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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.
NOTE
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
Table of Contents
Chapter 1 - Introduction
Chapter 2 - Documentation
4.1 Introduction
4.2 A/C Publications
4.3 AMPI A/C Maintenance Publication Information
4.4 Limits
6.6 Drive Quills (LH/RH/Front Hyd. Pumps, ECS-Compressor and Fan drive
quill), removal procedures.
6.7 LH and RH Input Pinion Assembly (II stage of reduction), removal
procedures.
6.8 LH and RH Input Pinion Assy (II stage of reduction), disassembly
procedures.
6.9 Tail Rotor Drive Quill Assembly, removal procedures.
6.10 Tail Rotor Drive Quill Assembly, disassembly procedures.
6.11 Diaphragm, Oil Jets and Roller Bearing, removal procedures.
6.12 Collector Gear and Collector Bearing, removal procedures.
6.13 Main Case Assembly - Internal components (Roller Bearings, Shims and
Outer Race of the Roller bearing), removal procedures.
6.14 Left and Right Input Shaft Module, disassembly procedures Ref. doc.
6.15 Freewheel Group Assembly, removal and disassembly procedures.
6.16 Input Shaft Module, Backlash Check.
6.17 Input Shaft Module Input Drive Quill Group, removal procedures
6.18 Input Drive Quill Group, disassembly procedures.
6.19 Input Shaft Module Gear (I Stage of reduction), removal and disassembly
procedures
6.20 Upper Module, disassembly procedures
6.21 Mast-Planetary Assembly Disassembly procedures.
6.22 Planetary Gears Assembly Disassembly procedures.
6.23 LH & RH Lubrication Pumps Disassembly procedures.
6.24 ECS Compressor Drive Quill Disassembly procedures.
For Training purpose only 8 of 18
1 Introduction (continued)
THE END
Chapter 2 - Documentation
2 - Documentation
INDEX
Documentation 2 of 57
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
Limitations
Normal and Emergency Procedures
Documentation 3 of 57
2.2 - IETP Interactive Electronic Technical Publication
Documentation 4 of 57
2.3 - AMP A/C Maintenance Publication
Documentation 5 of 57
2.4 - DMC Data Module Code
1 2 3 4 5 6
39-A-XX-XX-XX-YXA-XXXA-A
Documentation 6 of 57
2.4.1 Model Identification Code
1 2 3 4 5 6
1 2 3 4 5 6
39-A-XX-XX-XX-YXA-XXXA-A
Documentation 7 of 57
2.4.2 System Difference Code
1 2 3 4 5 6
(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 8 of 57
2.4.3 Standard Numbering System (SNS) Code
1 2 3 4 5 6
Documentation 9 of 57
2.4.4 Disassembly Code & Disassembly Code Variant 1/2
1 2 3 4 5 6
The disassembly code is also used to identify the data modules in sequence.
Documentation 10 of 57
2.4.4 Disassembly Code & Disassembly Code Variant 2/2
1 2 3 4 5 6
Documentation 11 of 57
2.4.5 Information Code & Information Code Variant
1 2 3 4 5 6
Documentation 12 of 57
2.4.6 Item location code
1 2 3 4 5 6
A - on the helicopter.
B - on the removed assembly/component.
C - R&O shop
D - applicable to all the locations.
Documentation 13 of 57
2.5 - Descriptive Data Module 1/8
Documentation 14 of 57
2.5 - Descriptive Data Module 2/8
Documentation 15 of 57
2.5 - Descriptive Data Module 3/8
References
Documentation 16 of 57
2.5 - Descriptive Data Module 4/8
Preliminary requirements
Required conditions
Documentation 17 of 57
2.5 - Descriptive Data Module 5/8
Supplies
Spares
List of Consumables and Expendables
necessary to do the procedure
List of Spares
required to complete the job
Documentation 18 of 57
2.5 - Descriptive Data Module 6/8
Safety Conditions
Documentation 19 of 57
2.5 - Descriptive Data Module 7/8
Procedure
Documentation 20 of 57
2.5 - Descriptive Data Module 8/8
Documentation 21 of 57
2.6 - AMPI - Maintenance Planning Information 1/16
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.
Documentation 22 of 57
2.6 - AMPI - Maintenance Planning Information 2/16
AMPI :
Chapter 00 HELICOPTER
GENERAL
Chapter 04 AIRWORTHINESS
LIMITATIONS
Chapter 05 SCHEDULED/
UNSCHEDULED
MAINTENANCE
Documentation 23 of 57
2.6 - AMPI - Maintenance Planning Information 3/16
AMPI :
Chapter 04 AIRWORTHINESS
LIMITATIONS
Documentation 24 of 57
2.6 - AMPI - Maintenance Planning Information 4/16
Documentation 25 of 57
2.6 - AMPI - Maintenance Planning Information 5/16
Documentation 26 of 57
2.6 - AMPI - Maintenance Planning Information 6/16
Documentation 27 of 57
2.6 - AMPI - Maintenance Planning Information 7/169
Documentation 28 of 57
2.6 - AMPI - Maintenance Planning Information 8/16
AMPI :
Chapter 05 SCHEDULED/UNSCHEDULED
MAINTENANCE
05-00 SCHEDULED/UNSCHEDULED MAINTENANCE
05-10 TIME LIMITS
05-20 COMMON SCHEDULED MAINTENANCE CHECKS
Documentation 29 of 57
2.6 - AMPI - Maintenance Planning Information 9/16
Documentation 30 of 57
2.6 - AMPI - Maintenance Planning Information 10/16
Documentation 31 of 57
2.6 - AMPI - Maintenance Planning Information 11/16
Documentation 32 of 57
2.6 - AMPI - Maintenance Planning Information 12/16
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.
(*) 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.
Documentation 33 of 57
2.6 - AMPI - Maintenance Planning Information 13/16
Documentation 34 of 57
2.6 - AMPI - Maintenance Planning Information 14/16
Documentation 35 of 57
2.6 - AMPI - Maintenance Planning Information 15/16
Documentation 36 of 57
2.6 - AMPI - Maintenance Planning Information 16/16
Documentation 37 of 57
2.7 CR&OP Component Repair & Overhaul Publication 1/10
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
Documentation 38 of 57
2.7 CR&OP Component Repair & Overhaul Publication 2/10
Documentation 39 of 57
2.7 CR&OP Component Repair & Overhaul Publication 3/10
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 40 of 57
2.7 CR&OP Component Repair & Overhaul Publication 4/10
Publication layout
Documentation 41 of 57
2.7 CR&OP Component Repair & Overhaul Publication 5/10
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.
Documentation 42 of 57
2.7 CR&OP Component Repair & Overhaul Publication 6/10
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-....
For P/N : 4G
Documentation 43 of 57
2.7 CR&OP Component Repair & Overhaul Publication 7/10
Usable on code
assembly and model
version and
effectivity column
(UOCA MVEFFECT)
Interchangeability column Source, maintenance and
(ICY) recoverability code
column (SMR)
Documentation 44 of 57
2.7 CR&OP Component Repair & Overhaul Publication 8/10
Documentation 45 of 57
2.7 CR&OP Component Repair & Overhaul Publication 9/10
Documentation 46 of 57
2.7 CR&OP Component Repair & Overhaul Publication 10/10
Documentation 47 of 57
2.8 - IPD Illustrated Part Data
IPD: Section 63-20 Main gearbox group
Documentation 48 of 57
2.9 - ITEP Illustrated Tools & Equipment Publication
Documentation 49 of 57
2.10 -RFM Rotorcraft Flight Manual
Documentation 50 of 57
2.11 - QRH Quick Reference Handbook
Documentation 51 of 57
2.12 - MGB LOG CARD (Section 1)
Mxxx
XX-XXX XXXXX
XXXXX
XXXXX
XX-XXX XXXXX
Documentation 52 of 57
2.12 - MGB LOGCARD (Section 2)
Mxxx
Documentation 53 of 57
2.12 - MGB LOGCARD (Section 2, Cont.s)
Mxxx
Documentation 54 of 57
2.12 - MGB LOGCARD (Section 3)
Documentation 55 of 57
2.12 - MGB LOGCARD (Section 4)
Documentation 56 of 57
Chapter 2 - Documentation
THE END
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)
Rotor
Brake
Intermediate
RH Hyd. Pump (Hyd. Sys. No. 2) Gearbox
AC Generator (Optional)
- The Main Gearbox (that includes a mechanical assembly and a lubrication system)
- The Oil Cooler
- The Oil Cooler Fan
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).
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).
Mast-Planetary Assy
Gimbal Crosshead Torque Tube
Engine No. 2
2^ stage
of 1^ stage of reduction Flexible
reduction
Coupling
Input Pinion + Gear MGB Input Drive Quill
Collector Gear + Freewheel unit Connection Torque Tube
+ Input Pinion (Input Shaft Module)
Rotor
Brake
Flange
Case
Collector Gear
(1355 rpm)
Fan Drive Quill
Front Hyd. Pump (16014 rpm)
Drive Quill
(7732 rpm)
ECS Compressor
Drive Quill (4868 rpm)
RH HYD. PUMP
drive quill
UPPER FITTING
Oil
Filter
PRV
CHECK
VALVES
LUB.
PUMPS
SUMP CHIP
DETECTORS
N11
N6 N12 N7
N10
N9
N3 N3
N 16
N16 N5
N8 N4
N4
N13
N15 N14
Notes
FWD
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 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.
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.
A/C GENERATORS
drive quills
MAIN CASE
Input Pinion
Bottom
Cover
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 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 18 of 51
3.3.1 - Left and Right Input Shaft Module description (Continued)
Left Input
Shaft Module
Oil Jet
Cover
Gear, I Stage
of reduction
Input
Flange
Bearing
Thermocouple
Input
Pinion
Gimbal
Freewheel Assy
Unit
(I Stage of reduction)
EDS
Input shaft
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 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):
Top Case
Upper
Module
Assembly
Mast-Planetary
assembly
5 Planetary
Gears Assy
Packing
Planetary Crown
(Fixed Ring Gear)
Ts Ps
Tsw
Lightning
Conductor Jumper
Pop-Out +
Caution alarm Oil Filter Head
Switch
Oil jet
filter
Oil Jets No. 1
and No. 2
Oil Cooler adapter
O-ring (Oil Filter case)
O-ring
O-ring
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.
A
A
Screw (2)
Nylon
Screw (2)
LH/ RH Hyd. Pump B
A Drive Quill
Shim
O-ring Screw (3)
Screw (3)
Shim B
Setscrew
(2)
O-ring
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
Shim
ECS -
Compressor
Drive Quill
Screw (2)
Setscrew (3)
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.
Nut,
Washer
(3)
Seal-Cover
O-ring
Lip-Seal
V Fan Drive
Screw Quill
Shim
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.
Gear
Pinion (tail rotor take
Off pinion)
Retaining ring
Locking washer
Locking ring
Ring
Flange
Nut + Retaining ring
Washer
Seal case
Seal
Rotor brake case
O-ring
Bearing cage
Plug
Figure 9 Tail-Rotor drive quill Figure 1 Tail-Rotor drive quill Pinion
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.
The sump is obtained in the bottom of the MGB and is designed to contain about 18 litres of oil (MIL-PRF-
23699 if the ambient temperature is above -30C or MIL-PRF-7808L if the ambient temperature is above
-40C, 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.
T> 140C
The By-Pass opens at p = 190 kPa (1.9 Bar)
T> 140C The By-Pass opens at T +80 C
Anti-Spill Valve
P = 1.7 Bar
P = 1.25 Bar
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.
