking rings – Tests for surface cracks with dye penetrant Locking ring Rotor brake Case Seal Case

CR&OP Data Module: 39-A-63-20-05-28A-351A-C Tail rotor drive quill (main gearbox) – Tests for surface cracks with dye penetrant. See from Para. 1 to Para. 5, Figure 1 3) Rotor brake Case P/N:……………………………………… S/N:……………………………………….

Locking ring

2) Seal Case P/N:……………………………………… S/N:……………………………………….

Locking ring

1) Locking ring P/N:……………………………………… S/N:………………………………………. 4) Locking ring P/N:……………………………………… S/N:………………………………………. 5) Locking ring (*) P/N:……………………………………… S/N:……………………………………….

Fig. 1 – Tail rotor drive quill (MGB)

Dye Penetrant Classification : Type I (Fluorescent dye), Method D (methods of excess penetrant removal), Level 2 (items 2, 3) Level 3 (items 1, 4, 5). Inspection results: ..................................


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7.47 - Magnetic particles examination Hereinafter are shown the CR&OP Data Modules required to perform the Magnetic particles examination : 7.48) 39-A-60-20-01-00A-352A-C Disassembled metal components – Tests for surface cracks with magnetic particles (General guidelines for Magnetic Particles Examination) 7.49) 39-A-63-20-05-00A-352A-C Main gearbox – Tests for surface cracks with magnetic particles 7.50) 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) – Tests for surface cracks with magnetic particles 7.50) 39-A-63-20-05-02A-352A-C Right input shaft module (main gearbox) – Tests for surface cracks with magnetic particles 7.51) 39-A-63-20-05-03A-352A-C Upper module (main gearbox) – Tests for surface cracks with magnetic particles 7.52) 39-A-63-20-05-04A-352A-C Front hyd. pump drive quill (main gearbox) – Tests for surface cracks with magnetic particles 7.53) 39-A-63-20-05-05A-352A-C ECS compressor drive quill (main gearbox) – Tests for surface cracks with magnetic particles


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7.54) 39-A-63-20-05-06A-352A-C Left lubrication pump (main gearbox) – Tests for surface cracks with magnetic particles 7.54) 39-A-63-20-05-24A-352A-C Right lubrication pump (main gearbox) – for surface cracks with magnetic particles 7.55) 39-A-63-20-05-07A-352A-C Fan drive quill (main gearbox) – Tests for surface cracks with magnetic particles

7.56) 39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) – Tests for surface cracks with magnetic particles 7.57) 39-A-63-20-05-14A-352A-C Planetary gear assembly (upper module) – Tests for surface cracks with magnetic particles 7.58) 39-A-63-20-05-27A-352A-C Left/right hyd. pump drive quill (main gearbox) – Tests for surface cracks with magnetic particles 7.59) 39-A-63-20-05-28A-352A-C Tail rotor drive quill (main gearbox) – Tests for surface cracks with magnetic particles

7.48 – General guidelines for Magnetic Particles Examination CR&OP Data Module:

39-A-60-20-01-00A-352A-C Disassembled metal components - Tests for surface cracks with magnetic particles Safety conditions: WARNING You must be careful when you do the magnetic particle inspection. Make sure you know the safety precaution given in standard practices for magnetic particle inspection (ASTM-E1444).

CAUTION Only approved personnel are permitted to do this procedure.

Procedure 1) Unpainted component. Clean the component. Refer to CR&OP 39-A-60-10-01-00A-251A-C.

2) Painted component. Remove the paint finish from the component. Refer to 39-A-60-10-01-00A-252A-C (this Data Module is in preparation). 3) Do a magnetic particle inspection of the component to find cracks. Obey the standard practices for magnetic particle inspection (ASTM-E1444). 4) Use the products that follow (or approved alternatives):

– Particles Ardrox 8515 or Magnaflux Magnaglo 14A – Liquid carrier Ardrox Fluxal. 5) Clean the component. Refer to Step 1. 6) Put the component in an applicable container. Make sure the component has sufficient protection against environmental condition.


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7.49 - Main gearbox (Main case) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles

Procedure

To do the test of metal components for surface cracks with magnetic particles. Refer to CR&OP 39-A-60-20-01-00A-352A-C for general guideline.


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7.49.1 - MGB (Main case) components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles. Refer to Figure 1

The components involved are: 1) Collector gear P/N:……………………………………… S/N:………………………………………. 2) Sliding Adapter P/N:……………………………………… S/N:………………………………………. 3) Collector gear Locking ring P/N:……………………………………… S/N:………………………………………. 4) LH and RH Input Pinions (II° stage) P/N:……………………………………… S/N:………………………………………. 5) LH and RH Cross Shafts P/N:……………………………………… S/N:………………………………………

6) LH and RH input pinions Locking Rings P/N:……………………………………… S/N:……………………………………… 7) LH and RH Pump gears P/N:………………………………………. S/N:……………………………………… 8) and 9) LH and RH Retaining Rings P/N:………………………………………. S/N:……………………………………… 10) LH and RH Pinion Bearing Sleeves P/N:……………………………………… S/N:……………………………………… Fig. 1 – Main gearbox – Components for magnetic particles test


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7.49.2 - Collector gear – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para.1 and to Figure 2

Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 2 – Collector gear – Magnetic Particles Test Procedure


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7.49.3 - Left and right Input pinions – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para.2 and to Figure 3


Fig. 3 – Input Pinion – Magnetic Particles Test Procedure


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7.49.4 - Left and right Pump Gears – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para.3 and to Figure 4


Fig. 4 – Pump gear – Magnetic Particles Test Procedure


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7.49.5 - Sliding Adapter - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para.4 and to Figure 5


Fig. 5 – Sliding Adapter – Magnetic Particles Test Procedure


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7.49.6 - Left and right input Pinions Bearing Sleeves – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para.5 and to Figure 6


Fig. 6 – Input Pinion Bearing Sleeve – Magnetic Particles Test Procedure


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7.49.7 - Left and right input pinions Locking Rings – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para.6 and to Figure 7


Fig. 7 – Input Pinion Locking ring – Magnetic Particles Test Procedure


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7.49.8 - Collector gear Locking Ring – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para. 7 and to Figure 8


Fig. 8 – Collector gear Locking ring – Magnetic Particles Test Procedure


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7.49.9 - Left and right Cross Shafts – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para. 8 and to Figure 9


Fig. 9 – Cross shaft – Magnetic Particles Test Procedure


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7.49.10 - Left and right Retaining Rings (8) and (9) – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-00A-352A-C Main gearbox - Tests for surface cracks with magnetic particles Refer to Para. 9 and to Figure 10

Inspection results: ............................................................................... ............................................................................... ............................................................................... Item 9

Item 8

Fig. 10 – Retaining rings– Magnetic Particles Test Procedure


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7.50 - Left and right Input Shaft Module (main gearbox) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) - Tests for surface cracks with magnetic particles 39-A-63-20-05-02A-352A-C Right input shaft module (main gearbox) - Tests for surface cracks with magnetic particles Procedure To do the test of metal components for surface cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for general guideline. General Note The data to do a test for surface cracks with magnetic particles of the left-input shaft module are applicable also to the right-input shaft module. See CR&OP 39-A-63-20-05-02A-352A-C.


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7.50.1 - Input Shaft Module Components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Figure 1

The components involved are: 1) LH and RH Gimbal P/N:……………………………………… S/N:………………………………………. 2) LH and RH Flange P/N:……………………………………… S/N:………………………………………. 3) LH and RH Pinion Locking Ring P/N:……………………………………… S/N:………………………………………. 4) LH and RH Gear Locking Ring P/N:……………………………………… S/N:………………………………………. 5) LH and RH Input Shaft P/N:……………………………………… S/N:……………………………………… 6) LH and RH Input Pinion P/N:……………………………………… S/N:……………………………………… 7) LH and RH Sleeve P/N:………………………………………. S/N:……………………………………… 8) LH and RH Gear (I° stage) P/N:………………………………………. S/N:………………………………………

Fig. 1 – Input Shaft Module – Components for magnetic particles test


260 of 313

7.50.2 - Gimbal - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 1 and Figure 2


TBD

Fig. 2 – Gimbal – Magnetic Particles Test Procedure


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7.50.3 - Input Pinion - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 2 and Figure 3


Fig. 3 – Pinion – Magnetic Particles Test Procedure


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7.50.4 - Gear (I° stage of reduction) – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 3 and Figure 4


Fig. 4 – Gear – Magnetic Particles Test Procedure


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7.50.5 - Input shaft - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 4 and Figure 5


Fig. 5 – Input Shaft – Magnetic Particles Test Procedure


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7.50.6 - Sleeve - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 5 and Figure 6


Fig. 6 – Sleeve – Magnetic Particles Test Procedure


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7.50.7 - Flange - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 6 and Figure 7


Fig. 7 – Flange – Magnetic Particles Test Procedure


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7.50.8 - Gear Locking ring - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 7 and Figure 8


Fig. 8 - Gear locking ring – Magnetic Particles Test Procedure


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7.50.9 - Pinion locking ring - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-01A-352A-C Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 8 and Figure 9


Fig. 9 - Pinion locking ring – Magnetic Particles Test Procedure


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7.51 - Upper Module (main gearbox) - Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-03A-352A-C Upper module (main gearbox) – Tests for surface cracks with magnetic particles

Procedure



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7.51.1 - Upper module (main gearbox) Components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-03A-352A-C Upper module (main gearbox) – Tests for surface cracks with magnetic particles. Refer to Figure 1

Fig. 1 – Upper Module – Components for magnetic particles test


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The components involved are: 1) Ring gear P/N:……………………………………… S/N:………………………………………. 2) Locking ring P/N:……………………………………… S/N:……………………………………….

7.51.2 - Ring gear - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-03A-352A-C Upper module (main gearbox) – Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2.


Fig. 2 – Ring gear – Magnetic Particles Test Procedure


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7.51.3 - Locking ring - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-03A-352A-C Upper module (main gearbox) – Tests for surface cracks with magnetic particles. Refer to Para. 2 and to Figure 3.


Fig. 3 – Locking ring – Magnetic Particles Test Procedure


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7.52 - Front hyd. pump drive quill (main gearbox) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-04A-352A-C Front pump drive quill (main gearbox) - Tests for surface cracks with magnetic particles

Procedure



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7.52.1 - Front pump drive quill (main gearbox) Components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-04A-352A-C Front pump drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Figure 1.

Fig. 1 – Front pump drive quill (main gearbox)– Components for magnetic particles test


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The components involved are: 1) Pinion P/N:……………………………………… S/N:………………………………………. 2) Locking ring P/N:……………………………………… S/N:……………………………………….

7.52.2 - Pinion - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-04A-352A-C Front pump drive quill (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2.


Fig. 2 – Pinion - Magnetic Particles Test Procedure


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7.52.3 - Locking ring - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-04A-352A-C Front pump drive quill (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 2 and to Figure 3.


Fig. 3 – Locking ring - Magnetic Particles Test Procedure


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7.53 - ECS compressor drive quill (main gearbox) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-05A-352A-C ECS compressor drive quill (main gearbox) Tests for surface cracks with magnetic particles Procedure



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7.53.1 - ECS compressor drive quill (main gearbox) Components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-05A-352A-C ECS compressor drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Figure 1.

Fig. 1 – ECS Compressor drive quill (main gearbox) – Components for magnetic particles test


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7.53.2 - Pinion - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-05A-352A-C ECS compressor drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2. Inspection results: ............................................................................... ............................................................................... ...............................................................................



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7.53.3 - Locking ring – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-05A-352A-C ECS compressor drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Para. 2 and to Figure 3.




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7.54 - Left and Right Lubrication Pump - Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-06A-352A-C Left lubrication pump (main gearbox) - Tests for surface cracks with magnetic particles 39-A-63-20-05-24A-352A-C Right lubrication pump (main gearbox) - Tests for surface cracks with magnetic particles Procedure To do the test of metal components for surface cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for general guideline. General Note The tests for surface cracks with magnetic particles given for the right lubrication pump are applicable to the left lubrication pump. See CR&OP 39-A-63-20-05-24A-352A-C.


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7.54.1 - Lubrication pump (main gearbox) components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-06A-352A-C Left lubrication pump (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Figure 1.

Fig. 1 – Left lubrication pump (main gearbox) – Components for magnetic particles test


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The components involved are: 1) Gear P/N:……………………………………… S/N:………………………………………. 2) Locking ring P/N:……………………………………… S/N:……………………………………….

7.54.2 - Gear - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-06A-352A-C Left lubrication pump (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 2 – Gear - Magnetic Particles Test Procedure


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7.54.3 - Locking ring - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-06A-352A-C Left lubrication pump (main gearbox) Tests for surface cracks with magnetic particles. Refer to Para. 2 and to Figure 3. Inspection results: ............................................................................... ............................................................................... ...............................................................................



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7.55 - Fan drive quill (main gearbox) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-07A-352A-C Fan drive quill (main gearbox) - Tests for surface cracks with magnetic particles

Procedure



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7.55.1 - Fan drive quill (main gearbox) components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-07A-352A-C Fan drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Figure 1.

Fig. 1 – Fan drive quill (main gearbox) – Components for magnetic particles test


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7.55.2 - Pinion - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-07A-352A-C Fan drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2. Inspection results: ............................................................................... ............................................................................... ...............................................................................



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7.55.3 - Locking ring - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-07A-352A-C Fan drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Para. 2 and to Figure 3. Inspection results: ............................................................................... ............................................................................... ...............................................................................



288 of 313

7.56 - Mast-planetary assembly (upper module) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) Tests for surface cracks with magnetic particles Procedure



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7.56.1 - Mast-planetary assembly (upper module) components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Figure 1.

The components involved are: 1) Main Rotor Shaft (Mast) P/N:……………………………………… S/N:………………………………………. 2) Planetary Gear Spacers (5 items) P/N:……………………………………… 3) Spider Plate P/N:……………………………………… S/N:………………………………………. 4) Planetary Pins (5 items) P/N:……………………………………… S/N:………………………………………. 5) Spider Plate Spacers (5 items) P/N:……………………………………… S/N:………………………………………. 6) Ring Nuts (5 items) P/N:……………………………………… S/N:……………………………………….

Fig. 1 – Mast Planetary assembly – Components for magnetic particles test


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7.56.2 - Main Rotor Shaft (Mast) – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 2 – Main Rotor Shaft - Magnetic Particles Test Procedure


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7.56.3 - Spider Plate - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Para. 2 and to Figure 3. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 3 - Spider Plate - Magnetic Particles Test Procedure


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7.56.4 - Planetary Pins (five items) – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Para. 3 and to Figure 4. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 4 – Planetary Pins - Magnetic Particles Test Procedure


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7.56.5 - Ring Nuts (five items) – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Para. 4 and to Figure 5. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 5 – Ring Nuts - Magnetic Particles Test Procedure


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7.56.6 - Spider plate spacers (five items) – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Para. 5 and to Figure 6. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 6 – Spider plate spacer - Magnetic Particles Test Procedure


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7.56.7 - Planetary gear spacers (five items) – Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-13A-352A-C Mast-planetary assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Para. 6 and to Figure 7. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 7 – Planetary gear spacer - Magnetic Particles Test Procedure


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7.57 - Planetary gear assembly (upper module) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-14A-352A-C Planetary gear assembly (upper module) Tests for surface cracks with magnetic particles Procedure



297 of 313

7.57.1 - Planetary gear assembly (upper module) components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-14A-352A-C Planetary gear assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Figure 1.

The components involved are:

Planetary Gear Assy (5 items) P/N:……………………………………… S/N:………………………………………. 1) Gear 2) Inner Bearing Race

Fig. 1 – Planetary gear assembly – Components for magnetic particles test


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7.57.2 - Gear - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-14A-352A-C Planetary gear assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 2 – Gear (planetary gear assembly) - Magnetic Particles Test Procedure


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7.57.3 - Inner bearing race - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-14A-352A-C Planetary gear assembly (upper module) Tests for surface cracks with magnetic particles. Refer to Para. 2 and to Figure 3. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 3 – Inner Bearing Race (planetary gear assembly) - Magnetic Particles Test Procedure


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7.58 - Left/Right hyd. pump drive quill (main gearbox) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-27A-352A-C Left/right pump drive quill (main gearbox) Tests for surface cracks with magnetic particles Procedure



301 of 313

7.58.1 - Left/right pump drive quill (main gearbox) components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-27A-352A-C Left/right pump drive quill (main gearbox) Tests for surface cracks with magnetic particles. Refer to Figure 1.

Fig. 1 – Left/right pump drive quill – Components for magnetic particles test


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The components involved are: 1) Pinion (LH & RH) P/N:……………………………………… S/N:………………………………………. 2) Locking ring (LH & RH) P/N:………………………………………

7.58.2 - Pinion - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-27A-352A-C Left/right pump drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 2 – Pinion (Left/right pump drive quill) - Magnetic Particles Test Procedure


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7.58.3 - Locking ring - Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-27A-352A-C Left/right pump drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Para. 2 and to Figure 3. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 3 – Locking ring (Left/right pump drive quill) - Magnetic Particles Test Procedure


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7.59 - Tail rotor drive quill (main gearbox) – Magnetic Particles Test CR&OP Data Module:

39-A-63-20-05-28A-352A-C Tail rotor drive quill (main gearbox) - Tests for surface cracks with magnetic particles

Procedure



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7.59.1 - Tail rotor drive quill (main gearbox) components involved for the Magnetic Particles Test CR&OP Data Module: 39-A-63-20-05-28A-352A-C Tail rotor drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Figure 1. The components involved are: 1) Flange P/N:……………………………………… S/N:……………………………………….

2) Locking Ring P/N:……………………………………… S/N:………………………………………. 3) Fan gear P/N:……………………………………… S/N:……………………………………….

4) Locking ring P/N:……………………………………… S/N:………………………………………. 5) and 6) Pinion P/N:……………………………………… S/N:……………………………………….

Fig. 1 – Tail rotor drive quill – Components for magnetic particles test


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7.59.2 - Pinion (Main gearbox P/N 3G6320A00132) Magnetic Particles Test Procedure CR&OP Data Module: 39-A-63-20-05-28A-352A-C Tail rotor drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Para. 1 and to Figure 2. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 2 – Pinion (Tail rotor drive quill) - Magnetic Particles Test Procedure


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7.59.3 - Pinion (Main gearboxes P/N 3G6320A00133 and subsequent P/N with different two last digits) - Magnetic Particles Test Procedure CR&OP Data Module:

39-A-63-20-05-28A-352A-C Tail rotor drive quill (main gearbox) - Tests for surface cracks with magnetic particles. Refer to Para. 6 and to Figure 7. Inspection results: ............................................................................... ............................................................................... ...............................................................................

