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MAIN TRANSMISSION GEARBOX

(MGB) REPAIR & OVERHAUL


TECHNICIAN TRAINING

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

DOCUMENT No.: 39-A0126-MG001-00


ISSUE: 002
ISSUE DATE: 16 April 2014
Document Name: 39-A0126-MG001-00

ISSUE DATE REMARKS


001 2013.07.25 1st Issue

002 2014.04.16 2st Issue

NOTE

All information reported in this Manual


must be considered for Training
purpose only

For Training purpose only 2 of 18


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

The information reported in this training manual are relevant to the Repair & Overhaul
procedures described on AW139 IETP data modules for MGB P/Ns:

3G6320A00132,
3G6320A00133,
3G6320A00134,
3G6320A00135

Hereinafter is shown the Table of Contents of this manual.

For Training purpose only 4 of 18


1 Introduction

Table of Contents

Chapter 1 - Introduction

Chapter 2 - Documentation

2.1 A/C Publication


2.2 IETP Interactive Electronic Technical Publication
2.3 AMP A/C Maintenance Publication
2.4 DMC Data Module Code
2.5 Descriptive Data Module
2.6 AMPI A/C Maintenance Planning Information
2.7 CR&OP Component Repair & Overhaul Publication
2.8 IPD Illustrated Part Data
2.9 ITEP Illustrated Tolls & Equipment Publication
2.10 RFM Rotorcraft Flight Manual
2.11 QRH Quick Reference and Handbook
2.12 MGB Log card

For Training purpose only 5 of 18


1 Introduction (continued)

Chapter 3 - General information

3.1 General description


3.2 MGB description
3.3 Mechanical assembly description
3.3.1 Left and Right Input Shaft Module description
3.3.2 Upper Module description
3.3.3 Hydraulic Pumps drive quills description
3.3.4 ECS compressor drive quill description
3.3.5 FAN drive quill description
3.3.6 Tail-rotor drive quill description
3.4 Lubrication system description
3.4.1 General
3.4.2 Chip detection operation
3.4.3 Pumps
3.4.4 Pressure regulation
3.4.5 Oil Filter
3.4.6 Oil Cooler
3.4.7 Sensors and Jets
3.5 Leading Particulars
3.6 Controls and Indicators
3.7 Warning, Caution Messages
3.8 Components that must be removed from the MGB before its overhaul

For Training purpose only 6 of 18


1 Introduction (continued)
Chapter 4 General Procedures

4.1 Introduction
4.2 A/C Publications
4.3 AMPI A/C Maintenance Publication Information
4.4 Limits

Chapter 5 Pre-Disassembly Procedures

5.1 Safety Information


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

Chapter 6 Disassembly Procedures


6.1 Left and Right Input Shaft Module and Cross Shaft, removal and 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 .
For Training purpose only 7 of 18
1 Introduction (continued)

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)

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.
Chapter 7 - Components Cleaning, Paint removal, Protection and Inspection
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 Damages code list
7.11 Example of damages
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
For Training purpose only 9 of 18
1 Introduction (continued)

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
7.26 Dimensions Check
7.27 Main gearbox Dimensions check
7.28 LH/RH Input Shaft Module Dimensions check
7.29 Upper Module Dimensions Check
7.30 Mast-Planetary Assembly Dimensions check
7.31 Planetary Gears Dimensions check
7.32 LH/RH Hyd. Pump Drive Quill Dimensions check
7.33 Front Hyd. Pump Drive Quill Dimensions check
7.34 ECS Compressor Drive Quill Dimensions check
7.35 Fan Drive Quill Dimension check
7.36 LH/RH Lubrication Pump Dimensions check
7.37 Tail Rotor Drive Quill Dimensions check
7.38 Dye Penetrant Examination
7.39 General guidelines for Dye Penetrant Examination

For Training purpose only 10 of 18


1 Introduction (continued)

7.40 Main gearbox Dye Penetrant Examination


7.41 LH/RH Input Shaft Module Dye penetrant Examination
7.42 Upper Module Dye Penetrant Examination
7.43 Front Hyd. Pump Drive Quill Dye Penetrant Examination
7.44 ECS Compressor Drive Quill Dye Penetrant Examination
7.45 LH/RH Hyd. Pump Drive Quill Dye Penetrant Examination
7.46 Tail Rotor Drive Quill Dye Penetrant Examination
7.47 Magnetic Particles Examination
7.48 General guidelines for Magnetic Particles Examination
7.49 Main gearbox Magnetic Particles Examination
7.50 LH/RH Input Shaft Module Magnetic Particles Examination
7.51 Upper Module Magnetic Particles Examination
7.52 Front Hyd. Pump Drive Quill Magnetic Particles Examination
7.53 ECS Compressor Drive Quill Magnetic Particles Examination
7.54 LH/RH Lubrication Pump Magnetic Particles Examination
7.55 Fan Drive Quill Magnetic Particles Examination
7.56 Mast-Planetary Assembly Magnetic Particles Examination
7.57 Planetary Gears Assembly Magnetic Particles Examination
7.58 LH/RH Hyd. Pump Drive Quill Magnetic Particles Examination
7.59 Tail Rotor Drive Quill Magnetic Particles Examination

For Training purpose only 11 of 18


1 Introduction (continued)

Chapter 8 Assembly Procedures

8.1 Pre-Assembly Requirements


8.2 MGB, Assembly procedures
8.2.1 Main Case, Assembly procedures
8.2.1.1 Shims, installation.
8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing,
installation.
8.2.1.3 Diaphragm Assy, assembly.
8.2.1.4 Collector Gear Assy, assembly.
8.2.1.5 RH / LH Input Pinion Assy (II stage of reduction), assembly.
8.2.1.6 Tail Rotor Drive Quill Assy, assembly.
8.2.1.7 Left and Right Hyd. Pump Drive Quill, assembly.
8.2.1.8 Front Hyd. Pump Drive Quill, assembly.
8.2.1.9 ECS-Compressor Drive Quill, assembly.
8.2.1.10 Fan Drive Quill, assembly.
8.2.1.11 Collector Gear Assy, installation.
8.2.1.12 Diaphragm Assy, installation.
8.2.1.13 Tail Rotor Drive Quill Assy, installation.
8.2.1.14 RH / LH Input Pinion Assy (II stage of reduction), installation.
8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation.
8.2.1.16 Front Hyd. Pump Drive Quill Assy, installation.
8.2.1.17 ECS-Compressor Drive Quill Assy and Seal Cover, installation.
8.2.1.18 Fan Drive Quill Assy, installation.
For Training purpose only 12 of 18
1 Introduction (continued)

8.2.1.19 Main Case, Backlash check


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

For Training purpose only 13 of 18


1 Introduction (continued)

8.2.3 Main Case, External components installation procedures


8.2.3.1 Oil draining Pipe, Oil Level Gauge and low Oil Level sensor,
installation.
8.2.3.2 Oil Filter Head, Oil Temperature sensor, Oil Pressure sensor and Oil
Temperature SW, installation.
8.2.3.3 Rotor Speed Sensor, installation.
8.2.3.4 Check valves and Pressure Relief Valve, installation.
8.2.3.5 Borescope Port, Two Chip Detectors, Washers, Plugs and Flange,
installation
8.2.3.6 Fifteen (from No. 1 to No. 13) Oil Jets, installation.
8.2.4 LH / RH Input Shaft Module, assembly procedures
8.2.4.1 Shims, installation.
8.2.4.2 Bearings, installation.
8.2.4.3 Diaphragm Assy, assembly.
8.2.4.4 Gear (I stage of reduction), assembly.
8.2.4.5 Gear Assy and Diaphragm Assy, installation.
8.2.4.6 Input Drive Quill group, assembly.
8.2.4.7 Input Drive Quill group and Gimbal Assy, installation.
8.2.4.8 Input Shaft Module, Backlash check.
8.2.4.9 Freewheel Group, assembly.
8.2.4.10 Freewheel Group and Oil Jet Cover, installation.
8.2.4.11 Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation
8.2.4.12 LH/RH Input Shaft Module, installation.
8.2.5 Anti-Torque Beam, Installation procedures
For Training purpose only 14 of 18
1 Introduction (continued)

Chapter 9 Functional Check


9.1 Preliminary Actions
9.1.1 Introduction
9.1.2 Description of operations of flushing
9.2 Functional Check (Test A)
9.2.1 Procedures

Chapter 10 Disassembly procedure after functional check


10.1 Introduction
10.2 MGB - Disassembly procedures, initial phase
10.3 Main Case, Backlash check
10.4 MGB - Disassembly procedure, final phase
10.5 Left / Right Input Shaft Module - Disassembly procedures, initial phase
10.6 Input Shaft Modules, Backlash check
10.7 Left / Right Input Shaft Module - Disassembly procedures, final phase
10.8 Upper module, disassembly procedures
10.9 Mast-Planetary Assy, disassembly procedures
10.10 Front Hyd. Pump drive quill, disassembly procedures
10.11 LH/RH Hyd. Pump drive quills, disassembly procedures

For Training purpose only 15 of 18


1 Introduction (continued)

Chapter 11 - Inspection Criteria after Functional check


11.1 General guideline for visual examination of components after functional
check
11.2 Main gearbox Detailed Visual Examination
11.2.1 Collector gear Wear Pattern Check
11.2.2 Input pinion (II stage of reduction) Wear Pattern Check
11.2.3 Gear (Hyd. Pump drive quill) Wear Pattern Check
11.3 LH/RH Right Input Shaft Module Detailed Visual Examination
11.3.1 Freewheel Detailed Visual Examination
11.4 Upper Module Detailed Visual Examination
11.4.1 Ring Gear Wear Pattern Check
11.5 Mast-Planetary Assembly Detailed Visual Examination
11.5.1 Planetary Gear Assembly Wear Pattern Check
11.6 LH/RH Hyd. Pump Drive Quill Detailed Visual Examination
11.6.1 LH/RH Hyd. Pump Drive Quill Wear Pattern Check
11.7 Front Hyd. Pump Drive Quill Detailed Visual Examination
11.7.1 Front Hyd. Pump Drive Quill Wear Pattern Check
11.8 ECS Compressor Drive Quill Detailed Visual Examination
11.8.1 ECS Compressor Drive Quill Wear Pattern Check
11.9 LH/RH Lubrication Pump Detailed Visual Examination
11.9.1 LH/RH Lubrication Pump Wear Pattern Check
11.10 Fan Drive Quill Detailed Visual Examination
11.10.1 Fan Drive Quill Wear Pattern Check
11.11 Tail Rotor Drive Quill Detailed Visual Examination & Wear Pattern Check
For Training purpose only 16 of 18
1 Introduction (continued)
Chapter 12 Assembly procedures after Functional Check
12.1 Introduction
12.2 MGB - Assembly procedures, initial phase
12.3 Main Case, Backlash check
12.4 MGB - Assembly procedures, intermediate phase
12.5 Mast-Planetary Assy, Assembly procedures
12.6 Upper Module, Assembly procedures
12.7 Upper Module, Installation procedures
12.8 MGB - External components installation
12.9 MGB - Oil jets installation
12.10 Left / Right Input Shaft Module - Assembly procedures, initial phase
12.11 Input Shaft Modules, Backlash check
12.12 Left / Right Input Shaft Module - Assembly procedures, final phase
12.13 Left / Right Input Shaft Module, Installation procedures
12.14 MGB Assembly procedures, final phase
Chapter 13 - Leak Check
13.1 Leak Check (Test B)
Chapter 14 - Finish after leak check
14.1 Oil Filter Element installation
14.2 Nylon setscrews installation
Chapter 15 - Painting procedures
Chapter 16 - Final Acceptance

For Training purpose only 17 of 18


Chapter 1 - Introduction

THE END

RETURN TO LESSON SUMMARY RETURN TO COURSE MENU


For Training purpose only 18 of 18
MAIN TRANSMISSION GEARBOX
(MGB) REPAIR & OVERHAUL
TECHNICIAN TRAINING

Chapter 2 - Documentation
2 - Documentation

INDEX

2.1 A/C Publication


2.2 IETP Interactive Electronic Technical Publication
2.3 AMP A/C Maintenance Publication
2.4 DMC Data Module Code
2.5 Descriptive Data Module
2.6 AMPI A/C Maintenance Planning Information
2.7 CR&OP Component Repair & Overhaul Publication
2.8 IPD Illustrated Part Data
2.9 ITEP Illustrated Tolls & Equipment Publication
2.10 RFM Rotorcraft Flight Manual
2.11 QRH Quick Reference and Handbook
2.12 MGB Log card

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

The AgustaWestland AW139


Interactive
Electronic
Technical
Publication
is distributed on CD-ROM

Documentation 4 of 57
2.3 - AMP A/C Maintenance Publication

Maintenance Publication (AMP)

The Technical Publications are


arranged in CHAPTERS and
Sections.

Each chapter is composed of


DATA MODULES.

Documentation 5 of 57
2.4 - DMC Data Module Code

Each Data Module is identified by a unique Data Module Code (DMC)


having the following structure:

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

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

The Model Identification Code for the AW139 is 39.

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

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


The System Difference Code is a letter (letters I and O are not used).
It is used when two or more subsystems can be installed in the A/C as alternatives to do the same function
(hereinafter is reported an example relevant to differents MGB group that can be installed on A/C).

(AMP) 39-A-63-20-00-00A-041A-A
Main gearbox group - Description of how it is made
(P/N 3G6320A00132 and subsequents P/N) with
different last two digits)

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

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

Documentation 8 of 57
2.4.3 Standard Numbering System (SNS) Code

1 2 3 4 5 6

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


The Standard Numbering System Code includes three pairs of digits which show:
SYSTEM eg: IPD 39-A-29-00-00-010-941A-A Hydraulic system Fuselage Section

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


and SUB-SUBSYSTEM eg: AMP 39-A-29-11-00-00A-041A-A Number 1 main hydraulic system - Description of how it is made

COMPONENT eg: IPD 39-A-29-11-01-010-941A-A Number 1 Power Control Module Assy

Documentation 9 of 57
2.4.4 Disassembly Code & Disassembly Code Variant 1/2

1 2 3 4 5 6

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

The Disassembly Code has two digits


The Disassembly Code Variant has one letter

The Disassembly Code in AMP shows the breakdown of a component, as follows:

- 00 - Data module for all of the helicopter, system, subsystem or component


- 01 - Data module for the first assembly that you remove from the component
- 02 - Data module for the second assembly that you remove from the component
- 03 and subsequent codes refer to the third, fourth, etc. assembly that you remove from the component

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

Documentation 10 of 57
2.4.4 Disassembly Code & Disassembly Code Variant 2/2

1 2 3 4 5 6

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

The Disassembly Code Variant


A
is a letter which identifies alternative items
(letters I and O are not used)

eg: These items are different,


but the difference is too small to cause a change
in the System Difference Code.
B

Documentation 11 of 57
2.4.5 Information Code & Information Code Variant

1 2 3 4 5 6

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

The Information Code has three digits and Code Definition


identifies the types of information you can find in 0XX Function, data for plans and description
1XX Operation
that data module. 2XX Servicing
3XX Examination, tests and checks
4XX Fault reports and isolation procedures
5XX Disconnect, remove and disassemble
The Information Code Variant has one letter and procedures
6XX Repairs and locally make procedures and
is used for different data modules that are applicable data
7XX Assemble, install and connect procedures
to the same component and type of operation. 8XX Storage procedures and data
9XX Miscellaneous

Documentation 12 of 57
2.4.6 Item location code

1 2 3 4 5 6

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


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

Examples of location codes:

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

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

List of Data Modules and


Technical Publications
associated to the procedure

References

Documentation 16 of 57
2.5 - Descriptive Data Module 4/8

List of Tasks to be performed


before starting the procedure

Preliminary requirements
Required conditions

List of Special Tools and Support Equipment


required to do the procedure
Support Equipment

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

General Warnings and Cautions

Safety Conditions

Documentation 19 of 57
2.5 - Descriptive Data Module 7/8

Sequence of Steps and Illustrations


necessary to do the procedure

Procedure

Documentation 20 of 57
2.5 - Descriptive Data Module 8/8

Instructions necessary to return


the helicopter back to operation

Requirement After Job Completion

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

04-00 AIRWORTHINESS LIMITATIONS

04-10 RETIREMENT LIVES

04-20 MANDATORY INSPECTIONS

04-30 CERTIFICATION MAINTENANCE


REQUIREMENTS

Documentation 24 of 57
2.6 - AMPI - Maintenance Planning Information 4/16

04-00 AIRWORTHINESS LIMITATIONS

Documentation 25 of 57
2.6 - AMPI - Maintenance Planning Information 5/16

04-10 RETIREMENT LIVES

Documentation 26 of 57
2.6 - AMPI - Maintenance Planning Information 6/16

04-20 MANDATORY INSPECTIONS

Documentation 27 of 57
2.6 - AMPI - Maintenance Planning Information 7/169

04-30 CERTIFICATION MAINTENANCE REQUIREMENTS

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

05-30 PHASED and PROGRESSIVE SCHEDULED


MAINTENANCE CHECKS

05-40 STANDARD SCHEDULED MAINTENANCE CHECKS

05-50 UNSCHEDULED MAINTENANCE CHECKS

Documentation 29 of 57
2.6 - AMPI - Maintenance Planning Information 9/16

05-00 SCHEDULED/UNSCHEDULED MAINTENANCE

Documentation 30 of 57
2.6 - AMPI - Maintenance Planning Information 10/16

05-00 SCHEDULED/UNSCHEDULED MAINTENANCE (example)

Documentation 31 of 57
2.6 - AMPI - Maintenance Planning Information 11/16

05-10 TIME LIMITS

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.