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.
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:
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:
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 filtration capacity of the filter is 10 m 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.
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 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.
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):
Furthermore, in the system, on each Input Shaft Module a Bearing Thermocouple is installed near to
duplex ball bearing of the Input Drive Quill.
N3 N3
N 16
N16 N5
N8 N4
N4
N13
N15 N14
Notes
(LH/RH)
(FRONT)
(TQ: 140%)
(TQ: 160%)
(18 Liters)
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.
NOTE
This test is operative with the A/C on ground and NR < 2%.
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 109C. Reset below
97C
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 SUMP Debris is detected in one of the two Sump Chip
Detectors
CHIP MAST FAIL Sensing channel of Mast Chip Detector is faulty
CHIP SUMP FAIL Sensing channel of Sump Chip Detector is faulty
For Training purpose only 44 of 51
3.7 - Warning, Caution Messages and Indications (continued)
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 140C. Resets below 135 C.
In case double bearing temp caution, 1-2 BRG TEMP will be displayed.
AVIONICS FAULT Loss of communication to single MAU is detected for
the Chip Detector Power Unit.
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.
For Training purpose only 45 of 51
3.7 - Warning, Caution Messages and Indications (continued)
Note
COMPOSITE FORMAT
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.
- 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.
THE END
INDEX
4.1 Introduction
4.2 A/C Publications
4.3 AMPI A/C Maintenance Publication Information
4.4 Limits
3G6320A00132 or
3G6320A00133 or
3G6320A00134 or
3G6320A00135
NOTE
IETP
Interactive Electronic Technical Publication
Maintenance Publication (AMP)
Maintenance Planning Information (AMPI)
Master Minimum Equipment List (MMEL)
Component Repair & Overhaul Publication (CR&OP)
AMPI (EASA), Data Module Ref Component Part number Overhaul interval
AMPI (EASA), Data Module Ref Component Part number Discard time
AMPI (EASA), Data Module Ref Part Part number Retirement life
THE END
INDEX
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.
(Conts)
4. 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).
5. 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.
6. After then removal of the sealing compound beads, clean the surfaces with the Cloth and the Solvent.
7. Dry the cleaned surfaces with the Cloth and the compressed air until you fully remove all solvent.
(Conts)
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.
(MGB) 39-A-63-20-05-00A-222A-C
Main gearbox - Drain oil
Support Equipments:
Draining Pipe
removal-
CR&OP Data Module:
(Coupling Half)
39-A-63-20-05-00A-530A-C
(Drain Cap) Main gearbox - Disassemble
procedures.
Support Equipments:
Nomenclature Identification No.
MGB Assembly
Note:
Bottom Cover
Anti-Torque Beam
Standard
Screw
Extractors
RH
Anti-Torque Beam
Nylon Screw LH
Nylon Screw (x 2)
Washers + LH
Washers
Nut (x 23) + Nut
Main Case
Lifting tool, main 3G6320A00131A181A
gearbox
Lifting device Local supply
Bottom
Cover
Nylon
Screw Washers
(x 3) O-ring + Nut
(x 13)
Slip ring
Retaining ring
Bottom Cover
O-ring
Bottom Cover
Nylon
Screw Washers
(x 3) O-ring + Nut
(x 13)
Slip ring
Retaining ring
Main Case
Assembly Nomenclature Identification No.
Main Case
Assembly
Support
Maintenance
Trolley
THE END
INDEX
6.1 Left and Right Input Shaft Module removal and Cross Shaft disassembly procedures
6.2 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.
6.3 Main Case Oil Jets, removal procedures.
6.4 Upper Module, Oil Unions and Planetary Crown (fixed ring gear), removal procedures.
6.5 Main Case, Backlash Check.
6.6 Drive Quills (LH/RH/Front Hyd. Pumps, ECS-Compressor and Fan drive quill), removal
procedures.
6.7 LH and RH Input Pinion Assembly (II stage of reduction), removal procedures.
6.8 LH and RH Input Pinion Assy (II stage of reduction), disassembly procedures.
6.9 Tail Rotor Drive Quill Assembly, removal procedures.
6.10 Tail Rotor Drive Quill Assembly, disassembly procedures.
6.11 Diaphragm, Oil Jets and Roller Bearing, removal procedures.
6.12 Collector Gear and Collector Bearing, removal procedures.
(Conts)
6.13 Main Case Assembly - Internal components (Roller Bearings, Shims and Outer Race of the
Roller bearing), removal procedures.
6.14 Left and Right Input Shaft Module, disassembly procedures Ref. documentations
6.15 Freewheel Group Assembly, removal and disassembly procedures.
6.16 Input Shaft Module, Backlash Check.
6.17 Input Shaft Module Input Drive Quill Group, removal procedures
6.18 Input Drive Quill Group, disassembly procedures.
6.19 Input Shaft Module Gear (I Stage of reduction), removal and disassembly procedures
6.20 Upper Module, disassembly procedures
6.21 Mast-Planetary Assembly Disassembly procedures.
6.22 Planetary Gears Assembly Disassembly procedures.
6.23 LH & RH Lubrication Pumps Disassembly procedures.
6.24 ECS Compressor Drive Quill Disassembly procedures.
6.25 FAN Drive Quill Disassembly procedures.
6.26 Front Hyd. Pump Drive Quill Disassembly procedures.
6.27 LH & RH Hyd. Pump Drive Quill (No.1 and No. 2) Disassembly 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
Union
Washers
Washers
Cross Shaft Nuts
Washers
O-rings
Bracket
Washers
Nuts NutsWashers
Washers
Bracket
+ Nuts
Bracket Set screw (Nylon)
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 Plug
(inner side)
Engine 2 Inlet
(Drive Shaft) Details
B
Components removed:
B
- Nylon Screws (2 positions)
- Plug
Nylon Screw
Front Side
Plug
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures.
Seal Lip
Cover Seal Components removed:
O-ring
Plug
- Plug
C - Retaining Ring
- Seal Cover + O-ring
- Lip seal
ECS Compressor Retaining Ring - Nipple or Plug (Oil drain)
Drive Quill
Support Equipments:
Front Side
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
Components removed:
D - Plug
- Nylon Screw (2 positions)
Hydraulic Pump Drive Quill Nylon Screw
Plug
Front Side
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
Support Equipments:
E
Screw Shim
O-ring
Nut,
Washers
AC
O-ring
Generator
Drive Cover
Plug
Front Side
39-A-63-20-05-00A-530A-C
Main gearbox Disassemble
procedures.
Oil level
Gauge
Nuts + Washers
OUT Oil
IN Cooler
Pop-Out + Caution
alarm Switch
Ts Ps
Tsw
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
39-A-63-20-05-00A-530A-C
J Main gearbox - Disassemble procedures
Plug
Plug
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
O-ring
Washer
Nut
Screw + Washer(4)
Front Servo
L L
Support L
Setscrew (2)
LH Servo RH Servo
M Support Support N L
O
CR&OP Data Module:
O-ring
39-A-63-20-05-00A-530A-C Main
Washers gearbox - Disassemble procedures.
Screws
Borescope Port
P P
Retaining ring
O-ring PRV
O-ring
Q Q
Rear View
Rear View
For Training purpose only 19 of 126
6.2 Detail R - Chip Detectors removal
O-ring
Chip Detector
Chip Detector Valve
Rear View
R R
S
S
Flange
S T
Rear View
RH Lubrication Pump removal
Washers + Nut
- Plug
- Seal Cover
Support Equipments:
Rear View
Support Equipments:
Top View Nomenclature Identification No.
O-ring O-ring
Screw
Screw
+
+
Washer
Washer
Rear View
O-ring
O-ring
O-ring O-ring
O-ring
Support Equipments:
A / A1
6 pos. 1 pos.
C Nut D
Nut
Washer
Bracket Washers
1 pos. 22 pos.
Top View
A
A
Main Case
A
A
Oil Union
(5 positions)
Collector Gear
Diaphragm
Tool installation
Planetary Crown
(inner view)
Support Equipments
LH Input Pinion II
Front Hyd. Pump Stage
3 Knobs (4)
4 Bolt
6 Bolts (4)
7 Registers (2)
8 Retainers
9 Bolts (2)
14 Collector Gear
1 7
Register
Expander,
installation
Wrench
2
Retainer
Tool Top
Section,
installation
Nylon Split
Ring Bolts
5
4
Collector
Gear
Knobs
10
Dial gauges
(3 positions)
Bottom Section
Note: 12 Note:
Lock the Collector Gear with the Use the two Registers to adjust the
Expander as required. levelness as required.
Tighten the Bolts as required.
Note:
Note:
Support Equipments:
Support Equipments:
Note:
- Lock the tool expander.
- Push the pinion internally as required.
- Measure and record the backlash in three
positions, 120 apart.
Note:
- Lock the tool expander.
Left/Right Pump - Pull the pinion externally as required.
(Hyd. Pump No. 1 - Measure and record the backlash in
and No. 2) three positions, 120 apart.
Drive Quill
- Perform this action on both Hyd. Pumps.
Engine 2 Inlet
(Drive Shaft) Details
Engine 1 Inlet
(Drive Shaft)
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
3
O-ring
Screw (3)
Shim
2
1
Extractors
installation
Screws removal
For Training purpose only 40 of 126
6.6.2 - ECS-Compressor Drive Quill removal
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures.
C
Screw (3)
Support equipment:
O-ring
Nomenclature Identification No.
Shim
Screw (2)
ECS- Compressor
Setscrew (3) Drive Quill
Extractors
installation
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
D
Support equipment:
Shim
Screw (3) Nomenclature Identification No.
O-ring
Extractors
installation
1 2
Bearings 1
Spacer
Pump
Nuts, Washers gear
Pump Retaining Ring
(parts to be
removed) gear
Retaining Locking Ring
Ring Locking
Washer Nuts, Washers
2
LH and RH Input Pinion
Assembly removed
For Training purpose only 45 of 126
6.8 - LH & RH Input Pinion Assembly (II Stage), Disassembly
O-ring
Bearings
Input Pinion II Bearing Input Pinion II
Stage Sleeve Stage
Spacers
Pump
gear
Retaining Ring
TRDQ
Main Case Tools Assembly
rotated installation removed
Wrench 3G6320A00331A026A
Plug
Pinion Removal tool, bearing 3G6320A00331A029S
STEP 1
Support equipment:
Pinion STEPS 2 7
Removal Tool
(3G6320A00331A028A)
Detail A Detail B
Detail C
Pinion STEPS 8 13
8 - Remove the Retaining Ring (6) from the
Rotor-Brake Case (11).
9 - Remove the Seal Case (7) from the Rotor-
Brake Case (11). Use the Removal Tool No.
G6320A00331A029Y (see Detail D).
10 Remove the O-rings (8) and (9) from the
Seal Case (7).
Retaining ring 11 - Remove the Lip Seal (10) from the Seal
Nut +
Seal case case (7). Use the Extractor Tool No.
Washer
O-rings
3G6320A00331A029W (see Detail E).
Lip Seal
12 - Remove the six Nuts (15) and the six
Rotor brake case Washers (16).
O-ring
13 - Remove the Rotor-Brake Case (11) from
Shim Nipple the Flanged bearing (17). Use the Removal
Screw Tool No. 3G6320A00331A029U as required
Flanged Extractor Tool
(G6320A00331A029W) (see Detail F).
bearing
(spherical)
Removal Tool
Removal Tool
(G6320A00331A029U)
(G6320A00331A029Y)
Pinion
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
Nut + required. See Detail G.