Fig. 7 – Pinion (Tail rotor drive quill) - Magnetic Particles Test Procedure


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7.59.4 - Fan gear - Magnetic Particles Test Procedure CR&OP Data Module:


Fig. 3 – Fan gear (Tail rotor drive quill) - Magnetic Particles Test Procedure


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7.59.5 - Flange - Magnetic Particles Test Procedure CR&OP Data Module:


Fig. 4 – Flange (Tail rotor drive quill) - Magnetic Particles Test Procedure


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7.59.6 - Locking ring (Main gearbox P/N 3G6320A00132) Magnetic Particles Test Procedure CR&OP Data Module:


Fig. 5 – locking ring (Tail rotor drive quill) - Magnetic Particles Test Procedure


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7.59.7- Locking ring - Magnetic Particles Test Procedure CR&OP Data Module:


Fig. 6 – locking ring (Tail rotor drive quill) - Magnetic Particles Test Procedure


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Chapter 7 – Components Cleaning, Paint removal, Protection and Inspection

THE END




Chapter 8 - Assembly Procedures

8 – Assembly Procedure INDEX 8.1 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5

Pre-Assembly Requirements MGB, Assembly procedures Main Case, Assembly procedures Upper Module, Assembly procedures Main Case, External components installation procedures LH / RH Input Shaft Module, assembly procedures Anti-Torque Beam, Installation procedures

(Cont’s)


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8.1 – Pre-Assembly Requirements During this phase there are conditions and actions that must be carried out i.a.w. the current issue of the IETP, these are: 1. 2. 3. 4. 5. 6. 7.

Refer to CR&OP : 39-A-63-20-05-00A-714A-C (Main gearbox - General guidelines for assemble procedures). Make sure that the work area is cleaned. Before assembly, clean all parts. At assembly, use new parts (bolts, screws, nuts, lips seals, etc.......) as required Select the spare parts from the Illustrated Parts Data (39-A-ZG-W5-01-010-941A-C). Before assembly, apply the surface finish protection on the external surfaces of the components as required. During assembly phase Lubricate the packings with Grease (C115), lip seals with Grease (C147) and Lubricate the fasteners and the matching surfaces (where required) with the Oil (C006).

Supplies Nomenclature

Identification No


Ref. Documents

Solvent, cleaning

C010

P-D-680 type II

(AMDI) 39-A-00-50-00-09A-078A-D

Grease

C115

Parker “super O-lube”.

(AMDI) 39-A-00-50-00-08A-078B-D

Grease (NS-3913-G1)

C147

None

(AMDI) 39-A-00-50-00-13B-078A-D

Oil

C006

MIL-PRF-7808L

(AMDI) 39-A-00-50-00-05A-078A-D


3 of 152

8.2 – MGB, Assembly procedures During the MGB assembly procedure perform the following actions: • •

Record and identify the P/N and the S/N of all Components / Main assemblies used during the MGB assembly phase. The assembly procedure of the MGB is essentially the reverse of the disassembly procedure.

8.2.1

Main Case, Assembly procedures.

8.2.1.1 8.2.1.2 8.2.1.3 8.2.1.4 8.2.1.5 8.2.1.6 8.2.1.7 8.2.1.8 8.2.1.9 8.2.1.10 8.2.1.11 8.2.1.12 8.2.1.13

Shims, installation. Roller Bearings and Outer Race of the tail-rotor roller bearing, installation. Diaphragm Assy, assembly. Collector Gear Assy, assembly. RH / LH Input Pinion Assy (II° stage of reduction), assembly. Tail Rotor Drive Quill Assy, assembly. Left and Right Hyd. Pump Drive Quill, assembly. Front Hyd. Pump Drive Quill, assembly. ECS-Compressor Drive Quill, assembly. Fan Drive Quill, assembly. Collector Gear Assy, installation. Diaphragm Assy, installation. Tail Rotor Drive Quill Assy, installation.

(cont.s) For Training purpose only

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8.2 – MGB, Assembly procedures 8.2.1.14 8.2.1.15 8.2.1.16 8.2.1.17 8.2.1.18 8.2.1.19 8.2.1.20 8.2.1.21 8.2.1.22 8.2.1.23 8.2.1.24 8.2.1.25

RH / LH Input Pinion Assy (II° stage of reduction), installation. Left and Right Hyd. Pump Drive Quill Assy, installation. Front Hyd. Pump Drive Quill Assy, installation. ECS-Compressor Drive Quill Assy and Seal Cover, installation. Fan Drive Quill Assy, installation. Main Case, Backlash check Fan Seal Cover, installation. Left / Right Lubrication Pump, assembly. Left / Right lubrication Pump, installation. Bottom Cover, assembly. Bottom Cover, installation. AC Generators drive cover and plug, installation

8.2.2

Upper Module, Assembly procedures

8.2.2.1 8.2.2.2 8.2.2.3 8.2.2.4 8.2.2.5 8.2.2.6 8.2.2.7 8.2.2.8 8.2.2.9 8.2.2.10 8.2.2.11

Planetary gears assembly (mast planetary assembly), assembly. Mast-planetary assembly (upper module), assembly. Upper Fittings, Brackets, installation. Mast-planetary assembly, installation. Planetary Crown (Fixed Ring Gear), installation. Roller Bearing and Cover seal, Installation. Upper Cooler Adapter, installation Four Oil jets, installation. Oil Filler plug, Mast Chip detector, Mast Cover and Ident. Plate installation Unions, installation procedures Upper Module Assy, installation.

(cont.s) For Training purpose only

5 of 152

8.2 – MGB, Assembly procedures 8.2.3

Main Case, External components installation procedures

8.2.3.1 8.2.3.2 8.2.3.3 8.2.3.4 8.2.3.5 8.2.3.6

Oil draining Pipe, Oil Level Gauge and low Oil Level sensor, installation. Oil Filter Head, Oil Temperature sensor, Oil Pressure sensor and Oil Temperature SW, installation. Rotor Speed Sensor, installation. Check valves and Pressure Relief Valve, installation. Borescope Port, Two Chip Detectors, Washers, Plugs and Flange, installation Fifteen (from No. 1 to No. 13) Oil Jets, installation.

8.2.4 8.2.4.1 8.2.4.2 8.2.4.3 8.2.4.4 8.2.4.5 8.2.4.6 8.2.4.7 8.2.4.8 8.2.4.9 8.2.4.10 8.2.4.11 8.2.4.12

LH / RH Input Shaft Module, assembly procedures Shims, installation. Bearings, installation. Diaphragm Assy, assembly. Gear (I° stage of reduction), assembly. Gear Assy and Diaphragm Assy, installation. Input Drive Quill group, assembly. Input Drive Quill group and Gimbal Assy, installation. Input Shaft Module, Backlash check. Freewheel Group, assembly. Freewheel Group and Oil Jet Cover, installation. Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation LH/RH Input Shaft Module, installation.

8.2.5

Anti-Torque Beam, Installation procedures


6 of 152

8.2.1 – Main Case, Assembly procedures Safety conditions

WARNING The materials that follow are dangerous. Before you do this procedure, make sure that you know all the safety precautions and first aid instructions for the materials reported hereinafter. Refer to CR&OP: 39-A-60-50-00-00A-074A-C. Nomenclature

Identification No. Specification references

Ref. Documents

Solvent, cleaning

C010

P-D-680 type II

(AMDI) 39-A-00-50-00-09A-078A-D

Oil

C006

MIL-PRF-7808L

(AMDI) 39-A-00-50-00-05A-078A-D

Adhesive (Loctite 222)

C029

MIL-S-46163, Type II grade M

(AMDI) 39-A-00-50-00-28A-078A-D

Grease (Parker super O-lube).

C115

None

(AMDI) 39-A-00-50-00-08A-078B-D

Grease (Aeroshell 22)

C009

MIL-PRF-81322F

(AMDI) 39-A-00-50-00-08A-078A-D

Grease (Aeroshell Grease 17)

C022

MIL-PRF-21164

(AMDI) 39-A-00-50-00-21A-078A-D

Grease (NS-3913-G1)

C147

None

(AMDI) 39-A-00-50-00-13B-078A-D

Solvent (Loctite quick clean 7031)

C023

None

(AMDI) 39-A-00-50-00-22A-078A-D

Sealing compound (Naftoseal MC-236 Class B)

C030

AMS-S-8802B

(AMDI) 39-A-00-50-00-29A-078A-D

Compound (Dykem Steel Blue)

C162

None

(AMDI) 39-A-00-50-00-28B-078A-D

Adhesive (Shellac)

C163

None

(AMDI) 39-A-00-50-00-29B-078A-D

Sealing compound (AMS-S-8802, Class A- C164 1/2)


7 of 152

AMS-S-8802, Class A-1/2.

(AMDI) 39-A-00-50-00-30B-078A-D

8.2.1 – Main Case, Assembly procedures CAUTION During this procedure, do not touch the components made of metal with your bare hands. Put on applicable cotton gloves before you touch the components. Contamination from your bare hands will cause corrosion of the metals. Procedure Note 1 – Refer to CR&OP data module: 39-A-63-20-05-00A-710A-C (Main gearbox - Assemble procedures) if the Test Bench is available. – If the Test Bench is not available, you can do the functional check with the main gearbox installed on the helicopter. In this case refer to CR&OP data module: 39-A-63-20-05-00A710B-C (Main gearbox - Assemble procedures).9 -A-63-20-05-00A-710B-C Note 2 – In this section will be described the actions reported on CR&OP data module 39-A-63-20-05-00A-710A-C following a specific guideline. Note 3 - During this procedure, obey the general guidelines applicable to the assemble procedures. Refer to CR&OP data module 39-A63-20-05-00A-714A-C.


8 of 152

8.2.1 – Main Case, Assembly procedures Install the Main Case assembly with the Support on the Maintenance Trolley CR&OP data module: 1

39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures.

Support equipments: Nomenclature

2


9 of 152

Identification No.

Lifting tool, main case assembly

3G6320A00131A181B


3G6320A00131A188C

Lifting device

Local supply

8.2.1.1 – Shims Installation Action No. 1: Shims location Shim (102)

Shim (113)

Screw (103) x 3

CR&OP data module:

Screw (114) x 3 Shim (187)

Shim (193) Screw (194) x 3

Screw (186) x 4

Screw (184) x 3 Shim (177)

Shim (102) Screw (103) x 3

Shim (92) Screw (91) x 3

Shim (193) Screw (194) x 3 Shim (98) Screw (97) x 3 Shim (199K) x 2 Screw (199L) x 3

39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures

Procedure The shims (tot. 11) that must be installed on the Main Case are the following: - LH / RH Shim (193). - Shim (177). - Shim (187). - LH / RH Shim (102). - Shim (113). - Shim (92). - Shim (98). - LH / RH Shim (199K).

AFT

RH

LH

Main Case without Shims

FWD


10 of 152

8.2.1.1 – Shims Installation Action No. 2: RH Shim (193) and LH Shim (193) installation CR&OP Data Module: RH Shim (193)

Screw (194) x 3

39-A-63-20-05-00A-710A-C procedures.

- Main gearbox - Assemble

Procedure Install the Right and Left Shim (193) as follows: 1. Make sure that the Right Shim and the Left Shim have the same S/N as the Main Case assembly. 2. Verify / Calculate / Record the Thickness of the RH Shim and LH Shim with this formula: RH Shim Thickness = X - CG LH Shim Thickness = X - CH

Main Case – Right side (Input Pinion II° stage of reduction)

where X (mm): refer to the D.M.as necessary.

LH Shim (193)

and CG is the dimension (mm) engraved on the RH side of the Main Case. CH is the dimension (mm) engraved on the LH side of the Main Case.

Screw (194) x 3 Main Case – Left side (Input Pinion II° stage of reduction)


11 of 152

8.2.1.1 – Shims Installation Action No. 2: RH Shim (193) and LH Shim (193) installation

Procedures (cont. s) 3.

Measure the thickness of the shim and make sure that it is as specified in previous Step 2. If the thickness of the shim is not in the limits, do step 3.1 or Step 3.2 as necessary. Contact the AW Customer Support as necessary.

3.1

Machine the Shim and remove material until the thickness is correct (measure the thickness of the shim regularly while you machine it). Restore the protection as required.

3.2

Discard the Shim and install a new item. Adjust the thickness of the new shim and restore the protection as required.

4.

Put each Shim (193) in its housing of the main case assembly.

5.

Install the three Screws (194) to attach the Shim (193).

Note: The procedure reported on Step 3 can be used for all other shims installed on the Main Case.


12 of 152

8.2.1.1 – Shims Installation Action No. 3: Shim (177) installation CR&OP Data Module: 39-A-63-20-05-00A-710A-C - Main gearbox - Assemble procedures.

Procedure (TBD) Install the Shim (177) as follows: 1. Make sure that the Shim has the same S/N as the Main Case assembly. 2. Verify / Calculate / Record the Thickness of the Shim with this formula: Shim Thickness = X - CJ where X (mm): refer to the D.M.as necessary. RH Shim (177)

Screw (184) x 3

and CJ is the dimension (mm) engraved on the Main Case.

Main Case – Rear side (Tail Rotor drive quill)


13 of 152

8.2.1.1 – Shims Installation Action No. 4: Shim (187) installation CR&OP Data Module: 39-A-63-20-05-00A-710A-C - Main gearbox - Assemble procedures. Procedure Install the shim (187) as follows: 1. Make sure that the shim has the same S/N as the main case assembly. 2. Verify / Calculate / Record the thickness of the shim with this formula: Shim Thickness = CF - X

Screw (186) x 4

where CF is the dimension (mm) engraved on the main case, and X (mm): refer to the D.M.as necessary.

RH Shim (187)

Main Case – Internal view, lower side


14 of 152

8.2.1.1 – Shims Installation Action No. 5: LH Shim (102) and RH Shim (102) installation CR&OP Data Module:

LH Shim (102)

39-A-63-20-05-00A-710A-C - Main gearbox - Assemble procedures. Procedure Install the Right and Left Shim (102) as follows: Screw (103) x 3

1. Make sure that the Right Shim and the Left Shim have the same S/N as the Main Case assembly. 2. Verify / Calculate / Record the Thickness of the RH Shim and LH Shim with this formula: Main Case – LH side (LH Hyd. Pump drive quill)

RH Shim Thickness = X - CM LH Shim Thickness = X - CP

RH Shim (102)

where X (mm): refer to the D.M.as necessary. CM is the dimension (mm) engraved on the RH side of the main case. CP is the dimension (mm) engraved on the LH side of the main case. Screw (103) x 3

Main Case – RH side (RH Hyd. Pump drive quill)


15 of 152

8.2.1.1 – Shims Installation Action No. 6: Shim (113) installation CR&OP Data Module: 39-A-63-20-05-00A-710A-C Assemble procedures.

- Main gearbox -

Procedure

Shim (113)

Install the shim (113) as follows: 1. Make sure that the shim has the same serial number as the main case assembly 2. Verify / Calculate / Record the thickness of the shim with this formula: Shim Thickness = X – CS Screw (114) x 3

where X (mm): refer to the D.M.as necessary. CS is the dimension (mm) engraved on the main case.

Main Case – Rear side (Fan drive quill)


16 of 152


- Main gearbox -

Procedure Install the shim (92) as follows: 1.

Make sure that the shim has the same serial number as the main case assembly 2. Calculate the thickness of the shim with this formula: Shim Thickness = X - CL Screw (91) x 3

Where

Shim (92)

X (mm): refer to the D.M.as necessary. CL is the dimension (mm) engraved on the main case.

Main Case – Front side (ECS-Compressor drive quill)


17 of 152


- Main gearbox -

Procedure Install the shim (98) as follows: 1. Make sure that the shim has the same serial number as the main case assembly.

2. Verify / Calculate / Record the thickness of the shim with this formula: Shim Thickness = X – CK Shim (98) Screw (97) x 3

Where

X : refer to the D.M.as necessary. CK is the dimension (mm) engraved on the main case.

Main Case – Front side (Front Hyd. Pump drive quill)


18 of 152

3. Measure the thickness of each shim and make sure that it is as specified in previous Step 2. If the thickness of the shim is not in the limits, perform the corrective action required. See page 12 for further info. 4. Put the shim (98) in its housing of the main case assembly. 5. Install the 3 screws (97) to attach the shim (98).

8.2.1.1 – Shims Installation Action No. 9: LH Shim (199K) and RH Shim (199K) installation CR&OP Data Module:

RH Shim (199K)

39-A-63-20-05-00A-710A-C Assemble procedures.

- Main gearbox -

Procedure Install the LH / RH Shim (199K) as follows: Screw (199L) x 3

Main Case – Front side (RH AC Generator drive quill)

LH Shim (199K)

1. Make sure that the LH / RH shim has the same serial number as the main case assembly. 2. Verify / Calculate / Record the thickness of the left / right shim with this formula: LH Shim Thickness = X - CR RH Shim Thickness = X - CN Where X : refer to the D.M.as necessary. CR is the dimension (mm) engraved on the main case. CN is the dimension (mm) engraved on the main case.

Screw (199L) x 3

Main Case – Front side (LH AC Generator drive quill)


19 of 152

3. Measure the thickness of each shim and make sure that it is as specified in previous Step 2. If the thickness of the shim is not in the limits, perform the corrective action required. See page 12 for further info. 4. Put each shim (199K) in its housing of the main case assembly. 5. Install the 3 screws (199L) to attach the shim (199K).

8.2.1.2 – Roller Bearings and Outer Race of the tail-rotor roller bearing, installation Action No. 1: 2 Roller bearings installation

CR&OP Data Module:

Washer + Nut x 4 Surfaces Lubricated with Oil


- Main gearbox -

Supplies:

RH Roller Bearing See Detail A (next page)

Heated area LH Roller Bearing

Nomenclature

Identification No.


Solvent, cleaning

C010

P-D-680 type II

Oil

C006

MIL-PRF-7808L

1

Support equipment:

Washer + Nut x 4

2

Nomenclature

Identification No.

Heat gun

Local supply

Bearing installation tool

3G6320A00331A023E

4

3

6 5


20 of 152

8.2.1.2 – Roller Bearings and Outer Race of the tail-rotor roller bearing, installation Action No. 2:Outer Race of the tail-rotor roller bearing installation Detail “A”

CR&OP Data Module:

Al Washer x 3 Washer x 3 Nut x 3

Surfaces Lubricated with Oil

Heated area

Screw x 3

39-A-63-20-05-00A-710A-C - Main gearbox Assemble procedures. Supplies: Nomenclature

Identification No.



C011

None

Solvent, cleaning

C010

P-D-680 type II

Oil

C006

MIL-PRF-7808L

Outer Race of the Tailrotor roller bearing

Support equipment:

1


2

3

21 of 152

Nomenclature

Identification No.

Heat gun

Local supply

Outer race installation tool, roller bearing

3G6320A00331A023F

4

8.2.1.3 – Diaphragm Assy, assembly procedures CR&OP Data Module: Heated area Surfaces Lubricated with Oil


- Main gearbox -

Supplies:

Roller Bearing

Nuts+ Washers Oil Jets – Pre-Mod. Packing

Nomenclature

Identification No.



C011

None

Solvent, cleaning

C010

P-D-680 type II

Oil

C006

MIL-PRF-7808L


C115

None

Support equipment: Nuts+ Washers Nuts+ Washers

Nuts+ Washers Packing

Nuts

Oil Jets – Post-Mod. Nuts

Nuts


Nuts 22 of 152

Nomenclature

Identification No.

Heat gun

Local supply


3G6320A00331A023A

8.2.1.3 – Diaphragm Assy, assembly procedures

Diaphragm + Tool + Bearing Oil Jets Post-Mod. installed

Heating phase

Roller Bearing installed

Bearing installation


23 of 152

8.2.1.4 – Collector Gear Assy, assembly procedures CR&OP Data Module:

Collector Gear

Loctite application

Surfaces Lubricated with Oil

39-A-63-20-05-00A-710A-C Assemble procedures. Supplies:

Collector Bearing

Note:

Locking Ring

Nomenclature

Identification No.