List of components: Refer to the following Table (see Note)

Ref Component Part number Overhaul interval (FH)

CO63-01 Main gearbox assembly 3G6320A00132 5000 (*)


CO63-05 Lubricating pump 3G6320V04252 2500
CO63-07 Main gearbox assembly 4G6320A00132 5000
CO63-09 Lubricating pump 3G6320A18731 2500

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

Note: Refer to AMPI for further and more detailed information

Documentation 33 of 57
2.6 - AMPI - Maintenance Planning Information 13/16

05-20 COMMON SCHEDULED MAINTENANCE CHECKS LIST

Documentation 34 of 57
2.6 - AMPI - Maintenance Planning Information 14/16

05-30 PHASED and PROGRESSIVE SCHEDULED MAINTENANCE CHECKS

Documentation 35 of 57
2.6 - AMPI - Maintenance Planning Information 15/16

05-40 STANDARD SCHEDULED MAINTENANCE CHECKS

Documentation 36 of 57
2.6 - AMPI - Maintenance Planning Information 16/16

05-50 UNSCHEDULED MAINTENANCE CHECKS

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

Sec. 39-A-00-00-00-00A-011E-C : List of effectivity codes

The meaning of the effectivity codes used is as follows:

All : Helicopters AW139:

- S/N 31005 and subsequent


- S/N 41001 and subsequent

Documentation 39 of 57
2.7 CR&OP Component Repair & Overhaul Publication 3/10

Sec. 39-A-00-00-00-00A-018E-C : Introduction


General

This publication gives you all the data necessary for the repair and the
overhaul of the components of the Agusta Westland AW139.
It includes the data that are necessary for the requisition and
identification of the spare parts at the repair/overhaul level.
Publication contents
The publication gives repair and overhaul data for:
System Title
60 Standard practices - rotors
62 Main rotor
63 Main rotor drive
64 Tail rotor
65 Tail rotor drive
67 Rotors flight control
Documentation 40 of 57
2.7 CR&OP Component Repair & Overhaul Publication 4/10

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

Publication layout

This publication contains:

This introduction and the general data modules (39-A-63-....)


The repair/overhaul data modules (39-A-63-......)
The illustrated parts data modules (IPD: ZG-.....Main gearbox)

Documentation 41 of 57
2.7 CR&OP Component Repair & Overhaul Publication 5/10

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

Illustrated parts data modules (IPD)

General

Each Illustrated Parts Data (IPD) module includes a figure and the
related text (detailed parts list).
A code identifies each IPD module as required. Hereinafter is reported
an example.

Documentation 42 of 57
2.7 CR&OP Component Repair & Overhaul Publication 6/10

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


Data Module Code (DMC)

The IPD at the repair/overhaul level refers to components of the helicopter not to
systems. Thus, data is not-chapterized.
The DMC structure is as follows: ZG-W5-....

Z - identifies that the data module is non-chapterized.


G - is the code that identifies Agusta as responsible company.
W5- .... followed by a sequential number (assigned by Agusta) identifies the project
number; see the example reported hereinafter:

01 - for the main gearbox.


02 - for the intermediate gearbox.
03 - for the tail gearbox.
For P/N : 3G

For P/N : 4G

Documentation 43 of 57
2.7 CR&OP Component Repair & Overhaul Publication 7/10

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


Detailed parts list
The detailed parts list is a table. Each column of the table has a heading that gives the contents.
The columns include the information that follows:

Usable on code
assembly and model
version and
effectivity column
(UOCA MVEFFECT)
Interchangeability column Source, maintenance and
(ICY) recoverability code
column (SMR)

Quantity per next higher assembly


and unit of issue column (QNHA UI)

Documentation 44 of 57
2.7 CR&OP Component Repair & Overhaul Publication 8/10

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

Documentation 45 of 57
2.7 CR&OP Component Repair & Overhaul Publication 9/10

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


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

Documentation 46 of 57
2.7 CR&OP Component Repair & Overhaul Publication 10/10

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

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

RETURN TO LESSON SUMMARY RETURN TO COURSE MENU


Documentation 57 of 57
MAIN TRANSMISSION GEARBOX
(MGB) REPAIR & OVERHAUL
TECHNICIAN TRAINING
Chapter 3 MGB General
information
3 MGB General information
INDEX

3.1 General description


3.2 MGB description
3.3 Mechanical assembly description
3.3.1 Left and Right Input Shaft Module description
3.3.2 Upper Module description
3.3.3 Hydraulic Pumps drive quills description
3.3.4 ECS compressor drive quill description
3.3.5 FAN drive quill description
3.3.6 Tail-rotor drive quill description
3.4 Lubrication system description
3.4.1 General
3.4.2 Chip detection operation
3.4.3 Pumps
3.4.4 Pressure regulation
3.4.5 Oil Filter
3.4.6 Oil Cooler
3.4.7 Sensors and Jets
3.5 Leading Particulars
3.6 Controls and Indicators
3.7 Warning, Caution Messages
3.8 Components that must be removed from the MGB before its overhaul

For Training purpose only 2 of 51


3.1 General description

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

Main Gearbox
Main Rotor Shaft (Mast)

Engine No. 2 Tail Gearbox

Lub. Pump FAN, Oil Cooler Unit

Rotor
Brake
Intermediate
RH Hyd. Pump (Hyd. Sys. No. 2) Gearbox

Tail Rotor Drive System (3 shafts)

AC Generator (Optional)

Lub. Pump Engine No.1


ECS Compressor
LH Hyd. Pump (Hyd. Sys. No. 1)
Front Hyd. Pump (Hyd. Sys. No. 2)
AC Generator (Optional)

Fig. 1 - Drive system

For Training purpose only 3 of 51


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

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

Figure 2 Main Gearbox Group Continued

For Training purpose only 4 of 51


3.2 MGB description
Hereinafter is described the MGB, type 3G.

As already mentioned before, the Main Gearbox has the primary functions to transmit the Power/Torque
coming from the two Engines to the Main Rotor Shaft (Mast), to the Tail Rotor Mast and to the Accessories
installed on the MGB.

The Power / Torque produced by each Engine is transmitted to the MGB by means of specific Engine Drive
Shaft (EDS) equipped with Flexible couplings connected to the MGB Input drive quills. Each engine rotate
clockwise at 21000 RPM (see Figure 1). The EDS and the Torque Tube is built in Steel Alloy.

The MGB that is 5 tilted forward, drives the Main Rotor Shaft (MAST) at 296.4 RPM (CCW), the Tail Rotor
Shaft (Mast) at 1435.7 (CCW) by means of the Tail Rotor Drive System (TRDS) that includes: 3 Shafts, the
Intermediate Gearbox (IGB) and the Tail Gearbox (TGB). Furthermore, the MGB drives some accessories at
the required speeds (see from Figure 1 to Figure 5).

The MGB reduces the engine output speed to the main rotor speed by means of three reduction stages (see
Figure 1):

First and Second stage of reduction is carried out by means of spiral bevel gears
Third stage of reduction is carried out by means of an epicyclical planetary gear

Each MGB input is provided with a freewheel unit, to override each engine drive in case of engine shut-down
or failure, allowing the rotor to be continuously driven by the remaining engine.

The MGB includes a Tail Rotor Take-OFF Pinion for the Tail Rotor Drive System (TRDS). The Housing of the
Tail Rotor Take-Off Pinion also provides the support for the Rotor Brake Actuator. The Brake Calliper is
attached to the Flange that is bolted to the Main Case assembly of the MGB. The drive Flange for the Tail
Rotor Drive Shaft also permits the attachment of the Rotor Brake Disc (see Figure 2).

For Training purpose only 5 of 51


3.2 MGB description (Continued)

The MGB can drive the following components (see Figure 3):
The Front Hydraulic Pump drive pinion, driven by the Collector Gear,
The ECS Compressor drive pinion, driven by the Collector Gear,
Left and Right Lubrication Pump drive pinion, driven by the Collector Gear,
Two AC Generators (optional) drive pinions, driven by the relevant Input Pinion 2^ stage of
reduction,
The Fan Cooling drive pinion, driven by the Tail Rotor Take-Off Pinion,
Left and Right Hydraulic Pump drive pinion, driven by the relevant Input Pinion 2^ stage of
reduction.

The MGB is pressure lubricated and includes a lubrication and cooling system; all the oil ducts are cored in
the MGB housings.
The lubrication and cooling system is composed by (see Figures 4a, 4b and 4c):
Two Positive Displacement Pumps (Gerotor type).
Two Pressure Relief Valves (PRV).
Two Check Valves.
An Oil Filter provided of a Disposable Filter, a By-pass Valve, an Impending bypass indicator (Pop-out)
with the relevant caution alarm switch.
An Oil Cooler and Cooling Fan.
29 oil Jets (17 located in the Main Case, 4 located in the Upper Module and 4 on each Input Shaft
Module).
An oil Level Gauge and a Low Level Sensor located on the Main Case.
An oil Filler Plug.
An oil Pressure Senor, oil Temperature Sensor and an oil Temperature Switch located on the Filter
Housing .
Two Low Pressure Switch (one located on each Input Shaft Module).
Three Chip detectors (2 located in lower side of the Main Case and 1 located on the Upper Module).

For Training purpose only 6 of 51


3.2 MGB description (Continued)

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

One Rotor Speed Sensor (NR) located on the Main Case.


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

For Training purpose only 7 of 51


3.2 MGB description (Continued)

1435.7 rpm (CCW)


296.4 rpm (CCW)

Mast-Planetary Assy
Gimbal Crosshead Torque Tube

3^ stage of reduction TGB

Engine No. 2

T.R. Drive Quill Assy


IGB
RB
TRDS
Engine Drive Shaft
Input Shaft Module

Engine No.1 Crosshead


connected to
the Gimbal

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)

Engine Drive Shaft


Fig. 1 - Drive system (EDS)

For Training purpose only 8 of 51


3.2 MGB description (Continued)

Rotor
Brake
Flange
Case

Fig. 2 Rotor Brake Assy


For Training purpose only 9 of 51
3.2 MGB description (Continued)

Collector Gear
(1355 rpm)
Fan Drive Quill
Front Hyd. Pump (16014 rpm)
Drive Quill
(7732 rpm)

Tail Rotor Take-Off


Pinion (4532 rpm)

ECS Compressor
Drive Quill (4868 rpm)

AC Gen. Drive LH / RH Hyd. Pump LH / RH Lubrication


Quill (12050 rpm) Drive Quills (9111 rpm) Pump (7302 rpm)

Input Pinion 2^ stage of


reduction (6917.6 rpm)
Fig. 3 Components driven by the MGB

For Training purpose only 10 of 51


3.2 MGB description (Continued)

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

OIL TEMPERATURE SWITCH

OIL TEMPERATURE SENSOR

OIL PRESSURE SENSOR

RH HYD. PUMP
drive quill

UPPER FITTING

TAIL ROTOR DRIVE


QUILL Assy
LH HYD. PUMP drive quill
AC GENERATOR LH INPUT SHAFT MODULE
drive quill SUMP CHIP DETECTORS
OIL LOW LEVEL SWITCH
UPPER MODULE
ECS COMP. drive quill
FRONT HYD. PUMP
Drive quill

OIL LEVEL GAUGE AC GENERATOR MAIN CASE


drive quill ANTI-TORQUE BEAM

For Training purpose only 11 of 51


3.2 MGB description (Continued)

Oil
Filter

PRV

CHECK
VALVES

LUB.
PUMPS

SUMP CHIP
DETECTORS

Fig. 4.b Lubrication System - Components and Sensors location


For Training purpose only 12 of 51
3.2 MGB description (Continued)

N11
N6 N12 N7
N10
N9

N3 N3

N 16
N16 N5
N8 N4
N4

N13
N15 N14

Notes

In the MGB are installed 29 Oil Jets:


- 17 oil jets in the Main Case
- 4 oil jets in the Upper Module
- 3 oil jets in each Input Shaft Module (6 total)
- 1 oil jet in each Cover of each Input Shaft Module (2 total)

Fig. 4.c Lubrication System - Components and Sensors location

For Training purpose only 13 of 51


3.2 MGB description (Continued)

FWD

Fig. 5 Mounts and Attachments

For Training purpose only 14 of 51


3.3 Mechanical assembly description

The Main Gearbox is a set of Cases which are the housings of the gears of the reduction / transmission
stages, the accessories and the other components of the main gearbox.
It is a three stages reduction gearbox.
The Main Gearbox drives the Main rotor mast, the accessories and the Tail rotor mast (and the rotor brake)
through the Tail Rotor drive quill, 3 drive shafts, an IGB and a TGB.

The Cases (made of Aluminium Alloy) of the MGB are (see Figure 1):

The two Input Shaft Modules (left input shaft module and right input shaft module)
The Main Case (*)
The Upper Module.

(*) A Bottom Cover (Al. Alloy) and an Anti-Torque Beam (Al. Alloy) are connected to the lower side of the
Main Case by means of Studs.

The Primary Internal Assy of the main gearbox are:

The Input Pinion and the Bevel Gear of the Left and Right Input Shaft Modules (first stage of reduction)
The Input Pinions and the Collector Gear of the Main Case (second stage of reduction) and the
Diaphragm.
The Mast-Planetary Gear and the Fixed Ring Gear located in the Upper module (third stage of reduction).

Through 3 reduction stages , the Main Rotor Mast will rotates (CCW) at about 296 rpm.

For Training purpose only 15 of 51


3.3 - Mechanical assembly description (continued)
The drive quills installed in the Main Case are (see figure 1):

the Front Hyd. Pump drive quill


the Left / Right Hyd. Pumps drive quills
the ECS Compressor drive quill
the Fan drive quill
the Tail Rotor drive quill.
the A/C Generators drive quills (optional)

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

For Training purpose only 16 of 51


3.3 - Mechanical assembly description (continued)

A/C GENERATORS
drive quills

Collector Gear (Sun gear, in view)


Planetary

MAIN CASE

Input Pinion

Bottom
Cover

Fig. 1 MGB Cases and Drive Quills

For Training purpose only 17 of 51


3.3.1 - Left and Right Input Shaft Module description

There are two Input Shaft Modules installed on the main gearbox, the left input shaft module and the right
input shaft module.
The two input shaft modules are interchangeable, because they have the same shape, configuration and
components.
The left and the right input shaft modules are installed on the related side of the main gearbox (studs).
The primary components of each module are (see Figure 2 and 3):

the Housing and the Cover


the Gimbal
the Input Flange
the Input Pinion Assy,
the Bevel Gear, I Stage of reduction
the Freewheel Unit .