Washer
Detail G
STEPS 17 20
Retaining ring 17 - Remove the retaining ring (18) and the
Locking washer locking washer (19) from the Pinion (30) or
Locking ring (30A). Use the Extractor Tool No.
Gear 3G6320A00431A029C (see Detail H).
Shim 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).
Pinion 20 - Remove the Shim (22) from the Pinion
(30) or (30A).
Removal Tool
(3G6320A00331A029T)
Pinion
(3G6320A00431A029C)
(3G6320A00331A026B)
STEPS 21 26
21 - (Main gearbox P/N 3G6320A00132). Remove the
Bearing Inner Race (28) from the Pinion (30) as
follows:
Removal Tool
(3G6320A00331A029S)
Detail K Detail L
Detail M
Collector Gear
1a Screws (14)
Diaphragm
3
Roller Bearing
Collector Gear
1b
Diaphragm removed
from the Main Case
2
Extractor Tool
installation
Diaphragm
Roller
Bearing
Collector Gear
3
2
Retaining Ring Main Case
Washers
Nuts
1
Note:
1 Roller Record the thickness of the shim
Bearing
(188)
2 3
Shim
(193)
Screws Shim
2 Screws
Outer Race of the
roller bearing
Tail Rotor
Drive Quill Nuts +
1 location Washers
Shim
Main Case
external view
Note:
A
Screws
Shim
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Hyd. Pump
Main gearbox - Disassemble
(No.1 and No.2) procedures.
drive quill
location
Note:
Shim
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble
procedures.
Note:
Note:
Note:
AC Generator
drive covers
location
Shim
39-A-63-20-05-00A-530A-C
Screws Main gearbox - Disassemble
procedures.
Note:
Engine 1 Inlet
Or
(Drive Shaft)
39-A-63-20-05-01B-530A-C Left input shaft
module (main gearbox) - Disassemble
procedures (Effectivity Code: B02)
Or
Left input 39-A-63-20-05-01C-530A-C Left input shaft
shaft module
module (main gearbox) - Disassemble
procedures (Effectivity Code: B03)
Effectivity Codes: And
CR&OP Data Module: 39-A-63-20-05-00A-000A-C Main 39-A-63-20-05-02A-530A-C Right input shaft
gearbox General module (main gearbox) - Disassemble
procedures
- B01 : Input shaft module P/N 3K6320A00133 (installed on MGB
P/N 3G6320A00132 and 3G6320A00133) Note
- B02 : Input shaft module P/N 3K6320A00135 (installed on MGB
P/N 3G6320A00134 and 3G6320A00135) The disassemble procedures given for the left-
- B03 : Input shaft module P/N 3K6320A00136 (installed on MGB input shaft module are applicable to the right-
P/N 3G6320A00134, 3G6320A00135, 3G6320A00132 and input shaft module.
3G6320A00133) Refer to: [B01], [B02], [B03] as necessary.
Support equipment:
Plastic Caps/Plugs
Cotton gloves
Oil Jet
Oil Jet Note
Cover Perform this action on both Input Shaft Modules.
Use the specific Data Module
Oil Jet Oil Pressure
Cover Switch
Thermocouple
RH Input Shaft
Module
For Training purpose only 71 of 126
6.15 - Freewheel Group Assy, removal and disassembly procedures
Action No. 2 : Remove the Sealant and Clean the mating areas
39-A-63-20-05-01A-530A-C
Oil Pressure
Switch Left input shaft module (main
gearbox) - Disassemble procedures.
Support equipment:
Supplies:
RH Input Shaft
Module Note
Perform this action on both Input Shaft Modules.
Use the specific Data Module
39-A-63-20-05-01A-530A-C
Left input shaft module (main
gearbox) - Disassemble procedures.
O-ring
Screw
Oil Pressure Thermocouple
Switch
Washer
Oil Jet
O-ring
Oil Pressure
Switch
Note
Perform this action on both Input Shaft Modules.
Use the specific Data Module
RH Input Shaft
Module
For Training purpose only 73 of 126
6.15 - Freewheel Group Assy, removal and disassembly procedures
Action No. 4 : Oil Jet Cover removal
LH Input Shaft CR&OP Data Module:
Module
39-A-63-20-05-01A-530A-C
Left input shaft module (main gearbox) - Disassemble
Freewheel procedures.
Group
Support equipment:
Note
Perform this action on both Input Shaft Modules.
O-ring Use the specific Data Module
Oil Jet
Cover Nuts +
Washers
1 2 3
Freewheel Group
disassembled
C D
Gear, 1 Stage
of reduction (2)
Input
Pinion
(4)
Plug Note
Input
Perform this action on both Input Shaft Modules.
Bolt Pinion
Use the specific Data Module
Roller
Bearing Sleeve
Washer Bearing
Nut O-ring Support equipment:
Locknut
removal
Bearing
Gimbal Sleeve
removal Carbon Seal
removal Ring removal
39-A-63-20-05-01A-530A-C
Left input shaft module (main
gearbox) - Disassemble procedures.
Support Equipment:
Procedure
Disassemble the input drive-quill group. To do this obey the instructions that follow:
Items - Remove the input pinion (60) from the duplex ball bearing (49) and bearing sleeve
disassembled (47) group. Use the Tool No. 3K6320A00131A029B.
Keys
- 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.
Note
3 Perform this action on both Input Shaft Modules.
Use the specific Data Module
Bolt
CR&OP Data Module:
Washer Roller Bearing 39-A-63-20-05-01A-530A-C
Nut Left input shaft module (main
gearbox) - Disassemble procedures
Support Equipment:
Note
Perform this action on both Input Shaft Modules.
Use the specific Data Module
LH Input Shaft
Module
Note
Perform this action on both Input Shaft Modules.
Use the specific Data Module
LH Input Shaft
Module
Nuts +
O-ring
Washers
Support Equipment:
Bolts Note
Perform this action on both Input Shaft Modules.
Screws Lock ring Use the specific Data Module
Lock nut
Gear
Tools installation, Shim
Lock nut removal Lock ring & Lock nut removed
Diaphragm Assembly removal
2 Bearing
5
8
11
3 9 10
4
Mast-Planetary
assembly
Note
Packing
Planetary Crown
(Fixed Ring Gear)
39-A-63-20-05-03A-530A-C
Upper module (main gearbox) -
Disassemble procedures.
Support equipment:
Supplies:
39-A-63-20-05-03A-530A-C
Upper module (main gearbox) -
Disassemble procedures.
39-A-63-20-05-03A-530A-C Upper
module (main gearbox) - Disassemble
procedures.
Oil jet
filter
Oil Jets No. 1
and No. 2
O-ring
O-ring
O-ring
Oil Jets No. 1
and No. 2
removed
39-A-63-20-05-03A-530A-C
Upper module (main
gearbox) - Disassemble
procedures.
Upper Cooler
Adapter
removed
A A B
Top Oil Duct
O-ring Nuts +
(q.ty 4)
Washers
(q.ty 5)
O-ring
Upper Cooler
Adapter
O-ring
Mast-Planetary
assembly CR&OP Data Module:
A
39-A-63-20-05-03A-530A-C Upper
module (main gearbox) - Disassemble
procedures.
Support equipment:
O-ring
Top Case
Nuts +
Washers CR&OP Data Module:
E
Support equipment:
D
Nomenclature Identification No.
Mast-
Work trolley 3G6320A00231A188A
Planetary
Assembly Clamp 3G6320A00231A023M
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)
B: Remove the installed in the
Nuts and the TOP Case
Washers (44, 45,
46) from the Top
Case and the
flanged Outer
race of the Ball
Bearing.
Detail B C: Packing
(42), removal
Mast-Planetary
Assembly, TOP Case
D5 inner view
lifting tool installation.
D2
D4
39-A-63-20-05-03A-530A-C Upper
module (main gearbox) -
Disassemble procedures.
5
3
Spacers 3
Plate
Bushings
Pins
Lock washers
Bolts
4
Mast
Lock washer,
Bolts
removal
Lock
Retaining
washers 2
springs
Bushings
Ring nuts
Flange
Planetary Pins
Gear Assy.
Spacers
Plate
Bushings Ring Nut
Pins
Lock washers
Bolts
Support equipment:
Ball
bearing Nomenclature Identification No.
Oil Work table Local supply
collector
Reaction tool 3G6320A07231A023E
Planetary
Pins
Gear Assy.
Spacers
Plate
Bushings
Pins
Lock washers
Bolts
1 6
8 Ring Nut,
3 removed
4
Ball
bearing
Servo-multiplier
Retaining
ring
CR&OP Data Module:
Lock 39-A-63-20-05-13A-530A-C Mast-planetary assembly
washer (upper module) - Disassemble procedures.
Ring Nut
Support equipment:
Ball
bearing
Oil Nomenclature Identification No.
collector Work table Local supply
Lifting tool 3G6320A00131A181A
Spacers
Plate
Bushings
Pins
Lock washers
Bolts
(3G6320A07231A023D) (3G6320A07231A029C)
(3G6320A00131A181A)
(Enerpack RC-252)
(3G6320A07231A023F)
Ball
bearing
Oil
collector
Work Table
(3G6320A07231A023D)
Retaining
ring
CR&OP Data Module:
Lock 39-A-63-20-05-13A-530A-C Mast-planetary assembly
washer (upper module) - Disassemble procedures.
Ring Nut
3 Ring nut,
Ball Support equipment: removed
bearing
Nomenclature Identification No.
Oil
collector Work table Local supply
Reaction tool 3G6320A07231A023D
assembly
Mast (Wrench)
Bolts
Lock
Retaining 1
washers
springs
Bushings
Ring nuts
2
Flange
Planetary
Gear Assy. Pins
Spacers
Plate
Bushings
Pins
Lock washers
Bolts
Retaining
ring
CR&OP Data Module:
Lock 39-A-63-20-05-13A-530A-C Mast-planetary assembly
washer (upper module) - Disassemble procedures.
Ring Nut
Support equipment:
Ball
bearing
Oil Nomenclature Identification No.
collector Work table Local supply
Spacers
Plate
Bushings
Pins
Lock washers
Bolts
Flange (11)
Pins (17) Planetary disassembled,
Gear Assy. Planetary gear
Plate (19) Assy (19)
Spacers (18)
(13) removed
partially removed
from the Planetary
gear Assy
Plate (13)
removal
Items 6,
details
39-A-63-20-05-14A-530A-C
Planetary gear assembly
(mast planetary assembly) -
Disassemble procedures
Planetary Support equipment:
Gears Assy.
Nomenclature Identification No.
Note
Identify and record the installation position of the top and
bottom-inner bearing race (2) and (8) on the planetary gear
Gear
(outer bearing
assembly (1). This is to put them again in their correct
race) position during the assembly.
Gear
(outer bearing
Rollers removal tool 3G6320A07231A029D
A race)
B
Bottom-inner
Bottom-inner bearing race
Top-inner
bearing race bearing race Roller cage
Roller cage Roller cage
Rollers
Rollers Rollers
Roller cage
Bottom side F
Inner Bearing
race
Rollers
Inner Bearing
race
E
Top side Roller cage
Gear Ring
nut Retaining ring CR&OP Data Module:
Lubrication Key
pump 39-A-63-20-05-06A-530A-C Left lubrication
pump (main gearbox)- Disassemble procedures
Lock washer
39-A-63-20-05-24A-530A-C Right lubrication
pump (main gearbox) - Disassemble procedures
A
Shaft
Support equipment:
Lubrication
B Vice
pumps,
disassembled
Lock washer Ring Key Shaft
nut
C D E F G
ECS-compressor
drive quill
Vice
Retaining
ring,
removal
Locking ring,
removal
Support equipment:
Case
Flanged
bearing Nomenclature Identification No.