Locking Washer


C011

None

Oil

C006

MIL-PRF-7808L


C023

None


C029


Retaining Ring


Support equipment:



- Main gearbox -

Main Case

24 of 152

Nomenclature

Identification No.


3G6320A00331A023C

Induction oven

Local supply

Work table

MS3-01300

Hydraulic cylinder

BRW 104N


3G6320A00331A181A

Lifting device

Local supply

Torque tool, collector gear

3G6320A00331A023D

8.2.1.4 – Collector Gear Assy, assembly procedures View of the bearing installation tool and torque tool



3G6320A00331A023C

25 of 152

Torque tool, collector gear

3G6320A00331A023D

8.2.1.4 – Collector Gear Assy, assembly procedures Collector gear assembly phase 1

4 7

3

5 2

6


26 of 152

8.2.1.4 – Collector Gear Assy, assembly Collector gear assembly phase 8 13 11

9

10


27 of 152

12

8.2.1.5 – RH / LH Input Pinion (II° Stage of reduction), assembly procedures CR&OP Data Module: 39-A-63-20-05-00A-710A-C Assemble procedures.

- Main gearbox -

Supplies: Heated area “V” incision

Main Case O-rings Bearing Sleeve Bearings Nuts, Washers Shim


Nomenclature

Identification No.



C011

None

Oil

C006

MIL-PRF-7808L


C023

None


C029


Support equipment:

Heated area

Oil application Loctite application Retaining Ring

Retaining Ring (Typical for RH side) Pump gear Locking Ring Locking Washer


28 of 152

Nomenclature

Identification No.

Induction oven

Local supply


3G6320A00331A023U

Arbor press

Local supply

Installation tool, sleeve

3G6320A00331A023V

Reaction tool, pinion locking ring

3G6320A00331A023W

8.2.1.5 – RH / LH Input Pinion (II° Stage of reduction), assembly proc. Retaining Ring – Step Thickness evaluation •

Measure the distance between the end of the outer race of the bearing (I2) and the flange of the bearing sleeve (N) in three equally spaced positions. Calculate the arithmetical mean between the three values, and record it as dimension “P”

•

Calculate the thickness of the step on the retaining ring as follows:

Step

Thickness of step (mm) = P - (*). (*) refer to the D.M. as necessary. •

Measure the thickness of the step on the retaining ring and make sure that it is as calculated. If the thickness of the step is not within the limits, do the following actions as necessary. 



Retaining Ring

Machine the retaining ring and remove material until the thickness of the step is correct (measure the thickness of the step regularly while you machine it), or Discard the retaining ring and install a new item. Adjust the thickness of the step on the new retaining ring as necessary.

(cont.s)


29 of 152

8.2.1.5 – RH / LH Input Pinion (II° Stage of reduction), assembly proc. Thickness evaluation of the Shim •

Measure the total height of the inner races of the triplex bearing. Record this value as “I1”.

•

Calculate the thickness (M) of the shim with this formula: (RH) M = G - (H + I1 + L) (LH) M = G - (H + I1 + L) where G “CU” is the dimension engraved on the main case assembly (RH). G “CT” is the dimension engraved on the main case assembly (LH). H is the dimension engraved on the pinion I1 is the measured dimension. L is the dimension engraved on the pump gear.

Shim


30 of 152

•

Measure the thickness of the shim and make sure that it is as calculated. If the thickness of the shim is not in the limits, perform the actions reported hereinafter as necessary.  Machine the shim and remove material until the thickness is correct (measure the thickness of the shim regularly while you machine it).  Discard the shim and install a new item. Adjust the thickness of the new shim as necessary.

•

Install the Shim and the Retaining ring on the right/left input pinion as required.

8.2.1.5 – RH / LH Input Pinion (II° Stage of reduction), assembly proc. Assembly phase – step 1 5 Bearing Sleeve

1

Retaining Ring Input Pinion II° stage

“Triplex” ball bearing

Pump gear Bearing installation tool

3

2

Inner race bearing thickness measurement


4

Bearing alignment

31 of 152

Sleeve installation tool

8.2.1.5 – RH / LH Input Pinion (II° Stage of reduction), assembly proc. Assembly phase – step 2 6

Oil application

8

9

7

Pinion + Bearings

Arbor Press


32 of 152


13

14

Thickness Check

Pump Gear + Locking Ring

11

12 Pinion Assy + Supplies + Locking Washer + Retaining Ring

Thickness Check


Retaining Ring installation

33 of 152


15

21 17

Retaining installation 19

Locking Ring, Reaction tool

Locking Ring, Reaction tool + Wrench

Locking washer installation

16 18

Locking Ring, Reaction tool + Wrench


Torque Wrench

34 of 152

Input Pinion II° stage Assy

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures CR&OP Data Module: 39-A-63-20-05-28A-710A-C Tail rotor drive quill (main gearbox) - Assemble procedures Supplies:

Nylon Screw (3)

Main Case Main Case

Tail Rotor Drive Quill Assembly Tail Rotor Drive Quill Assembly

Support equipment:


Nomenclature

Id. No.



C011

None

Oil

C006

MIL-PRF-7808L


C023

None


C029


Safety wire

C014

MS20995C32

NS-3913-G1 (Syn-Tech Ltd)

C147

None

Parker super O-lube

C115

None

Nomenclature

Identification No.

Nomenclature

Identification No.

Oven

Local supply

Arbor press

Local supply

Assembly tool

3G6320A00331A023Y

3G6320A00331A026D


3G6320A00331A023Z

Pusher tool, rotor brake case assembly

Wrench

3G6320A00331A026A

Installation tool, lip seal

3G6320A00331A026E

Wrench

3G6320A00331A026B

Wrench

3G6320A00331A026F

Installation tool, flanged bearing

3G6320A00331A026C

Work table

MS3-01300

35 of 152

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Action No. 1 – Bearing inner race (28) installation on Pinion (30) CR&OP Data Module: 39-A-63-20-05-28A-710A-C Tail rotor drive quill (main gearbox) Assemble procedures. Retaining ring

Note: This procedure is applicable only to Main gearbox P/N : 3G6320A00132).

Locking washer Locking ring Ring Flange Retaining ring O-rings Seal case

Nut + Washer

Support equipment:

Seal

Rotor brake case O-ring Shim Flanged bearing

Nipple

Retaining ring

Screw

Locking washer Locking ring

Part heated

Gear Shim Oil application

Nomenclature

Identification No.

Oven

Local supply

Assembly tool

3G6320A00331A023Y


3G6320A00331A023Z

Work table

MS3-01300

Wrench

3G6320A00331A026A


Supplies:

Oil application Bearing inner race (roller) Pinion

Plug

Bearing cage Plug Pinion


36 of 152

Nomenclature

Id. No.



C011

None


C023

None


C029


Oil

C006

MIL-PRF-7808L

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Action No. 1 – Bearing inner race (28A) installation on Pinion (30A) CR&OP Data Module: 39-A-63-20-05-28A-710A-C Tail rotor drive quill (main gearbox) Assemble procedures. Retaining ring Locking washer Locking ring

This procedure is applicable to Main gearbox P/N: 3G6320A00133 and sub. P/N with different last two digits

Ring Flange Retaining ring O-rings Seal case

Nut + Washer

Note:

Seal

Rotor brake case O-ring Shim Flanged bearing

Supplies:

Nipple

Retaining ring

Screw

Locking washer Locking ring Gear Shim Retaining ring Locking washer Locking ring Bearing inner race (roller)

Pinion

O-ring

Plug

Bearing cage Plug Pinion


37 of 152

Nomenclature

Id. No.


Oil

C006

MIL-PRF-7808L

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Action No. 2 – Calculate the thickness of the Shim (22) CR&OP Data Module:

39-A-63-20-05-28A-710A-C Tail rotor drive quill (main gearbox) - Assemble procedures. See Para. 3 for Main Gearbox P/N: 3G6320A00132 and to Para. 4 for Main gearbox P/N: 3G6320A00133 and sub P/N with different last two digits. Procedure:

3. (Main gearbox P/N 3G6320A00132) Calculate and record the thickness F of the shim (22) with this formula: F(*) = [(C + D) - E] - (A - B) where – A = (*) – B is the dimension (mm) engraved on the pinion (30) – C is the dimension (mm) engraved on the main gearbox case – D and E are the dimensions (mm) engraved on the gear (21). 4. Main gearboxes P/N 3G6320A00133 and subsequent P/N with different last two digits) Calculate and record the thickness F of the shim (22) with this formula: F(*) = [(C + D) - E] - (A - B)

where

– A = (*) – B is the dimension K (mm) engraved on the pinion (30A) – C = (*) – D = (*) – E is the dimension K (mm) engraved on the gear (21). (*): Refer to the D.M. as necessary.


38 of 152

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Action No. 3 – Shim (22) and Gear (21) installation CR&OP Data Module: 39-A-63-20-05-28A-710A-C Tail rotor drive quill (main gearbox) Assemble procedures. Support equipment:

Part heated

Nomenclature

Identification No.

Oven

Local supply

Wrench

3G6320A00331A026B


3G6320A00331A023Z


Supplies:

Gear Shim

Oil application

Oil application


39 of 152

Nomenclature

Id. No.



C011

None

Oil

C006

MIL-PRF-7808L


C023

None


C029


8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures

Action No. 4 – Shim (14), Flanged bearing (17), installation on Item 11 CR&OP Data Module: 39-A-63-20-05-28A-710A-C Tail rotor drive quill (main gearbox) - Assemble procedures. Part heated

Note: Calculate and record the thickness of the shim (14) with this formula:

Oil application

Thickness = X - Y where – X (mm) : refer to the D.M. as necessary. – Y is the dimension (mm) engraved on the rotor brake case.

Nut + Washer

Rotor brake case

Shim Flanged bearing


Identification No.

Oven

Local supply

Screw

Installation tool, flanged bearing 3G6320A00331A026C Arbor press

Local supply

Supplies:


40 of 152

Nomenclature

Id. No.


Oil

C006

MIL-PRF-7808L


C011

None


C023

None

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Action No. 5 – Rotor Brake Case Assy (11), installation on Pinion CR&OP Data Module: 39-A-63-20-05-28A-710A-C Tail rotor drive quill (main gearbox). Grease (147)

Support equipment:

Retaining ring Locking washer Locking ring Ring Flange Retaining ring O-rings Seal case

Parts heated

Seal

Rotor brake case O-ring Nipple

Oil application

Nomenclature

Identification No.

Oven

Local supply

Assembly tool

3G6320A00331A023Y

Pusher tool, rotor brake case assembly

3G6320A00331A026D


3G6320A00331A026E

Wrench

3G6320A00331A026F

Arbor press

Local supply

Supplies:

O-ring

Pinion

Pinion


41 of 152

Nomenclature

Id. No.



C011

None

Oil

C006

MIL-PRF-7808L


C023

None


C029


Safety wire

C014

MS20995C32


C147

None

Parker super O-lube

C115

None

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Assembly phase (Main gearbox P/N 3G6320A00133), step 1 7

6

1

R.B.C. assembled 4

3

Rotor Brake Case + Shim 2

Input Pinion (II°stage of reduction) For Training purpose only

Locking ring 42 of 152

Flanged bearing installed on the R.B.C. 5

Flanged bearing + tool

Flanged bearing installation phase

Bearing cage

Gear

Flanged bearing


9 8

10

Installation phase of the Lip Seal in the Seal case For Training purpose only

43 of 152

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Assembly phase (Main gearbox P/N 3G6320A00133), step 3 12 14 13

Shim (22) installation

Bearing cage (28A) installation


44 of 152

Gear (21) installation

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Assembly phase (Main gearbox P/N 3G6320A00133), step 4

15 17

16

Locking ring (20) installation


Locking ring, wrench installation

45 of 152

18

Locking Washer and Retaining Ring installation

Rotor Brake Case Assy – heating phase -

8.2.1.6 – Tail Rotor Drive Quill Assy, assembly procedures Assembly phase (Main gearbox P/N 3G6320A00133), step 5

19

21

20

Rotor Brake Case Assy installation


Seal and Seal Case installation

46 of 152

Retaining Ring installation


22

Flange (5) installation

25

Nipple (13) installation

23

Locking Washer (2) and Retaining Ring (1) installation 26

Locking ring (3) installation Tail Rotor Drive Quill Assy For Training purpose only

47 of 152

8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures CR&OP Data Module: Retaining ring Seal cover

39-A-63-20-05-27A-710A-C Left/right pump drive quill (main gearbox) - Assemble procedures

C147 application

Support equipment:

Lip seal Packing Retaining ring Locking washer Locking ring Flanged bearing+ Washers and Nuts

C115 application

Plug

Identification No.

Induction oven

Local supply

Installation tool, bearing

3G6320A00431A023A

Arbor press

Local supply

Installation tool, pinion

3G6320A00431A023B


3G6320A00431A023C


3G6320A00431A023D

Holder tool, pump case

3G6320A00431A023E

Supplies:

O-ring

O-ring

Pump case

Fitting

Pinion Left/right pump drive quill (Hyd. pump No.1 and N0.2 drive quill)


Nomenclature

48 of 152

Nomenclature

Id. No.



C011

None

Oil

C006

MIL-PRF-7808L


C023

None


C029



C147

None

Parker super O-lube

C115

None

Safety wire

C014

MS20995C32

8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures

Action No. 1 – Installation of the Flanged bearing (11) on the Pump Case (14)

Flanged bearing

Heated area Pump case



49 of 152

8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures Action No. 2 – Installation of Pinion (15) in the Pump Case Assy (14)

External side Retaining ring

Left/right pump drive quill (Hyd. pump No.1 and N0.2 drive quill)

Locking washer Locking ring Heated area



Pump case

Inner side

Pinion



50 of 152

8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures Action No. 3 – Pump Drive Quill, final assembly Retaining ring Seal cover

Lip seal Packing

Plug O-ring Fitting

O-ring Pump case



51 of 152


8.2.1.8 - Front Hyd. Pump Drive Quill, assembly procedures CR&OP Data Module: Pinion Pump case

39-A-63-20-05-04A-710A-C Front pump drive quill (main gearbox) - Assemble procedures Support equipment:

Plug


O-ring

O-ring

Heated area

Fitting

C115 application C147 application

Flanged bearing


Nomenclature

Identification No.

Induction oven

Local supply


3G6320A00431A023A


3G6320A00531A023A

Arbor press

Local supply


3G6320A00431A023D


3G6320A00431A023E


3G6320A00531A023B

Washers + Nuts Locking ring Locking washer Retaining ring Packing Lip seal Seal cover Retaining ring Note The assembly procedure relevant to the Front Pump are similar to the LH/RH Hyd. Pump previously described.


52 of 152


Id. No.



C011

None

Oil

C006

MIL-PRF-7808L


C023

None


C029



C147

None

Parker super O-lube

C115

None

Safety wire

C014

MS20995C32

8.2.1.9 - ECS-Compressor Drive Quill, assembly procedures Action No.1 : Flanged Bearing (4) installation CR&OP Data Module: 39-A-63-20-05-05A-710A-C ECS compressor drive quill (main gearbox) - Assemble procedures Support equipment:

Heated area

Locking ring Pinion

ECS-compressor drive quill


Locking washer

Nuts + Washers

Nomenclature

Identification No.

Induction oven

Local supply


3G6320A00731A023A


3G6320A00731A023B

Arbor press

Local supply


3G6320A00731A023C

1

Supplies:

2

3

Nomenclature

Id. No.



C011

None

Solvent, cleaning

C010

P-D-680 type II

Oil

C007

MIL-PRF-23699


C023

None


C029


Case

Flanged bearing


53 of 152

8.2.1.9 - ECS-Compressor Drive Quill, assembly procedures Action No.2 : Pinion (2) installation and final assembly

Heated area

8

7

Locking ring Pinion


Locking washer

Nuts + Washers

5

Locking Retaining washer ring 4


6

Locking ring

Pinion

Case Assy

Installation tool, pinion For Training purpose only

54 of 152

8.2.1.10 - Fan Drive Quill, assembly procedures CR&OP Data Module: 39-A-63-20-05-07A-710A-C Fan drive quill (main gearbox) - Assemble procedures

Fan drive quill Fan drive quill

Support equipment:

Supplies:

Heated area

Pinion

Nomenclature

Id. No.



C011

None

Oil

C006

MIL-PRF-7808L


C023

None

Adhesive (Loctite 222) C029


Nomenclature

Identification No.

Induction oven

Local supply


3G6320A00931A023A

Arbor press

Local supply

Removal/installation tool, 3G6320A00931A023B locking ring


Retaining ring

2

1

Locking washer

Locking ring

Pinion


55 of 152

3

8.2.1.11 - Collector Gear Assy, installation procedures CR&OP Data Module:

39-A-63-20-05-00A-710A-C Main gearbox Assemble procedures.

Collector Gear Assy

Bolts Bolts

Bolts Bolts Bearing Bolts

Support equipment:

Heated area

Nomenclature

Identification No.

Heat gun

Local supply


3G6320A00331A181A

Lifting device

Local supply

Main Case

Supplies:

Washers + Nuts


56 of 152

Nomenclature

Id. No.



C011

None

Solvent, cleaning

C010

P-D-680 type II

Oil

C006

MIL-PRF-7808L

8.2.1.11 - Collector Gear Assy, installation procedures Installation phases 1

4

Bolts

Heated area

Main Case 2 3

Collector Gear Assy, installed

Collector Gear Assy


57 of 152

Collector bearing, locked

8.2.1.12 - Diaphragm Assy and two Oil Jets No. 4 installation procedures CR&OP Data Module:


Diaphragm Screws

Supplies:

Oil Jet No. 4 (2)

Main Case

O-rings

Filter

O-ring

1

Screw + Washer

Note Install the Oil Jets No. 4 before to install the 14 locking Screws of the Diaphragm.


58 of 152

2

Nomenclature

Id. No.



C011

None

Solvent, cleaning

C010

P-D-680 type II

Oil

C006

MIL-PRF-7808L

Grease (Parker super C115 O-lube).

None

Safety wire

MS20995C32

C014

8.2.1.13 - Tail Rotor Drive Quill Assy, installation procedures Note

CR&OP Data Module:

Apply the Compound (C162) on the three-equally spaced teeth of the pinion of the tail-rotor drive quill


Washers + Nuts

Support equipment:

Heated area

Rotor Brake Housing Tail Rotor Drive Quill Assy

Identification No.

Installation tool, tail rotor drive quill

3G6320A00331A026M

Heat gun

Local supply

Lifting device

Local supply

Supplies:

2

O-ring

1


Nomenclature

59 of 152

Nomenclature

Id. No.



C162

None

Solvent, cleaning

C010

P-D-680 type II


C011

None

Oil

C006

MIL-PRF-7808L

8.2.1.14 - RH / LH Input Pinion Assy (II° stage of reduction), installation procedures. Apply the Compound C162 on the threeequally spaced teeth of the pinion of the right / left input pinion

CR&OP Data Module: Heated area


Support equipment: Apply the Oil C006 on the Sleeve

Nomenclature

Identification No.