The Housing is made of Aluminium alloy and contains the components that turn (first reduction stage).
The Gimbal has the function to hold the crosshead and the torque tube connected to the engine and is
attached to the housing with eight washers and nuts.
The Input Flange receives the torque from the Engine Drive Shaft and transmits it to the Input Pinion. The
input flange has internal splines and is installed on the splined end of the input pinion. Between the Input
Pinion and the Bevel Gear there is the first stage of reduction.
A duplex ball bearing and a roller bearing hold the input pinion and let it turn, the input pinion engages the
gear that is held in position by a ball bearing and a roller bearing.
Three oil jets are installed in each housing of the Input Shaft Module. They lubricates the pinion, the gear
and the related bearings. Furthermore, another Oil jet is installed in each Cover of each Input Shaft Module.
The freewheel unit is of the "sprag" type and the centrifugal force operates it. It is installed between the gear
and the input shaft. The freewheel has two ball bearings that hold it and let it turn. The freewheel is
lubricated through an oil jet part of the cover. (see Figure 3).
A Low Pressure switch and a Bearing Thermocouple is installed on each Input Shaft Module.
For Training purpose only 18 of 51
3.3.1 - Left and Right Input Shaft Module description (Continued)

Left Input
Shaft Module

Housing Oil Housing


Jet
Cover
Low Oil Pressure
Switch

Oil Jet
Cover
Gear, I Stage
of reduction

Input
Flange

Bearing
Thermocouple

Input
Pinion
Gimbal
Freewheel Assy
Unit

Figure 2 - Input Shaft Module


For Training purpose only 19 of 51
3.3.1 - Left and Right Input Shaft Module description (Continued)

Input Pinion (II Stage


of reduction), part of the
Main Case.

(I Stage of reduction)

EDS

Input shaft

Figure 3 Freewheel unit


For Training purpose only 20 of 51
3.3.2 - Upper Module description

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

the Top case,


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

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

These sensors / components are installed on the Upper Module (see Figure 5):

the mast chip detector,


the oil cooler adapter,
the oil temperature switch, the oil temperature sensor, the oil pressure sensor, the Pop-out and oil filter
caution alarm switch,
four oil jets,
the oil filler cap.

For Training purpose only 21 of 51


3.3.2 - Upper Module description (Continued)

Top Case

Upper
Module
Assembly

Mast-Planetary
assembly

5 Planetary
Gears Assy

Packing

Planetary Crown
(Fixed Ring Gear)

Figure 4 Upper module

For Training purpose only 22 of 51


3.3.2 - Upper Module description (Continued)

Ts Ps
Tsw
Lightning
Conductor Jumper

Pop-Out +
Caution alarm Oil Filter Head
Switch

Upper Fittings (4)


2 Oil Jets No. 1
A B
2 Oil Jets No. 2
C D
Oil Filler cap Screw +
Mast Chip
detector washer

Oil jet
filter
Oil Jets No. 1
and No. 2
Oil Cooler adapter
O-ring (Oil Filter case)
O-ring
O-ring

Figure 5 Upper module (sensors /components )

For Training purpose only 23 of 51


3.3.3 - Hydraulic Pumps drive quills description

Three Hyd. pump drive quills are installed in the main gearbox.
One is installed in the left side of the main case, the second is installed in the right side, in symmetrical
position while the third drive quill is installed in the front of the main case. Each of them drives one
(hydraulic) pump.

The Front pump is driven by the Collector gear while, the LH and RH pumps are driven by the relevant Input
Pinion II stage of reduction.

The drive quills are shown on Figure attached.

For Training purpose only 24 of 51


3.3.3 - Hydraulic Pumps drive quills description (continued)

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

Screw (2) FRONT Hyd. Pump


Drive Quill

Figure 6 Hyd. Pump drive quills

For Training purpose only 25 of 51


3.3.4 - ECS compressor drive quill description

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

C
Screw (3)

O-ring

Shim

ECS -
Compressor
Drive Quill
Screw (2)
Setscrew (3)

Figure 7 ECS Compressor drive quill

For Training purpose only 26 of 51


3.3.5 - FAN drive quill description

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

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

Figure 8 Fan drive quill

For Training purpose only 27 of 51


3.3.6 - Tail-rotor drive quill description

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

For Training purpose only 28 of 51


3.3.6 - Tail-rotor drive quill description (continued)

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

Shim Nipple Retaining ring


Screw Locking washer
Flanged
bearing Locking ring
Gear
Shim
Retaining ring
Locking washer
Locking ring
Bearing inner
race (roller)
Plug O-ring
Pinion

Bearing cage

Plug
Figure 9 Tail-Rotor drive quill Figure 1 Tail-Rotor drive quill Pinion

For Training purpose only 29 of 51


3.4 - Lubrication system description
3.4.1 - General -
The AB/AW139 MGB lubrication system is based on the wet sump concept. With this concept, the lower
part of the MGB perform also the function of oil tank whereby the pressure pumps suck the oil for
feeding the delivery circuit.
Note:

The "dry sump" concept where the gearbox sump is maintained virtually dry by means of a scavenge pump(s) sending all the oil to a separate
oil tank, normally placed upward from which the pressure pump(s) suck the oil for feeding the distribution system.
The "wet sump" concept where the scavenge pump(s) and the external tank is eliminated leaving only the pressure pump(s) and the gearbox
housing serves also as a tank.

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

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

For Training purpose only 30 of 51


3.4.1 General (continued)

The sump is obtained in the bottom of the MGB and is designed to contain about 18 litres of oil (MIL-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.

For Training purpose only 31 of 51


3.4.1 General (continued)

MAST CHIP DETECTOR T> 109C

Oil cooler By-pass


Valve (Therm. / Diff.
Pressure)

P < 3.1 Bar P < 3.1 Bar

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

SUMP CHIP DETECTOR

SUMP CHIP DETECTOR

Figure 1 Lubrication system schematic


For Training purpose only 32 of 51
3.4.2 - Chip Detection Operation

The chip detector senses the unwanted ferrous particles contained in the lubricating oil of the gearbox.
The sensor is a magnet with a coil around it, this coil is electrically connected to the circuit in the sensor.

The magnetic force of the magnet pulls the ferrous particles to the magnet. When the particles go
through the magnetic field, they change the properties of the signal of the coil. The electronic circuit of
the sensor amplifies this signal and sends it to the MAU 1 and MAU 2 (Modular Avionics Units) of the
vehicle monitoring system.

If the metallic particles have a diameter lower than 0.05 mm (0.0019685 in), they can be burned by
pressing the CHIP BURNER switch on the miscellaneous control panel. See Figure 2.

For Training purpose only 33 of 51


3.4.2 - Chip Detection Operation (continued)

Figure 2 Chip Detection Operation

For Training purpose only 34 of 51


3.4.3 - Pumps

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

Figure 3 Gerotor pump

The basic pump characteristics are as follows :

Inlet pressure pi =47.5 kPa (approximately).


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

For Training purpose only 35 of 51


3.4.4 - Pressure Regulation

Each pump delivery duct is provided with its own Pressure Relief Valve (PRV) which maintain the required
constant pressure inside the circuit. These valves are of the spring actuated poppet type and can easily be
adjusted at MGB acceptance testing in order to provide a gearbox with the most appropriate system
pressure.
The pressure relief valve, also called pressure regulating valve, is set at:

Outlet pressure =700 kPa (7 Bar)

However the valve is capable of being adjusted over a range allowing correct pressure regulation of the
system.
After the pressure relief valves, the Check Valves are placed. Their purpose is to exclude the oil backflow in
case of pump malfunction or blockage. In fact if one pump fails, the other pump will provide more flow to the
system and the flow will be prevented to go back to the sump through the failed pump by means of the check
valves.
The check valves are of the full flow poppet type giving very little flow resistance (about 1 kPa)
during normal operation.

After the check valves the two branches of the oil system are joined together before entering the Oil Filter.
At this stage the total system flow should have been reduced (by means of the pressure relief valves) to
about:

Flow Q=70 liters/min (NOMINAL)

Giving ample regulation margins during development and testing.

For Training purpose only 36 of 51


3.4.5 - Oil Filter

The oil filter is provided with a bypass valve excluding the filter in case of clogging of the filter element.
Before opening the bypass, an electrical sensor will provide advance information that the filter is being
clogged and that will be bypassed.

The by-pass opens at p=17028 kPa (1.7 Bar)


The impending bypass alarm switch actuates at p=12514 kPa (1.25 Bar)
Clean filter assembly pressure drop p=38 kPa (0.38 bar)

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.

For Training purpose only 37 of 51


3.4.6 - Oil Cooler

After having been filtered, the oil is delivered to the oil-air heat exchanger also called the oil cooler.
The oil cooler is simply connected to the above filter housing assembly avoiding the need of external pipes
or fittings as normally required by different, more conventional designs.

The oil cooler is provided with a by-pass valves which actuates in case of both high differential pressure
and low oil temperature :

The by-pass opens at p=190 kPa (NOMINAL) (1.9 Bar)


The by-pass opens at T < +80 2C.

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.

For Training purpose only 38 of 51


3.4.7 - Sensors and Jets

At the outlet of the fan the following sensors are fitted :

Oil pressure sensor


Oil temperature sensor
Oil temperature switch (actuation point T > 109C)
Oil low pressure switch (actuation point P < 3.1 Bar)

The oil is subsequently delivered to the several points of the MGB, where, by means of dedicated nozzles,
it is directed to all the lubrication points.
The oil nozzles (total: 29 Oil Jets) are of peculiar design having the following important characteristics (see
Figure 4):

Aluminum alloy construction


Removable screen filter
Each and every nozzle can be removed from the outside

Furthermore, in the system, on each Input Shaft Module a Bearing Thermocouple is installed near to
duplex ball bearing of the Input Drive Quill.

For Training purpose only 39 of 51


3.4.7 - Sensors and Jets (continued)
Oil Jet Screen
N11
N6 N12 N7 Filter
N10
N9

N3 N3

Example of Oil Jet

N 16
N16 N5
N8 N4
N4

N13
N15 N14

Notes

In the MGB are installed 29 Oil Jets:


- 17 oil jets in the Main Case
- 4 oil jets in the Upper Module
- 3 oil jets in each Input Shaft Module (6 total)
- 1 oil jet in each Cover of each Input Shaft Module (2 total)

Figure 4 Oil Jets

For Training purpose only 40 of 51


3.5 - Leading Particulars

(LH/RH)

(FRONT)

(TQ: 100% +100%)

(TQ: 110% +110%)

(TQ: 140%)

(TQ: 160%)
(18 Liters)

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


- in OEI condition the Maximum transient (5 sec) TO is 176%

For Training purpose only 41 of 51


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

The Miscellaneous Panel provides the following function:

CHIP BURNER: ........................ when pressed a burning attempt


for the MGB CHIP MAST or MGB
CHIP SUMP is performed.

NOTE

If the MGB CHIP MAST or MGB CHIP SUMP cautions illuminate when
MGB OIL PRESS warning is illuminated the CHIP BURNER must not be activated.

The Test Control Panel provides the following function:

MGB OIL LEVEL


Push button test switch: ..... when pressed the caution MGB
OIL LOW in inverse video is
displayed in the CAS window.

NOTE

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

For Training purpose only 42 of 51


3.6 - Controls and Indications (continued)

For Training purpose only 43 of 51


3.7 - Warning, Caution Messages and Indications

MGB OIL PRESS Oil pressure below limits at one or both MGB
inputs and in MGB oil system (less than 3.1 Bar)
MGB OIL TEMP MGB Oil temp is above 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 MAST Debris is detected on the Mast Chip Detector

MGB CHIP SUMP Debris is detected in one of the two Sump Chip
Detectors
CHIP MAST FAIL 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 FILTER Differential pressure exceeds 1.25 bar

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

1 (2) BRG TEMP MGB - Engine 1 (2) Input stage bearing temp is
above 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.

XMNS OVTQ During AEO TQ1>110% or TQ2>110%.


During OEI TQ >160%

CHIP DET UNIT Chip Detector Power Unit does not respond on
Power-up Test and Continuous BIT
CHIP DET TEST Chip Detector Power Unit responds on manual test.
Caution will be displayed when test switch on CDPU is
pressed and all is normal.
For Training purpose only 45 of 51
3.7 - Warning, Caution Messages and Indications (continued)

Note

For Training purpose only 46 of 51


3.7 - Warning, Caution Messages and Indications (continued)

For Training purpose only 47 of 51


3.7 - Warning, Caution Messages and Indications (continued)

COMPOSITE FORMAT

For Training purpose only 48 of 51


3.8 - Components that must be removed from the MGB before its overhaul

In order to remove the Main Gearbox group from the helicopter it is necessary to follow the instructions
reported on AMP 39-A-63-20-00-00A-520A-A.
In particular, the following preliminary actions are required:

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

Then

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

For Training purpose only 49 of 51


3.8 - Components that must be removed from the MGB before its overhaul
(continued)

- Remove the Crossheads from their Gimbals


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

Then these remaining parts from the MGB:

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

For Training purpose only 50 of 51


Chapter 3 MGB Genaral information

THE END

RETURN TO LESSON SUMMARY RETURN TO COURSE MENU


For Training purpose only 51 of 51
MAIN TRANSMISSION GEARBOX
(MGB) REPAIR & OVERHAUL
TECHNICIAN TRAINING
Chapter 4 - General Procedures
4 General Procedures

INDEX

4.1 Introduction
4.2 A/C Publications
4.3 AMPI A/C Maintenance Publication Information
4.4 Limits

For Training purpose only 2 of 8


4.1 - Introduction

Before describing the procedure of disassembling of the MGB it is


important to know the Retirement lives, the Discard time of the
MGB components and the Overhaul intervals of the MGB and
where it is possible to find them in the IETP.
In this section will be shown the Publications, the Data Modules
and the Limits involved.
The information reported hereafter are relevant to MGB P/N:

3G6320A00132 or
3G6320A00133 or
3G6320A00134 or
3G6320A00135

NOTE

All information reported hereinafter must be considered for


Training purpose only

For Training purpose only 3 of 8


4.2 - Aircraft Publications

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

For Training purpose only 4 of 8


4.3 - AMPI - Maintenance Planning Information

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.

For Training purpose only 5 of 8


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

MGB Overhaul intervals (EASA)

AMPI (EASA), Data Module Ref Component Part number Overhaul interval

39-A-05-12-00-00A-000A-A CO63-01 Main gearbox assembly 3G6320A00132 5000 FH (*)


Component overhaul Note:
schedule General The overhaul interval is
extended to 6000 FH if
the retromod P/N
3G6306P01511 is
applied to the MGB,
independently from the
date of its application. (*)
39-A-05-12-00-00A-000A-A CO63-05 Lubricating pump 3G6320V04252 2500 FH (*)
Component overhaul
schedule General
39-A-05-12-00-00A-000A-A CO63-09 Lubricating pump 3G6320A18731 2500 FH (*)
Component overhaul
schedule General

MGB Discard time (EASA)

AMPI (EASA), Data Module Ref Component Part number Discard time

39-A-05-13-00-00A-000A-A DT63-03 MGB Gimbal support 3K6320A01131 46000 FH (*)


Discard time schedule assembly
General

(*): Refer to AMPI for further and more detailed information.

For Training purpose only 6 of 8


4.4 Limits (Part 2)

MGB Retirement lives (EASA)

AMPI (EASA), Data Module Ref Part Part number Retirement life

39-A-04-10-00-00A-000A-A RL021 MGB Case, Top 3G6320A01033 8800 FH or 23000


Retirement lives - General Assembly landings whichever
comes first (*)
MGB Case, Top 3G6320A01035 17000 FH (*)
Assembly
39-A-04-10-00-00A-000A-A RL022 MGB Shaft, Main Rotor 3G6320A01852 15300 FH or 54000
Retirement lives - General landings whichever
comes first (*)
39-A-04-10-00-00A-000A-A RL023 MGB Case, Main 3G6320A02734 5000 FH or 27000
Retirement lives - General Assembly landings whichever
comes first (*)
MGB Case, Main 3G6320A02736 10000 FH or 77500
Assembly landings whichever
comes first (*)
39-A-04-10-00-00A-000A-A RL024 MGB Upper Fitting 3G6330A00232 95800 landings (*)
Retirement lives - General
39-A-04-10-00-00A-000A-A RL025 MGB Antitorque Beam 3G6330A00532 20000 FH or 63000
Retirement lives - General landings whichever
comes first (*)

(*): Refer to AMPI for further and more detailed information.