Retaining Locking Nuts +
Removal tool, pinion 3G6320A00731A029B
ring washer Washers
Arbor press Local supply
IN OUT
Support equipment:
Case
Flanged
bearing
Nomenclature Identification No.
Retaining Locking Nuts +
ring washer Washers Arbor press Local supply
Removal tool, 3G6320A00731A029A
flanged bearing
IN
OUT
Support equipment:
Work table
Flanged
bearing
Locking
ring
Locking
Retaining washer
ring
Vice
PINION
(REF.)
IN OUT
Support equipment:
Front Hyd. Plug
pump drive Nomenclature Identification No.
quill O-ring O-ring
Pinion
39-A-63-20-05-04A-530A-C Front pump drive
Pump
quill (main gearbox) - Disassemble procedures.
case
Support equipment:
Flanged
bearing
Lip seal
Seal cover
Retaining ring
Seal cover
Pinion
39-A-63-20-05-04A-530A-C Front pump drive
Pump
quill (main gearbox) - Disassemble procedures.
case
Support equipment:
Nomenclature Identification No.
Front hyd. Plug
Work table and Vice Local supply
pump drive
quill O-ring O-ring
Extractor tool, locking washer 3G6320A00431A029C
Removal/installation tool, locking ring 3G6320A00531A023B
Fitting
(wrench)
Flanged
bearing
Washers + Nuts
Locking ring
Locking washer
Retaining ring
Packing
Lip seal
Seal cover
Retaining ring
Pinion
39-A-63-20-05-04A-530A-C Front pump drive
Pump
quill (main gearbox) - Disassemble procedures.
case
Support equipment:
Nomenclature Identification No.
Front hyd. Plug
Work table Local supply
pump drive
quill O-ring O-ring
Removal tool, pinion 3G6320A00531A029A
Arbor press Local supply
Fitting
Removal tool, flanged bearing 3G6320A00431A029A
Flanged
bearing
Washers + Nuts
Locking ring
Locking washer Pump
Retaining ring case
Packing
Lip seal
Seal cover
Retaining ring
Support equipment:
Packing
Retaining ring
CR&OP Data Module:
Flanged
bearing+
Washers
and Nuts
Plug
O-ring O-ring
Fitting Pump
case
Seal cover
Pinion
Pump
case
Retaining ring
CR&OP Data Module:
Seal cover
39-A-63-20-05-27A-530A-C Left/right pump drive
quill (main gearbox) - Disassemble procedures.
Lip seal Support equipment:
Removal/installation 3G6320A00431A023C
Flanged tool, locking ring
bearing+ (Wrench)
Washers
and Nuts
Plug
O-ring O-ring
Fitting Pump
case
Pinion
Retaining ring
CR&OP Data Module:
Seal cover
39-A-63-20-05-27A-530A-C Left/right pump drive
quill (main gearbox) - Disassemble procedures.
Lip seal Support equipment:
Plug
O-ring O-ring
Pump
Pump case
Fitting
case
Pinion
THE END
INDEX
7.1 Introduction
7.2 Cleaning procedures
7.3 Paint removal
7.4 Protection procedures
7.5 Detailed Visual Examination
7.6 Defects definition
7.7 Surface finish protection restoration (Main Case)
7.8 Surface finish protection restoration (Upper Module)
7.9 Surface finish protection restoration (LH/RH Input Shaft Module)
7.10 Damage codes list
7.11 Example of damage general information
7.12 Detailed visual examination, applicable Data Modules list
7.13 Main gearbox Detailed Visual Examination
7.14 Chip detectors Detailed Visual Examination
7.15 LH/RH Right Input Shaft Module Detailed Visual Examination
7.16 Freewheel Detailed Visual Examination
7.17 Upper Module Detailed Visual Examination
7.18 Mast-Planetary Assembly Detailed Visual Examination
7.19 Planetary Gears Assembly Detailed Visual Examination
7.20 LH/RH Hyd. Pump Drive Quill Detailed Visual Examination
7.21 Front Hyd. Pump Drive Quill Detailed Visual Examination
7.22 ECS Compressor Drive Quill Detailed Visual Examination
7.23 Fan Drive Quill Detailed Visual Examination
7.24 LH/RH Lubrication Pump Detailed Visual Examination
7.25 Tail Rotor Drive Quill Detailed Visual Examination
(Conts)
For Training purpose only 2 of 313
7 Components Cleaning, Paint removal, Protection and Inspection
(Conts)
Dimensions Check
Magnetic Inspection
NOTE
All information reported hereinafter must be considered for Training purpose only.
Refer to CR&OP as required
Supplies
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.
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
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:
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
Procedure
The Paint Removers must not be used on composite parts and adhesive bonded structures.
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 Identification No Specification references Ref. Documents
Note
Before you examine the component, clean it with the Cloth and the Cleaning Solvent.
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:
Defects definition :
Small
It's a defect that will not have unwanted effects on the component life or on the overhaul
period.
Moderate
Its a defect that does not cause the component to become unserviceable. This defect can
decrease the component life and overhaul period.
Bad
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)
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.
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-60-10-01-
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 5 the surface finishes that follow:
The cadmium plating (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A-
647A-C
The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.
The chromate conversion coating (C237: Alodine 1200). The cadmium plating (C282 or C183 as required).
Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C
The epoxy primer (C042: MIL-P-23377) . The epoxy primer (C042: MIL-P-23377) .
Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C. Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.
Figure 4 Figure 5
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-60-10-01-
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 7 the surface finishes that follow:
The cadmium plating (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A-
647A-C
The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.
The chromate conversion coating (C237: Alodine 1200). The cadmium plating (C282 or C183 as required).
Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C
The epoxy primer (C042: MIL-P-23377) . The epoxy primer (C042: MIL-P-23377) .
Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C. Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.
Figure 6 Figure 7
Sheet 1 of 9
Sheet 2 of 9
Sheet 3 of 9
Sheet 4 of 9
Sheet 5 of 9
T9 Liners Polishing. Accept the part if you find polishing. Heat discoloration, seizure, cracks,
Corrosion. Accept the part if you find small corrosion that you can repair moderate and bad circumferential
with a Scotchbrite pad or Number 600 abrasive paper. scores, spinning marks and
Staining. Accept the part if the staining is not related to overheating. moderate and bad fretting.
Fretting. Accept the part if you find small fretting that you can repair with Reject the part if you find one of
a Scotchbrite pad or Number 600 abrasive paper. Make sure that the these defects.
fretting is not more than 10% of the working surface. Usually, the areas Reject the part if you find rusting.
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.
T10 Sleeve Polishing. Accept the part if you find polishing. Bad fretting and seizure. Reject the
seats part if you find one of these defects.
Sheet 6 of 9
Criteria of acceptability for an indentation noted on the surface of the Casting (sheet 1 of 3)
Damage Area of Acceptable damage Examples of indentation
Code Inspection
T10 Surface of Indentation (Nick)
the casting INDENTATION
Accept the part if:
INDENTATION
Photo No.1
Sheet 7 of 9
Criteria of acceptability for an indentation noted on the surface of the Casting (sheet 2 of 3)
Damage Area of Acceptable Examples of indentation
Code Inspection damage
T10 Surface of Indentation (Nick)
the casting
Accept the part if:
INDENTATION
The indentation has INDENTATION
a dimension of
approximately 2.5 x
2.5 mm with a
depth of 0.25 mm
with paint INDENTATION
removal. Refer to
photos No. 2, 3 and
4.
INDENTATION INDENTATION
INDENTATION
Sheet 8 of 9
Criteria of acceptability for an indentation noted on the surface of the Casting (sheet 3 of 3)
Picture No.6
Sheet 9 of 9
Sheet 1 of 9
Sheet 2 of 9
Damage Definition Example
Discoloration Discoloration is a
(Staining) phenomenon in which
the bearing surface is
discoloured by staining
or heat generated
during operation.
Heat It is a phenomenon in
Discoloration which the bearing
surface is heavy
discoloured by
overheating generated
during operation.
Sheet 3 of 9
Damage Definition Example
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 Flaking on inner ring of Cylindrical Roller Bearing
Flaking on inner ring of Deep Groove Ball Bearing
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 Fretting on inner ring bore surface of Tapered Roller Fretting on outer ring O.D. surface of Deep
Bearing Groove Ball Bearing
Sheet 4 of 9
Damage Definition Example
Indentation A depression in a
(Nick) 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)
sheet 5 of 9
Damage Definition Example
Example of pitting
corrosion
Sheet 6 of 9
Or
A scratch is a relatively
shallow flaw caused by
sliding contact.
Sheet 7 of 9
Dent A depression in a
(Brinelling) 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 Dent
Heavy - Gear teeth Heavy Roller Bearing Race
Sheet 8 of 9
Sheet 9 of 9
Damage Definition Example
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.
Hereinafter are shown the CR&OP Data Modules required to perform a DV Examination:
7.13) 39-A-63-20-05-00A-311A-C 7.20) 39-A-63-20-05-27A-311A-C
Main gearbox - Detailed visual examination Left/right pump drive quill (main gearbox) - Detailed
visual examination
7.14) 39-A-63-20-05-00A-311B-C
Main gearbox - Chip detectors - Detailed visual 7.21) 39-A-63-20-05-04A-311A-C
examination Front pump drive quill (main gearbox) - Detailed visual
examination
7.15) 39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) - Detailed visual 7.22) 39-A-63-20-05-05A-311A-C
examination ECS compressor drive quill (main gearbox) - Detailed
visual examination
7.15) 39-A-63-20-05-02A-311A-C
Right input shaft module (main gearbox) - Detailed visual 7.23) 39-A-63-20-05-07A-311A-C
examination Fan drive quill (main gearbox) - Detailed visual
examination
7.16) 39-A-63-20-05-01A-311B-C
Left input shaft module (main gearbox) - Freewheel - 7.24) 39-A-63-20-05-06A-311A-C
Detailed visual examination Left lubrication pump (main gearbox) - Detailed visual
examination
7.17) 39-A-63-20-05-03A-311A-C
Upper module (main gearbox) - Detailed visual 7.24) 39-A-63-20-05-24A-311A-C
examination Right lubrication pump (main gearbox) - Detailed visual
examination
7.18) 39-A-63-20-05-13A-311A-C
Mast-planetary assembly (upper module) - Detailed visual 7.25) 39-A-63-20-05-28A-311A-C
examination Tail rotor drive quill (main gearbox) - Detailed visual
examination
7.19) 39-A-63-20-05-14A-311A-C
Planetary gear assembly (mast-planetary assembly) -
Detailed visual examination
For Training purpose only 38 of 313
7.13 MGB - Main Case - Detailed visual examination (Sheet 1 of 5)
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:
........................................................................
........................................................................
........................................................................
CAUTION
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:
........................................................................
........................................................................
........................................................................
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:
........................................................................
........................................................................
........................................................................
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:
........................................................................
........................................................................
........................................................................
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:
........................................................................
........................................................................
........................................................................
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:
........................................................................
........................................................................
........................................................................
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:
........................................................................
........................................................................
........................................................................
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:
........................................................................
........................................................................
........................................................................
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:
........................................................................
........................................................................
........................................................................