Installation tool, input pinion 3G6320A00331A023H Apply the grease C115 on O-rings Washers + Nuts


60 of 152

RH / LH Input Pinion Assy (II° Stage of reduction)

Heat gun

Local supply


Id. No.



C162

None

Solvent, cleaning

C010

P-D-680 type II


C011

None

Oil

C006

MIL-PRF-7808L


C115

None

8.2.1.14 - RH / LH Input Pinion Assy (II° stage of reduction), installation procedures. Installation phases. 4

1

5

Input Pinion Assy

Main Case Assy rotate of 90°.

Main Case Assy. Inner view Main Case Assy, LH side. External view

2

3

Grease C115 application on O-rings


Installation tool, input pinion 3G6320A00331A023H

61 of 152

8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation procedures. CR&OP Data Module:


Support equipment:

Screws

RH / LH Input Hydraulic Pump drive quill Assy

Apply the Oil C006 on the Sleeve

Nomenclature

Identification No.

Installation tool, pump drive quill

3G6320A00331A023L

Heat gun

Local supply

Apply the grease C115 on the O-ring

l e

Supplies:

Heated area


62 of 152

Nomenclature

Id. No.


Solvent, cleaning

C010

P-D-680 type II


C011

None

Oil

C006

MIL-PRF-7808L


C115

None

8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation procedures. Installation phases 1

Heated area, Main Case Assy LH side

2

Main Case Assy, RH side


Installation tool, pump drive quill 63 of 152

3G6320A00331A023L

8.2.1.16- Front Hyd. Pump Drive Quill Assy, installation procedures A

CR&OP Data Module:


Support equipment:

Front Hydraulic Pump drive quill Assy

Identification No.

Installation tool, pump drive quill

3G6320A00331A023L

Heat gun

Local supply

Supplies: Heated area Apply the grease C115 on the O-ring

Screws

Nomenclature



64 of 152

Nomenclature

Id. No.


Solvent, cleaning

C010

P-D-680 type II


C011

None

Oil

C006

MIL-PRF-7808L


C115

None

8.2.1.17 - ECS-Compressor Drive Quill Assy and Seal Cover, installation procedures. CR&OP Data Module:

39-A-63-20-05-00A-710A-C Main gearbox Assemble procedures. Refer to Para. 31. Support equipment:

Apply the grease C115 on the O-rings Nipple

Apply the grease C115 on the O-rings

ECS-Compressor Drive quill Assy

Heated area

Nomenclature

Identification No.


3G6320A00731A023D

Holder tool, ECScompressor drive quill

3G6320A00731A023E

Installation tool, ECS compressor drive quill

3G6320A00331A023M

Heat gun

Local supply

Supplies: Apply the grease C147 on the Lip Seal (inner side) Screws

Nomenclature

Id. No.


Solvent, cleaning

C010

P-D-680 type II


C011

None

Oil

C006

MIL-PRF-7808L


C115

None

Grease (NS-3913G1)

C147

None

Seal Cover Apply the grease C115 on the O-ring



Retaining Ring

65 of 152

Hyd. Pumps drive quills and ECS-Compressor drive quill. RH Hyd. Pump Drive quill Assy

LH Hyd. Pump Drive quill Assy

Front Hyd. Pump Drive quill Assy

ECS-Compressor Drive quill Assy


66 of 152

8.2.1.18 - Fan Drive Quill Assy, installation procedures. CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures. Nuts + Washers

Fan drive Quill


Identification No.

Installation tool, fan drive quill

3G6320A00331A023N

Heat gun

Local supply

Arbor press

Local supply

Heated area

Supplies:

Main Case Assy, rear side


67 of 152

Nomenclature

Id. No.


Solvent, cleaning

C010

P-D-680 type II


C011

None

Oil

C006

MIL-PRF-7808L

8.2.1.19 - Main Case, Backlash check



CR&OP Data Module:






ECS-










Front Hyd. Pump



68 of 152

8.2.1.19.1 - Main Case, Backlash tool (Collector gear) installation CR&OP Data Module: 39-A-63-20-05-00A-713A-C Main gearbox - Backlash/gear pattern check, Para. 1

Nomenclature

Identification No.

Backlash tool, collector gear

3G6320A00331A676L

Dial gauge

Local supply

Support Equipments:

Legend: Item No.


69 of 152

Nomenclature

1

Dial Gauge Support (3)

2

Tool Top section

3

Knobs (4)

4

Bolt

5

Nylon Split Ring

6

Bolts (4)

7

Registers (2)

8

Retainers

9

Bolts (2)

10

Wrench (Torque application point)

11

Expander

12

Tool Bottom Section

13

Torque application point

14

Collector Gear

8.2.1.19.2 - MGB (Collector gear) Top Tool Section installation 7

1

Register Expander, installation 6 Wrench

2

Retainer

Tool Top Section, installation 3

Nylon Split Ring

Bolts 5

4

Collector Gear

Knobs


70 of 152

8.2.1.19.3 – MGB, (Collector gear) Tool Bottom Section installation


71 of 152

8.2.1.19.4 – MGB, Backlash tool (Collector gear), torque wrench application and Collector Gear levelness check Top Section Register (2 positions)

Dial gauges (3 positions)

Bottom Section

Note:

Note:

Lock the Collector Gear with the Expander as required.

Use the two Registers to adjust the levelness of the Collector Gear as required.

Note: Push the tool bottom section up as required.


72 of 152

8.2.1.19.5 - Backlash check between the Collector Gear and the Input

pinions

CR&OP Data Module:

Input Pinion

39-A-63-20-05-00A-713A-C Main gearbox Backlash/gear pattern check, Para. 2 Support Equipments: Identification No.

Backlash tool, input pinions

3G6320A00331A676B

Dial gauge

Local supply Note: - Lock the tool expander and the backlash tool to the main case as required. - Pull the input pinion externally as required. - Install the Dial Gauge on its support. - Measure and record the backlash in three positions, 120˚ apart, as required. - Perform this action on both Input pinions.

Input Pinion Backlash Tool installation

LH Input Pinion II° Stage, Backlash Tool installation


Nomenclature

RH Input Pinion II° Stage, Backlash Tool installation 73 of 152

8.2.1.19.6 - Backlash check between the Collector Gear and Tail-Rotor Drive Quill Tail Rotor Drive Quill, Backlash Tool installation

CR&OP Data Module: 39-A-63-20-05-00A-713A-C Main gearbox - Backlash/gear pattern check, Para. 3 Support Equipments: Nomenclature

Identification No.

Backlash tool, tail rotor 3G6320A00331A676C drive quill Dial gauge

Local supply

Tail Rotor Drive Quill

Output Pinion

Note: - Lock the tool expander and the backlash tool to the main case as required. - Push pinion internally as required. - Install the Dial Gauge on its support. - Measure and record the backlash in three positions, 120˚ apart, as required.


74 of 152

8.2.1.19.7 - Backlash check between the Collector Gear and the ECS-Compressor Drive Quill CR&OP Data Module: ECS Compressor Drive Quill


ECS Compressor Drive Quill, Backlash Tool installation

Nomenclature

Identification No.

Backlash tool, ECScompressor drive quill

3G6320A00331A676E

Dial gauge

Local supply

Note: -Lock the tool expander and the backlash tool to the main case as required. - Push the pinion internally. - Install the Dial Gauge on its support. - Measure and record the backlash in three positions, 120˚ apart, as required.


75 of 152

8.2.1.19.8 - Backlash check between the Collector Gear and the Front Hyd. Pump drive quill CR&OP Data Module: Front Hyd. Pump Drive Quill


Front Hyd. Pump, Backlash Tool installation

Nomenclature

Identification No.

Backlash tool, front pump drive quill

3G6320A00331A676H

Dial gauge

Local supply

Note: - Lock the tool expander and lock the backlash tool to the main case with the four tool knobs. - Push the pinion internally. - Install the Dial Gauge on its support. - Measure and record the backlash in three positions, 120˚ apart, as required.


76 of 152

8.2.1.19.9 - Backlash check between the Left/Right Input Pinion II° Stage and Left/Right Pump (Hyd. Pump No. 1 & No. 2) Drive Quill CR&OP Data Module: 39-A-63-20-05-00A-713A-C Main gearbox Backlash/gear pattern check, Para. 6 Support Equipments: Left/Right Pump (Hyd. Pump No. 1 and No. 2) Drive Quill, Backlash Tool

Nomenclature

Identification No.

Backlash tool, left and right pump drive quill

3G6320A00331A676D

Dial gauge

Local supply Note: - Lock the tool expander ad the backlash tool to the main as required. - Pull the pinion externally. - Install the Dial Gauge on its support. - Measure and record the backlash in three positions, 120˚ apart, as required. - Perform this action on both Hyd. Pumps.

Left/Right Pump (Hyd. Pump No. 1 and No. 2) Drive Quill

Left Pump (Hyd. Pump No. 1) Drive Quill


Right Pump (Hyd. Pump No. 2) Drive Quill 77 of 152

8.2.1.19.10 - Backlash check between the Tail-Rotor Drive Quill and Fan Drive Quill CR&OP Data Module: 39-A-63-20-05-00A-713A-C Main gearbox Backlash/gear pattern check, Para. 7 Support Equipments:

Fan Drive Quill, Backlash Tool Fan Drive Quill


78 of 152

Nomenclature

Identification No.

Backlash tool, fan drive quill

3G6320A00331A676F

Dial gauge

Local supply Note: - Lock the tool expander and the backlash tool to the main case as require. - Pull the pinion externally. - Install the Dial Gauge on its support. - Measure and record the backlash in three positions, 120˚ apart, as required.

8.2.1.20 - Fan Seal Cover, installation procedures CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures.

Support equipment:

Nuts + Washers

Fan Seal Cover

Nomenclature

Identification No.


3G6320A00331A023P

Arbor press

Local supply

O-ring Lip seal

Supplies:


79 of 152

Nomenclature

Id. No.


Grease (NS-3913-G1)

C147

None


C115

None

8.2.1.21 - Left / Right Lubrication Pump, assembly procedures CR&OP Data Module: 39-A-63-20-05-06A-710A-C Left lubrication pump (main gearbox) Assemble procedures

Gear

Locking Ring

Retaining ring

Key

39-A-63-20-05-24A-710A-C Right lubrication pump (main gearbox) Assemble procedures Support equipment:

Lubrication Pump Lock washer

Nomenclature

Identification No.

Reaction tool

3G6305G00931

Wrench, oil pump ring nut

3G6305G01051

Shaft


Id. No.



C011

None

Solvent, cleaning

C010

P-D-680 type II

Oil

C007

MIL-PRF-23699


C023

None

Adhesive (Loctite 222) C029


80 of 152


8.2.1.21.1 - LH & RH Lubrication Pumps, assembly phases Support equipment

A Lubrication pumps, disassembled

Nomenclature

Identification No.

Reaction tool

3G6305G00931

Wrench, Locking ring

3G6305G01051

Shaft

Key

A

B G Lock washer Retaining ring

Gear C

Locking Ring

D


E

81 of 152

F

8.2.1.22 - Left / Right lubrication Pump, installation procedures CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures.

Supplies:

Washers + Nut

Nomenclature

Id. No.



C115

None

C

B O-rings

Lub. Pump

A

Rear View – RH Lubrication Pump

Rear View – LH Lubrication Pump Rear View RH Lubrication Pump, installation


82 of 152

8.2.1.23 - Bottom Cover, assembly procedures CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures. Support equipment: Nomenclature

Identification No.

Installation tool, slip ring

3G6320A00331A023Q

Special pliers

3G6320A00331A023R

Supplies: O-ring

Nomenclature

Id. No.



C115

None

O-rings

Bottom Cover

O-ring Slip ring


Retaining ring


83 of 152

8.2.1.24 - Bottom Cover, installation procedures Main Case

CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures. Supplies:

Support equipment Nomenclature

Identification No.

Lifting tool, main case assembly

3G6320A00131A181B

Nomenclature

Id. No.

Lifting device

Local supply


C115


3G6320A00131A188C

O-ring O-ring

B

Bottom Cover A


Bottom Cover


84 of 152

8.2.1.25 – AC Generators drive cover and plug, installation procedures. CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures .

Supplies: Washers + Nut

O-ring (C115)

O-ring (C115)

AC Generator Drive Cover Plug (C014)


85 of 152

Nomenclature

Id. No.



C115

None

Safety wire

C014

MS20995C32

8.2.2 - Upper Module, assembly procedures General note During the assembly of the Upper Module do the operations that follow:      

Use new fasteners Clean (where applicable) the components with Solvent (C010). Lubricate (where requirerd) the components with Oil (C008) or oil (C007) Apply Grease (C115) on the packings as required. Check the conditions of each components for damage, before its installation on the module. Record and identify the P/N and the S/N of all Components / Main Assemblies used during the assembly of the Module.  Refer to the specific IPD as necessary.  Observe the Cautions, Warnings, Notes and the Procedures reported on the Data Modules as required. Supplies Nomenclature

Identification No


Ref. Documents

Solvent, cleaning

C010

P-D-680 type II

(AMDI) 39-A-00-50-00-09A-078A-D

Grease

C115


(AMDI) 39-A-00-50-00-08A-078B-D

Oil

C008

DOD-L-85734

(AMDI) 39-A-00-50-00-07A-078A-D

Oil

C007

MIL-PRF-23699

(AMDI) 39-A-00-50-00-06A-078A-D


86 of 152

8.2.2.1 - Planetary Gears Assy, assembly procedures.

CR&OP Data Module: 39-A-63-20-05-14A-710A-C Planetary gear assembly (mast assembly) - Assemble procedures

Planetary Gears Assy


planetary

Procedure Roller cage Rollers

Put the components of the planetary gear assembly (1), on an applicable work table. Assemble the planetary gear assembly (1). Obey the instructions that follow:


Rollers Bottom-inner bearing race


Roller cage

87 of 152

- Install the bottom-inner bearing race (8), the roller cage (7) and the rollers (6) in their correct position on the gear (5). Make sure that you install the same parts you removed during the disassembly. Also make sure to put them on the side you identified at the disassembly. - Install the top-inner bearing race (2), the roller cage (3) and the rollers (4) in their correct position on the gear (5). Make sure that you install the same parts you removed during the disassembly. Also make sure to put them on the side you identified at the disassembly.

8.2.2.1 - Planetary Gears, assembly phase.

A Inner Bearing race

D

Roller cage


B

Bottom-inner bearing race


Roller cage

Roller cage

Rollers

C

Bottom-inner bearing race Roller cage Rollers

Rollers


88 of 152

8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 1: Install the Mast on the Work Trolley. Items that must be assembled

Retaining ring Lock washer Ring Nut

CR&OP Data Module:

39-A-63-20-05-13A-710A-C Mast-planetary assembly (upper module) - Assemble procedures.

Ball bearing


Identification No.

Lifting tool

3G6320A00131A181A

Lifting device

Local supply

Work trolley

3G6320A07231A188A

Oil collector Mast

Retaining springs Ring nuts Planetary Gear assemblies

Screws Lock washers Bushings Flange Pins

Spacers Plate Pins

Bushings Lock washers Screws


89 of 152

Note: Turn the Mast (7) of 180°.

8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 2: Install Bushings (10) and Pins (12) on the Flange (11) CR&OP Data Module: 39-A-63-20-05-13A-710A-C Mast-planetary assembly (upper module) - Assemble procedures. Supplies:

Mast

Nomenclature

Id. No.



C023

None


C029



Identification No.

Refrigerator

Local supply

Heat gun

Local supply

Bushing installation tool

3G6320A07131A023A

Spacer (Pin) installation tool

3G6320A07131A023C

B

Screws Lock washers Bushings Heated area

Note: Put the Bushings (10) in the refrigerator as required

Flange Pins Pins (x5)

AA


90 of 152

Note: Heat the pins (12) as required

8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 3: Planetary Gears (19), Pins (17) and Bushing (14) installation. Support equipment:

CR&OP Data Module: 39-A-63-20-05-13A-710A-C Mast-planetary assembly (upper module) - Assemble procedures.

Nomenclature

Identification No.

Heat gun

Local supply

Planetary installation tool

3G6320A07231A023B

Jack

RCH-12H

Guide tool

3G6320A07231A023C

Bushing installation tool

3G6320A07131A023A

Refrigerator

Local supply

Heated area

Ring nuts Flange Planetary Gears Assy

Pins

Spacers Plate Bushings Lock washers

Pins Heated area


Screws

91 of 152

Note: Put the Bushings (14) in the refrigerator as required

8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 3: Planetary Gears (19) installation phase

A

E

C

B


92 of 152

D

8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 3: Pins (17), Bushing (14) and Plate (13) installation phase. F L

G

I

H


93 of 152

8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 4: Apply the final torque on Ring Nut (20) and on Screw (16) CR&OP Data Module: 39-A-63-20-05-13A-710A-C Mast-planetary assembly (upper module) - Assemble procedures.


Identification No.

Installation tool, ring nut

3G6320A07231A023D

Supplies:

Ring nuts

Screws


94 of 152

Nomenclature

Id. No.



C023

None


C029


8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 5: Ball Bearing (4) installation Put the top and bottom races of the ball bearing (4) in the Oven

Retaining ring

CR&OP Data Module:

Lock washer

39-A-63-20-05-13A-710A-C Mast-planetary assembly (upper module) - Assemble procedures.

Ring Nut Ball bearing Oil collector


Identification No.

Lifting tool

3G6320A00131A181A

Lifting device

Local supply

Oven

Local supply

Tightening tool, ring nut

3G6320A07231A023E

Reaction Tool

3G6320A07231A023G

Supplies: Mast

Retaining springs


95 of 152

Nomenclature

Id. No.



C023

None


C029


8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 5: Ball Bearing (4) installation phase

A

C

B


96 of 152

D

8.2.2.2 - Mast-planetary Assy, assembly procedures. Action No. 5: Ball Bearing (4) installation phase

E

H I F

G


97 of 152

8.2.2.3 - Upper Fittings, Brackets installation Note: Put the upper fitting (2) in the Refrigerator

Upper Fittings

CR&OP Data Module:

39-A-63-20-05-03A-710A-C Upper module (main gearbox) Assemble procedures.

Bolts + Washers Brackets

Support equipment:

TOP CASE Nomenclature

Screws

Identification No.

Aligning pin, fitting (2) 3G6320A00231A023I Refrigerator

Local supply

Heat gun

Local supply


Id. No.


Oil

C006

MIL-PRF-7808L

Safety wire

C014

MS20995C32

Sleeve (Polyurethane transparent tube)

C049

MIL-T-7444.


C009

MIL-PRF-81322F

Sealing compound (Naftoseal C030 MC-236 Class B)


98 of 152

AMS-S-8802B

8.2.2.3 - Upper Fittings, Brackets installation Installation phase F

A

Aligning pin, fitting (2) C

B


E

D

99 of 152

8.2.2.4 – Mast-Planetary Assy, installation procedures. Action No. 1: Install the Top Case on an appropriate Work trolley. CR&OP Data Module:

39-A-63-20-05-03A-710A-C Upper module (main gearbox) - Assemble procedures. 1

Support equipment:

2

Note: turn the TOP CASE 180°

Nomenclature

Identification No.