For Training purpose only 7 of 8


Chapter 4 - General Procedures

THE END

RETURN TO LESSON SUMMARY RETURN TO COURSE MENU


For Training purpose only 8 of 8
MAIN TRANSMISSION GEARBOX
(MGB) REPAIR & OVERHAUL
TECHNICIAN TRAINING
Chapter 5 - Pre-Disassembly
Procedures
5 Pre-Disassembly Procedures

INDEX

5.1 Safety Information


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

For Training purpose only 2 of 12


5.1 Safety Information

Dangerous materials

Every time you use a dangerous material make sure you know the related safety precautions and
first aid instructions.
For more data refer to:
The label of the material container
The manufacturer safety data sheet
The local safety regulations.
Refer to CR&OP data module 39-A-60-50-00-00A-074A-C.

Critical parts

Critical parts are those parts the failure of which during ground or flight operations can have
catastrophic effects on the helicopter.
Refer to AMP data module 39-A-00-60-00-00A-010A-A.

Note

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

(Conts)

For Training purpose only 3 of 12


5.2 - Pre-disassembly Requirements

1. Refer to CR&OP: 39-A-63-20-05-00A-531A-C (Main gearbox General guidelines for disassemble


procedures)
2. Make sure that the work area is clean.
3. Install the main gearbox on the Trolley (main gearbox support).

Support equipment: Nomenclature Identification No.

Trolley, main gearbox transport HE-04-00, or


3G6320A00131A188B, or
3G6320A00331A188E, or equivalent

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.

Supplies: Nomenclature Identification No Specification references Ref. Documents

Cloth, soft lint-free C011 None (AMDI) 39-A-00-50-00-10A-078A-D


Cleaning solvent C010 P-D-680 type II (AMDI) 39-A-00-50-00-09A-078A-D

(Conts)

For Training purpose only 4 of 12


5.2 - Pre-disassembly Requirements

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

For Training purpose only 5 of 12


5.3 - MGB Drain oil and Draining Pipe removal procedures

CR&OP Data Module:

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

Support Equipments:

Nomenclature Identification No.


(Filler Cap +
Breather) Trolley, main gearbox 3G6320A00131A188B
support
Adapters kit, helicopter 3G1205G00131
servicing
(Oil Filler
Neck) Hose, MGB oil draining 3G1205G00332
A
Pump, MGB oil draining E1224/30-40

Container Local supply

Draining Pipe
removal-
CR&OP Data Module:
(Coupling Half)

39-A-63-20-05-00A-530A-C
(Drain Cap) Main gearbox - Disassemble
procedures.

For Training purpose only 6 of 12


5.4 - Anti-Torque Beam & Bottom Cover, removal procedures

CR&OP Data Module:

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

Support Equipments:
Nomenclature Identification No.

M/R Shaft (MAST) Lifting tool, main 3G6320A00131A181A


gearbox
Lifting device Local supply

MGB Assembly
Note:

During this procedure, obey the general guidelines applicable to the


disassemble procedures. Refer to 39-A-63-20-05-00A-531A-C.
Before to remove the Anti-torque Beam and the Bottom Cover from the
MGB Main case, it is necessary to disconnect the MGB assembly from its
Trolley Support .

Bottom Cover
Anti-Torque Beam

Trolley, main gearbox HE-04-00, or


transport 3G6320A00131A188B, or
3G6320A00331A188E, or
equivalent

For Training purpose only 7 of 12


5.4.1 - Anti-Torque Beam, removal procedures

CR&OP Data Module:


39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures.
Upper Module Support Equipments:
Nomenclature Identification No.
MGB
Lifting tool, 3G6320A00131A181A
main gearbox
Main Case
Lifting device Local supply

Standard
Screw
Extractors

Anti-Torque Beam removed,


Main Case Stud detail
RH
Main Case

RH

Anti-Torque Beam
Nylon Screw LH

Nylon Screw (x 2)

Washers + LH
Washers
Nut (x 23) + Nut

Anti-Torque beam, looking from the bottom view

For Training purpose only 8 of 12


5.4.2 - Bottom Cover , removal procedures

CR&OP Data Module:


39-A-63-20-05-00A-530A-C
Support Equipments:

Nomenclature Identification No.

Main Case
Lifting tool, main 3G6320A00131A181A
gearbox
Lifting device Local supply

O-ring Bottom Cover


Extractor, drive 3G6320A00331A029G removed
quill
O-ring

Bottom
Cover

Nylon
Screw Washers
(x 3) O-ring + Nut
(x 13)
Slip ring

Retaining ring

Bottom Cover

For Training purpose only 9 of 12


5.4.3 - Retaining ring and Slip ring, removal procedures

CR&OP Data Module:


39-A-63-20-05-00A-530A-C
Support Equipments:

Nomenclature Identification No.

Extractor tool, 3G6320A00331A023R


retaining ring
Removal tool, 3G6320A00331A023Q
slip ring
O-ring

O-ring

Bottom Cover

Nylon
Screw Washers
(x 3) O-ring + Nut
(x 13)
Slip ring

Retaining ring

For Training purpose only 10 of 12


5.5 - Installation of the Main Case on the Support Trolley

CR&OP Data Module:


39-A-63-20-05-00A-530A-C
Support Equipments:

Main Case
Assembly Nomenclature Identification No.

Trolley, main case maintenance 3G6320A00131A188C

Main Case
Assembly
Support

Maintenance
Trolley

Side View Front View

For Training purpose only 11 of 12


Chapter 5 - Pre-Disassembly Procedures

THE END

RETURN TO LESSON SUMMARY RETURN TO COURSE MENU


For Training purpose only 12 of 12
MAIN TRANSMISSION GEARBOX
(MGB) REPAIR & OVERHAUL
TECHNICIAN TRAINING
Chapter 6 - Disassembly
Procedures
6 MGB Disassembly Procedures

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)

For Training purpose only 2 of 126


6 MGB, Disassembly 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. 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.

For Training purpose only 3 of 126


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

Notes: The removal procedure used for LH Input Module is also applicable
for RH Input Module.
Support Equipments: Std Screw Extractors

Main Case

O-ring

Plug

Cross Shaft

LH Input Shaft Module

Union
Washers
Washers
Cross Shaft Nuts
Washers
O-rings
Bracket
Washers
Nuts NutsWashers
Washers
Bracket
+ Nuts
Bracket Set screw (Nylon)

For Training purpose only 4 of 126


6.1.1 - LH and RH Cross Shaft, disassembly procedures

CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
Cross Shaft
Support Equipments: Std Tools

Plug

Input Shaft
Module Input Shaft Module Plug
(inner side)

For Training purpose only 5 of 126


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

Engine 2 Inlet
(Drive Shaft) Details

A Input Shaft Module (1 & 2)


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

CR&OP Data Module:


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

For Training purpose only 6 of 126


6.2 Detail B - (No. 1 & No. 2 Hyd. Pump drive quill), external
components removal

CR&OP Data Module:


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

B
Components removed:
B
- Nylon Screws (2 positions)
- Plug
Nylon Screw

Front Side

Hydraulic Pump Drive Quill

Plug

For Training purpose only 7 of 126


6.2 Detail C - (ECS Compressor drive quill), external components
removal

CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures.
Seal Lip
Cover Seal 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:

Nomenclature Identification No.

Removal tool, seal cover 3G6320A00731A029E

Extractor tool, lip seal 3G6320A00731A029D

Front Side

For Training purpose only 8 of 126


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

CR&OP Data Module:

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

Components removed:
D - Plug
- Nylon Screw (2 positions)
Hydraulic Pump Drive Quill Nylon Screw

Plug

Front Side

For Training purpose only 9 of 126


6.2 Detail E - AC Generator Drive Cover, Shim and Plug removal

CR&OP Data Module:

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

Support Equipments:
E

E Nomenclature Identification No.

Extractor tool, generator 3G6320A00132A029A


drive cover

Screw Shim
O-ring

Nut,
Washers

AC
O-ring
Generator
Drive Cover
Plug

Front Side

For Training purpose only 10 of 126


6.2 Detail F - Oil Level gauge removal

CR&OP Data Module:

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

Oil level gauge disassembled

Oil level
Gauge

Nuts + Washers

Front View, LH side

For Training purpose only 11 of 126


6.2 Detail G - Oil filter head, Oil Filter Element, Anti-spill Valve, Oil
press. Sensor, Oil Temp. Sensor and Oil Temp. Switch removal
References:
Oil Pressure sensor CR&OP: 39-A-63-20-05-29A-520A-C Oil filter element (main gearbox) - Remove procedures
AMP: 39-A-63-41-05-00A-920A-A Oil temperature sensor Replacement
AMP: 39-A-63-41-06-00A-920A-A Oil pressure sensor - Replacement
AMP: 39-A-63-41-07-00A-920A-A Oil temperature switch - Replacement

Oil Temp. sensor


Components removed:

- Oil Filter Head


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

OUT Oil
IN Cooler
Pop-Out + Caution
alarm Switch

Ts Ps
Tsw

Oil Filter Head

For Training purpose only 12 of 126


6.2 Detail H - Low Oil Level Sensor removal

CR&OP Data Module:

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

Low Oil Level Sensor

Front View, RH side


For Training purpose only 13 of 126
6.2 Detail J - Plugs removal

CR&OP Data Module:

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

Plug

Plug

For Training purpose only 14 of 126


6.2 Detail K - Rotor Speed Sensor (NR) removal

K CR&OP Data Module:

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

Washer
Nut

Rotor Speed Sensor

Front View, LH side

For Training purpose only 15 of 126


6.2 Details L, M, N - Front Servo Support, Left Servo Support and
Right Servo Support removal

CR&OP Data Module:


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

M Nomenclature Identification No.


Support Equipments:
Extractor tool, servo 3G6320A00331A029N
L support

Screw + Washer(4)

Front Servo
L L
Support L
Setscrew (2)

LH Servo RH Servo
M Support Support N L

For Training purpose only 16 of 126


6.2 Detail O - Borescope Port removal

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

Screws

Borescope Port

Rear View, LH side

For Training purpose only 17 of 126


6.2 Detail P - Check Valves removal

CR&OP Data Module:


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

P P

Check Valve Plug


O-ring Rear View
P
O-ring
Check Valve

Retaining ring

For Training purpose only 18 of 126


6.2 Detail Q - Pressure Relief Valves removal

CR&OP Data Module:


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

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

CR&OP Data Module:


R
39-A-63-20-05-00A-530A-C Main gearbox -
Chip Detector
Disassemble procedures.
O-ring

Chip Detector Valve

O-ring

Chip Detector
Chip Detector Valve

Rear View
R R

For Training purpose only 20 of 126


6.2 Details S, T - Washers, Screws and Flange removal

CR&OP Data Module:


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

S
S
Flange
S T

Rear View LH side Rear View RH side


Nylon Screw
S Nut
T Flange
Flange
O-ring
Washer
+ Screw
Washer
S
Washer S S

Rear View Rear View LH side Rear View RH side

For Training purpose only 21 of 126


6.2 Detail U - LH and RH Lubrication Pump removal

CR&OP Data Module:


39-A-63-20-05-00A-530A-C Main gearbox -
Disassemble procedures.
U
Nomenclature Identification No.
Support Equipments:
Extractor, drive quill 3G6320A00331A029G

Rear View
RH Lubrication Pump removal
Washers + Nut

Nylon Screw (3)

O-rings Lub. Pump

Rear View RH Lubrication Pump


Extractor tool installation

Rear View LH Lubrication Pump Rear View RH Lubrication Pump

For Training purpose only 22 of 126


6.2 Detail V - (Fan Drive quill), external components removal

CR&OP Data Module:


V
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures.
Components removed:

- Plug
- Seal Cover

Support Equipments:

Nomenclature Identification No.

Extractor tool, seal cover 3G6320A00331A029L

Rear View

For Training purpose only 23 of 126


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

Support Equipments:
Top View Nomenclature Identification No.

applicable plastic Local supply


scraper

Oil Jets Oil Jets


Filter Filter

O-ring O-ring
Screw
Screw
+
+
Washer
Washer
Rear View

O-ring
O-ring
O-ring O-ring
O-ring

For Training purpose only 24 of 126


6.4 - Upper Module, Oil Unions and Fixed ring Gear Assy removal

Oil Union CR&OP Data Module:


A (x4) D Upper Module
Assy 39-A-63-20-05-00A-530A-C
Oil Union C
B Main gearbox - Disassemble
procedures.
B

Support Equipments:
A / A1

Nylon Screw (x 3) Nomenclature Identification No.

Planetary Lifting tool, main 3G6320A00131A181A


Crown gearbox
Main Case Side View (Fixed Ring Lifting device Local supply
Gear)
Details Trolley, upper module 3G6320A00231A188B
A / A1 B support
Nut
Nut
Washer Washer
Bracket Bracket

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

1 pos. 22 pos.

Top View

For Training purpose only 25 of 126


6.4.1 - Oil Unions removal

CR&OP Data Module:


Planetary
Crown 39-A-63-20-05-00A-530A-C
(Fixed Ring Main gearbox - Disassemble
Oil Union Gear)
procedures.
A (x4)
Support Equipments:
Oil Union
B
Nomenclature Identification No.

Extractor tool, oil union 3G6320A00131A029A


A

A
A

Main Case

A
A

Oil Union
(5 positions)

For Training purpose only 26 of 126


6.4.2 - Planetary Crown (Fixed Ring Gear) removal

Planetary Crown Planetary Crown


(external view) (Removal)

Collector Gear

Diaphragm

Tool installation
Planetary Crown
(inner view)

Support Equipments

Nomenclature Identification No.

Lifting device Local supply

Disassembly tool, 3G6320A00231A029F


planetary crown

For Training purpose only 27 of 126


6.5 - Main Case, Backlash check

Backlash check required


RH Input Pinion II
Stage Check of the backlash CR&OP Data Module:
between:
Collector Gear and the Input 39-A-63-20-05-00A-713A-C
Collector Gear Pinions (LH/RH) II Stage Main gearbox - Backlash/gear

Hyd. Pump Main Case pattern check, Para. 2


Fan Drive Quill
No. 2 Collector Gear and Tail-Rotor 39-A-63-20-05-00A-713A-C
Tail-Rotor Drive Quill Main gearbox - Backlash/gear
Drive Quill pattern check, Para. 3

Collector Gear and ECS- 39-A-63-20-05-00A-713A-C


Compressor Drive Quill Main gearbox - Backlash/gear
pattern check, Para. 4

Hyd. Pump Collector Gear and Front Hyd. 39-A-63-20-05-00A-713A-C


No. 1 Pump Drive Quill Main gearbox - Backlash/gear
pattern check, Para. 5

Left/Right Input Pinion II Stage 39-A-63-20-05-00A-713A-C


ECS and Left/Right Pump Drive Quill Main gearbox - Backlash/gear
Compressor (Hyd. Pump No. 1 & No. 2) pattern check, Para. 6
Drive Quill
Tail-Rotor Drive Quill and Fan 39-A-63-20-05-00A-713A-C
Drive Quill Main gearbox - Backlash/gear
pattern check, Para. 7

LH Input Pinion II
Front Hyd. Pump Stage

For Training purpose only 28 of 126


6.5.1 - Main Case, Backlash tool (Collector gear) installation

CR&OP Data Module: Nomenclature Identification No.

39-A-63-20-05-00A-713A-C Backlash tool, 3G6320A00331A676L


collector gear
Main gearbox - Backlash/gear
pattern check, Para. 1 Dial gauge Local supply

Support Equipments: Legend:


Item No. Nomenclature

1 Dial Gauge Support (3)

2 Tool Top section

3 Knobs (4)

4 Bolt

5 Nylon Split Ring

6 Bolts (4)

7 Registers (2)

8 Retainers

9 Bolts (2)

10 Wrench (Torque application


point)
11 Expander

12 Tool Bottom Section

13 Torque application point

14 Collector Gear

For Training purpose only 29 of 126


6.5.2 - MGB (Collector gear) Top Tool Section installation

1 7

Register
Expander,
installation

Wrench

2
Retainer
Tool Top
Section,
installation

Nylon Split
Ring Bolts

5
4

Collector
Gear

Knobs

For Training purpose only 30 of 126


6.5.3 MGB, (Collector gear) Tool Bottom Section installation

10

For Training purpose only 31 of 126


6.5.4 MGB, Backlash tool (Collector gear), torque wrench
application and Collector Gear levelness check
Top Section 11 13
Bolts
Register
(2 positions)

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:

Push the tool bottom section


up as required.