N13
N15 N14
Notes
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 7 and Figure 7
Inspection results:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 8 and Figure 8
Inspection results:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 9 and Figure 9
Inspection results:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 10 and Figure 10
Inspection results:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 11 and Figure 11
Inspection results:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 12 and Figure 12
Inspection results:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 13 and Figure 13
Inspection results:
...................................................................................
...................................................................................
...................................................................................
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:
...................................................................................
...................................................................................
...................................................................................
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:
...................................................................................
...................................................................................
...................................................................................
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:
...................................................................................
...................................................................................
...................................................................................
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:
...................................................................................
...................................................................................
...................................................................................
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:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 19 and Figure 19
Inspection results:
...................................................................................
...................................................................................
...................................................................................
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:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 21 and Figure 21
Inspection results:
...................................................................................
...................................................................................
...................................................................................
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 22 and Figure 22
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Supplies:
Mast Chip
Detector Nomenclature Identification No Specification references Ref. Documents
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.
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.
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
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
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:
........................................................................
........................................................................
........................................................................
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
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
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
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
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
39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 9 and Figure 9
Inspection results:
........................................................................
........................................................................
........................................................................
Note
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:
Inspection results:
........................................................................
Right Input Shaft module:
Oil Jet A No.
P/N:
Check with filtered compressed air the possible occlusion of the oil jet holes Oil Jet C No.
P/N:
Fig. 10 Oil jets (Left input shaft module)
Inspection results:
........................................................................
For Training purpose only 77 of 313
7.15.11 - Two locking ring nuts - Detailed visual examination
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:
........................................................................
Ring nut A
P/N:
S/N:.
Ring nut B
P/N:
S/N:.
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:
........................................................................
Ring
P/N:
S/N:.
Inspection results:
Fig. 12 Carbon Seal and Ring (Left input shaft 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:
........................................................................
........................................................................
........................................................................
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:
........................................................................
........................................................................
........................................................................
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)
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)
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)
39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 18 and Figure 18
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 18 Duplex Ball Bearing of the Input pinion - (Left input shaft module)
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:
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 1 and Figure 1.
Top case
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 2 and Figure 2.
Cooler adapter
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 3 and Figure 3.
Seal cover
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 4 and Figure 4.
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)
C D
A B
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 5 and Figure 5.
Inspection results:
........................................................................
........................................................................
........................................................................
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 6 and Figure 6.
Ring gear
P/N:
S/N:
Inspection results:
........................................................................
........................................................................
........................................................................
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 7 and Figure 7.
Roller Bearing
P/N:
S/N:
Inspection results:
........................................................................
........................................................................
........................................................................
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 8 and Figure 8.
Inspection results:
.......................................................................
Procedure
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:
39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 1 and Figure 1.
P/N:
S/N:..
Inspection results:
.......................................................................
39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 2 and Figure 2.
Spider plate
P/N:
S/N:..
Inspection results:
.......................................................................
39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 3 and Figure 3.
Ring nut
P/N:
S/N:..
Inspection results:
.......................................................................
39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 4 and Figure 4.
Ball bearing
P/N:
S/N:..
Inspection results:
.......................................................................
39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 5 and Figure 5.
39-A-63-20-05-13A-311A-C Mast-
planetary 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:..
39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 7 and Figure 7.
39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 8 and Figure 8.
Inspection results:
.......................................................................
39-A-63-20-05-13A-311A-C Mast-
planetary 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
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:
39-A-63-20-05-14A-311A-C Planetary
gear assembly (mast-planetary
assembly) - Detailed visual
examination. See Para.1 and Figure 1
39-A-63-20-05-14A-311A-C Planetary
gear assembly (mast-planetary
assembly) - Detailed visual
examination. See Para.2 and Figure 2
Inspection results:
.......................................................................
For Training purpose only 109 of 313
7.19.3 - Rollers and Cages Detailed visual examination
39-A-63-20-05-14A-311A-C Planetary
gear assembly (mast-planetary
assembly) - Detailed visual
examination. See Para.3 and Figure 3
Inspection results:
.......................................................................
For Training purpose only 110 of 313
7.20 - Left/Right hyd. pump drive quill (main gearbox)
Detailed visual examination
CR&OP Data Module:
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:
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:
.......................................................................
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.
Locking ring
P/N:
Seal Cover
P/N:
S/N:
Locking ring
P/N:
Seal Cover
P/N:
S/N:
Inspection results:
Fig. 2 Locking ring and Seal cover (left/right pump drive quill)
.......................................................................
39-A-63-20-05-27A-311A-C Left/right
pump drive quill (main gearbox) -
Detailed visual examination.
See Para.4 and Figure 3.
Inspection results:
.......................................................................
T8
39-A-63-20-05-27A-311A-C Left/right
pump drive quill (main gearbox) -
Detailed visual examination.
See Para.5 and Figure 4.
Inspection results:
.......................................................................
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
Plug
Do the detailed visual examination of the following P/N:
components for corrosion, wear and damage: Fitting
P/N:.......................................
The plug Locking washer
P/N:.......................................
The fitting
The locking washer Right pump drive quill
Plug
P/N:
Fitting
P/N:.......................................
Locking washer
P/N:.......................................
Inspection results:
......................................................................
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:
Pinion
P/N:
S/N:.......................................
Inspection results:
......................................................................
Locking ring
P/N:
Seal Cover
P/N:
S/N:
Inspection results:
......................................................................
Fig. 2 Locking ring and Seal cover (Front pump drive quill)
Pump case
P/N:
S/N:
Inspection results:
......................................................................
Flanged bearing
P/N:
S/N:
Inspection results:
......................................................................
Plug
Procedure P/N:
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:
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:
......................................................................
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:
......................................................................
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:.......................................
Inspection results:
......................................................................
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:.......................................
Inspection results:
......................................................................
39-A-63-20-05-05A-311A-C ECS
compressor drive quill (main gearbox) -
Detailed visual examination.
See Para.5.
Locking washer
P/N:
Inspection results:
......................................................................
Procedure
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:
Pinion
P/N:
S/N:.......................................
Inspection results:
......................................................................
Locking ring
P/N:
Inspection results:
......................................................................
Flanged bearing
P/N:
S/N:
Inspection results:
......................................................................
Locking washer
P/N:
Inspection results:
......................................................................
Procedure
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:
Note:
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:
Inspection results:
......................................................................
39-A-63-20-05-06A-311A-C Left
lubrication pump (main gearbox) -
Detailed visual examination.
See Para. 2 and Figure 2.
Inspection results:
......................................................................
39-A-63-20-05-06A-311A-C Left
lubrication pump (main gearbox) -
Detailed visual examination.
See Para. 3.
Inspection results:
......................................................................
Procedure
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:
Inspection results:
......................................................................
Pinion
P/N:
S/N:.......................................
Inspection results:
......................................................................
T4
Fan gear
P/N:
S/N:.......................................
Inspection results:
......................................................................
Flange
P/N:
S/N:.......................................
Inspection results:
......................................................................
Locking ring
P/N:
S/N:.......................................
Locking ring
P/N:
S/N:.......................................
Locking ring
P/N:
S/N:.......................................
Inspection results:
......................................................................
Roller bearing
P/N:
S/N:.......................................
Inspection results:
......................................................................
Inspection results:
......................................................................
Inspection results:
......................................................................
Procedure:
Hereinafter are shown the CR&OP Data Modules required to perform the Dimensions check:
39-A-63-20-05-00A-361A-C
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.
Inspection results:
........................................................................
(MGB A03)
Diaphragm
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Inspection results:
........................................................................
........................................................................
........................................................................
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
178.030 / 7.0090
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Sliding adaptor
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Inspection results:
........................................................................
........................................................................
........................................................................
Inspection results:
........................................................................
........................................................................
........................................................................
Inspection results:
........................................................................
........................................................................
........................................................................
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Inspection results:
........................................................................
........................................................................
........................................................................
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Anti-torque beam
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Note:
39-A-63-20-05-01A-361A-C
Left input shaft module (main gearbox) -
Dimensions check
39-A-63-20-05-02A-361A-C
Right input shaft module (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.
General note
LH Case Assy
P/N:
S/N:.
RH Case Assy
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
LH Gear
P/N:
S/N:.
RH Gear
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
LH Input shaft
P/N:
S/N:.
D
RH Input shaft
P/N:
S/N:.
D
Inspection results:
........................................................................
........................................................................
........................................................................
LH Diaphragm
P/N:
S/N:.
RH Diaphragm
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
LH Sleeve
P/N:
S/N:.
RH Sleeve
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
LH Flange
P/N:
S/N:.
D
RH Flange
P/N:
S/N:.
D
Inspection results:
........................................................................
........................................................................
........................................................................
LH Gimbal support
P/N:
S/N:.
RH Gimbal support
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
LH Inner bearing
P/N:
S/N:.
RH Inner bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
LH Outer bearing
P/N:
S/N:.
RH Outer bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
LH Ball bearing
P/N:
S/N:.
RH Ball bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
LH Roller bearing
P/N:
S/N:.
RH Roller bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Roller bearing OD
LH Roller bearing
P/N:
S/N:.
RH Roller bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:
Inspection results:
...............................................
39-A-63-20-05-03A-361A-C
Upper module (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.
Top Case
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Ring gear
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Roller bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
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:
39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper
module) - 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.
39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper module) -
Dimensions check
See Para. 1 and Figure 1
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
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:
.........................................................................
.........................................................................
......................................................................
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:.
Inspection results:
Fig. 3 Planetary pin (Mast planetary assembly)
.........................................................................
.........................................................................
......................................................................
For Training purpose only 195 of 313
7.30.4 - Ball bearing Dimensions check
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:
.........................................................................
.........................................................................
......................................................................
39-A-63-20-05-14A-361A-C
Planetary gear (mast-planetary
assembly) - 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.
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:.
Inspection results:
Fig. 1 Planetary gear (Mast planetary assembly)
.........................................................................
.........................................................................
For Training purpose only 198 of 313
7.32 - Left/right hyd. pump drive quill (main gearbox)
Dimensions check
39-A-63-20-05-27A-361A-C
Left/right pump drive quill (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.
Left pinion
P/N:
S/N:.
Right pinion
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Inspection results:
.........................................................................
.........................................................................
......................................................................
Inspection results:
.........................................................................
.........................................................................
......................................................................
39-A-63-20-05-04A-361A-C
Front pump drive quill (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.
Pinion
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Pump Case
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Flanged bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
39-A-63-20-05-05A-361A-C
ECS compressor drive quill (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.
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:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
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:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
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:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
39-A-63-20-05-07A-361A-C
Fan drive quill (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.
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:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
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:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
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:
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:
.........................................................................
.........................................................................
......................................................................
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:
.........................................................................
.........................................................................
......................................................................
39-A-63-20-05-28A-361A-C
Tail rotor drive quill (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.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Pinion
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fan gear
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Flange
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Flanged bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
P/N:
S/N:.
Inspection results:
..................................................................................
..................................................................................
....................................................
Roller bearing
P/N:
S/N:.
Inspection results:
..................................................................................
..................................................................................
....................................................
Hereinafter are shown the CR&OP Data Modules required to perform the
dye penetrant examination on the MGB components:
7.42) 39-A-63-20-05-03A-351A-C
Upper module (main gearbox)
Tests for surface cracks with dye penetrant
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
Procedure
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 (ASTM-
E1417).
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).
39-A-63-20-05-00A-351A-C
Main gearbox - Tests for surface cracks with
dye penetrant
Procedure
Diaphragm
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)
1) Main case
P/N:
S/N:.