Lifting tool, mast

3G6320A00231A181B

Lifting device

Local supply

Work trolley (dummy roller bearing and guide are parts of the Work Trolley)

3G6320A00231A188A


3G6320A00231A181C

Aligning pin, bearing

3G6320A00231A023D

Heat gun

Local supply

Supplies:

3


100 of 152

Nomenclature

Id. No.


Oil

C006

MIL-PRF-7808L

8.2.2.4 – Mast-Planetary Assy, installation procedures. Action No. 2: Install the Mast-Planetary assembly in the Top Case. CR&OP Data Module: TOP CASE

39-A-63-20-05-03A-710A-C Upper gearbox) - Assemble procedures.

module

(main

Support equipment:

Mast-planetary Assy.

Nomenclature

Identification No.


3G6320A00231A181C

Lifting device

Local supply

Aligning pin, bearing

3G6320A00231A023D

Heat gun

Local supply

Ball bearing

Supplies:

Oil collector Nuts + Washers Note: During the installation of the Mast-Planetary Assy in the Top case, align the holes of the Ball Bearing and the holes of the Oil Collector with the two Aligning Pins installed on the Top Case.


Heated area 101 of 152

Nomenclature

Id. No.


Oil

C006

MIL-PRF-7808L

8.2.2.4 – Mast-Planetary Assy, installation procedures. Action No. 2: installation phase A

D

C

B


102 of 152

8.2.2.5 – Planetary Crown (Fixed Ring Gear), installation procedures CR&OP Data Module: 39-A-63-20-05-03A-710A-C Upper gearbox) - Assemble procedures.

module

(main

Support equipment:

TOP CASE

Nomenclature

Identification No.

Lifting tool, ring gear

3G6320A00231A181A

Lifting device

Local supply

Clamp

3G6320A00231A023M

Heat gun

Local supply


Packing

103 of 152


Cloth, soft lint-free C011

None

Solvent, cleaning

C010

P-D-680 type II

Grease

C115

Parker “super Olube”.

Oil

C006

MIL-PRF-7808L

Ring gear


Id. No.

C011

8.2.2.5 – Planetary Crown (Fixed Ring Gear), installation procedures installation phase

3

2

1


104 of 152

8.2.2.6 - Roller Bearing and Cover seal, Installation procedures CR&OP Data Module: 39-A-63-20-05-03A-710A-C Upper gearbox) - Assemble procedures.

A

module

(main


Identification No.

Screw (M8)

Local supply

Heat gun

Local supply

Seal installation tool

3G6320A00231A023G


3G6320A00231A023C

TOP CASE

A Nylon Screw (C030)

Washers + Nuts

Supplies:

Cover Seal Lip seal (C147)

Roller Bearing (C006)

Packing (C115)

Packing (C115)

Heated area


105 of 152

Nomenclature

Id. No.


Cloth, soft lint-free C011

None

Solvent, cleaning

C010

P-D-680 type II

Grease

C115


Oil

C006

MIL-PRF-7808L

Grease (NS3913-G1)

C147

None

Sealing compound (Naftoseal MC236 Class B)

C030

AMS-S-8802B

8.2.2.6 - Roller Bearing and Cover seal, installation procedures View of the components installed on the TOP Case.


106 of 152

8.2.2.7 – Upper Cooler Adapter, installation CR&OP Data Module: Washers + Nuts

Upper Cooler Adapter

Nomenclature

Id. No.


Union


C011

None

Packing (C115)

Solvent, cleaning

C010

P-D-680 type II

Grease

C115


Packing (C115)

TOP CASE


107 of 152

39-A-63-20-05-03A-710A-C Upper module (main gearbox) Assemble procedures. Supplies:

-

8.2.2.8 - Four Oil jets, installation. CR&OP Data Module: 39-A-63-20-05-03A-710A-C Upper module (main gearbox) Assemble procedures. Supplies: Oil Jets

Id. No.

Grease

C115


Safety wire

C014

MS20995C32

Screw + Washer

TOP CASE

A

C

Oil Jet Filter

Packing (C115)



Nomenclature

108 of 152

B

D

-

8.2.2.9 - Oil Filler Neck, Mast Chip det., Mast Cover and Id. Plate installation CR&OP Data Module:

Identification Plate (C054) Mast Cover

39-A-63-20-05-03A-710A-C Upper module (main gearbox) - Assemble procedures.

Packing (C115) MastPlanetary Assy

TOP CASE

Chip Detector (C014)

Packing (C115)

Oil Filler plug


Identification No.

Wrench

3G6320A00231A023L

Support trolley

3G6320A00231A188B

Lifting tool

3G6320A00131A181A

Lifting device

Local supply

Clamp

3G6320A00231A023M

Packing (C115)

Supplies:

Oil Filler Neck (C014)

Chip Det. Valve

Packing (C115)

Oil Scupper

Packing (C115)


109 of 152

Nomenclature

Id. No.


Grease

C115


Safety wire

C014

MS20995C32


C011

None

Solvent, cleaning

C010

P-D-680 type II

Adhesive.

C054

199-05-002 class 2, type II (EA934NA)

8.2.2.9 - Oil Filler Neck, Mast Chip det., Mast Cover and Id. Plate installation - Components installation phases

Mast Cover installation

E

A Oil Filler Neck installation Chip Detector installation

B


C

110 of 152

Identification Plate installation

D

8.2.2.9 - Oil Filler Neck, Mast Chip det., Mast Cover and Id. Plate installation - Installation of the Upper Module on the Support Trolley


111 of 152

8.2.2.10 - Unions, installation procedures CR&OP Data Module:


39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures.

Oil Union “B”

Supplies:

Main Case

Side View


112 of 152

Nomenclature

Id. No.


Grease

C115


8.2.2.11 - Upper module Assy, installation procedures CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures.

Nuts + Washers Upper module Assy


Identification No.

Lifting tool, mast

3G6320A00231A181C

Lifting device

Local supply

Clamp

3G6310A00231A023M

Packing

Trolley, upper module 3G6320A00231A188B support

Supplies: Main Case


113 of 152

Nomenclature

Id. No.


Oil

C006

MIL-PRF-7808L

Grease

C115


8.2.2.11 - Upper module Assy, installation procedures Installation phase A C

B


114 of 152

8.2.3 Main Case, External components installation procedures

8.2.3.1 Oil Draining Pipe, Oil Level Gauge and Low Oil level Sensor, installation CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures.

Oil Level Gauge

Nuts + Washers

Supplies:

Low Oil Level Sensor

Packings (C115) Quick disconnect coupling

Packing (C115) Packings (C115)

Drain Cap

Nuts + Washers

Oil Draining Pipe


115 of 152

Nomenclature

Id. No.

Grease

C115

Specification references Parker “super Olube”.

8.2.3.2 Oil Filter Head, Oil Temperature sensor, Oil Pressure sensor and Oil Temperature SW, installation procedures Packings (C007)

Apply Grease (C009) each sensors

References: CR&OP: 39-A-63-20-05-29A-720A-C Oil filter element (main gearbox) - Remove procedures AMP: 39-A-63-41-05-00A-920A-A Oil temperature sensor – Replacement AMP: 39-A-63-41-06-00A-920A-A Oil pressure sensor - Replacement AMP: 39-A-63-41-07-00A-920A-A Oil temperature switch - Replacement

Oil Pressure sensor

Note :

Oil Temp. sensor

Oil Filter Head

Oil Temp. Sw

Anti-Spill Valve

Oil Filter element Packing (C007)

Upper Cooler Adapter

OUT

Do not install the Anti-Spill Valve and the Oil Filter Element during this phase


Identification No.

Lifting tool, mast

3G6320A00231A181C

Lifting device

Local supply

Clamp

3G6310A00231A023M

Trolley, upper module 3G6320A00231A188B support

Oil

Supplies:

IN Cooler

Tsw

Ts

Ps

Nomenclature

Id. No.



C011

None

Solvent, cleaning

C010

P-D-680 type II

Oil

C007

MIL-PRF-23699

Grease (Aeroshell 22) C009 Oil Filter Head


116 of 152

MIL-PRF-81322F

8.2.3.3 - Rotor Speed Sensor, installation CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures. A

Nuts + Washers

Supplies:

Packings (C115)

Nomenclature

Id. No.

Grease

C115

Speed sensor


117 of 152

Specification references Parker “super Olube”.

8.2.3.4 - Check valves and Pressure Relief Valve, installation. CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures.

PRV

Supplies:

Packings (C115)

Note: Apply Grease (C009) each sensors

Packings (C115)

Plug (C009)

Check Valve Retaining Ring) Packings (C115)


118 of 152


Nomenclature

Id. No.

Grease

C115



C009

MIL-PRF-81322F

8.2.3.5 – Borescope Port (A), Two Chip Detectors (B), Washers (C), Plugs (D) and “Flange” Plug (E), installation CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures.

D D

Borescope port

O-ring (C115)

Supplies: Screws + washers

Nomenclature

Id. No.


Grease

C115



C009

MIL-PRF-81322F

E D Plugs O-ring (C115) Chip Detector

“Flange” Plug

E

O-ring (C115)

O-ring (C115) Washer + screw


Chip Detector Valve (C009) O-ring (C115) 119 of 152

Nuts + Washers

8.2.3.6 - Fifteen (from No. 1 to No. 13) Oil Jets, installation. CR&OP Data Module: 39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures. Supplies: Nomenclature

Id. No.


Grease

C115


Safety wire

C014

MS20995C32

Top View

Oil Jets

Filter O-ring (C115) Screw + Washer

Oil Jets

Filter O-ring (C115) Screw + Washer

Rear View

O-rings (C115)

O-rings (C115)


120 of 152

8.2.4 LH / RH Input Shaft Module, assembly procedures – Ref. documentations Engine 2 Inlet (Drive Shaft)

39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) - Assemble procedures (Effectivity Code: B01)


Or


39-A-63-20-05-01B-710A-C Left input shaft module (main gearbox) - Assemble procedures (Effectivity Code: B02) Or 39-A-63-20-05-01C-710A-C Left input shaft module (main gearbox) - Assemble procedures (Effectivity Code: B03) And


39-A-63-20-05-02A-710A-C Right input shaft module (main gearbox) - Assemble procedures

Effectivity Codes: CR&OP Data Module: gearbox – General

39-A-63-20-05-00A-000A-C

- B01 : Input shaft module P/N 3K6320A00133 (installed on P/N 3G6320A00132 and 3G6320A00133) - B02 : Input shaft module P/N 3K6320A00135 (installed on P/N 3G6320A00134 and 3G6320A00135) - B03 : Input shaft module P/N 3K6320A00136 (installed on P/N 3G6320A00134, 3G6320A00135, 3G6320A00132 3G6320A00133)


121 of 152

Note Main

MGB MGB MGB and

The assembly procedures given for the left-input shaft module are applicable to the right-input shaft module. Refer to: – [B01], – [B02], – [B03] as necessary. During this activity, replace all old fasteners (bolts, screws, washers, nuts, packings .....) with new items. Record the P/N and S/N of the components used during the assembly phase and also record the P/N and S/N of the main assy.

8.2.4.1 - Shims, installation CR&OP Data Module: Shim


Screws

39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) - Assemble procedures. Supplies:

Shim

Nomenclature

Id. No.



C011

None

Solvent, cleaning

C010

P-D-680 type II

Procedure Screws

- Make sure that the Serial Numbers of the shim (4) and the left input module are the same. - Calculate the thickness of the shim (4) as required (refer to the D.M.). - Install the shim (4) in the left input module. - Attach the shim (4) to the left input module with the two screws (5). - Make sure that the Serial Numbers of the shim (2) and of the left input module are the same. - Calculate the thickness of the shim (2) as required (refer to the D.M.). - Install the shim (2) in the left input module - Attach the shim (2) to the left input module with the two screws (3). Note 1: Perform the same actions on RH input shaft module.


122 of 152

8.2.4.2 - Bearings, installation CR&OP Data Module: Screws

Nuts + Washers

39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) - Assemble procedures.

Flanged Roller Bearing

Support equipment:

Nuts + Washers

Flanged Ball Bearing (outer race)

Nomenclature

Identification No.

Oven

Local supply

Holder, bearing

3K6320A00131A023Y

Supplies:

Screws



123 of 152

Nomenclature

Id. No.


Oil

C007

MIL-PRF-23699

8.2.4.3 - Diaphragm Assy, assembly procedures CR&OP Data Module:

Flanged Roller Bearing

Diaphragm

39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) - Assemble procedures.

Screw


Identification No.

Oven

Local supply

Supplies: Nuts + Washers

B

A


124 of 152

Nomenclature

Id. No.


Oil

C007

MIL-PRF-23699

8.2.4.4 - Gear (I° stage of reduction), assembly procedures Flanged Ball Bearing (Bottom Inner half-race)

A

CR&OP Data Module: 39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) - Assemble procedures. Support equipment:

B

Nomenclature

Identification No.

Oven

Local supply

Stand, gear

3K6320A00131A023D

Pusher, gear bearing 3K6320A00131A023N inner race Arbor press

Local supply

Gear

Supplies: C

Note: Put the Bottom Inner halfrace and the Top Inner half-race in the Oven


125 of 152

Nom.

Id. No.

Oil

C007

Specification references MIL-PRF23699

8.2.4.5 - Gear Assy and Diaphragm Assy, installation procedures Bolts + Washers

Diaphragm Assy

CR&OP Data Module: 39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) Assemble procedures.

Supplies: Nom. Oil

Id. No. C007


Support equipment:

Oil Dam Packing

MIL-PRF23699 Gear

Heated area

Nomenclature

Identification No.

Stand, gear

3K6320A00131A023D

Reaction, locknut installation

3K6320A00131A023H

Wrench

3K6320A00131A023I

Heat gun

Local supply

Pusher, oil dam

3K6320A00131A023Z

Ball Bearing Cage Lock Ring

Lock Nut LH Input Shaft Module


Flanged Ball Bearing (Top Inner half-race) Input Shaft Module

126 of 152

Flanged Ball Bearing , (installation completed on Gear)

8.2.4.5 - Gear Assy and Diaphragm Assy, installation procedures - Gear Assy, installation phase on the Input Shaft Module A

C

Lock nut and lock ring installed on the Gear

Lock ring, installation

B

G

E

Torque phase of the Lock nut with Wrench

Pusher, Oil dam

D H

F

Lock nut, installation


Input shaft module and Gear installed on the Reaction tool, installation

127 of 152

Bending phase of the Locking ring (two position)

Oil dam, installation phase

8.2.4.5 - Gear Assy and Diaphragm Assy, installation procedures - Diaphragm Assy, installation phase on the Input Shaft Module Heated area

Gear

A C

Input Shaft Module, Inner view

Bolts installation phase

B

D Diaphragm, installation view


Bolts, torque phase

128 of 152

8.2.4.6 - Input Drive Quill group, assembly procedures CR&OP Data Module: 39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) Assemble procedures. Support equipment: Key (2 position)

Heated components

Input Pinion

Plug (C042)

Bearing Sleeve

Bolts + Washers

Heated component

Nomenclature

Identification No.

Oven

Local supply

Pusher, pinion bearing outer race

3K6320A00131A023C

Arbor press

Local supply

Stand, pinion

3K6320A00131A023B

Pusher, input pinion 3K6320A00131A023A bearing

Duplex Ball Bearing

Supplies:

Note:



Put these components in the Oven as required. - The bearing sleeve (13) - The two inner half-races (top and bottom) of the ball bearing (15A) - The inner race of the ball bearing (15B).

129 of 152


Nom.

Id. No.

Oil

C007

MIL-PRF23699

Epoxy Primer

C042

MIL-P-23377.

8.2.4.6 - Input Drive Quill group, assembly procedures - Duplex ball bearing installation phase

Pusher used to install the Bottom Outer race (15B) and the Top Outer race (15A) of the duplex ball bearing in the Bearing Sleeve

(15A) (15B)

Pusher used to install the Bottom Inner race (15B) and the Bottom and TOP Inner HalfRace (15A) on the Input Pinion


130 of 152

8.2.4.6 - Input Drive Quill group, assembly procedures - Assembly phase

A

Bottom Outer Race (15B) installed in the Bearing Sleeve.

C

Marks applied on the Duplex Ball Bearing

D

B

E

Mark applied on the Bearing Sleeve


131 of 152

Mark applied on the stem of the input pinion

Bottom Inner Race (15B), installation phase on the Input Pinion.

8.2.4.6 - Input Drive Quill group, assembly procedures - Assembly phase H

F

View of the Plug, (the outer surface of the plug is protected with Primer C042)

L

G

View of the Plug installed inside the Input Pinion.

I

View of the Key installed in the Bearing Sleeve

Plug, installation phase in the input Pinion View of the Ball bearing 15B and of the two Keys. installed inside the bearing sleeve.


132 of 152

8.2.4.6 - Input Drive Quill group, assembly procedures - Assembly phase Q

O

M

Top Outer Race (15A) installed in the Bearing Sleeve.

Ball Bearing Cage (15A), installation phase

Pusher install Inner (15A), Pinion

N P

used to the Top half-race on the

R

Top Inner HalfRace (15A), installed on the Pinion

Bottom Inner Half-Race (15A) installed on the Pinion.


133 of 152

View of the Input drive quill group assembled.

8.2.4.7 - Input Drive Quill group and Gimbal Assy, installation procedures. Support equipment:

Supplies:

Nomenclature

Identification No.

Oven

Local supply

Heat gun

Local supply

Pusher

CR&OP Data Module:

Nom.

Id. No.


Oil

C007

MIL-PRF-23699

GJ-06-02

Epoxy Primer

C042

MIL-P-23377.

Arbor press

Local supply

Grease

C009

MIL-PRF-81322F

Tool, bushing installation

EA6305G631-041

39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) - Assemble procedures. Nuts + Washers Retaining Spring

Gimbal Locknut (C009)

Packing (C007)

Tool, gimbal carbon 3G6305G13231 seal installation

Carbon seal

Pusher, flange

3G6305G11731

Ring

Reaction, locknut installation

3K6320A00131A023F

Wrench

3G6305G11331


3K6320A00131A676A

Flange (C007)

Bushings (C042)

Mating Ring

Carbon Seal

Spacer Packing

Heated area

Input Drive Quill Group



134 of 152

Items Heated

Items Heated

8.2.4.7 - Input Drive Quill group and Gimbal Assy, installation procedures. - Installation phase A

C

Ring (30), installation on the Pinion

B

Carbon seal (31), installation phase on the Gimbal

D

Gimbal (33), pre-installation phase of the carbon seal (31)


E

F

Carbon seal (31), installation phase – view of the Arbor press + Gimbal carbon seal installation tool 135 of 152

Carbon seal (31), installed in the Gimbal

Gimbal installed on the Input drive quill group.

8.2.4.7 - Input Drive Quill group and Gimbal Assy, installation procedures. - Installation phase G

I

Flange (40), installation phase in the spline of Input Pinion.

M

Torque application on the locknut

Marks applied on the Locknut

H L

Marks applied on the Flange


N

Wrench installation

136 of 152

Retaining Spring (39) installation

8.2.4.7 - Input Drive Quill group and Gimbal Assy, installation procedures. - Installation phase

O

P

Tool, bushing installation


Use of the tool

137 of 152

8.2.4.7 - Input Drive Quill group and Gimbal Assy, installation procedures. - Installation phase

Q

View of the Heated area of the Input Shaft Model + Gimbal Assy.