For Training purpose only 32 of 126


6.5.5 - Backlash check between the Collector Gear and the Input pinions

CR&OP Data Module:


39-A-63-20-05-00A-713A-C Main gearbox -
Input Pinion
Backlash/gear pattern check, Para. 2
Support Equipments:
Nomenclature Identification No.

Backlash tool, input pinions 3G6320A00331A676B


Dial gauge Local supply

Note:

- Lock the tool expander.


Input Pinion
Backlash Tool - Pull the input pinion externally as required.
installation - Measure and record the backlash in three
positions, 120 apart.
- Perform this action on both Input pinions.

LH Input Pinion II Stage, RH Input Pinion II Stage,


Backlash Backlash
Tool installation Tool installation

For Training purpose only 33 of 126


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

Tail Rotor Drive Quill,


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

Nomenclature Identification No.

Backlash tool, tail rotor 3G6320A00331A676C


drive quill
Dial gauge Local supply

Output Pinion Tail Rotor


Drive Quill
Note:

- Lock the tool expander.


- Push the pinion internally as required.
- Measure and record the backlash in three
positions, 120 apart.

For Training purpose only 34 of 126


6.5.7 - Backlash check between the Collector Gear and the ECS-Compressor Drive
Quill

CR&OP Data Module:


ECS Compressor 39-A-63-20-05-00A-713A-C
Drive Quill
Main gearbox - Backlash/gear
pattern check, Para. 4

Support Equipments:

Nomenclature Identification No.

Backlash tool, ECS- 3G6320A00331A676E


compressor drive quill
ECS Compressor
Drive Quill, Dial gauge Local supply
Backlash Tool
installation
Note:
- Lock the tool expander.
- Push the pinion internally as required.
- Measure and record the backlash in three
positions, 120 apart.

For Training purpose only 35 of 126


6.5.8 - Backlash check between the Collector Gear and the Front Hyd.
Pump drive quill

CR&OP Data Module:

Front Hyd. Pump 39-A-63-20-05-00A-713A-C


Drive Quill
Main gearbox - Backlash/gear
pattern check, Para. 5

Support Equipments:

Nomenclature Identification No.

Backlash tool, front 3G6320A00331A676H


Front Hyd. Pump,
pump drive quill
Backlash Tool
installation Dial gauge Local supply

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

For Training purpose only 36 of 126


6.5.9 - Backlash check between the Left/Right Input Pinion II Stage and
the Left/Right Pump (Hyd. Pump No. 1 & No. 2) Drive Quill

CR&OP Data Module:


39-A-63-20-05-00A-713A-C Main gearbox -
Backlash/gear pattern check, Para. 6
Support Equipments:
Left/Right Pump
Nomenclature Identification No.
(Hyd. Pump No. 1
and No. 2)
Drive Quill,
Backlash tool, left and right pump drive quill 3G6320A00331A676D
Backlash Tool Dial gauge Local supply

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.

Left Pump (Hyd. Right Pump (Hyd.


Pump No. 1) Pump No. 2)
Drive Quill Drive Quill

For Training purpose only 37 of 126


6.5.10 - Backlash check between the Tail-Rotor Drive Quill and the Fan Drive
Quill

CR&OP Data Module:


39-A-63-20-05-00A-713A-C Main gearbox -
Backlash/gear pattern check, Para. 7
Support Equipments:

Nomenclature Identification No.

Backlash tool, fan drive quill 3G6320A00331A676F

Dial gauge Local supply

Fan Drive Quill,


Backlash Tool Note:
- Lock the tool expander.
- Pull the pinion externally as required.
Fan Drive Quill - Measure and record the backlash in
three positions, 120 apart.

For Training purpose only 38 of 126


6.6 - Drive Quills (Hyd. Pumps, ECS- Compressor and Fan) removal

Engine 2 Inlet
(Drive Shaft) Details

B - LH/RH Hydraulic Pump Drive Quills


C - ECS Compressor Drive Quill
D - Front Hydraulic Pump Drive Quill
V - Fan Drive Quill

Engine 1 Inlet
(Drive Shaft)
CR&OP Data Module:

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

For Training purpose only 39 of 126


6.6.1 - Hydraulic Pump (No. 1 & No. 2) Drive Quill removal

CR&OP Data Module:


39-A-63-20-05-00A-530A-C
B
Main gearbox - Disassemble procedures
B
Screw (2)
Nylon Support equipment:
Screw (2)
Hyd. Pump Nomenclature Identification No. Shim
B Drive Quill Extractor, drive quill 3G6320A00331A029G

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

CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures.
C
Screw (3)
Support equipment:

O-ring
Nomenclature Identification No.

C Extractor, drive quill 3G6320A00331A029G

Shim

Screw (2)
ECS- Compressor
Setscrew (3) Drive Quill

Extractors
installation

For Training purpose only 41 of 126


6.6.3 - Front Hyd. Pump Drive Quill removal

CR&OP Data Module:

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

Support equipment:
Shim
Screw (3) Nomenclature Identification No.

Extractor, drive quill 3G6320A00331A029G


D
Setscrew
(2)

O-ring

Screw (2) Hyd. Pump


Drive Quill

Extractors
installation

For Training purpose only 42 of 126


6.6.4 - Fan Drive Quill removal

CR&OP Data Module:


V
39-A-63-20-05-00A-530A-C
Nut, Main gearbox - Disassemble procedures
Washer
(3)
Seal-Cover Support equipment:
O-ring
Lip-Seal Nomenclature Identification No.
V Extractor, drive quill 3G6320A00331A029G
Screw
Shim
Fan Drive
Quill

1 2

For Training purpose only 43 of 126


6.6.5 - Drive Quills removed

LH Hyd. RH Hyd. Front Hyd. ECS- Compressor Fan


Pump Pump Pump Drive Quill Drive Quill
Drive Quill Drive Quill Drive Quill

For Training purpose only 44 of 126


6.7 - LH & RH Input Pinion Assembly (II Stage of reduction),
removal

CR&OP Data Module:


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

Bearing Support equipment:


Sleeve
V incision Main Case Nomenclature Identification No.

Extractor, input pinions 3G6320A00331A029F


O-ring Input Pinion II
Stage

Bearings 1
Spacer
Pump
Nuts, Washers gear
Pump Retaining Ring
(parts to be
removed) gear
Retaining Locking Ring
Ring Locking
Washer Nuts, Washers

Input Pinion Assembly


installed inside the Main Case
(RH Side)

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

CR&OP Data Module:


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

Bearing Support equipment:


Sleeve
V incision Main Case Nomenclature Identification No.

Installation tool, input 3G6320A00331A023W


O-ring
Input Pinion II pinions
Stage Removal tool, pump gear 3G6320A00331A029R
Bearings
Spacer Removal tool, pinion 3G6320A00331A029O

Removal tool, bearings 3G6320A00331A029P


Nuts, Washers
Pump Retaining Ring
gear
Retaining Locking Ring Note
Ring
Locking
Washer Details of the Input Pinion Assembly
disassembled are available on the next
page.

For Training purpose only 46 of 126


6.8.1 - Details of the Input Pinion Assy disassembled

Inner side of External side


the Pinion of the Pinion

O-ring

Bearings
Input Pinion II Bearing Input Pinion II
Stage Sleeve Stage

Spacers

Pump
gear

Retaining Ring

For Training purpose only 47 of 126


6.9 - Tail-Rotor Drive Quill Assembly, removal

CR&OP Data Module:


39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
Nut + Washer
Nylon Screw (8)
(3)
Support equipment:

Rotor Nomenclature Identification No.


Main Brake
Case Housing Trolley, main case 3G6320A00131A188C
maintenance
Lifting device Local supply
Tail Rotor Drive
Quill Assembly Extractor, tail rotor drive 3G6320A00331A029I
quill
2
Lifting tool, pinion 3G6320A00331A026M
assembly

TRDQ
Main Case Tools Assembly
rotated installation removed

For Training purpose only 48 of 126


6.10 - Tail-Rotor Drive Quill Assembly, disassembly procedures

CR&OP Data Module:


39-A-63-20-05-28A-530A-C Tail
rotor drive quill (main gearbox) -
Disassemble procedures
Retaining ring
Locking washer
Support equipment:
Locking ring
Ring Nomenclature Identification No.
Flange
Nut + Retaining ring Reaction tool, pinion 3G6320A00331A023Z
Washer
O-rings Seal case
Extractor tool, locking 3G6320A00431A029C
Seal
washer
Rotor brake case
O-ring Wrench 3G6320A00331A026F

Shim Nipple Retaining ring Removal tool, flange 3G6320A00331A028A


Screw Locking washer
Flanged
bearing Locking ring Removal tool, seal cover 3G6320A00331A029Y
(spherical) O-rings Gear
Shim Extractor tool, lip seal 3G6320A00331A029W
Retaining ring
Locking washer
Removal tool, rotor brake 3G6320A00331A029U
case
Locking ring
Bearing inner Removal tool, flanged 3G6320A00331A029V
race (roller) bearing
Plug O-ring Wrench 3G6320A00331A026B
Pinion

Removal tool, gear 3G6320A00331A029T


Bearing cage

Wrench 3G6320A00331A026A
Plug
Pinion Removal tool, bearing 3G6320A00331A029S

For Training purpose only 49 of 126


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

STEP 1

Put the Tail-Rotor Drive Quill on the


Reaction Tool attached to an applicable
work table.

Support equipment:

Nomenclature Identification No.

Reaction tool, pinion 3G6320A00331A023Z

For Training purpose only 50 of 126


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

Pinion STEPS 2 7

2 - Remove the Retaining Ring (1) from the


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

Removal Tool
(3G6320A00331A028A)
Detail A Detail B
Detail C

For Training purpose only 51 of 126


6.10.3 - Tail-Rotor Drive Quill Ass. , disassembly procedures Steps 8 13

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)

Detail D Detail E Detail F

For Training purpose only 52 of 126


6.10.4 - Tail-Rotor Drive Quill Ass. , disassembly procedures Steps 14 16

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

Rotor brake case


O-ring Removal Tool
(G6320A00331A029V)
Shim Nipple
Screw
Flanged
bearing
(spherical)

Detail G

For Training purpose only 53 of 126


6.10.5 - Tail-Rotor Drive Quill Ass. , disassembly procedures Steps 17 20

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)

Detail H Detail I Detail J

For Training purpose only 54 of 126


6.10.6 -Tail-Rotor Drive Quill Ass., disassembly procedures Steps 21 26

STEPS 21 26
21 - (Main gearbox P/N 3G6320A00132). Remove the
Bearing Inner Race (28) from the Pinion (30) as
follows:

21.1 Remove the Retaining Ring (23) and the Locking


O-rings Washer (24) from the Pinion (30). Use the Extractor
Tool No. 3G6320A00431A029C (see Detail K).
Retaining ring 21.2 Remove the Locking Ring (25) from the pinion
Locking washer (30). Use the Wrench No. 3G6320A00331A026A (see
Locking ring Detail L).
Bearing inner
21.3 Remove the Bearing Inner Race (28) from the
race (roller) Pinion (30). Use the Removal Tool No.
Plug
3G6320A00331A029S (see Detail M).
Pinion O-ring 21.4 Remove the Pinion (30) from the Reaction Tool.
Bearing cage
Plug
22 (Main gearboxes P/N 3G6320A00133 and
subsequent P/N with different last two digits). Remove
the Bearing Cage (28A) from the pinion (30A).
23 Remove the O-rings (31) and (32) from the pinion
Pinion (30) or (30A).

(3G6320A00431A029C) 24 (Main gearbox P/N 3G6320A00132). Remove the


Tool Plug (29) from the Pinion (30).
(G6320A00331A026A)
25 (Main gearboxes P/N 3G6320A00133 and
subsequent P/N with different last two digits). Remove
the Plug (29A) from the Pinion (30A).
26 (Main gearboxes P/N 3G6320A00133 and
subsequent P/N with different last two digits). Remove
the O-ring (33) from the Plug (29A).

Removal Tool
(3G6320A00331A029S)
Detail K Detail L
Detail M

For Training purpose only 55 of 126


6.11 - Diaphragm, Oil Jets and Roller Bearing removal
Nuts,
Washers
Screws (14) CR&OP Data Module:
Diaphragm
39-A-63-20-05-00A-530A-C Main
Roller Bearing gearbox - Disassemble procedures.
Bolts

Collector Gear

Oil Jets pre-mod.


Support equipment:

Nomenclature Identification No.

Extractor Tool 3G6320A00331A029I

Extractor tool, roller bearing 3G6320A00331A029A

Oil Jets post-mod.

For Training purpose only 56 of 126


6.11.1 - Diaphragm removal

1a Screws (14)

Diaphragm
3

Oil Jets pre-mod.

Roller Bearing

Collector Gear

1b
Diaphragm removed
from the Main Case
2

Oil Jets post-mod.

Extractor Tool
installation

For Training purpose only 57 of 126


6.11.2 Oil Jets removal

Diaphragm

Oil Jets pre-mod.

Oil Jets post-mod.

For Training purpose only 58 of 126


6.11.3 Roller Bearing removal
(A) Diaphragm +
Roller Bearing
Diaphragm

Roller
Bearing

(B) Roller bearing removed


Nuts,
Washers Upper side

Extractor tool, roller bearing


(3G6320A00331A029A)

For Training purpose only 59 of 126


6.12 - Collector Gear removal

CR&OP Data Module:


Collector Gear 39-A-63-20-05-00A-530A-C Main
gearbox - Disassemble procedures
Bolts Collector Bearing
Support equipment:
Locking Ring
Locking Washer Nomenclature Identification No.
(B) Note:
Retaining Ring
Retaining Ring installed Removal tool, collector 3G6320A00331A029E
on MGB gear
P/N 3G6320A00135 only
Lifting device Local supply

Collector Gear
3
2
Retaining Ring Main Case
Washers
Nuts
1

For Training purpose only 60 of 126


6.12.1 - Collector Bearing and Retaining Ring removal

CR&OP Data Module:


Collector Gear
39-A-63-20-05-00A-530A-C Main
gearbox - Disassemble
Collector procedures.
Main Case
Bolts Bearing
Support equipment:
Locking Ring
Locking Washer
(B) Note:
Retaining Ring Nomenclature Identification No.
Retaining Ring installed
on MGB Lifting tool, collector gear 3G6320A00331A181C
P/N 3G6320A00135 only

Lifting device Local supply

Removal tool, Locking ring 3G6320A00331A023D


Collector Gear
Removal tool, collector 3G6320A00331A023C
Retaining Ring bearing
Washers
Nuts Hydraulic cylinder Local supply

For Training purpose only 61 of 126


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

Removal tool, Locking ring 3G6320A00331A023D Removal tool, collector 3G6320A00331A023C


bearing

For Training purpose only 62 of 126


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

Nuts + Screws CR&OP Data Module:


Shim Washers
Shim
Screws
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble
procedures. (Roller bearing
4 188), (Shim 193) and (Shim
Shim (187) 187).
Roller Support equipment:
Bearing

Nomenclature Identification No.