2) Bottom cover
Main Case P/N:
S/N:.
3) Anti-torque beam
P/N:
S/N:.
Bottom
4) Diaphragm
Cover
P/N:
S/N:.
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)
P/N:
S/N:.
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:.
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:.
Procedure
Nota
1) RH Case Assy
P/N:
S/N:.
3) LH Diaphragm
P/N:
Dye Penetrant Classification : S/N:.
3) RH Diaphragm
Type I (Fluorescent dye), Method D P/N:
(methods of excess penetrant removal), S/N:.
Level 2 (Sensitivity level: Medium),
Time: 30.
39-A-63-20-05-03A-351A-C
Upper module (main gearbox) - Tests for
surface cracks with dye penetrant
Procedure
39-A-63-20-05-03A-351A-C
Upper module (main gearbox) - Tests for
Seal cover surface cracks with dye penetrant.
See Para. 1, 2, 4 and Figure 1 (sheet 1 of 2)
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 :
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:.
39-A-63-20-05-04A-351A-C
Front pump drive quill (main gearbox) - Tests
for surface cracks with dye penetrant
Procedure
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:.
39-A-63-20-05-05A-351A-C
ECS compressor drive quill (main gearbox) -
Tests for surface cracks with dye penetrant
Procedure
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:.
39-A-63-20-05-27A-351A-C
Left/right pump drive quill (main gearbox) -
Tests for surface cracks with dye penetrant
Procedure
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:.
39-A-63-20-05-28A-351A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with dye penetrant
Procedure
1) Locking ring
P/N:
S/N:.
4) Locking ring
P/N:
S/N:.
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 7.54) 39-A-63-20-05-06A-352A-C
Disassembled metal components Left lubrication pump (main gearbox)
Tests for surface cracks with magnetic particles Tests for surface cracks with magnetic particles
(General guidelines for Magnetic Particles Examination)
7.54) 39-A-63-20-05-24A-352A-C
7.49) 39-A-63-20-05-00A-352A-C Right lubrication pump (main gearbox)
Main gearbox for surface cracks with magnetic particles
Tests for surface cracks with magnetic particles
7.55) 39-A-63-20-05-07A-352A-C
7.50) 39-A-63-20-05-01A-352A-C Fan drive quill (main gearbox)
Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles
Tests for surface cracks with magnetic particles
7.56) 39-A-63-20-05-13A-352A-C
7.50) 39-A-63-20-05-02A-352A-C Mast-planetary assembly (upper module)
Right input shaft module (main gearbox) Tests for surface cracks with magnetic particles
Tests for surface cracks with magnetic particles
7.57) 39-A-63-20-05-14A-352A-C
7.51) 39-A-63-20-05-03A-352A-C Planetary gear assembly (upper module)
Upper module (main gearbox) Tests for surface cracks with magnetic particles
Tests for surface cracks with magnetic particles
7.58) 39-A-63-20-05-27A-352A-C
7.52) 39-A-63-20-05-04A-352A-C Left/right hyd. pump drive quill (main gearbox)
Front hyd. pump drive quill (main gearbox) Tests for surface cracks with magnetic particles
Tests for surface cracks with magnetic particles
7.59) 39-A-63-20-05-28A-352A-C
7.53) 39-A-63-20-05-05A-352A-C Tail rotor drive quill (main gearbox)
ECS compressor drive quill (main gearbox) Tests for surface cracks with magnetic particles
Tests for surface cracks with magnetic particles
For Training purpose only 246 of 313
7.48 General guidelines for Magnetic Particles Examination
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).
6) Put the component in an applicable container. Make sure the component has sufficient protection against environmental condition.
39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Procedure
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:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
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
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.
7) LH and RH Sleeve
P/N:.
S/N:
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
Inspection results:
...............................................................................
...............................................................................
TBD ...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
Inspection results:
...............................................................................
...............................................................................
...............................................................................
39-A-63-20-05-03A-352A-C
Upper module (main gearbox) Tests for
surface cracks with magnetic particles
Procedure
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.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
39-A-63-20-05-04A-352A-C
Front pump drive quill (main gearbox) - Tests
for surface cracks with magnetic particles
Procedure
Fig. 1 Front pump drive quill (main gearbox) Components for magnetic particles test
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.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
39-A-63-20-05-05A-352A-C
ECS compressor drive quill (main gearbox) -
Tests for surface cracks with magnetic
particles
Procedure
Fig. 1 ECS Compressor drive quill (main gearbox) Components for magnetic particles test
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:
...............................................................................
...............................................................................
...............................................................................
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.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
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
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.
Fig. 1 Left lubrication pump (main gearbox) Components for magnetic particles test
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:
...............................................................................
...............................................................................
...............................................................................
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:
...............................................................................
...............................................................................
...............................................................................
39-A-63-20-05-07A-352A-C
Fan drive quill (main gearbox) - Tests for
surface cracks with magnetic particles
Procedure
Fig. 1 Fan drive quill (main gearbox) Components for magnetic particles test
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:
...............................................................................
...............................................................................
...............................................................................
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:
...............................................................................
...............................................................................
...............................................................................
39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) -
Tests for surface cracks with magnetic
particles
Procedure
3) Spider Plate
P/N:
S/N:.
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:
...............................................................................
...............................................................................
...............................................................................
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:
...............................................................................
...............................................................................
...............................................................................
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:
...............................................................................
...............................................................................
...............................................................................
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:
...............................................................................
...............................................................................
...............................................................................
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:
...............................................................................
...............................................................................
...............................................................................
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:
...............................................................................
...............................................................................
...............................................................................
39-A-63-20-05-14A-352A-C
Planetary gear assembly (upper module) -
Tests for surface cracks with magnetic
particles
Procedure
1) Gear
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:
...............................................................................
...............................................................................
...............................................................................
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
39-A-63-20-05-27A-352A-C
Left/right pump drive quill (main gearbox) -
Tests for surface cracks with magnetic
particles
Procedure
Fig. 1 Left/right pump drive quill Components for magnetic particles test
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:
...............................................................................
...............................................................................
...............................................................................
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
39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles
Procedure
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.
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
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
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
39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 2 and to Figure 3.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 Fan gear (Tail rotor drive quill) - Magnetic Particles Test Procedure
39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 3 and to Figure 4.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 4 Flange (Tail rotor drive quill) - Magnetic Particles Test Procedure
39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 4 and to Figure 5.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 5 locking ring (Tail rotor drive quill) - Magnetic Particles Test
Procedure
39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 5 and to Figure 6.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 6 locking ring (Tail rotor drive quill) - Magnetic Particles Test
Procedure
THE END
INDEX
(Conts)
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. Refer to CR&OP : 39-A-63-20-05-00A-714A-C (Main gearbox - General guidelines for assemble procedures).
2. Make sure that the work area is cleaned.
3. Before assembly, clean all parts.
4. At assembly, use new parts (bolts, screws, nuts, lips seals, etc.......) as required
5. Select the spare parts from the Illustrated Parts Data (39-A-ZG-W5-01-010-941A-C).
6. Before assembly, apply the surface finish protection on the external surfaces of the components as required.
7. 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
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.
(cont.s)
(cont.s)
Sealing compound (AMS-S-8802, Class A- C164 AMS-S-8802, Class A-1/2. (AMDI) 39-A-00-50-00-30B-078A-D
1/2)
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
39-A-63-20-05-00A-710A-C
Main gearbox - Assemble procedures.
Support equipments:
Identification No.
Nomenclature
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 39-A-63-20-05-00A-710A-C
Shim (177) Main gearbox - Assemble procedures
Procedure
Shim (102)
Shim (92) Screw (103) x 3
Screw (91) x 3 The shims (tot. 11) that must be installed on the
Main Case are the following:
- LH / RH Shim (193).
- Shim (177).
Shim (193) - Shim (187).
Screw (194) x 3 - LH / RH Shim (102).
Shim (98) - Shim (113).
Screw (97) x 3 - Shim (92).
Shim (199K) x 2 - Shim (98).
Screw (199L) x 3 - LH / RH Shim (199K).
AFT
RH LH
Main Case
without
FWD
Shims
For Training purpose only 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
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
Main Case Right side (Input Pinion II stage of reduction) LH Shim Thickness = X - CH
where
and
Screw (194) x 3
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.
Note:
The procedure reported on Step 3 can be used for all other shims installed on the
Main Case.
39-A-63-20-05-00A-710A-C - Main
gearbox - Assemble procedures.
Procedure (TBD)
Install the Shim (177) as follows:
Shim Thickness = X - CJ
where
39-A-63-20-05-00A-710A-C - Main
gearbox - Assemble procedures.
Procedure
where
LH Shim (102)
CR&OP Data Module:
Screw (103) x 3
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
Procedure
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.
1. Make sure that the shim has the same serial number
as the main case assembly.
Shim Thickness = X CK
Shim (98)
Where
Screw (97) x 3
RH Shim (199K)
CR&OP Data Module:
Procedure
Where
1
Support equipment:
Washer +
Nut x 4
Nomenclature Identification No.
2
3 4 6
1 2 3 4
Support equipment:
Nuts+
Washers Nomenclature Identification No.
Nuts+
Nuts+ Washers Heat gun Local supply
Washers
Bearing installation tool 3G6320A00331A023A
Packing Nuts
Nuts
Nuts Nuts
Heating phase
Bearing installation
For Training purpose only 23 of 152
8.2.1.4 Collector Gear Assy, assembly procedures
Collector Gear
CR&OP Data Module:
39-A-63-20-05-00A-710A-C - Main gearbox -
Surfaces Loctite application Assemble procedures.
Lubricated with Oil
Collector Bearing Supplies:
1
4
7
8
13
11
10 12
Supplies:
Heated area
Nomenclature Identification No. Specification references
V incision Main Case Cloth, soft lint-free C011 None
(cont.s)
(RH) M = G - (H + I1 + L)
(LH) M = G - (H + I1 + L)
where
5
Bearing Sleeve
1
Retaining Ring
Triplex ball bearing Pump gear
Input Pinion II stage
Bearing
installation tool
2 3
4
Pinion + Bearings
Arbor Press
10 13
14
Pump Gear +
Thickness Check Locking Ring
11 12
Pinion Assy +
Supplies +
Locking Washer +
Retaining Ring
20
15
21
17
Retaining installation
19
Locking Ring,
Reaction tool Locking Ring, Reaction
tool + Wrench Locking washer
installation Input Pinion II stage Assy
16
18
Bearing cage
Plug
Pinion
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).
Support equipment:
Retaining ring
Locking washer
Locking ring
Supplies:
Gear
Shim
Oil application Nomenclature Id. No. Specification references
Oil application
Part heated
Note:
Calculate and record the thickness of the shim (14) with this formula:
Oil application
Thickness = X - Y where
Nut + X (mm) : refer to the D.M. as necessary.
Washer Y is the dimension (mm) engraved on the rotor brake case.
Supplies:
7 6
1
Flanged bearing
R.B.C. assembled installed on the R.B.C.