S

T

R

View of the Input drive quill group installed on the Input drive module. Installation of the Input Drive Quill group + Gimbal Assy on the Input Shaft Module.


Gimbal Assy, front view.

138 of 152

8.2.4.8 - Input Shaft Module, Backlash check. CR&OP Data Module:




Support equipment: Flange

Input Pinion


139 of 152

Nomenclature

Identification No.


3K6320A00131A676A

Stopper, gear

3K6320A00131A023L

Backlash tool, input drive quill

3K6320A00131A676B

Dial gauge

Local supply

8.2.4.8 -Input shaft module (main gearbox) – Backlash check. - Procedures Left Input Shaft Module (1), Input side

A A

Stand (3K6320A00131A676A )

Stopper, gear (3K6320A00131A023L) Backlash tool, installation (3K6320A00131A676B)

B

Procedure: 1 - Put the left input module (1) on the Stand. 2 - Install the Stopper on the Stand. 3 - Lock the gear (2) in the left input module (1) with the Stopper. 4 - Install the Backlash Tool on the input side of the left input module (1). 5 - Lock the Backlash Tool to the flange (3). 6 - Do a check of the backlash between the gear (2) and the input pinion (4) as follows: 6.1 Install the Dial Gauge on the support of the Stand. 6.2 Set the dial gauge to zero. 6.3 Pull and Turn the input pinion (4) through the arc allowed by the tooth clearance. Note Measure three position at 120˚ to each other. The value is the average of the three measures. 6.4 Measure, calculate and record the backlash as required. 6.5 Push and Turn the input pinion (4) through the arc allowed by the tooth clearance. Note Measure three position at 120˚ to each other. The value is the average of the three measures. 6.6 Measure, calculate and record the backlash as required.

D

C


Gear, 1° Stage of reduction (2) Input Pinion (4) Flange (3)


Dial gauge, installation 140 of 152

Backlash check

8.2.4.9 - Freewheel Group, assembly procedures. LH Input Shaft Module

CR&OP Data Module: 39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) Assemble procedures. Inner Bearing (oven)

Oil Vane Left Input Shaft Freewheel

Outer Bearing (oven)


Identification No.

Oven

Local supply

Pusher, outer bearing installation

3G6305G04631

Arbor press

Local supply

Supplies: Nom.

Id. No.

Oil

C007

Oil Vane Freewheel


141 of 152


8.2.4.9 - Freewheel Group, assembly procedures. - Assembly phase B A

Pusher

Input Shaft Inner Bearing Oil Vane

C

Freewheel

Outer Bearing Arbor Press For Training purpose only

142 of 152

8.2.4.10 - Freewheel Group and Oil jet Cover, installation LH Input Shaft Module

CR&OP Data Module:

Note: During the installation phase of the Oil Jet Cover (57) use the Heat Gun to increase the temperature of the Input Shaft Module.

39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) Assemble procedures. Support equipment:

Packing Spacer Packing

Freewheel Group

Nomenclature

Identification No.

Oven

Local supply

Pusher, clutch inner race installation

3G6305G04731

Heat gun

Local supply

Supplies:

Retaining ring Packings Oil Jet Cover


143 of 152

Nuts + Washers

Nom.

Id. No.

Oil

C007


8.2.4.10 - Freewheel Group and Oil jet Cover, installation - Installation phase of the freewheel group

Phase 2 Phase 1 Installation of the Freewheel Group on the Pusher and the positioning of the Pusher on the Input Shaft Module


144 of 152

Final positioning of the Freewheel group inside the Gear. During this phase continue to use the pusher until the freewheel group is fully against the shoulder in the gear.

8.2.4.10 - Freewheel Group and Oil jet Cover, installation - Installation phase of the freewheel group

B

A

C

Positioning of the Pusher inside the Freewheel group


Positioning of the Freewheel group on the Input Shaft Module

145 of 152

Installation phase of the freewheel group inside the Gear

8.2.4.10 - Freewheel Group and Oil jet Cover, installation - Spacer and Oil Jet Cover installation phase H

F

D

Spacer Retaining ring installation phase

Oil Jet Cover preparation

E

G

Spacer installed inside the Gear


I

Oil Jet Cover

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Oil Jet Cover installed on the Input Shaft Module

8.2.4.11 - Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation LH Input Shaft Module

Plug C014) Packing (C009)

Thermocouple (C014, hexagon) (Input Pinion Bearing Temperature sensor)

Packing (C009)

CR&OP Data Module: 39-A-63-20-05-01A-710A-C Left input shaft module (main gearbox) Assemble procedures.

Washer + Screw Packing (C007)

Fitting (C014)

Packing (C009)

Nom.

Id. No.


Oil

C007

MIL-PRF-23699

Safety wire

C014

MS20995C32

Grease C009 (Aeroshell 22)

Pressure Sw (C014) Screw Washer

Packings (C007) Oil Jet (C014)


Supplies:

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MIL-PRF-81322F

8.2.4.11 - Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation - External components installation view E

C

A

Oil Jet (64B)

Oil Jet (64A)

B

Pressure Sw

D F

64C 64B 64A

View of the Oil Jets (64A,B,C) installed on the Input Shaft module

Oil Jet (64C)


148 of 152

Bearing Thermocouple

8.2.4.12 - LH/RH Input Shaft Module, installation. CR&OP Data Module:

C164)

39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures. Support equipment:

Cross Shaft Packing Outer Plug Packing

Nomenclature

Identification No.

Plug, installation tool

Tbd

Inner cap

Supplies:

Packing (C115)

Packing

Cork Plug (C163)


Union

Washers + nuts

Id. No.


Adhesive (Shellac)

C163

None

Sealing compound (AMS- C164 S-8802, Class A-1/2) Grease

C115

AMS-S-8802, Class A-1/2. Parker “super Olube”.

Note: The installation procedure used for LH Input Module is also applicable for RH Input Module. See D.M. as required.

Packings (C115)


Nom.

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8.2.4.12 - LH/RH Input Shaft Module, installation procedures. - Installation phase Plug + Cap

C

B

A

D

Plug, Installation Tool

Packing

E

Cross Shaft

F

Union, installation

RH Input Shaft Module (inner side) + Cross Shaft

RH Input Shaft Module (inner side) , installation phase

RH Input Shaft Module (inner side) , installation phase

G

H Main Case

Cross Shaft


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8.2.5 - Anti-Torque Beam, Installation procedures CR&OP Data Module:


Identification No.


3G6320A00131A181A

Lifting device

Local supply

MGB Trolley, main gearbox support

3G6320A00131A188B

39-A-63-20-05-00A-710A-C Main gearbox - Assemble procedures. Upper Module

C

Main Case

A

RH

Main Case

RH

Anti-Torque Beam

LH

LH



B

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Chapter 8 - Assembly Procedures

THE END




Chapter 9 – Functional Check

9 – MGB Functional Check

INDEX 9.1 Preliminary Actions 9.1.1 Introduction 9.1.2 Description of operations of flushing 9.2 Functional Check (Test A) 9.2.1 Procedure


(Cont’s) 2 of 9

9.1 – Preliminary Actions 9.1.1 INTRODUCTION Before to carrying out a Functional Check , the internal areas of the MGB should be flushed to remove any dirt or debris. This procedure is reported in the following CR&OP data module: 39-A-63-20-05-00A-255A-C (Main gearbox –

Purge).


Identification No.

Electric motor

GJ-34-04

Flushing bench

156-1


HE-04-00

Refer to the data module for further information

Supplies / Spares

9.1.2 DESCRIPTION OF OPERATIONS OF FLUSHING

Nomenclature

Identification No

Oil

C007 (Turbo Oil 2380)

Plug

CJ-34-10 and CJ-34-09

Specification references MIL-PRF-23699

Refer to the data module for further information

The operation is performed by flow of oil under pressure sent into circulation by the pump discharge flow bench, adjusted to obtain a pressure value equal to 5.5 +/- 0.5 Bar (80 +/- 7 PSI). The fluid in circulation at a temperature of about 80° C, thought the Oil Jets of the Transmission, is used for rinsing dynamic components such as gear teeth, bearings and their slopes. The fluid is simultaneously conveyed to the tank of the bench through the recovery pump. Limited to flushing expected before the Functional Check, the rotation of the dynamic parts of the MGB (gears - bearings) performed by the Electrical Motor installed on No.1 Hyd. Pump Drive Quill helps to improve the effectiveness of the operation. The Flushing cycle should be performed for 30 minutes.


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9.2 - Functional Check (Test A) 9.2.1 PROCEDURE In the IETP/CR&OP the operator can find 2 different procedures, one can be used when a Test Bench is available and one when the Test Bench is not available, in particular:

If the Test Bench is available refer to CR&OP data module: 39-A-63-20-05-00A-344A-C (Main gearbox Functional check) vice versa, if the Test Bench is not available, you can do the functional check with the main gearbox installed on the helicopter applying the procedure reported on the CR&OP data module: 39-A63-20-05-00A-344B-C (Main gearbox - Functional check). In this section will be described the actions reported on CR&OP data module 39-A-63-20-05-00A-344A-C following a specific guideline. Hereinafter are reported the equipments and the supplies required to perform this action. Supplies:


Identification No.

Nomenclature

Identification No

Test bench, gearbox

139G6300E001

Oil

or

or


Test bench

LTR100-2000-02

or equivalent Transport trolley


139G6320A00331A188E

4 of 9

Specification references MIL-PRF-23699

9.2 - Functional Check (Test A) a) b)

The MGB must be installed on the Test Bench carrying out the necessary mechanical and electrical connections required. Fill the transmission with approximately 20 dm3 (5.3 US gal) of Oil (C007) as required. Refer to CR&OP 39-A-63-20-05-00A-212A-C.

Test Bench, front view

Test Bench, side view

(Cont’s) For Training purpose only

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9.2 - Functional Check (Test A) Note: During the Functional Check, make sure that the Temperature and Pressure indications are not more than the values that follow: - Input Pinion Bearing Temperature : 130°C - Oil Temperature : 110°C - Oil Temperature variation (input/output of the MGB) : < 15°C - Oil Pressure : 5 thru 5.5 Bar. c) d)

Start the Test Bench and gradually get the 100% of the nominal speed (21000 RPM). During this phase make sure that : - The test bench operates correctly - The oil pressure is 5 thru 5.5 bar - The oil low pressure indicator is off

e)

If the oil pressure is not in the specified range, stop the test bench and adjust the PRV (Pressure Relief Valve) before to continue.

Note The pressure setting must be the same for the two pressure relief valves. Procedure Adjust the two pressure relief valves as follow: • Get access to the pressure relief valve • Loosen the lock nut fully. • Adjust the pressure relief valve as follow: – Turn the adjustment screw clockwise to increase the pressure setting – Turn the adjustment screw (3) counter clockwise to decrease the pressure setting. Note One complete turn of the adjustment screw (3) changes the pressure setting by approximately 0.5 bar. • Tighten the lock nut (2).


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Adjustment Screw Lock nut

Pressure Relief Valve

9.2 - Functional Check (Test A) f)

After the adjustments Start the Test Bench and do the “green run” cycle. Obey the instructions given in the Table reported hereinafter:


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9.2 - Functional Check (Test A) g)

At the end of the Functional Check (green run cycle) perform the following actions: -

Compile a specific Test Report Remove the MGB from the Test Bench Install the MGB on the Transport Trolley Disassemble the MGB and perform the visual examination of the components.


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Chapter 9 – Functional Check

THE END



MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 10 – Disassembly procedures after Functional check

10 – Disassembly procedures after Functional Check INDEX 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11

Introduction MGB - Disassembly procedures, initial phase Main Case, Backlash check MGB - Disassembly procedures, final phase Left / Right Input Shaft Module - Disassembly procedures, initial phase Input Shaft Modules, Backlash check Left / Right Input Shaft Module - Disassembly procedures, final phase Upper module, disassembly procedures Mast-Planetary Assy, disassembly procedures Front Hyd. Pump drive quill, disassembly procedures LH/RH Hyd. Pump drive quills, disassembly procedures


2 of 28

10.1 – Introduction In order to inspect and check the internal components of the MGB after the Functional Check performed on specific Test Bench, the MGB must be disassembled once again; this action is required before to perform the Leak Check (Test “B”) and before it can be declared serviceable. During this phase the MGB will be disassembled but to a lesser degree. In particular, will be performed the following actions: - If not already performed just after the Functional Check, drain the Oil from the Main Case. Refer to CR&OP data module: 39-A-63-20-05-00A-222A-C (Main gearbox – Drain Oil) - Start with the disassembly phase of the MGB. Refer to CR&OP data module: 39-A-63-20-05-00A-539A-C (Main gearbox – Disassemble procedures after functional check). - Perform the Backlash check on the Main Case and on each Input Shaft Module as required. Refer to the following CR&OP data modules:

39-A-63-20-05-00A-713A-C (Main gearbox - Backlash/gear pattern check), 39-A-63-20-05-01A-713A-C (Left input shaft module – Backlash/gear pattern check) and to 39-A-63-20-05-02A-713A-C (Right input shaft module – backlash/gear pattern check). - After completion of the MGB disassembly, each parts removed (Main Case, Upper Module, Input Shaft modules and Mast-Planetary Assy) or disassembled must be re-inspected (Visual Examinations) i.a.w. the specific CR&OP data modules.


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10.2 – MGB Disassembly procedures, initial phase During this phase refer to CR&OP data module: 39-A-63-20-05-00A-539A-C (Main gearbox – Disassemble procedures after functional check). In particular, referring to this D.M. disassemble the MGB as necessary to perform the backlash check on the Main Case. Perform the following actions: 1.

Remove the Draining Pipe as required.

2.

Remove the Anti-Torque Beam as required.


4 of 28

10.2 – MGB Disassembly procedures, initial phase 3.

Remove the Bottom Cover as required.

MastPlanetary assembly

4.

Install the MGB on the Maintenance Trolley

Upper Module RH Input Shaft Module


Main Case Assembly

Maintenance Trolley Side View


5 of 28


Remove the Left and Right Input Shaft Module.

6.

Remove the Plugs from the open Drive Quills (Hydraulic Pumps drive quills, ECS drive quill and FAN drive quill) and the Seal Cover from the Fan Drive Quill and from the ECS Compressor Drive Quill.

LH/RH Hydraulic Pump, Drive Quill plug

ECS Compressor, Drive Quill plug + Seal Cover


6 of 28

Front Hydraulic Pump, Drive Quill plug

FAN, Drive Quill plug + Seal Cover


Remove the Oil Filter Head from the Upper Module.

8.

Remove Rotor Speed Sensor (NR).


7 of 28


Remove the two Check Valves.

10. Remove the two Pressure Relief Valves.


8 of 28

10.2 – MGB Disassembly procedures, initial phase 11. Remove the two (LH/RH) Chip Detectors

12. Remove the Left and Right Lubrication Pump.


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10.2 – MGB Disassembly procedures, initial phase 13. Remove the Fifteen Oil Jets from the Main Case.

Top View

Rear View


10 of 28


Remove the left/right-input shaft module

Main Case

O-ring Plug Cross Shaft LH Input Shaft Module Union

Cross Shaft Washers

O-rings

Washers Washers Nuts Bracket

Nuts Bracket

Washers + Nuts Bracket


11 of 28

Washers NutsWashers Set screw (Nylon)

10.2 – MGB Disassembly procedures, initial phase 15. Remove the Upper Module, the Unions and the Planetary Crown (Ring gear).


Upper Module Assy Oil Union “B”


Main Case


12 of 28

10.3 - Main Case, Backlash check Backlash check required RH Input Pinion II° Stage Collector Gear Hyd. Pump No. 2


CR&OP Data Module:






ECS-










Front Hyd. Pump


Note Measure and Record the backlash


13 of 28

10.4 – MGB Disassembly procedures, final phase During this phase refer to CR&OP data module: 39-A-63-20-05-00A-539A-C (Main gearbox – Disassemble procedures after functional check). In particular, referring to this D.M. perform the final disassemble of the MGB as follows. 1.

Remove the Fan, LH & RH Hyd. Pump, Front Hyd. Pump and ECS-Compressor Drive Quills.


Details B - LH/RH Hydraulic Pump Drive Quills C - ECS Compressor Drive Quill D - Front Hydraulic Pump Drive Quill V - Fan Drive Quill Engine 1 Inlet (Drive Shaft)


14 of 28

10.4 – MGB Disassembly procedures, final phase 2.

Remove the Right & Left Input Pinion Assy (II° stage of reduction).


Input Pinion Assembly installed inside the Main Case (RH Side) LH and RH Input Pinion Assembly removed


15 of 28


Remove the Tail-rotor drive-quill Assy.


4.

Remove the Diaphragm.


16 of 28


Remove the Collector Gear. See Para. 39.

6.

Remove the Collector Bearing. See Para. 39.6


17 of 28

10.5 - Left / Right Input Shaft Mod. – Disassembly proc., initial phase – Ref. documentations Engine 2 Inlet (Drive Shaft)

CR&OP Data Module:


39-A-63-20-05-01A-539A-C Left input shaft module (main gearbox) - Disassemble procedures after functional check (Effectivity Code: B01) Engine 1 Inlet (Drive Shaft)

Or 39-A-63-20-05-01B-539A-C Left input shaft module (main gearbox) - Disassemble procedures after functional check (Effectivity Code: B02)


Effectivity Codes: - B01 : Input shaft module P/N 3K6320A00133 (installed on [MGB A01] P/N 3G6320A00132 and 3G6320A00133) - B02 : Input shaft module P/N 3K6320A00135 (installed on [MGB A02] P/N 3G6320A00134 and 3G6320A00135)


18 of 28

And 39-A-63-20-05-02A-539A-C Right input shaft module (main gearbox) - Disassemble procedures after functional check Note The disassemble procedures given for the leftinput shaft module are applicable to the rightinput shaft module.

10.5 - Left / Right Input Shaft Mod. – Disassembly proc., initial phase – Description During this phase refer to CR&OP data module: 39-A-63-20-05-01A-539A-C, 39-A-63-20-05-01B-539A-C or to 39-A-63-20-05-02A-539A-C as required. In particular, taking into account the D.M. 39-A-63-20-05-01A-539A-C (as example), perform the actions reported hereinafter: •

Remove the three Oil Jets, the Oil Jet Cover, the Thermocouple, the Freewheel Group and disassemble the Freewheel Group as required. Note Perform this action on both Input Shaft Modules. Use the specific Data Module Thermocouple


Thermocouple

Freewheel Group

Oil Jet Cover

Oil Jet


Oil Jet Cover

19 of 28


10.6 - Input Shaft Modules, Backlash check CR&OP Data Module:




Flange

Input Pinion


20 of 28

10.7 Left / Right Input Shaft Mod. - Disassembly proc., final phase - Description During this phase refer to CR&OP data module: 39-A-63-20-05-01A-539A-C, 39-A-63-20-05-01B-539A-C or to 39-A-63-20-05-02A-539A-C as required. In particular, taking into account the D.M. 39-A-63-20-05-01A-539A-C (as example), remove the Input drivequill group as required.


Note Use the Heat Gun and increase the temperature (as required) of the LH Input Module locally in the housing area of the Input Pinion.