Extractor tool, 3G6320A00331A029C


roller bearing

Note:
1 Roller Record the thickness of the shim
Bearing
(188)
2 3

Shim
(193)

Input Pinions II Stage,


installation side Shim (193)
Roller Bearing, removal
For Training purpose only 63 of 126
6.13 - Main Case Ass., Internal Components removal Step 2

Main Screws CR&OP Data Module: Support equipment:


Case Nuts + 39-A-63-20-05-00A-530A-C
Washers
Main gearbox - Disassemble Nomenclature Identification No.
procedures.
Extractor tool, 3G6320A00331A029D
outer race roller
bearing

Screws Shim

2 Screws
Outer Race of the
roller bearing

Tail Rotor
Drive Quill Nuts +
1 location Washers

Shim
Main Case
external view

Note:

Screws Record the thickness of the shim


Main Case Main Case
internal view external view
For Training purpose only 64 of 126
6.13 - Main Case Ass., Internal Components removal Step 3

A
Screws

Shim
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Hyd. Pump
Main gearbox - Disassemble
(No.1 and No.2) procedures.
drive quill
location
Note:

Record the thickness of the shim

For Training purpose only 65 of 126


6.13 - Main Case Ass., Internal Components removal Step 4

Fan drive quill


A CR&OP Data Module:
location Screws

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

Note:

Record the thickness of the shim

For Training purpose only 66 of 126


6.13 - Main Case Ass., Internal Components removal Step 5

CR&OP Data Module:


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

Note:

Record the thickness of the shim


ECS drive quill
location

For Training purpose only 67 of 126


6.13 - Main Case Ass., Internal Components removal Step 6

CR&OP Data Module:


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

Note:

Record the thickness of the shim

AC Generator
drive covers
location

For Training purpose only 68 of 126


6.13 - Main Case Ass., Internal Components removal Step 7

CR&OP Data Module:

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

Note:

Record the thickness of the shim


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

For Training purpose only 69 of 126


6.14 - LH and RH Input Shaft Module, disassembly procedures
Ref. documentations
Engine 2 Inlet
(Drive Shaft) CR&OP Data Module:
Right input
shaft module 39-A-63-20-05-01A-530A-C Left input shaft
module (main gearbox) - Disassemble
procedures (Effectivity Code: B01)

Engine 1 Inlet
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.

For Training purpose only 70 of 126


6.15 - Freewheel Group Assy, removal and disassembly procedures
Action No. 1 : Install the Input Module on the applicable Stand
LH Input Shaft
Module CR&OP Data Module:
Thermocouple
39-A-63-20-05-01A-530A-C Left input
Freewheel shaft module (main gearbox) -
Disassemble procedures.
Group

Support equipment:

Nomenclature Identification No.


Oil Pressure
Switch Stand, backlash check 3K6320A00131A676A

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

CR&OP Data Module:

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

Support equipment:

Nomenclature Identification No.


Oil Jets
Plastic scraper Local supply

Supplies:

Nomenclature Identification No.

Cloth, soft lint free C011


Oil Jet
Cover Solvent, cleaning C010 (P-D-680 type II)

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

For Training purpose only 72 of 126


6.15 - Freewheel Group Assy, removal and disassembly procedures
Action No. 3 : Oil Jets, Thermocouple and Oil Pressure Switch removal
Screw + Washer
LH Input Shaft
Module CR&OP Data Module:
Thermocouple

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

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:

Nomenclature Identification No.

Jackscrew, MGB 3G6005G00531

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

Oil Jet
Cover Nuts +
Washers

1 2 3

For Training purpose only 74 of 126


6.15 - Freewheel Group Assy, removal and disassembly procedures
Action No. 5 : Freewheel Group removed and disassembled
Note
LH Input Shaft CR&OP Data Module: Perform this action on both Input Shaft Modules.
Module
Freewheel Use the specific Data Module
39-A-63-20-05-01A-530A-C
Group
Left input shaft module (main gearbox) - Disassemble
Inner Bearing procedures.
Oil Vane
Input Shaft Support equipment:
Freewheel
Outer Bearing Nomenclature Identification No.
O-ring
Spacer Tool, clutch removal 3K6320A00131A029D
O-ring
Tool, inner/outer bearing 3K6320A00131A029G
removal
Arbor press Local supply
Retaining ring

Freewheel Group
disassembled

For Training purpose only 75 of 126


6.16 - Input shaft module Backlash check

Left Input CR&OP Data Module:


Shaft Module
39-A-63-20-05-01A-713A-C
Left input shaft module (main gearbox) -
Backlash/gear pattern check
Note

Perform this action on both Input Shaft Modules.


Use the specific Data Module.
Gear, I Stage Record the backlash found between the Input Pinion and the Gear.
of reduction
Support equipment:

Flange Nomenclature Identification No.

Stand, backlash check 3K6320A00131A676A

Stopper, gear 3K6320A00131A023L

Backlash tool, input drive quill 3K6320A00131A676B

Dial gauge Local supply


Input
Pinion

For Training purpose only 76 of 126


6.16.1 Input shaft module (main gearbox) Backlash check, Procedures

Left Input Shaft Procedure:


A
A Module (1),
Input side 1 - Put the left input module (1) on the Stand.
2 - Install the Gear Stopper on the Stand.
3 - Lock the gear (2) in the left input module (1) with the Stopper.
4 - Install the Backlash Tool on the input side of the left input module (1).
Stand 5 - Lock the Backlash Tool to the flange (3).
(3K6320A00131A676A) 6 - Do a check of the backlash between the gear (2) and the input pinion (4) as
follows as required. Perform in phases, first by pulling and turning the Input pinion
and second by pushing and turning the Input pinion.

Stopper, gear Note


(3K6320A00131A023L) Measure these value in three position at 120 to each other. Calculate for each
condition the average value and then record these values are required.
B Backlash tool, installation
Note
(3K6320A00131A676B) Perform this action on both Input Shaft Modules.
Use the specific Data Module
Flange (3)

C D

Gear, 1 Stage
of reduction (2)

Input
Pinion
(4)

Flange Dial gauge,


(3) installation Backlash check

For Training purpose only 77 of 126


6.17 - Input shaft module, Input Drive-Quill Group removal

CR&OP Data Module:


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

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:

Duplex Ball Nomenclature Identification No.


Bearing
Heat gun Local supply
+
Washers
Nuts
Plug Nuts Jackscrew, MGB 3G6005G00531
Retaining
Gimbal Spring
Input Drive-
O-ring
Quill Group
O-ring Locknut removal
Carbon
Seal Flange
LH Input Shaft Bushings
Module Ring Note
O-ring
Fitting Use the Heat Gun and
increase the temperature
Carbon Seal (6070C) of the LH Input
Module locally in the
housing area of the Input
Pinion.
Spacer

For Training purpose only 78 of 126


6.18 - Input drive-quill group - Disassembly procedures
Action No. 1: Locknut, Flange, Gimbal, Bushing, Carbon Seal Assy removal
Bushings
A Locknut CR&OP Data Module:
(already Plug Retaining
removed) Spring
Gimbal
O-ring 39-A-63-20-05-01A-530A-C
Left input shaft module (main
O-ring Locknut gearbox) - Disassemble procedures.
Carbon
Seal Flange
Support Equipment:
Ring Bushings
Gimbal Flange Retaining Spring
Nomenclature Identification No.
O-ring Reaction, locknut removal 3K6320A00131A023F
Fitting
Wrench 3K6320A00131A023P

Pinion Tool, pinion support 3K6320A00131A023B


Mating Ring
Tool, flange removal 3K6320A00131A029E
Bearing Sleeve

Spacer Tool, Gimbal removal 3K6320A00131A029F

Tool, carbon seal removal 3K6320A00131A023T


B Note
Perform this action on both Input Shaft Modules. Tool, bushing removal EA6305G630-041
Use the specific Data Module
Puller, mating ring GJ-06-01
C
D E Pinion

Locknut
removal

Bearing
Gimbal Sleeve
removal Carbon Seal
removal Ring removal

For Training purpose only 79 of 126


6.18 - Input drive-quill group - Disassembly procedures
Action No. 2: Bushings removal

CR&OP Data Module:

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

Support Equipment:

Nomenclature Identification No.

Tool, bushing removal EA6305G630-041

For Training purpose only 80 of 126


6.18 - Input drive-quill group - Disassembly procedures
Action No. 3: Pinion, Duplex Ball Bearing and Bearing Sleeve disassembly
CR&OP Data Module:
Two 39-A-63-20-05-01A-530A-C
Keys Left input shaft module (main gearbox) - Disassemble
procedures.
Plug
Pinion Duplex Ball
Support Equipment:
Bearing
Nomenclature Identification No.
Bearing Sleeve
O-ring Tool, bearing sleeve removal 3K6320A00131A029B

Arbor press Local supply

1 Bearing race removal 3K6320A00131A029A

Bearing Sleeve + Bearings

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

For Training purpose only 81 of 126


6.18 - Input drive-quill group - Disassembly procedures
Action No. 4: Roller Bearing Removal

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:

Nomenclature Identification No.

Tool, roller bearing removal 3K6320A00131A029M

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

Left Input Shaft Module, Input side

For Training purpose only 82 of 126


6.18 - Input shaft module
Action No. 5 : Shim (input side) removal

CR&OP Data Module:

Shim Screw 39-A-63-20-05-01A-530A-C


Left input shaft module (main
gearbox) - Disassemble procedures.

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

LH Input Shaft
Module

For Training purpose only 83 of 126


6.19 - Input Shaft Module Gear (I Stage of reduction).
Removal and disassembly procedures
Bolts + Washers
Flanged Roller
Bearing Diaphragm
CR&OP Data Module:
Bolts
39-A-63-20-05-01A-530A-C
Left input shaft module (main
gearbox) - Disassemble procedures
Oil dam

Nuts +
O-ring
Washers
Support Equipment:

Nomenclature Identification No.

Gear, 1 Stage Diaphragm, standard extractor Locally supply


of reduction
Nuts + Reaction, lock nut removal 3K6320A00131A023H
Washers (see next page)
Wrench 3K6320A00131A023I
(see next page)
Pusher 3K6320A00131A029C

Tool, gear support 3K6320A00131A023D

Flanged Ball Puller, oil dam 3K6320H02331


Shim
Bearing

Bolts Note
Perform this action on both Input Shaft Modules.
Screws Lock ring Use the specific Data Module
Lock nut

For Training purpose only 84 of 126


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

For Training purpose only 85 of 126


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

6 7 Flanged ball Bearing 12


1

Gear
Tools installation, Shim
Lock nut removal Lock ring & Lock nut removed
Diaphragm Assembly removal

2 Bearing
5
8
11

Gear, 1 Stage of reduction Outer Race of the


Lock ring Lock nut Gear, 1 Stage of reduction
looking from the base of the ISM Flanged Bearing

3 9 10
4

Diaphragm & Bearing removed Roller Bearing removal


Oil dam & O-ring removed from the Gear
For Training purpose only 86 of 126
6.20 - Upper Module, disassembly procedures
(Main Components)

CR&OP Data Module:


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

Mast-Planetary
assembly

Note

Planetary Crown (Fixed


Ring Gear) already
removed.

Packing

Planetary Crown
(Fixed Ring Gear)

For Training purpose only 87 of 126


6.20 - Upper Module, disassembly procedures
Action No. 1: Make sure that Upper Module is installed on the Support

CR&OP Data Module:

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

Support equipment:

Nomenclature Identification No.

Support trolley 3G6320A00231A188B

For Training purpose only 88 of 126


6.20 - Upper Module, disassembly procedures
Action No. 2: Ident. Plate, Cond. Jumper, Mast Cover removal

CR&OP Data Module:


Mast Cover
39-A-63-20-05-03A-530A-C
Packing Upper module (main gearbox) -
Disassemble procedures.
Upper
Module Mast-Planetary
Identification assembly Support equipment:
plate

Nomenclature Identification No.

Blade, sharp (for Id. Plate) Local supply

Extractor (For Mast Cover) 3G6320A00231A029E

Lifting tool (Upper fittings ) 3G6320A00231A181B

Lifting tool (Gear Ring) 3G6320A00131A181A

Lifting device Local supply


Lightning
Conductor Jumper Work trolley 3G6320A00231A188A

Supplies:

Nomenclature Identification No.


Cloth, soft lint free C011
Upper Fittings (4)
Solvent, cleaning C010 (P-D-680 type II)

For Training purpose only 89 of 126


6.20 - Upper Module, disassembly procedures
Action No. 3: Chip Detector Valve and Oil Filler Neck removal

CR&OP Data Module:

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

Oil Filler plug

Chip Detector O-ring

Oil Filler Neck


O-ring O-ring
Chip Det. Valve
O-ring

Oil drain cup

For Training purpose only 90 of 126


6.20 - Upper Module, disassembly procedures
Action No. 4: Four Oil Jets removal

CR&OP Data Module:

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

2 Oil Jets No. 1


A B
2 Oil Jets No. 2
C D
Screw +
washer

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

For Training purpose only 91 of 126


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

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

Upper Cooler
Adapter
removed

A A B
Top Oil Duct
O-ring Nuts +
(q.ty 4)
Washers
(q.ty 5)
O-ring

Upper Cooler
Adapter

O-ring

Main Oil Duct (q.ty 1)


O-ring
Rear View Side View

For Training purpose only 92 of 126


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

Mast-Planetary
assembly CR&OP Data Module:

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

Support equipment:

Nomenclature Identification No.

Removal tool, lip seal 3G6320A00231A029C


Nylon Screw A
(Q.ty 2)
Nuts +
Washers
Seal Cover +
Lip Seal
O-ring

O-ring
Top Case

For Training purpose only 93 of 126


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

Nuts +
Washers CR&OP Data Module:
E

Roller 39-A-63-20-05-03A-530A-C Upper


Bearing Top Case
module (main gearbox) -
Disassemble procedures.
O-ring

Support equipment:

D
Nomenclature Identification No.
Mast-
Work trolley 3G6320A00231A188A
Planetary
Assembly Clamp 3G6320A00231A023M

Lifting tool, gear ring 3G6320A00231A181A


Ball Bearing
Lifting device Local supply
Planetary Gear
Assembly Removal tool, mast- 3G6320A00231A029A
planetary assembly
B Packing
Hydraulic jack Local supply
Nuts + C
Washers Lifting tool, mast- 3G6320A00231A181C
Ring Gear
planetary assembly

Work trolley, mast- 3G6320A07231A188A


planetary assembly
Note
Removal tool, roller 3G6320A00231A029B
Ring Gear already removed. bearing

For Training purpose only 94 of 126


6.20 - Upper Module, disassembly procedures
Action No. 7.2: Details A, B and C

A: Temporary
install two Nuts
and two Washers
(33,34) on the
Roller Bearing.
Note: in this photo
the seal cover is
yet installed.

View of the
Mast-Planetary
Assembly (4)
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

For Training purpose only 95 of 126


6.20 - Upper Module, disassembly procedures
Action No. 7.3: Detail D of the Mast-Planetary Assembly removed from the TOP Case

Work trolley 3G6320A00231A188A


Mast-
D1
Planetary Assembly,
installed on the
Work trolley

Mast-Planetary
Assembly, TOP Case
D5 inner view
lifting tool installation.

Lifting tool, mast- 3G6320A00231A181C D3


planetary assembly

D2

D4

Work trolley, 3G6320A07231A188A


Mast-Planetary mast-planetary
Assembly, removed assembly
from the TOP Case

For Training purpose only 96 of 126


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

Details A,B,C and D are relevant to the


Upper Fittings (Item 49)
CR&OP Data Module:

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

Top Case Support equipment:


Nomenclature Identification No.
Lifting device Local supply

Lifting tool, mast 3G6320A00231A181B

Work trolley 3G6320A00231A188A

Work bench Local supply


Bolts
Plastic scraper Local supply
Screw Washers Adapter, MGB upper 3G6305G10931
fitting removal
Brackets
Grease gun Local supply
Upper
Fitting
Note
Install the Adapter in the threaded hole of the
upper fitting (49).
Connect the Grease Gun filled with Grease to
the Adapter Tool (code C009: Aeroshell 22).
Operate the Grease Gun and slowly remove
the upper fitting (49) from the top case.
Do this action on each position.

For Training purpose only 97 of 126


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

5
3

For Training purpose only 98 of 126


6.21 - Mast-Planetary assembly, disassembly procedures
Action No. 1: Ret. springs removal from the Ring Nuts and inst. of the M-P Ass. on the React. tool

Retaining 1 CR&OP Data Module:


ring
Lock
39-A-63-20-05-13A-530A-C Mast-planetary
washer assembly (upper module) - Disassemble
Ring Nut
procedures.
Support equipment:
Ball
bearing Nomenclature Identification No.
Retaining springs
Work trolley 3G6320A07231A188A
Oil removal
collector Reaction tool 3G6320A07231A023E
2 Lifting tool 3G6320A00131A181A

Mast Lifting device Local supply

Bolts Work table Local supply


Lock
Retaining
washers
springs
Bushings
Ring nuts
Ring nut
Flange (upper view)
Planetary
Gear Assy. Pins

Spacers 3
Plate
Bushings
Pins
Lock washers
Bolts
4

For Training purpose only 99 of 126


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

For Training purpose only 100 of 126


6.21 - Mast-Planetary assembly, disassembly procedures
Action No. 3: Retaining ring (1) and Lock washer (2) removal from the Ring nut.