3 4 5
Input Pinion
(IIstage of reduction) Locking ring Gear Flanged bearing
For Training purpose only 42 of 152
8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Assembly phase (Main gearbox P/N 3G6320A00133), step 2
9 11
10
12
14
13
15
17
16 18
Locking ring (20) Locking ring, Locking Washer Rotor Brake Case Assy
installation wrench and Retaining heating phase -
installation Ring installation
19 20 21
22 24 25
Flange (5)
installation Nipple (13)
installation
23
Locking Washer (2)
and Retaining Ring (1)
installation
26
Flanged
bearing
Heated area
Pump
case
External side
Pinion
Retaining ring
Seal cover
Lip seal
Packing
Plug
O-ring O-ring
Fitting Pump
case
Supplies:
Specification
Nomenclature Id. No.
references
2 3 Cloth, soft lint-free C011 None
Heated area
8 7
Locking
ring
Pinion
Case
Flanged
bearing
5
Retaining Locking Nuts +
ring washer Washers
Locking
ring
Pinion
Case
Assy
Locking 1 2 3
ring
Locking
Retaining washer
ring
Locking
Pinion ring
Bolts
Bolts
Bolts Bolts
Bearing
Bolts
Support equipment:
Main Case
Supplies:
Specification
Nomenclature Id. No.
references
Cloth, soft lint-free C011 None
Washers
+ Solvent, cleaning C010 P-D-680 type II
Nuts
Oil C006 MIL-PRF-7808L
Bolts
Heated area
Collector Gear
Collector Gear Assy, installed
Assy
Diaphragm 39-A-63-20-05-00A-710A-C
Main gearbox - Assemble
Screws
procedures.
Supplies:
Specification
Nomenclature Id. No.
references
Cloth, soft lint-free C011 None
Screw
O-ring +
1 2
Washer
Note
2 Supplies:
O-ring
Specification
Nomenclature Id. No.
references
1 Compound (Dykem C162 None
Steel Blue)
Solvent, cleaning C010 P-D-680 type II
Support equipment:
Apply the Oil
C006 on the
Sleeve Nomenclature Identification No.
1 4 5
Input Pinion Assy
Main Case
Assy rotate of
90. Main Case Assy.
Inner view
Main Case
Assy, LH side.
2 External view
Grease C115
application on Installation tool, input pinion 3G6320A00331A023H
O-rings
Apply the
l grease C115 on Supplies:
e the O-ring
Specification
Nomenclature Id. No.
references
Heated area,
Main Case Assy LH side
A
CR&OP Data Module:
39-A-63-20-05-00A-710A-C
Main gearbox - Assemble
procedures.
Support equipment:
Supplies:
Specification
Apply the grease Nomenclature Id. No.
references
C147 on the Lip Seal
(inner side)
Solvent, cleaning C010 P-D-680 type II
Screws Seal Cover
Apply the grease C115 on the O-ring Cloth, soft lint-free C011 None
RH Hyd. Pump
LH Hyd. Pump
Drive quill Assy
Drive quill Assy
Front Hyd.
Pump Drive
quill Assy
ECS-Compressor
Drive quill Assy
Nuts
+ Support equipment:
Washers
Nomenclature Identification No.
Heated area
Supplies:
Specification
Nomenclature Id. No.
references
LH Input Pinion II
Front Hyd. Pump Stage
3 Knobs (4)
4 Bolt
6 Bolts (4)
7 Registers (2)
8 Retainers
9 Bolts (2)
14 Collector Gear
1 7
Register
Expander,
installation
Wrench
2
Retainer
Tool Top
Section,
installation
Nylon Split
Ring Bolts
5
4
Collector
Gear
Knobs
Dial gauges
(3 positions)
Bottom Section
Note: Note:
Lock the Collector Gear with the Use the two Registers to adjust the
Expander as required. levelness of the Collector Gear as
required.
Note:
Note:
- Lock the tool expander and the backlash
tool to the main case as required.
Input Pinion
Backlash Tool - Pull the input pinion externally as required.
installation - 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.
Support Equipments:
Support Equipments:
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.
Note:
- Lock the tool expander ad the backlash
Left/Right Pump tool to the main as required.
(Hyd. Pump No. 1 - Pull the pinion externally.
and No. 2) - Install the Dial Gauge on its support.
Drive Quill
- Measure and record the backlash in
three positions, 120 apart, as required.
- Perform this action on both Hyd. Pumps.
Supplies:
Specification
Nomenclature Id. No.
references
Grease (NS-3913-G1) C147 None
39-A-63-20-05-24A-710A-C
Gear Locking Retaining ring Right lubrication pump (main gearbox) -
Ring
Assemble procedures
Key Support equipment:
Lubrication Pump
Nomenclature Identification No.
Lock washer
Reaction tool 3G6305G00931
Shaft Supplies:
Specification
Nomenclature Id. No.
references
Cloth, soft lint-free C011 None
A Support equipment
Key Shaft
B
G
Lock washer
Retaining ring
Locking
Gear Ring
C D E F
Supplies:
Specification
Nomenclature Id. No.
references
B
Lub. Pump
O-rings
Support equipment:
Nomenclature Identification No.
Supplies:
O-ring Specification
Nomenclature Id. No.
references
O-rings
Grease (Parker C115 None
super O-lube).
Bottom Cover
Washers
O-ring + Nut
(x 13)
Slip ring
Retaining ring
Main Case
CR&OP Data Module:
39-A-63-20-05-00A-710A-C
Main gearbox - Assemble procedures.
O-ring B
Bottom Cover
A
Washers
+ Nut
(x 13)
Bottom Cover
Supplies:
Specification
O-ring Nomenclature Id. No.
references
Washers (C115)
+ Grease (Parker super C115 None
Nut O-lube).
Safety wire C014 MS20995C32
O-ring
(C115)
AC Generator
Drive Cover
Plug
(C014)
During the assembly of the Upper Module do the operations that follow:
Supplies
Top-inner Procedure
bearing race
Roller cage
Put the components of the planetary gear assembly (1), on an
Rollers applicable work table.
Inner Bearing
race D
Roller cage
Gear
(outer bearing
B race)
C
Bottom-inner
Bottom-inner Top-inner bearing race
bearing race bearing race
Roller cage
Roller cage Roller cage
Rollers
Rollers Rollers
Screws
Lock
Retaining
washers
springs
Bushings
Ring nuts
Flange
Planetary
Gear
assemblies
Pins
Spacers
Plate
Bushings
Pins
Lock washers
Screws
Bushing 3G6320A07131A023A
Supplies: installation tool
Specification Spacer (Pin) 3G6320A07131A023C
Nomenclature Id. No.
references installation tool
Solvent (Loctite C023 None
quick clean 7031)
Pins
AA
Bushing 3G6320A07131A023A
installation tool
Refrigerator Local supply
Heated area
Ring nuts
Flange
Planetary
Gears Assy Pins
Spacers
Plate
Bushings
Pins Note:
Lock washers
Put the Bushings (14) in the
Screws refrigerator as required
Heated area
A E
D
C
F
L
Ring nuts
Screws
Supplies:
Mast Specification
Nomenclature Id. No.
references
Solvent (Loctite C023 None
Retaining quick clean 7031)
springs Adhesive (Loctite C029 MIL-S-46163,
222) Type II grade M
B D
I
F
Note:
Put the upper fitting (2) in the Refrigerator CR&OP Data Module:
39-A-63-20-05-03A-710A-C
Upper
Fittings
Upper module (main gearbox) -
Bolts + Assemble procedures.
Washers
Brackets
Support equipment:
TOP
CASE
Nomenclature Identification No.
Screws
Aligning pin, fitting (2) 3G6320A00231A023I
Supplies:
A F
B D
Support equipment:
Supplies:
Specification
Nomenclature Id. No.
references
3
Oil C006 MIL-PRF-7808L
Support equipment:
Ball
bearing Supplies:
Oil Nomenclature Id. No.
Specification
collector references
Nuts + Oil C006 MIL-PRF-7808L
Washers
Note:
Support equipment:
Clamp 3G6320A00231A023M
Supplies:
Specification
Nomenclature Id. No.
references
Ring gear
Specification
Packing Nomenclature Id. No.
references
(C115)
Union Cloth, soft lint-free C011 None
Packing Solvent, cleaning C010 P-D-680 type II
TOP CASE (C115)
Grease C115 Parker super O-
lube.
Supplies:
Specification
Oil Jets Nomenclature Id. No.
references
Grease C115 Parker super O-
lube.
Safety wire C014 MS20995C32
C D
Oil Jet
Filter
Packing
(C115)
Support equipment:
Mast-
Planetary
Assy Nomenclature Identification No.
Wrench 3G6320A00231A023L
Mast Cover
E installation
A
Oil Filler Neck
installation
Chip
Detector
installation
Identification
B C Plate installation D
Oil Union
CR&OP Data Module:
A (x4)
39-A-63-20-05-00A-710A-C
Oil Union Main gearbox - Assemble procedures.
B
Supplies:
Specification
Nomenclature Id. No.
references
Upper module
Assy
Support equipment:
Supplies:
A
C
Nuts Specification
+ Supplies: Nomenclature Id. No.
references
Washers
Grease C115 Parker super O-
lube.
Low Oil
Packings (C115) Level
Quick disconnect Sensor
coupling
Packing
(C115)
Packings (C115)
Oil Draining
Pipe
Nuts +
Washers
Drain Cap
Id. Specification
Nomenclature
No. references
Ts Ps
Tsw Cloth, soft lint-free C011 None
Solvent, cleaning C010 P-D-680 type II
Oil C007 MIL-PRF-23699
Grease (Aeroshell 22) C009 MIL-PRF-81322F
A
Nuts Packings (C115) Supplies:
+
Washers
Specification
Nomenclature Id. No.
references
Speed sensor
Grease C115 Parker super O-
lube.
Supplies:
Packings (C115)
Specification
Nomenclature Id. No.
Note: references
Apply Grease (C009)
each sensors Grease C115 Parker super O-
lube.
Check Valve
Retaining Ring)
Packings (C115)
D
39-A-63-20-05-00A-710A-C
Main gearbox - Assemble procedures.
D Borescope port
O-ring (C115)
Supplies:
Screws + Specification
washers Nomenclature Id. No.
references
E
D
Plugs
O-ring (C115)
E Flange
Chip Detector Plug
Supplies:
Specification
Nomenclature Id. No.
references
O-rings O-rings
(C115)
(C115)
Supplies:
Specification
Nomenclature Id. No.
references
Shim
Cloth, soft lint-free C011 None
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).
Screws Supplies:
Specification
Nomenclature Id. No.
references
Support equipment:
Supplies:
Nuts + Specification
Nomenclature Id. No.
Washers references
A B
Note:
Lock Ring
Lock Nut
LH Input Flanged Ball
Shaft Bearing (Top
Module Inner half-race) Flanged Ball Bearing ,
Input (installation completed on
Shaft Gear)
Module
A C E G
B D
F H
Heated
area
Gear
B
D
Diaphragm,
Bolts, torque phase
installation view
Support equipment:
Supplies:
Note:
LH Input - The two inner half-races (top and bottom) of the ball Oil C007 MIL-PRF-
Shaft bearing (15A) 23699
Module
- The inner race of the ball bearing (15B). Epoxy C042 MIL-P-23377.
Primer
Pusher used to install the Bottom Inner race (15B) and the Bottom and TOP Inner Half-
Race (15A) on the Input Pinion
Bottom Outer
A C Race (15B)
installed in the
Bearing Sleeve.
Marks applied
on the Duplex
Ball Bearing
D
Bottom Inner
Mark applied Mark applied on Race (15B),
on the Bearing the stem of the installation
Sleeve input pinion phase on the
Input Pinion.
Plug, installation
phase in the input
Pinion
View of the Ball bearing 15B and of the two
Keys. installed inside the bearing sleeve.
Top Outer
Race (15A)
installed in the
Ball Bearing Cage
Bearing Sleeve.