21 of 28

10.8 - Upper module, disassembly procedures During this phase refer to CR&OP data module: 39-A-63-20-05-03A-539A-C - Upper module (main gearbox) - Disassemble procedures after functional check , as required. In particular, taking into account this D.M. perform the actions reported hereinafter. 1.

Remove the four Oil Jets

2 Oil Jets No. 1 2 Oil Jets No. 2


22 of 28

A

B

C

D

10.8 - Upper module, disassembly procedures 2.

Remove the Chip Detector and the Chip Detector Valve .

Chip Detector O-ring

Chip Det. Valve O-ring


23 of 28

10.8 - Upper module, disassembly procedures 3.

Remove the Roller Bearing, the Seal cover and the Mast-Planetary Assy as required.

Top Case

MastPlanetary Assembly

Seal Cover Roller Bearing

Note: Planetary crown (Fixed ring gear) already removed


24 of 28

10.9 - Mast-Planetary Assy, disassembly procedures During this phase refer to CR&OP data module: 39-A-63-20-05-13A-539A-C - Mast-planetary assembly (upper module) - Disassemble procedures after functional check. In particular, remove one of the five Planetary Gear Assy from the Flange and then disassemble the Planetary gear Assy i.a.w. the following D.M.: 39-A-63-20-05-14A-530A-C Planetary gear assembly (mast planetary assembly) - Disassemble procedures.


Flange


Planetary Gear Assy. Rollers Bottom-inner bearing race


25 of 28

Roller cage

10.10 - Front Hyd. Pump drive quill, disassembly procedures During this phase refer to CR&OP data module: 39-A-63-20-05-04A-539A-C Front pump drive quill (main gearbox) - Disassemble procedures after functional check In particular, remove the Retaining Ring, the Seal Cover and the Packing from the drive quill. Front Hyd. pump drive quill

Inner side

Packing

Seal cover

External side

Retaining ring


26 of 28

10.11 - LH/RH Hyd. Pump drive quills, disassembly procedure During this phase refer to CR&OP data module: 39-A-63-20-05-27A-539A-C Left/right pump drive quill (main gearbox) - Disassemble procedures after functional check. In particular, remove the Retaining Ring, the Seal Cover and the Packing from the drive quills.

Retaining ring Seal cover

Left/right pump drive quill (Hyd. pump No.1 and No.2 drive quill) Inner side

Packing

External side


27 of 28

Chapter 10 –Disassembly procedure after Functional check

THE END



MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 11: Inspection criteria after Functional check

11 – Inspection Criteria after Functional check INDEX

11.1 11.2 11.2.1 11.2.2 11.2.3 11.3 11.3.1 11.4 11.4.1 11.5 11.5.1 11.6 11.6.1 11.7 11.7.1 11.8 11.8.1 11.9 11.9.1 11.10 11.10.1 11.11

General guideline for visual examination of components after functional check Main gearbox – Detailed Visual Examination Collector gear – Wear Pattern Check Input pinion (II° stage of reduction) – Wear Pattern Check Gear (Hyd. Pump drive quill) – Wear Pattern Check LH/RH Right Input Shaft Module – Detailed Visual Examination Freewheel – Detailed Visual Examination Upper Module – Detailed Visual Examination Ring Gear – Wear Pattern Check Mast-Planetary Assembly – Detailed Visual Examination Planetary Gear Assembly – Wear Pattern Check LH/RH Hyd. Pump Drive Quill – Detailed Visual Examination LH/RH Hyd. Pump Drive Quill – Wear Pattern Check Front Hyd. Pump Drive Quill – Detailed Visual Examination Front Hyd. Pump Drive Quill – Wear Pattern Check ECS Compressor Drive Quill – Detailed Visual Examination ECS Compressor Drive Quill – Wear Pattern Check LH/RH Lubrication Pump – Detailed Visual Examination LH/RH Lubrication Pump – Wear Pattern Check Fan Drive Quill – Detailed Visual Examination Fan Drive Quill – Wear Pattern Check Tail Rotor Drive Quill – Detailed Visual Examination & Wear Pattern Check


2 of 30

11.1 General guideline for visual examination of components after functional check This section lists the general criteria for the inspection of the main components of the main transmission. Note For more data on the visual examination of the components of the main gearbox and for the definition of the defects refer to the following CR&OP data modules: 

39-A-63-20-05-00A-919A-C Main gearbox - General guidelines for visual examination of components after functional check



39-A-63-20-05-00A-913A-C Main gearbox - General guidelines for visual examination of components

All information reported in this Chapter must be considered for Training purpose only 1. GEARS • •

Check the gear teeth for corrosion, overload indication, pitting and scoring. Light indication of contact are allowed on the top and on the bottom. Light particle passage indication is allowed. Verify the dimension and the pattern position.

2. BEARINGS • •

Check the ball and roller bearing for corrosion, scratches, pitting, spalling and check for free to rotate. Check the internal and external diameters for fretting and/or rotation; light indication of rotation between external race and housing is allowed for no flanged bearings. Light scratches on the rollers and on the races are allowed.


3 of 30

11.1 General guideline for visual examination of components after functional check (continued) 3. SPLINE Check the spline teeth for corrosion, fretting, overload indication and indentation. Light fretting is allowed. 4. FREEWHEELS • • •

Check the “SPRAG” of the freewheel for corrosion, cracks, wear and pitting. Check the cage outer diameter for heavy contact pattern and the “SPRAG” pocket for deformation. Check the races for wear, overheating and heavy contact pattern.

5. CASE • • • •

Check for damage due to movement and displacement before, during and after the green-run. Check the bearing housing on case and liner; light fretting is allowed. Check the connecting surfaces; light fretting is allowed. Check the studs for elongation, deformation, corrosion.

6. SEALS • • • •

Check the static and rotating seal for damage, deformation, scratches, breakage and rubber degradation Inspect the races of the rotating seal for wear. Inspect the input rotating seal. In case of leakage during the green-run change the seal.


4 of 30

11.2 Main gearbox – Detailed Visual Examination As reported on CR&OP data module: 39-A-63-20-05-00A-319A-C Main gearbox - Visual examinations after functional check, perform the following inspections: 1.

Examine the Splines of the two Cross-Shafts (1) for fretting.

2.

Examine the two roller bearings (2) for corrosion, scratches, pitting and spalling. The roller bearings stay in the main case.


5 of 30

11.2 Main gearbox – Detailed Visual Examination 3. Examine the interface planes of the diaphragm (3) for fretting. 4. Examine the bearing (4) for corrosion, scratches, pitting and spalling. The bearing (4) stays in the diaphragm (3). 5. Examine the teeth (spiral bevel gear and spur gear) of the collector gear (5) for corrosion, indentation, scoring and pitting. Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-05-00A379A-C. See Para. 11.2.1. of this Training Manual. 6. Examine the bearing race on the collector gear (5) for corrosion, scratches, pitting and spalling. 7. Examine the interface planes of the collector bearing (6) for fretting. Make sure that the collector bearing is free to turn. The collector bearing (6) stays on the collector gear (5). 8. Examine the main case (7) for: – General condition. This is very important on the external surfaces. – Fretting on the interface planes. This is very important for the interface planes with the ring gear, the diaphragm and the anti-torque beam. – Fretting on the line housings. 9. Examine the studs of the main case (7) for damage, scratches and distortion. For Training purpose only

6 of 30

(continued)

11.2 Main gearbox – Detailed Visual Examination (continued) 10. Examine the teeth of the two pinions (8) for corrosion, indentation, scoring and pitting. Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-0500A-379A-C. See Para. 11.2.2. of this Training Manual. 11. Examine the bearing races on the pinions (8) for corrosion, scratches, pitting and spalling. 12. Examine the splines of the pinions (8) for fretting. 13. Examine the interface surfaces of the bearing sleeve (9) for fretting. 14. Make sure that the bearing (10) is free to turn. 15. Examine the teeth of the gear (11) for corrosion, indentation, scoring and pitting. Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-05-00A-379A-C. See Para. 11.2.3. of this Training Manual.


7 of 30

11.2.1 Collector gear – Wear Pattern Check During this inspection it is required to examine the wear pattern located on the:

• Convex side of the Gleason Crown (W.P. with Second stage pinion); see detail A1. • Concave side of the Gleason crown (W.P. with Tail Rotor drive pinion); see detail A2. • Sun Gear (W.P. with Planetary gear); see detail A3. • Concave side of the Gleason Crown (W.P. with Front Pump drive quill gear); see detail A4. • Concave side of the Gleason Crown (W.P. with ECS Compressor drive quill gear); see detail A5. • Concave side of the Gleason Crown (W.P. with Lubrication Pump gear); see detail A6. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


8 of 30

11.2.2 Input pinion (II° stage of red.) – Wear Pattern Check During this inspection it is required to examine the wear pattern located on the:

• Concave side of the Gear (Eng. No. 1); see detail B1. • Concave side of the Gear (Eng. No. 2); see detail B2. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


9 of 30

11.2.3 Gear (Hyd. Pump drive quill) – Wear Pattern Check During this inspection it is required to examine the wear pattern located on the Convex side of the Gear (3); see detail C. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


10 of 30

11.3 LH/RH Right Input Shaft Module – Detailed Visual Examination As reported on the following CR&OP data modules: 39-A-63-20-05-01A-319A-C Left input shaft module (main gearbox) - Visual examinations after functional check, or 39-A-63-20-05-01B-319A-C Left input shaft module (main gearbox) - Visual examinations after functional check, or 39-A-63-20-05-02A-319A-C Right input shaft module (main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter: 1. 2.

Examine the oil jet cover (6) for conditions. Examine the input shaft (3). Use the Magnifying Glass and obey the instructions that follow: 2.1 Examine for corrosion, wear and seizure. 2.2 Examine for signs of not circumferential operation. 2.3 Examine for sprag engagement scratches with a depth more than 0.010 mm (0.0004 in). 3. Examine the ball and roller bearings (2), (5), (7), (12) and (13) and the duplex bearing (10) for damage. 4. Examine the outer diameters and the related seats of the ball bearings (2) and (5) for condition. 5. Examine the freewheel (4). Refer to CR&OP data module: 39-A-63-2005-01A-311B-C. See Para. 11.3.1 of this Training Manual. For Training purpose only 11 of 30

11.3 LH/RH Right Input Shaft Module – Detailed Visual Examination (continued) 6. 7.

Examine outer surfaces of the Gimbal (14) for damage and dents. Examine the attach holes and the mating surface of the flange (15) for fretting, dents and damage.


12 of 30

11.3 LH/RH Right Input Shaft Module – Detailed Visual Examination (continued) 8. 8.1 8.2 8.3 9.

Examine the input pinion (11) and the crown gear (8). Obey the instructions that follow: Examine the bearing seats for fretting and conditions. Examine the teeth for damage and condition. Examine the teeth for acceptable wear pattern. Examine the freewheel sprags engaging area of the gear (8) for corrosion, wear, seizure and sprag engagement deep scratches.

11

Note Only small contamination with material from freewheel springs is permitted. 10. 11.

11.1 11.2 11.3 11.4 11.5 12.

Examine the interface surfaces of the sleeve (9) for fretting and seizure. Examine the left input module (1). Obey the instructions that follow: Examine the case for general condition. Examine the outer surface for handling damage. Examine the interface planes for fretting. Examine the sleeve seats for fretting and seizure. Examine the studs for stretching, distortion and damage. Reject the parts that are damaged.


13 of 30

8

11.3.1 Freewheel – Detailed Visual Examination During the inspection of the Freewheel it is required to follow the procedure reported on CR&OP data module: 39-A-63-20-05-01A-311B-C Left input shaft module (main gearbox) - Freewheel - Detailed visual examination. In particular, perform a detailed visual examination with the aid of the Magnifying Glass, of a Mirror and of a strong light. Examine the freewheel for corrosion and distress caused by the heat. Reject it if you find one of these defects. Continue the inspection following the instructions reported this CR&OP Data Module.


14 of 30

11.4 Upper Module – Detailed Visual Examination As reported on the following CR&OP data module: 39-A-63-20-05-03A-319A-C Upper module (main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter: 1. 2. 3. 4. 5. 5.1 5.2 5.3

6. 6.1 6.2 6.3 6.4 6.5

Examine the lip seal (3) for wear. Examine the roller bearing (4) for corrosion, scratches, pitting and spalling. Examine the seal housing (2) for condition. Examine the bearing seat on the mast (5) for fretting and conditions. Do a check on the ring gear (6) as follows: Examine the pin seats for fretting and conditions. Examine the teeth for corrosion, dents, scoring and pitting. Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-0500A-379A-C. See Para. 11.4.1. of this Training Manual. Examine the upper module (1) as follows: Examine the case for general condition. Examine the outer surface for handling damage. Examine the interface planes for fretting. Examine the seat of the bearing (4) on the upper module for fretting. Examine the studs for stretching, distortion and damage.


15 of 30

1

11.4.1 Ring Gear – Wear Pattern Check During this inspection it is required to examine the wear pattern along the surface of the tooth (4) as shown on detail D. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


16 of 30

11.5 Mast-Planetary Assembly – Detailed Visual Examination As reported on the following CR&OP data module: 39-A-63-20-05-13A-319A-C Mast-planetary assembly (upper module) - Visual examinations after functional check, perform the actions reported hereinafter. 1. Examine the mast (5) as follows: 1.1 Examine the seat of the rotating seal for wear and corrosion. 1.2 Examine the spline teeth for fretting, dents and damage caused by the work trolley. 1.3 Examine seat of the roller bearing (1) for corrosion, scratches, pitting and spalling. 1.4 Examine the mating surface between the planetary gear support and the shims (2) for fretting. 2. Examine the mating surface between the plate (3) and the shims (2) for fretting. 3. Examine the opposite end surfaces of the shims (2) for fretting. 4. Do a check on the planetary gear (4) as follows: 4.1 Examine the teeth for corrosion, dents, scoring and pitting. 4.2 Examine the outer race and the rollers for corrosion, scratches, pitting and spalling. 4.3 Examine the inner race only if a defect is found on the outer race or on the rollers. Do a check for corrosion, scratches, pitting and spalling. 4.4 Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-05-00A-379AC. See Para. 11.5.1. of this Training Manual. For Training purpose only

17 of 30

11.5.1 Planetary Gear Assembly – Wear Pattern Check During this inspection it is required to examine the wear pattern along the surface of the tooth located on the sun-gear drive side of the Planetary gear (5, see detail E1) and on the ring-gear drive side of the planetary gear (5, see detail E2). These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


18 of 30

11.6 LH/RH Hyd. Pump Drive Quill – Detailed Visual Examination As reported on the following CR&OP data modules: 39-A-63-20-05-27A-319A-C Left/right pump drive quill (main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter. 1. 2. 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 4.4

Examine the cover (1) for conditions. Examine the lip seal (2) for wear and overheating. Examine the sleeve (3) and the related bearing as follows: Examine the mating surfaces with the components for fretting. Examine the bearing races for wear, breaks and deformation. Turn the bearing to do a check for the correct and freely operation. Do a check on the drive gear (4) as follows: Examine the spline teeth for fretting. Examine the race of the seal for wear. Examine the teeth for corrosion, dents, scoring and pitting. Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-0500A-379A-C. See Para. 11.6.1. of this Training Manual.


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11.6.1 LH/RH Hyd. Pump Drive Quill – Wear Pattern Check During this inspection it is required to examine the wear pattern located on the Concave side of the Gear (6); see detail F. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


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11.7 Front Hyd. Pump Drive Quill – Detailed Visual Examination As reported on the following CR&OP data module: 39-A-63-20-05-04A-319A-C Front pump drive quill (main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter. 1. 2. 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 4.4

Examine the cover (4) for conditions. Examine the lip seal (3) for wear and overheating. Examine the sleeve (2) and the related bearing as follows: Examine the mating surfaces with the components for fretting. Examine the bearing races for wear, breaks and deformation. Turn the bearing to do a check for the correct and freely operation. Do a check on the drive gear (1) as follows: Examine the spline teeth for fretting. Examine the race of the seal for wear. Examine the teeth for corrosion, dents, scoring and pitting. Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-0500A-379A-C. See Para. 11.7.1. of this Training Manual. 39-A-63-20-05-00A-379A-C.


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11.7.1 Front Hyd. Pump Drive Quill – Wear Pattern Check During this inspection it is required to examine the wear pattern located on the Convex side of the Gear (7); see detail G. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


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11.8 ECS Compressor Drive Quill – Detailed Visual Examination As reported on the following CR&OP data module: 39-A-63-20-05-05A-319A-C ECS compressor drive quill (main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter. 1. 2. 3. 3.1 3.2

3.3 4. 4.1 4.2 4.3 4.4

Examine the cover (4) for conditions. Examine the lip seal (3) for wear and overheating. Examine the sleeve (2) and the related bearing as follows: Examine the mating surfaces with the components for fretting. Examine the bearing races for wear, breaks and deformation. Turn the bearing to do a check for the correct and freely operation. Do a check on the drive gear (1) as follows: Examine the spline teeth for fretting. Examine the race of the seal for wear. Examine the teeth for corrosion, dents, scoring and pitting. Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-0500A-379A-C. See Para. 11.8.1. of this Training Manual


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11.8.1 ECS Compressor Drive Quill – Wear Pattern Check During this inspection it is required to examine the wear pattern located on the Convex side of the Gear (8); see detail H. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


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11.9 LH/RH Lubrication Pump – Detailed Visual Examination As reported on the following CR&OP data modules: 39-A-63-20-05-06A-319A-C Left lubrication pump (main gearbox) - Visual examinations after functional check, or 39-A-63-20-05-24A-319A-C Right lubrication pump (main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter.

1. Examine the lubrication pump (2) as follows: 1.1 Examine the mating surfaces with the main gearbox case for fretting. 1.2 Examine the shaft of the left lubrication pump (2) for wear. 1.3 Turn the lubrication pump (2) to do a check for the correct and freely operation. 2. Do a check on the drive gear (1) as follows: 2.1 Examine the key seat and the housing of the pump shaft for wear. 2.2 Examine the teeth for corrosion, dents, scoring and pitting. 2.3 Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-0500A-379A-C. See Para. 11.9.1. of this Training Manual


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11.9.1 LH/RH Lubrication Pump – Wear Pattern Check During this inspection it is required to examine the wear pattern located on the Convex side of the Gear (9); see detail J. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


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11.10 Fan Drive Quill – Detailed Visual Examination As reported on the following CR&OP data module: 39-A-63-20-05-07A-319A-C Fan drive quill (main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter. 1. 2. 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3

4.4

Examine the cover (4) for conditions. Examine the lip seal (3) for wear. Examine the sleeve (2) and the related bearing as follows: Examine the mating surfaces with the components for fretting. Examine the bearing races for wear, breaks and deformation. Turn the bearing to do a check for the correct and freely operation. Do a check on the drive gear (1) as follows: Examine the spline teeth for fretting. Examine the race of the seal for wear. Examine the teeth for corrosion, dents, scoring and pitting. Examine the teeth for acceptable wear pattern. Refer to CR&OP data module: 39-A-63-20-0500A-379A-C. See Para. 11.10.1. of this Training Manual


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11.10.1 Fan Drive Quill – Wear Pattern Check During this inspection it is required to examine the wear pattern located on the Concave side of the Gear (10); see detail K. These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


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11.11 Tail Rotor Drive Quill – Detailed Visual Examination & Wear Pattern Check Examine the Tail Rotor Drive Quill for general condition, check the roller bearing per corrosion and damages then inspect the wear pattern located on the Convex side of the fan drive gear (see detail L1) and on the Convex side of the Tail-rotor drive pinion (see detail L2). These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main gearbox - Gears - Wear pattern check.