Retaining CR&OP Data Module:


ring
Lock
39-A-63-20-05-13A-530A-C Mast-planetary
washer assembly (upper module) - Disassemble
Ring Nut
procedures.
Retaining ring, Support equipment:
Ball removal
bearing Nomenclature Identification No.
1
Oil Work table Local supply
collector Reaction tool 3G6320A07231A023E

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

For Training purpose only 101 of 126


6.21 - Mast-Planetary assembly, disassembly procedures
Action No. 4: Ring nut (3) removal from the Mast.

Retaining CR&OP Data Module:


ring
Lock 39-A-63-20-05-13A-530A-C Mast-planetary
washer assembly (upper module) - Disassemble
Ring Nut
procedures.

Support equipment:
Ball
bearing Nomenclature Identification No.
Oil Work table Local supply
collector
Reaction tool 3G6320A07231A023E

Ring nut, 3G6320A07231A023G


Mast rem./inst. tool

Bolts Servo-multiplier Sweeney 8200


Lock Lifting tool 3G6320A00131A181A
Retaining
washers
springs Lifting device Local supply
Bushings
Ring nuts
Flange

Planetary
Pins
Gear Assy.

Spacers
Plate
Bushings
Pins
Lock washers
Bolts

For Training purpose only 102 of 126


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

1 6

Ring nut, rem./inst. tool


7
2 Ring Nut,
5
location

8 Ring Nut,
3 removed
4

Ball
bearing

Servo-multiplier

For Training purpose only 103 of 126


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

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

Mast Lifting device Local supply

Bolts Reaction tool 3G6320A07231A023D


assembly
Lock
Retaining (adapter, spacer)
washers
springs Removal tool 3G6320A07231A029C
Bushings
Ring nuts assembly

Flange Removal tool 3G6320A07231A023F


assembly (plunger)
Planetary Jack Enerpack RC-252
Gear Assy.
Pins

Spacers
Plate
Bushings
Pins
Lock washers
Bolts

For Training purpose only 104 of 126


6.21 - Mast-Planetary assembly, disassembly procedures
Action No. 7: Ball bearing (4) and Oil collector (5) removal, tools installation

(3G6320A07231A023D) (3G6320A07231A029C)
(3G6320A00131A181A)

(Enerpack RC-252)

(3G6320A07231A023F)
Ball
bearing

Oil
collector

Work Table
(3G6320A07231A023D)

For Training purpose only 105 of 126


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

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

For Training purpose only 106 of 126


6.21 - Mast-Planetary assembly, disassembly procedures
Action No. 9: Pins (17), Items 6 and Planetary gear assemblies (19) removal

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


Mast Lifting device Local supply
Bolts
Work trolley (turn the 3G6320A07231A188A
Lock
Retaining Mast 180)
washers
springs Bushing removal tool 3G6320A07131A023B
Bushings
Ring nuts
Planetary gear removal 3G6320A07131A029A
Flange tool

Planetary Jack (planetary gear RCH-121H


Gear Assy. Pins removal)

Spacers
Plate
Bushings
Pins
Lock washers
Bolts

For Training purpose only 107 of 126


6.21 - Mast-Planetary assembly, disassembly procedures
Action No. 10: Pins (17), Items 6 and Planetary gear assemblies (19), details

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

For Training purpose only 108 of 126


6.22 - Planetary gears assembly, disassembly procedures

CR&OP Data Module:

39-A-63-20-05-14A-530A-C
Planetary gear assembly
(mast planetary assembly) -
Disassemble procedures
Planetary Support equipment:
Gears Assy.
Nomenclature Identification No.

Rollers removal 3G6320A07231A029D


tool
Top-inner
bearing race Procedure
Roller cage
Put the planetary gear assembly (1) on an applicable work table.
Rollers

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.

Disassemble the planetary gear assembly (1). Obey the


Rollers instructions that follow:
Bottom-inner Roller cage
bearing race
- Remove the rollers (4), the top-inner bearing race (2) and the
roller cage (3) from the gear (5). Always keep these parts
together. Do not interchange the rollers (4) with the rollers (6).
- Remove the rollers (6), the bottom-inner bearing race (8) and
the roller cage (7) from the gear (5). Always keep these parts
together. Do not interchange the rollers (6) with the rollers (4).

For Training purpose only 109 of 126


6.22.1 - Planetary gears disassembled, details

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

For Training purpose only 110 of 126


6.23 - LH & RH Lubrication Pumps, disassembly procedures

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:

Nomenclature Identification No.

Retaining ring Reaction tool 3G6305G00931

Removal tool, lock washer 3G6305G01431

Wrench, ring nut 3G6305G01051

Lubrication
B Vice
pumps,
disassembled
Lock washer Ring Key Shaft
nut

C D E F G

For Training purpose only 111 of 126


6.24 - ECS Compressor drive quill, disassembly procedures
Action No. 1: Retaining ring and Locking washer removal

CR&OP Data Module:

39-A-63-20-05-05A-530A-C ECS compressor drive


quill (main gearbox) - Disassemble procedures.
Locking
ring Support equipment:
Pinion
ECS-compressor Nomenclature Identification No.
Case drive quill
Extractor tool, locking 3G6320A00431A029C
Flanged washer
bearing

Retaining Locking Nuts +


ring washer Washers

ECS-compressor
drive quill
Vice
Retaining
ring,
removal

For Training purpose only 112 of 126


6.24 - ECS Compressor drive quill, disassembly procedures
Action No. 2: remove the Locking ring from the Pinion

CR&OP Data Module:

39-A-63-20-05-05A-530A-C ECS compressor drive


Locking
quill (main gearbox) - Disassemble procedures.
ring
Pinion
Support equipment:

Case Nomenclature Identification No.


Flanged
bearing Removal/installation 3G6320A00731A023C
tool, locking ring
Retaining Locking Nuts +
ring washer Washers

Locking ring,
removal

For Training purpose only 113 of 126


6.24 - ECS Compressor drive quill, disassembly procedures
Action No. 3: remove the Pinion from the Case

CR&OP Data Module:

39-A-63-20-05-05A-530A-C ECS compressor drive


Locking quill (main gearbox) - Disassemble procedures.
ring
Pinion

Support equipment:
Case
Flanged
bearing Nomenclature Identification No.
Retaining Locking Nuts +
Removal tool, pinion 3G6320A00731A029B
ring washer Washers
Arbor press Local supply

IN OUT

For Training purpose only 114 of 126


6.24 - ECS Compressor drive quill, disassembly procedures
Action No. 4: remove the Flanged Bearing from the Case

CR&OP Data Module:

39-A-63-20-05-05A-530A-C ECS compressor drive


Locking quill (main gearbox) - Disassemble procedures.
ring
Pinion

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

For Training purpose only 115 of 126


6.25 - Fan drive quill, disassembly procedures
Action No. 1: Retaining ring and Locking Washer removal from the pinion

CR&OP Data Module:


Fan drive quill

39-A-63-20-05-07A-530A-C Fan drive quill (main


gearbox) - Disassemble procedures.

Support equipment:

Nomenclature Identification No.

Work table

Tightening tool 3G6320A00931A023B

Extractor tool, locking 3G6320A00431A029C


Pinion washer

Flanged
bearing

Locking
ring
Locking
Retaining washer
ring

Vice

For Training purpose only 116 of 126


6.25 - Fan drive quill, disassembly procedures
Act. No. 2: Locking Ring removal from the Pinion and Pinion removal from the Flanged bearing

CR&OP Data Module:


Fan drive quill

39-A-63-20-05-07A-530A-C Fan drive quill (main


gearbox) - Disassemble procedures.
Pinion

Flanged Support equipment:


bearing
Locking Nomenclature Identification No.
ring
Work table Local supply
Locking
washer Tightening tool, 3G6320A00931A023B
Retaining
ring
Tightening tool 3G6320A00931A023B
(wrench)

Removal tool, 3G6320A00931A029A


pinion

Arbor press Local supply

PINION
(REF.)

IN OUT

For Training purpose only 117 of 126


6.26 - Front Hyd. Pump Drive Quill, disassembly procedures

CR&OP Data Module:


Pinion
39-A-63-20-05-04A-530A-C Front pump drive
Pump
case quill (main gearbox) - Disassemble procedures

Support equipment:
Front Hyd. Plug
pump drive Nomenclature Identification No.
quill O-ring O-ring

Work table Local supply


Fitting
Removal tool, lip 3G6320A00431A029E
seal cover

Extractor tool, lip 3G6320A00431A029D


Flanged seal
bearing
Extractor tool, 3G6320A00431A029C
Washers + Nuts locking washer
Locking ring
Locking washer Removal/installa 3G6320A00531A023B
Retaining ring
tion tool, locking
ring
Packing
Removal tool, 3G6320A00531A029A
Lip seal pinion
Seal cover
Arbor press Local supply
Retaining ring

Removal tool, 3G6320A00431A029A


flanged bearing

For Training purpose only 118 of 126


6.26 - Front Hyd. Pump Drive Quill, disassembly procedures
Action No.1: Items 15,14,13,12,11,10 and 9 removal from the Pump Case

CR&OP Data Module:

Pinion
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


pump drive Work table Local supply
quill O-ring O-ring
Removal tool, lip 3G6320A00431A029E
seal cover
Fitting
Extractor tool, lip 3G6320A00431A029D
seal

Flanged
bearing

Washers + Nuts Pump


case
Locking ring
Locking washer
Retaining ring
Packing

Lip seal

Seal cover

Retaining ring

Seal cover

For Training purpose only 119 of 126


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

CR&OP Data Module:

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

For Training purpose only 120 of 126


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

CR&OP Data Module:

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

For Training purpose only 121 of 126


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

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:
Packing

Left/right pump Retaining ring Nomenclature Identification No.


drive quill (Hyd.
Locking washer
pump No.1 and Work table Local supply
N0.2 drive quill) Locking ring
Removal tool, lip 3G6320A00431A029E
seal cover
Flanged
bearing+ Extractor tool, lip 3G6320A00431A029D
Washers seal
and Nuts
Extractor tool, 3G6320A00431A029C
Plug
locking washer
O-ring O-ring
Removal/installa 3G6320A00431A023C
tion tool, locking
Fitting Pump
case
ring
Removal tool, 3G6320A00431A029B
pinion

Arbor press Local supply


Pinion

Removal tool, 3G6320A00431A029A


flanged bearing

For Training purpose only 122 of 126


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

Retaining ring
CR&OP Data Module:

39-A-63-20-05-27A-530A-C Left/right pump drive


Seal cover
quill (main gearbox) - Disassemble procedures.

Lip seal Support equipment:


Nomenclature Identification No.
Packing
Work table Local supply
Retaining ring
Removal tool, lip seal cover 3G6320A00431A029E
Locking washer

Locking ring Extractor tool, lip seal 3G6320A00431A029D

Flanged
bearing+
Washers
and Nuts

Plug

O-ring O-ring

Fitting Pump
case

Seal cover

Pinion

Pump
case

For Training purpose only 123 of 126


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

Retaining ring
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:

Nomenclature Identification No.


Packing

Retaining ring Work table and Vice Local supply

Locking washer Extractor tool, 3G6320A00431A029C


Locking ring
locking washer

Removal/installation 3G6320A00431A023C
Flanged tool, locking ring
bearing+ (Wrench)
Washers
and Nuts

Plug

O-ring O-ring

Fitting Pump
case

Pinion

For Training purpose only 124 of 126


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

Retaining ring
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:

Nomenclature Identification No.


Packing

Retaining ring Work table Local supply

Locking washer Removal tool, 3G6320A00431A029B


Locking ring
pinion

Arbor press Local supply


Flanged
bearing+
Washers Removal tool, 3G6320A00431A029A
and Nuts flanged bearing

Plug

O-ring O-ring
Pump
Pump case
Fitting
case

Pinion

For Training purpose only 125 of 126


Chapter 6 - Disassembly Procedures

THE END

RETURN TO LESSON SUMMARY RETURN TO COURSE MENU


For Training purpose only 126 of 126
MAIN TRANSMISSION GEARBOX
(MGB) REPAIR & OVERHAUL
TECHNICIAN TRAINING
Ch. 7: Components Cleaning, Paint
removal, Protection and
Inspection
7 Components Cleaning, Paint removal, Protection and Inspection

INDEX

7.1 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

7.26 Dimensions Check


7.27 Main gearbox Dimensions check
7.28 LH/RH Input Shaft Module Dimensions check
7.29 Upper Module Dimensions Check
7.30 Mast-Planetary Assembly Dimensions check
7.31 Planetary Gears Dimensions check
7.32 LH/RH Hyd. Pump Drive Quill Dimensions check
7.33 Front Hyd. Pump Drive Quill Dimensions check
7.34 ECS Compressor Drive Quill Dimensions check
7.35 Fan Drive Quill Dimension check
7.36 LH/RH Lubrication Pump Dimensions check
7.37 Tail Rotor Drive Quill Dimensions check
7.38 Dye Penetrant Examination
7.39 General guidelines for Dye Penetrant Examination
7.40 Main gearbox Dye Penetrant Examination
7.41 LH/RH Input Shaft Module Dye penetrant Examination
7.42 Upper Module Dye Penetrant Examination
7.43 Front Hyd. Pump Drive Quill Dye Penetrant Examination
7.44 ECS Compressor Drive Quill Dye Penetrant Examination
7.45 LH/RH Hyd. Pump Drive Quill Dye Penetrant Examination
7.46 Tail Rotor Drive Quill Dye Penetrant Examination

(Conts)

For Training purpose only 3 of 313


7 Components Cleaning, Paint removal, Protection and Inspection

7.47 Magnetic Particles Examination


7.48 General guidelines for Magnetic Particles Examination
7.49 Main gearbox Magnetic Particles Examination
7.50 LH/RH Input Shaft Module Magnetic Particles Examination
7.51 Upper Module Magnetic Particles Examination
7.52 Front Hyd. Pump Drive Quill Magnetic Particles Examination
7.53 ECS Compressor Drive Quill Magnetic Particles Examination
7.54 LH/RH Lubrication Pump Magnetic Particles Examination
7.55 Fan Drive Quill Magnetic Particles Examination
7.56 Mast-Planetary Assembly Magnetic Particles Examination
7.57 Planetary Gears Assembly Magnetic Particles Examination
7.58 LH/RH Hyd. Pump Drive Quill Magnetic Particles Examination
7.59 Tail Rotor Drive Quill Magnetic Particles Examination

For Training purpose only 4 of 313


7.1 - Introduction

Hereinafter will be shown:


Cleaning procedures

Paint removal with Abrasive blast and with Paint remover

Surface protection (after cleaning procedures)

Detailed Visual Examination (damage codes list, example of damages, procedures)

Surface finish protection restoration (on repaired area)

Dimensions Check

Dye Penetrant Inspection

Magnetic Inspection

NOTE

All information reported hereinafter must be considered for Training purpose only.
Refer to CR&OP as required

For Training purpose only 5 of 313


7.2 - Cleaning procedures

Clean the disassembled metal components of the MGB as required.


Refer to CR&OP: 39-A-60-10-01-00A-251A-C

Supplies

Nomenclature Identification No Specification references Ref. Documents

Solvent C133 ASTM D4080-00 (AMDI)


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

Safety conditions

WARNINGS

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

2. You must use rubber gloves when you move the components during cleaning.

CAUTION

After cleaning, do not touch the metal components with bare hands. Put on clean, lint-free
cotton gloves before you touch the metal components. Contamination from your bare hands
will cause corrosion of the metal components.

For Training purpose only 6 of 313


7.3 - Paint removal
- with abrasive blast

In order to remove the paint layer from the MGB metal components use the Blasting Equipment
(Schlick Stripmaster 4S or equivalent) and the Abrasive plastic (C280) equivalent to MIL-PRF-85891 A.
Refer to CR&OP: 39-A-60-10-01-00A-651A-C
WARNING

Make sure you obey all applicable precautions when you use the blasting equipment.
CAUTIONS

The procedure described in this Data Module is not permitted on:

Plated Aluminium surfaces.