(15A), installation
phase
Pusher used to
install the Top
N Inner half-race
(15A), on the
P Pinion
Spacer
Packing
Heated
area Input Drive Items
Quill Group Heated
LH Input
Shaft
Module
A C E
B D F
Gimbal (33),
pre-installation
phase of the Carbon seal (31), installation
phase view of the Arbor Gimbal installed
carbon seal
press + Gimbal carbon seal on the Input drive
(31)
installation tool quill group.
G I M
Flange (40),
installation phase Marks applied on Torque application
in the spline of the Locknut on the locknut
Input Pinion.
L N
Backlash tool, installation Measure three position at 120 to each other. The value is the average of the three
B
measures.
(3K6320A00131A676B)
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.
Note
Gear, 1 Stage Perform this action on both
of reduction (2) Input Shaft Modules.
Use the specific Data Module
Input
Pinion (4)
LH Input
Shaft
CR&OP Data Module:
Module
39-A-63-20-05-01A-710A-C Left input shaft
module (main gearbox) - Assemble
procedures.
Inner Bearing (oven) Oil Vane
Support equipment:
Left Input Shaft
Freewheel
Nomenclature Identification No.
Supplies:
Specification
Nom. Id. No.
references
Oil Vane
Freewheel
Pusher
Input Shaft
Inner Bearing C
Oil
Vane
Freewheel
Outer
Bearing
Arbor Press
LH Input
Shaft CR&OP Data Module:
Note:
Module
During the installation phase 39-A-63-20-05-01A-710A-C Left input shaft
of the Oil Jet Cover (57) use module (main gearbox) - Assemble
the Heat Gun to increase the
temperature of the Input procedures.
Shaft Module.
Support equipment:
Retaining ring
Supplies:
Packings Specification
Nom. Id. No.
references
Oil Jet Oil C007 MIL-PRF-
Cover Nuts +
Washers 23699
Phase 2
Phase 1
Final positioning of the Freewheel group
Installation of the Freewheel Group on inside the Gear. During this phase
the Pusher and the positioning of the continue to use the pusher until the
Pusher on the Input Shaft Module freewheel group is fully against the
shoulder in the gear.
F H
D
Spacer
Retaining ring
installation phase
Washer
Packings
(C007)
Oil Jet
(C014)
C E
A
B D
F
64C
64B
64A
Packing E
Cross Shaft
RH Input Shaft Module
(inner side) + Cross Shaft
Cross Shaft
Main Case
Main Case RH
RH
Anti-Torque Beam
LH
Washers + LH
Nut (x 23) B
THE END
INDEX
(Conts)
For Training purpose only 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). Support equipments:
Supplies / Spares
Specification
Nomenclature Identification No
references
Oil C007 MIL-PRF-23699
(Turbo Oil 2380)
Plug CJ-34-10 and
CJ-34-09
9.1.2 DESCRIPTION OF OPERATIONS OF FLUSHING 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.
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-A-
63-20-05-00A-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.
Support equipments: Supplies:
a) The MGB must be installed on the Test Bench carrying out the necessary mechanical and electrical
connections required.
b) 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.
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 : 130C
- Oil Temperature : 110C
- Oil Temperature variation (input/output of the MGB) : < 15C
- Oil Pressure : 5 thru 5.5 Bar.
c) Start the Test Bench and gradually get the 100% of the nominal speed (21000 RPM).
d) 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 Adjustment
Turn the adjustment screw (3) counter clockwise to decrease the pressure setting. Screw
Note
One complete turn of the adjustment screw (3) changes the pressure setting by approximately Lock nut Pressure
0.5 bar. Relief Valve
Tighten the lock nut (2).
f) After the adjustments Start the Test Bench and do the green run cycle. Obey the instructions given in
the Table reported hereinafter:
g) At the end of the Functional Check (green run cycle) perform the following actions:
THE END
INDEX
10.1 Introduction
10.2 MGB - Disassembly procedures, initial phase
10.3 Main Case, Backlash check
10.4 MGB - Disassembly procedures, 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
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)
- Perform the Backlash check on the Main Case and on each Input Shaft Module as required.
Refer to the following CR&OP data modules:
- 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.
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.
Mast-
Planetary
assembly
RH Input
LH Input Shaft
Shaft Module
Module
Main Case
Assembly
Maintenance
Trolley
Side View
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, ECS Compressor, Drive Quill plug Front Hydraulic Pump, FAN, Drive Quill plug + Seal
Drive Quill plug + Seal Cover Drive Quill plug Cover
13. Remove the Fifteen Oil Jets from the Main Case.
Top View
Rear View
Main Case
O-ring
Plug
Cross Shaft
Union
Washers
Washers
Cross Shaft Nuts
Washers
O-rings
Bracket
Washers
Nuts NutsWashers
Washers
Bracket
+ Nuts
Bracket Set screw (Nylon)
15. Remove the Upper Module, the Unions and the Planetary Crown (Ring gear).
Oil Union
A (x4) Upper Module
Assy
Oil Union
B
Planetary
Crown
Main Case (Fixed Ring
Gear)
LH Input Pinion II
Front Hyd. Pump Stage
Note
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.
Engine 2 Inlet
(Drive Shaft)
Details
2. Remove the Right & Left Input Pinion Assy (II stage of reduction).
Input Pinion II
Stage
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
LH Input Shaft
Module
Thermocouple
Freewheel
Group
Oil Jet
Cover
Oil Jet
Oil Jet RH Input Shaft
Cover
Module
Flange
Input
Pinion
Input Drive-Quill
Group
Note
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.
A B
C D
Chip Detector
O-ring
Chip Det. Valve
O-ring
3. Remove the Roller Bearing, the Seal cover and the Mast-Planetary Assy as required.
Top Case
Mast-
Planetary
Assembly
Seal Cover
Roller
Bearing Note:
Planetary crown
(Fixed ring gear)
already removed
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.
Top-inner
bearing race
Roller cage
Rollers
Flange Gear
(outer bearing
Planetary race)
Gear Assy.
Rollers
Bottom-inner Roller cage
bearing race
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.
Inner side
Packing
Retaining ring
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.
Packing
External side
THE END
INDEX
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
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:
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.
(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.
2. Examine the two roller bearings (2) for corrosion, scratches, pitting and spalling. The roller bearings
stay in the main case.
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.
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.
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.
(continued)
6. Examine outer surfaces of the Gimbal
(14) for damage and dents.
7. Examine the attach holes and the mating
surface of the flange (15) for fretting,
dents and damage.
(continued)
8. Examine the input pinion (11) and the crown
gear (8). Obey the instructions that follow:
8.1 Examine the bearing seats for fretting and 11
conditions.
8.2 Examine the teeth for damage and condition.
8.3 Examine the teeth for acceptable wear pattern.
9. Examine the freewheel sprags engaging area of
the gear (8) for corrosion, wear, seizure and
sprag engagement deep scratches.
Note
Only small contamination with material from
freewheel springs is permitted.
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.
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:
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.
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.
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.
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.
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. Examine the cover (4) for conditions.
2. Examine the lip seal (3) for wear and overheating.
3. Examine the sleeve (2) and the related bearing as
follows:
3.1 Examine the mating surfaces with the components
for fretting.
3.2 Examine the bearing races for wear, breaks and
deformation.
3.3 Turn the bearing to do a check for the correct and
freely operation.
4. Do a check on the drive gear (1) as follows:
4.1 Examine the spline teeth for fretting.
4.2 Examine the race of the seal for wear.
4.3 Examine the teeth for corrosion, dents, scoring and
pitting.
4.4 Examine the teeth for acceptable wear pattern.
Refer to CR&OP data module: 39-A-63-20-05-
00A-379A-C. See Para. 11.7.1. of this Training
Manual. 39-A-63-20-05-00A-379A-C.
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.
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. Examine the cover (4) for conditions.
2. Examine the lip seal (3) for wear and overheating.
3. Examine the sleeve (2) and the related bearing as
follows:
3.1 Examine the mating surfaces with the components
for fretting.
3.2 Examine the bearing races for wear, breaks and
deformation.
3.3 Turn the bearing to do a check for the correct and
freely operation.
4. Do a check on the drive gear (1) as follows:
4.1 Examine the spline teeth for fretting.
4.2 Examine the race of the seal for wear.
4.3 Examine the teeth for corrosion, dents, scoring and
pitting.
4.4 Examine the teeth for acceptable wear pattern.
Refer to CR&OP data module: 39-A-63-20-05-
00A-379A-C. See Para. 11.8.1. of this Training
Manual
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.
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.
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.
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.
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.
THE END
INDEX
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
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:
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:
After completion of the assembly, the MGB must be tested on the specific Test Bench performing a Leak
Check (Test B).
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.
4. Install the Right & Left Input Pinion Assy (II stage of reduction).
Input Pinion
(II Stage of reduction)
5. 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:
LH Input Pinion II
Front Hyd. Pump Stage
Note
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.
2. Install the Left and Right Lubrication Pump and the Bottom Cover as required.
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-710A-
C (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.
Top-inner
bearing race
Roller cage
Rollers
Flange Gear
(outer bearing
Planetary race)
Gear Assy.
Rollers
Bottom-inner Roller cage
bearing race
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
Mast-
Planetary
Assembly
Seal
Cover
Roller
Planetary crown
Bearing
(Fixed ring gear)
and Packing
A B
C D
3. Install the Chip Detector and the Chip Detector Valve as required.
Chip
Detector
O-ring
Chip Det. Valve
O-ring
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.
Oil Union
A (x4) Upper Module
Assy
Oil Union
B
Main Case
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, ECS Compressor, Drive Quill plug Front Hydraulic Pump, FAN, Drive Quill plug
Drive Quill plug Drive Quill plug
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.
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.
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-A-
63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check.
PRV
Chip Detectors
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
Engine 2 Inlet
(Drive Shaft) CR&OP Data Module:
Right input
shaft 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)
Left input
shaft module And
39-A-63-20-05-02A-719A-C Right input shaft
module (main gearbox) - Assemble
Effectivity Codes: procedures after functional check
Input Drive-Quill
Group
Note
Continued
Note
Flange
Input
Pinion
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 RH Input Shaft
Cover
Module
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.
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).
THE END
INDEX
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-63-20-05-
00A-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:
Nomenclature Identification No Specification references
Support equipments:
Oil C007 (Turbo Oil 2380) MIL-PRF-23699
Nomenclature Identification No.
Cloth, soft lint free C011 None
Test bench, gearbox 139G6300E001 Solvent, cleaning C010 P-D-680 type II
a) The MGB must be installed on the Test Bench carrying out the necessary mechanical and electrical
connections required.
b) Fill the transmission up to the maximum level with Oil (C007).
c) Clean the external surfaces of the MGB with the Cloth (C011) and the Solvent (C010).
d) Dry the cleaned surfaces as necessary.
e) Start the Test Bench and operate the MGB as required for the phase 1. See the table reported
hereinafter.
(continued)
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:
THE END
INDEX
(Conts)
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)
Supplies:
Specification
Anti-Spill Oil Filter Head Nomenclature Identification No
references
Valve
Oil Filter Oil C007 (Turbo Oil MIL-PRF-
element 2380) 23699
Cloth, soft lint free C011 None
Solvent, cleaning C010 P-D-680 type
II
Grease C115 (parker super None
O-lube)
Anti-Spill
Valve
Oil Filter
element Oil Filter Head
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:
Specification
Nomenclature Identification No
references
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.
At the end these actions apply the Paint Finish to the MGB.
THE END
THE END
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.
THE END