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Chapter 11: Inspection criteria after Functional check

THE END



MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 12 – Assembly procedures after Functional check

12 – Assembly procedures after Functional Check

INDEX 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 12.14

Introduction MGB - Assembly procedures, initial phase Main Case, Backlash check MGB - Assembly procedures, intermediate phase Mast-Planetary Assy, Assembly procedures Upper Module, Assembly procedures Upper Module, Installation procedures MGB - External components installation MGB - Oil jets installation Left / Right Input Shaft Module - Assembly procedures, initial phase Input Shaft Modules, Backlash check Left / Right Input Shaft Module - Assembly procedures, final phase Left / Right Input Shaft Module, Installation procedures MGB – Assembly procedures, final phase


2 of 26

12.1 – Introduction When the examination of the components are completed the MGB must be re-assembled and then tested with a Leak Check (Test “B”). In this section will be described the assembly procedure of the MGB. During this phase, observe the procedures reported on the following CR&OP data modules: • 39-A-63-20-05-00A-714A-C (Main gearbox - General guidelines for assemble procedures), • 39-A-63-20-05-00A-719A-C (Main gearbox - Assemble procedures after functional check).

In particular, during the re-assembly phase performed i.a.w the specific data modules, it is required to re-check the Backlash on the Main Case and on each Input shaft module. For these actions refer to the following CR&OP Data Modules: • 39-A-63-20-05-00A-713A-C (Main gearbox - Backlash/gear pattern check), • 39-A-63-20-05-01A-713A-C (Left input shaft module – Backlash/gear pattern check) and to • 39-A-63-20-05-02A-713A-C (Right input shaft module – backlash/gear pattern check). After completion of the assembly, the MGB must be tested on the specific Test Bench performing a Leak Check (Test “B”).


3 of 26

12.2 MGB - Assembly procedures, initial phase During this initial phase refer to CR&OP data module: 39-A-63-20-05-00A-719A-C Main gearbox Assemble procedures after functional check. In particular, following the steps (from 1 to 5) reported hereinafter, prepare the Main Case of the MGB to the Backlash Check . 1.

Install the Collector Bearing and the Collector Gear in the Main Case as required.

2.

Install the Diaphragm as required. Refer to Para. 8.


4 of 26

12.2 MGB - Assembly procedures, initial phase 3.

Install the Tail-rotor drive quill.



5 of 26


Install the Right & Left Input Pinion Assy (II° stage of reduction).

Input Pinion (II° Stage of reduction)

Input Pinion Assembly installed inside the Main Case (RH Side) LH and RH Input Pinion Assembly


6 of 26


Install the Fan drive quill (without its Packing and Lip Seal Cover), the Right Hydraulic Pump drive quill, the Left Hydraulic Pump drive quill, the Front Hydraulic Pump drive quill and the ECS drive quill as required. The RH, LH and Front Pump Drive Quills, must be assemble before their installation on the Main Case. These specific procedures are reported in following CR&OP data modules: - 39-A-63-20-05-27A-719A-C Left/right pump drive quill (main gearbox) - Assemble procedures after functional check. - 39-A-63-20-05-04A-719A-C Front pump drive quill (main gearbox) - Assemble procedures after functional check. Engine 2 Inlet Details

(Drive Shaft)

B - LH/RH Hydraulic Pump Drive Quills C - ECS Compressor Drive Quill D - Front Hydraulic Pump Drive Quill V - Fan Drive Quill Engine 1 Inlet (Drive Shaft)


7 of 26

12.3 - Main Case, Backlash check



CR&OP Data Module:






ECS-










Front Hyd. Pump


Note Measure and Record the backlash


8 of 26

12.4 MGB - Assembly procedures, intermediate phase During this phase refer to CR&OP data module: 39-A-63-20-05-00A-719A-C (Main gearbox – Assemble procedures after functional check). In particular, following this D.M. continue with the assembly of the MGB performing the actions reported hereinafter . 1.

Install the Packing and the Lip Seal Cover of the Fan drive quill as required.

FAN, Drive Quill + Seal Cover

2.

Install the Left and Right Lubrication Pump and the Bottom Cover as required.


9 of 26

12.5 Mast-Planetary Assy, Assembly procedures During this phase refer to CR&OP data module: 39-A-63-20-05-13A-719A-C - Mast-planetary assembly (upper module) - Assemble procedures after functional check. In particular, assemble the Planetary Gear Assy previously removed i.a.w. D.M.: 39-A-63-20-05-14A-710AC (Planetary gear assembly (mast planetary assembly) - Assemble procedures) and then install it on the Flange and perform the final assembly of the Mast-Planetary Assy.


Flange


Planetary Gear Assy. Rollers Bottom-inner bearing race


10 of 26

Roller cage

12.6 Upper Module, Assembly procedures During this phase refer to CR&OP data module: 39-A-63-20-05-03A-719A-C Upper module (main gearbox) - Assemble procedures after functional check, as required. In particular , taking into account this D.M. Perform the actions (see steps 1, 2 and 3) reported hereinafter: 1.

Install the Mast-Planetary Assy, the Planetary Crown (Fixed ring gear), the Packing, the Roller Bearing and Seal Cover on the Top Case. Top Case

MastPlanetary Assembly Seal Cover Roller Bearing


Planetary crown (Fixed ring gear) and Packing

11 of 26

12.6 Upper Module, Assembly procedures 2.

Install the four Oil Jets.

2 Oil Jets No. 1 2 Oil Jets No. 2


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A

B

C

D

12.6 Upper Module, Assembly procedures 3.

Install the Chip Detector and the Chip Detector Valve as required.

Chip Detector O-ring Chip Det. Valve O-ring


13 of 26

12.7 Upper Module, Installation procedures Taking into account the procedures reported in the CR&OP data module 39-A-63-20-05-00A-719A-C (Main gearbox - Assemble procedures after functional check), install the Unions and the Upper Module Assy on the Main Case as required.


Upper Module Assy Oil Union “B”

Main Case


14 of 26

12.8 MGB - External components installation Taking into account the procedures reported in the CR&OP data module 39-A-63-20-05-00A-719A-C (Main gearbox - Assemble procedures after functional check), install the following external components (see steps from 1 to 7): 1.

Install the Plugs on the open Drive Quills (Hydraulic Pumps drive quills, ECS drive quill and FAN drive quill) and the Lip Seal Cover on the Fan Drive Quill as required.

LH/RH Hydraulic Pump, Drive Quill plug

ECS Compressor, Drive Quill plug


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Front Hydraulic Pump, Drive Quill plug

FAN, Drive Quill plug

12.8 MGB - External components installation 2.

Install the Oil Filter Head (during this phase without the Filter Element and the Anti-spill valve) as required. Refer to AMP data module: 39-A-63-20-05-21A-720A-A Oil filter head (main gearbox) – Install procedures.

3.

Install the Drain Pipe i.a.w. CR&OP data module :39-A-63-20-05-00A-719A-C Main gearbox Assemble procedures after functional check.


16 of 26

12.8 MGB - External components installation 4.

Install the Rotor Speed Sensor (NR). Refer to CR&OP Data module: 39-A-63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check.

5.

Install the 3 Servo-Actuator Brackets (Front, Left and Right) on the Main Case i.a.w. CR&OP Data module: 39-A-63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check.


17 of 26

12.7 Upper Module, Installation procedure 6.

Install the 2 Check Valves i.a.w. CR&OP data module :39-A-63-20-05-00A-719A-C Main gearbox Assemble procedures after functional check.

7.

Install the 2 Pressure Relief Valves (PRV) and the 2 Chip Detectors i.a.w. CR&OP data module :39-A63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check.

PRV Chip Detectors


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12.9 MGB - Oil jets installation 8.

Install the Oil jets on the Main Case i.a.w. CR&OP data module : 39-A-63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check.

Top View

Rear View


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12.10 Left / Right Input Shaft Module - Assembly procedures, initial phase Engine 2 Inlet (Drive Shaft)

CR&OP Data Module:


39-A-63-20-05-01A-719A-C Left input shaft module (main gearbox) - Assemble procedures after functional check (Effectivity Code: B01) Engine 1 Inlet (Drive Shaft)

Or 39-A-63-20-05-01B-719A-C Left input shaft module (main gearbox) - Assemble procedures after functional check (Effectivity Code: B02)


Effectivity Codes: - B01 : Input shaft module P/N 3K6320A00133 (installed on [MGB A01] P/N 3G6320A00132 and 3G6320A00133) - B02 : Input shaft module P/N 3K6320A00135 (installed on [MGB A02] P/N 3G6320A00134 and 3G6320A00135)


20 of 26

And

39-A-63-20-05-02A-719A-C Right input shaft module (main gearbox) - Assemble procedures after functional check Note The assemble procedures given for the left-input shaft module are applicable to the right-input shaft module.

12.10 Left / Right Input Shaft Module - Assembly procedures, initial phase During this phase refer to CR&OP data module: 39-A-63-20-05-01A-719A-C, 39-A-63-20-05-01B-719A-C or to 39-A-63-20-05-02A-719A-C as required. In particular, taking into account the D.M. 39-A-63-20-05-01A-719A-C (as example), install the Input DriveQuill Group as required.


Note Use the Heat Gun and increase the temperature (as required) of the LH Input Module locally in the housing area of the Input Pinion. Perform the same action on the RH Input Module.

Continued


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12.11 - Input Shaft Modules, Backlash check CR&OP Data Module:




Flange

Input Pinion


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12.12 Left / Right Input Shaft Module - Assembly procedures, final phase Taking into account the CR&OP Data Module 39-A-63-20-05-01A-719A-C (as example), assemble the Freewheel Group, install the Freewheel Group, the Oil Jet Cove, the three Oil Jets and the Thermocouple on the Input Shaft Module and then install the Brackets on the Oil Jet Cover as required. Note Perform this action on both Input Shaft Modules. Use the specific Data Module

Thermocouple

LH Input Shaft Module Thermocouple

Freewheel Group

Oil Jet Cover

Brackets Oil Jet


Oil Jet Cover

23 of 26


12.13 Left / Right Input Shaft Module, Installation procedures Taking into account the CR&OP data module : 39-A-63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check, install the Left and Right Input Shaft Module on the Main Case as required.


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12.14 MGB – Assembly procedures, final phase Taking into account the CR&OP data module : 39-A-63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check, install the Anti-Torque Beam on the Main Case as required. Then install the MGB on the specific Transport Trolley and perform the Test “B” (Leak Check).

Anti-Torque Beam, installation

MGB Transport Trolley For Training purpose only

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Chapter 12 – Assembly procedure after Functional check

THE END




Chapter 13 – Leak Check

13 – MGB Leak Check

INDEX 13.1

Leak Check (Test B)


2 of 8

13.1 - Leak Check (Test B) PROCEDURE In the IETP/CR&OP the operator can find 2 different procedures, one can be used when a Test Bench is available and one when the Test Bench is not available, in particular:

If the Test Bench is available refer to CR&OP data module: 39-A-63-20-05-00A-364A-C Main gearbox Leak check vice versa, if the Test Bench is not available, you can do the leak check with the main gearbox installed on the helicopter applying the procedure reported on the CR&OP data module: 39-A-63-20-0500A-364B-C Main gearbox - Leak check In this section will be described the actions reported on CR&OP data module 39-A-63-20-05-00A-364A-C following a specific guideline. Hereinafter are reported the equipments and the supplies required to perform this action. See Steps from A to N reported below. Supplies: Support equipments:

Nomenclature

Identification No


Oil


MIL-PRF-23699


C011

None

Nomenclature

Identification No.

Test bench, gearbox

139G6300E001

Solvent, cleaning

C010

P-D-680 type II

or

or

Aliphatic naphtha

C059

TT-N-95

Test bench

LTR100-2000-02

Dye penetrant

C131

QPL-SAE-AMS-2644-3.

Corrosion preventative

C132 (Brayco 599)

MIL-L-14107.

Corrosion preventive oil

C123 (Brayco 589)

MIL-PRF-8188D.

Oil

C366 (Aeroshell Turbine Oil 555

DOD-PRF-85734

or equivalent Bristle brush

Local supply

Transport trolley

139G6320A00331A188E


3 of 8

13.1 - Leak Check (Test B) a) b)

The MGB must be installed on the Test Bench carrying out the necessary mechanical and electrical connections required. Fill the transmission up to the maximum level with Oil (C007).

Test Bench, front view

Test Bench, side view

(continued) For Training purpose only

4 of 8

13.1 - Leak Check (Test B) c) d) e)

Clean the external surfaces of the MGB with the Cloth (C011) and the Solvent (C010). Dry the cleaned surfaces as necessary. Start the Test Bench and operate the MGB as required for the phase 1. See the table reported hereinafter.

(continued) For Training purpose only

5 of 8

13.1 - Leak Check (Test B) f) g) h) i) j) k)

At the end of the phase 1, stop the test bench. Clean and Examine all mating edges between the different parts for leaks. Apply the Dye Penetrant (C131) on the area. Start the test bench again (phase 2) and operate the MGB as required. Refer to the table reported on the previous page. If you do not find leaks, continue with Step I or M. If you find leaks: – Do the necessary operations to remove the leaks – Do the leakage check again – If used, remove the unwanted dye penetrant from the surfaces of the MGB. To do this, use the Bristle Brush.

l)

If you know that the MGB will remain in storage for more than 30 days, perform the instructions that follow:

I.1) Disconnect the oil cooling lines of the test bench from the MGB and install the oil bypass. I.2) Drain the oil from the MGB. Refer to CR&PO D.M.: 39-A-63-20-05-00A-222A-C Main gearbox - Drain oil I.3) Fill the MGB up to FULL level with the Corrosion Preventive Oil (C123). As an alternative to the corrosion preventive oil you can use a mixture of Oil (MIL-PRF-23699) or Oil (DOD-PRF-85734) and Corrosion Preventative (C132) (5 thru 15% by volume - 15% recommended). I.4) Start the test bench and operate the MGB at 100% rpm for 3 min maximum. I.5) Drain the oil from the MGB. l.6) Attach a warning tag to the filler neck to tell personnel that the MGB has an internal protection with the corrosion preventive oil (or mixture). m) Remove the MGB from the test bench and install it on the Transport Trolley. (continued) For Training purpose only

6 of 8

13.2 - Leak Check (Test B) n)

At the end of the Leak Check (Test B) perform the following actions: - Compile a specific Test Report - Install the Oil Filter Element and all the Nylon Setscrews on the MGB as required. - Apply the Paint Finish to the MGB.


7 of 8

Chapter 13 – Leak Check

THE END



MAIN TRANSMISSION GEARBOX (MGB) REPAIR & OVERHAUL TECHNICIAN TRAINING Chapter 14 – Finish after Leak Check

14 – MGB Finish after leak check

INDEX 14.1 14.2

Oil Filter Element installation Nylon setscrews installation

(Cont’s)


2 of 5

14.1 Oil Filter Element installation Following the instructions reported on the CR&OP data module: 39-A-63-20-05-29A-720A-C Oil filter element (main gearbox) - Install procedures, replace all packings, install the Anti-spill Valve into the Oil Filter Case and then install the Oil Filter Element and the Filter Head as required. In particular, during this phase make sure that the Filter Element engages the Anti-Spill Valve in the inner side of the Oil Filter Case and, holding in position the Oil Filter Head with hand lock the Filter Head with the relative fasteners as required.

Packing (C115) Packings (C007) Anti-Spill Valve

Supplies: Oil Filter Head

Oil Filter element

Anti-Spill Valve

Oil Filter element


Oil Filter Head 3 of 5


Nomenclature

Identification No

Oil

C007 2380)


C011

None

Solvent, cleaning

C010

P-D-680 type II

Grease

C115 (parker super None O-lube)

(Turbo

Oil MIL-PRF23699

14.2 Nylon setscrews installation Looking the CR&OP data module: 39-A-63-20-05-00A-719A-C (Main gearbox - Assemble procedures after functional check, Para. 38 and Para. 39), install the Nylon setscrews on the MGB as required. During the installation of the setscrew put a small quantity of Grease (C009) into the hole for the setscrew and then seal the area around the head of the setscrew with a bead of Sealing Compound (C030). During this last action be careful not to apply the sealing compound in the screwdriver slot. Supplies: Nomenclature Identification No


Grease

C009 (Aeroshell 22)

MIL-PRF-81322 F.

Sealing compound

C030 (Naftoseal MC- AMS-S-8802B 236 Class B)

In particular, install the Nylon Setscrews on the components reported hereinafter or verify their presence on the MGB as required. Refer to the specific data modules. -

LH / RH Input Shaft Module. ECS compressor drive quill. Front, LH and RH Hyd. Pump drive quills. LH and RH Lubrication Pumps. Front, LH and RH Servo-actuator, Brackets. Tail-Rotor drive quill Upper Fittings and Seal Cover (Upper Module). Bottom Cover. Anti-Torque Beam.

At the end these actions apply the Paint Finish to the MGB. For Training purpose only

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Chapter 14 – Finish after Leak Check

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Chapter 15 – Painting procedures

15 – MGB Painting procedures Taking into account the Procedure , the Figures and the Supplies reported on the CR&OP data module: 39-A63-20-05-00A-257A-C (Main gearbox - Paint and apply markings), perform the following actions: Supplies: Nomenclature

Identification No



C011

None

Solvent, cleaning

C010

P-D-680, Type II

Masking tape

C064

UU-T-106

Sealing compound

C153

MIL-S-8802, Type II, Class B2

Primer

C042

MIL-P-23377

Tape, adhesion testing

C276

PPP-T-42C, Type II

Paint, polyurethane or Paint, polyurethane

C277 C314

BSX34, Type A BSX34, Type B

     

Install the MGB on the Paint Stand as necessary, Clean and dry the external surface of the MGB as necessary Apply the Masking Tape on the surfaces of the MGB where the paint is not required. Apply a bead of Sealing Compound on the matching surface and on other parts of the MGB where required. Apply one layer of Primer to all external surface of the MGB. When the Primer is dried (minimum 4 hrs at ambient temperature) do an adhesion test. If you find signs of primer on the tape (length: 100 mm), remove the primer from the MGB and apply it again.  Within maximum 72 hours after of the primer application, apply a top layer of Poly. Paint (colour : light gray glossy).  Remove the MGB from the Paint Stand and put it into storage. For Training purpose only

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15 – MGB Painting procedures

MGB - Front side

MGB - Rear side MGB – Final view


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Chapter 15 – Painting procedures

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Chapter 16 – Final Acceptance

16 – Final Acceptance Hereinafter are described the most important actions that should be performed on the MGB during its final acceptance phase and before of the release to service of the part: • • • • •

Verify that the overhauled MGB configuration is congruent with the IETP and applicable for the involved helicopter. Verify that the Overhaul process has been completed correctly in any parts. Verify that , if required, the applicable SB (Service Bulletin) or AD (Airworthiness Directive) have been embodied as required. Fill the MGB Log Card as required. Install the MGB Serviceable Tag on the MGB as necessary.


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Chapter 16 – Final Acceptance

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aw139 mgb o/h training course

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