Aluminium sheets less than 0.8 mm (0.03 in) thick, without an applicable support.
Composite material surfaces (tell the Manufacturer for an authorization).

Only approved personnel can use the Blasting Equipment and the procedure described in this Data
Module.
Procedure

The procedure described in this Data Module permit to remove all paint, sealing compound and
adhesive from the metal components.
When operates the blasting equipment observe the following notes:

Blast pressure: 2.8 bar (41 lbf/in)


Distance from the surface: 100 mm (4 in)
Angle of impact: 45 to 60
Dwell time: less than 1 second.

For Training purpose only 7 of 313


7.3 - Paint removal
- with paint remover

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

Supplies

Nomenclature Identification No Specification references Ref. Documents

Solvent C005 TT-M-261 (AMDI) 39-A-00-50-00-04A-078A-D

Paint remover C348 MIL-PRF-25134 (AMDI) 39-A-00-50-00-10D-078A-D


Paint remover C349 MIL-R-81294 Type I and II (AMDI) 39-A-00-50-00-11D-078A-D
Cleaner, alkaline C255 None (AMDI) 39-A-00-50-00-23C-078A-D

Oil, protective C256 None (AMDI) 39-A-00-50-00-24C-078A-D

Procedure

Refer to the instructions reported in the D.M.


Note

The Paint Removers must not be used on composite parts and adhesive bonded structures.

For Training purpose only 8 of 313


7.4 - Protection procedures

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

Supplies
Nomenclature Identification No Specification references Ref. Documents

Cloth, soft lint-free C011 None (AMDI) 39-A-00-50-00-10A-078A-D

Cleaning solvent C010 P-D-680 type II (AMDI) 39-A-00-50-00-09A-078A-D

Corrosion preventative C150 MIL-C-15074 (AMDI) 39-A-00-50-00-16B-078A-D

Oil C008 DOD-L-85734 (AMDI) 39-A-00-50-00-07A-078A-D

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

Note

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

For Training purpose only 9 of 313


7.5 - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination

Safety conditions:

CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 10 of 313


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

Defects definition :

Small

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

Moderate

Its a defect that does not cause the component to become unserviceable. This defect can
decrease the component life and overhaul period.

Bad

Its a defect that causes the life of the component to decrease.

Note

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

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7.7 Surface finish protection restoration (MGB - Main Case)

CR&OP Data Module:

39-A-63-20-05-00A-640A-C
Main gearbox - Disassembled metal components -
Change the surface finish of materials

Procedure

Refer to Para. 1

Apply to the components shown in Fig 1 the chromate conversion coating (C237: Alodine1200)
Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C

Apply to the components shown in Fig 2 the surface finishes that follow:
The chromate conversion coating (C237) . Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C.
The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.

Apply to the components shown in Fig 3 the cadmium plating finish (C282 or C183 as required).
Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C.

On the pages reported hereinafter are shown the fig.1, 2 and 3.

For Training purpose only 12 of 313


7.7.1 - Main Case components Surface finishes - Fig. 1

On these components apply the chromate


conversion coating (C237: Alodine1200) .
Refer to data module CR&OP: 39-A-60-10-01-
00A-644A-C

For Training purpose only 13 of 313


7.7.2 Main Case components Surface finishes - Fig. 2

On these components apply the surface finishes that follow:


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

For Training purpose only 14 of 313


7.7.3 Main Case components Surface finishes - Fig. 3

On these components apply the cadmium


plating finish (C282 or C183 as required).
Refer to data module CR&OP: 39-A-60-10-01-
00A-647A-C.

For Training purpose only 15 of 313


7.8 - Surface finish protection restoration (MGB - Upper Module)

CR&OP Data Module:

39-A-63-20-05-00A-640A-C
Main gearbox - Disassembled metal components -
Change the surface finish of materials

Procedure

Refer to Para. 2

Apply to the components shown in Fig 4 the surface finishes that follow:

The chromate conversion coating (C237: Alodine 1200). Refer to data module CR&OP: 39-A-60-10-01-
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.

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

For Training purpose only 16 of 313


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

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

For Training purpose only 17 of 313


7.9 - Surface finish protection restoration
(MGB - LH/RH Input Shaft Module)

CR&OP Data Module:

39-A-63-20-05-00A-640A-C
Main gearbox - Disassembled metal components -
Change the surface finish of materials

Procedure

Refer to Para. 3

Apply to the components shown in Fig 6 the surface finishes that follow:

The chromate conversion coating (C237: Alodine 1200). Refer to data module CR&OP: 39-A-60-10-01-
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.

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

For Training purpose only 18 of 313


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

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

For Training purpose only 19 of 313


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

Sheet 1 of 9

Visual examination of Bearings


Damage Area of Acceptable damage Not-acceptable damage
Code Inspection
T1 Balls and Smearing. Accept the part if you find small smearing. Pitting, spalling, corrosion, heat
Rollers Staining. Accept the part if the staining is not related to pitting or discoloration, continuous
overheating. circumferential indentation,
Indentation that you can see only with a light reflection. Accept the part. brinelling, seizure and cracks.
Reject the part if you find one of
these defects.
T1 Bearing Smearing. Accept the part if you find small smearing. Pitting, spalling, heat discoloration,
races Staining. Accept the part if the staining is not related to pitting or brinelling, seizure, corrosion and
overheating. cracks.
Indentation that you can see only with a light reflection. Accept the part. Reject the part if you find one of
these defects.
T1 Not active Staining. Accept the part if the staining is not related to pitting or Bad circumferential scoring,
surfaces of overheating. spinning marks, cracks, heat
the bearings Corrosion. Accept the part if you find small corrosion that you can repair discoloration, bad fretting and
with a Scotchbrite pad or Number 600 abrasive paper. seizure.
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. Moderate and bad Reject the part if you find rusting.
fretting areas, usually, have the typical brown colour.
Scratches. Accept the part if you find small or moderate scratches.
T1 Cages Polishing. Accept the part if you find polishing. Corrosion, heat discoloration,
Staining. Accept the part if the staining is not related to pitting or seizure, pocket deformation,
overheating. peeling of the plated surface and
cracks.
Reject the part if you find one of
these defects.

For Training purpose only 20 of 313


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

Sheet 2 of 9

Visual examination of Gears (sheet 1 of 2)


Damage Area of Acceptable damage Not-acceptable damage
Code Inspection
T2 Teeth Wear of abrasive type. Accept the part if you find small worn areas Scores, flaking, pitting, spalling,
caused by small particles that go through the gear mesh. peening, heat discoloration and
Polishing. Accept the part if you find polishing. cracks.
Scratches. Accept the part if you find small scratches caused by burrs Reject the part if you find one of
that go through the gear mesh. these defects.
Interference wear. Accept the part if you find small interference wear. Reject the part if you find rusting.
Corrosion. Accept the part if you find small corrosion that you can
repair with a Scotch-brite pad or Number 600 abrasive paper.
Staining. Accept the part if the staining is not related to pitting or
overheating.
Indentation that you can see only with a light reflection. Accept the
part.
T3 Bearing Polishing. Accept the part if you find polishing. Pitting, spalling, heat discoloration,
races Staining. Accept the part if the staining is not related to pitting or brinelling and seizure.
overheating. Reject the part if you find one of
Scratches. Accept the part if you find small scratches caused by burrs these defects.
that go through the roller elements. Reject the part if you find moderate
Indentation that you can see only with a light reflection. Accept the and bad circumferential marks.
part. Reject the part if you find rusting.
Corrosion. Accept the part if you find small corrosion that you can
repair with a Scotch-brite pad.

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

Sheet 3 of 9

Visual examination of Gears (sheet 2 of 2)


Damage Area of Acceptable damage Not-acceptable damage
Code Inspection
T4 Journals Staining. Accept the part if the staining is not related to pitting or Bad circumferential scores,
overheating. spinning marks, flaking, heat
Corrosion. Accept the part if you find small corrosion that you can repair discoloration and seizure.
with a Scotchbrite pad or Number 600 abrasive paper. Reject the part if you find one of
Fretting. Accept the part if you find small fretting that you can repair with these defects.
a Scotchbrite pad or Number 600 abrasive paper. Make sure that the Reject the part if you find rusting.
fretting is not more than 10% of the working surface. Usually, the areas
that show fretting have a different colour from the surfaces that do not
show fretting. Moderate and bad fretting areas, usually, have the typical
brown colour.
T5 Shoulders Staining. Accept the part if the staining is not related to pitting or Moderate or bad wear, heat
overheating. discoloration, seizure and cracks.
Corrosion. Accept the part if you find small corrosion that you can repair Reject the part if you find one of
with a Scotchbrite pad or Number 600 abrasive paper. these defects.
Fretting. Accept the part if you find small fretting that you can repair with Reject the part if you find rusting.
a Scotchbrite pad or Number 600 abrasive paper. Make sure that the
fretting is not more than 10% of the working surface. Usually, the areas
that show fretting have a different colour from the surfaces that do not
show fretting. Moderate and bad fretting areas, usually, have the typical
brown colour.
Scratches. Accept the part if you find small scratches that are not more
than 10% of the working surface.
Polishing. Accept the part if you find polishing.
T6 Interface Small fretting. Accept the part if you find small fretting that you can Bad fretting and cracks.
planes repair with a Scotchbrite pad or Number 600 abrasive paper. Reject the part if you find one of
these defects.

For Training purpose only 22 of 313


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

Sheet 4 of 9

Visual examination of Splines


Damage Area of Acceptable damage Not-acceptable damage
Code Inspection
T7 Teeth Wear of abrasive type. Accept the part if you find small worn areas Pitting, spalling, cracks and bad
caused by small particles that go through the gear mesh. fretting.
Polishing. Accept the part if you find polishing. Reject the part if you find one of
Corrosion. Accept the part if you find small corrosion that you can repair these defects.
with a Scotchbrite pad or Number 600 abrasive paper. Reject the part if you find rusting.
Staining. Accept the part if the staining is not related to pitting or
overheating.
Fretting. Accept the part if you find small fretting that you can repair with
a Scotchbrite pad or Number 600 abrasive paper. Usually, the areas that
show fretting have a different colour from the surfaces that do not show
fretting. Moderate and bad fretting areas, usually, have the typical brown
colour.

For Training purpose only 23 of 313


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

Sheet 5 of 9

Visual examination of Casting


Damage Area of Acceptable damage Not-acceptable damage
Code Inspection
T8 Interface Fretting. Accept the part if you find small fretting that you can repair with Bad fretting and cracks. Reject the
planes a Scotchbrite pad or Number 600 abrasive paper. part if you find one of these defects.

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.

For Training purpose only 24 of 313


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

Sheet 6 of 9

Criteria of acceptability for an indentation noted on the surface of the Casting (sheet 1 of 3)
Damage Area of Acceptable damage Examples of indentation
Code Inspection
T10 Surface of Indentation (Nick)
the casting INDENTATION
Accept the part if:

The indentation has a dimension of approximately 2.5 x 2.5 mm with a


depth of 0.25 mm without paint removal. Refer to photo No. 1.

INDENTATION

Photo No.1

For Training purpose only 25 of 313


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

Sheet 7 of 9

Criteria of acceptability for an indentation noted on the surface of the Casting (sheet 2 of 3)
Damage 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

Photo No.2 Photo No.3 Photo No.4

For Training purpose only 26 of 313


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

Sheet 8 of 9

Criteria of acceptability for an indentation noted on the surface of the Casting (sheet 3 of 3)

Damage Area of Acceptable damage Examples of indentation


Code Inspection
T10 Surface of Indentation (Nick)
the casting INDENTATION
Accept the part if:

The indentation is on the corner (high thickness) and


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

- Blend the sharp corners.


- Apply the paint finish as required.39-A-60-10-01- INDENTATION
00A-257A-C

Picture No.6

For Training purpose only 27 of 313


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

Sheet 9 of 9

Visual examination of Threads


Damage Area of Acceptable damage Not-acceptable damage
Code Inspection
T11 Bolt threads, Mechanical damage. Corrosion, seizure, distortion and cracks.
Threaded Reject the part if you find one of these defects.
shafts, Accept the part if the mechanical damage is limited to
Nuts . one thread pitch at the input. If you find that a stud is damaged, you must
replace it. Refer to CR&OP: 39-A-60-30-02-
Damage must not be more than of the threaded 00A-921A-C.
depth after repair.

For Training purpose only 28 of 313


7.11 - Example of damage General information
(Note: Photos reported below are not related to the Transmission of the AW139)

Sheet 1 of 9

Damage Definition Example


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

Searing on Outer Ring raceway surface

Smearing on outer ring raceway surface Smearing on ball surface


of Cylindrical Roller Bearing

For Training purpose only 29 of 313


7.11 - Example of damage General information

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.

Discoloration on inner ring and roller of Roller Bearing


(Staining)

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

Heat Discoloration on inner ring Surface overheated

For Training purpose only 30 of 313


7.11 - Example of damage General information

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

For Training purpose only 31 of 313


7.11 - Example of damage General information

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)

Seizure The seizure described


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

Seizure of Tapered Roller Bearing


(Heat is generated on roller end face and Example of seizure on roller bearing
inner ring rib face)

For Training purpose only 32 of 313


7.11 - Example of damage General information

sheet 5 of 9
Damage Definition Example

Pitting Pitting corrosion is a


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

Example of pitting
corrosion

For Training purpose only 33 of 313


7.11 - Example of damage General information

Sheet 6 of 9

Damage Definition Example


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

Crack very heavy Crack in outer ring of Roller Bearing


on Cast Housing

Scratch A linear depression


with a sharp bottom
caused by the contact
and/or handling.

Or

A scratch is a relatively
shallow flaw caused by
sliding contact.

Scratch on roller rolling surface of Roller Bearing


Scratch
- Scratch occurring in circumference direction -
Medium Precision Surface

For Training purpose only 34 of 313


7.11 - Example of damage General information

Sheet 7 of 9

Damage Definition Example


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

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

For Training purpose only 35 of 313


7.11 - Example of damage General information

Sheet 8 of 9

Damage Definition Example


Rust Rust is a film of oxide, Rust on roller rolling
hydroxide, or carbonate surface of Cylindrical Roller
produced on a metallic Bearing
surface by chemical action.

Rust on outer ring raceway


surface
of Roller Bearing

Failure of 1) Cracks and Chips Distortion of Cylindrical


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

For Training purpose only 36 of 313


7.11 - Example of damage General information

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.

For Training purpose only 37 of 313


7.12 - Detailed visual examination, applicable Data Modules list

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)

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 1 and Figure 1 (Sheet 1 of 5)

P/N:

S/N:.

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

General Safety conditions:

CAUTION

During this procedure, do not touch the components made


of metal with bare hands.
Put on applicable cotton gloves before you touch the
components.
Contamination from your bare hands will cause corrosion
of the metals.
Procedure

To make an estimate of the damage, use the damage codes


on the tables of the detailed visual examination figures
and refer to CR&OP: 39-A-63-20-05-00A-913A-C for the
acceptability / rejection criteria.
Fig. 1 - Main case MGB (sheet 1 of 5)

For Training purpose only 39 of 313


7.13 MGB - Main Case - Detailed visual examination (Sheet 2 of 5)

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 1 and Figure 1 (Sheet 2 of 5).

P/N:

S/N:.

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

Fig. 1 - Main case MGB (sheet 2 of 5)

For Training purpose only 40 of 313


7.13 - Main Case - Detailed visual examination (Sheet 3 of 5)

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 1 and Figure 1 (Sheet 3 of 5).

P/N:

S/N:.

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

Fig. 1 - Main case MGB (sheet 3 of 5)

For Training purpose only 41 of 313


7.13 - Main Case - Detailed visual examination (Sheet 4 of 5)

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 1 and Figure 1 (Sheet 4 of 5).

P/N:

S/N:.

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

Fig. 1 - Main case MGB (sheet 4 of 5)

For Training purpose only 42 of 313


7.13 MGB - Main Case - Detailed visual examination (Sheet 5 of 5)

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 1 and Figure 1 (Sheet 5 of 5).

P/N:

S/N:.

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

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

For Training purpose only 43 of 313


7.13.1 MGB - Diaphragm - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 2 and Figure 2

P/N:

S/N:.

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

Fig. 2 Diaphragm (MGB)

For Training purpose only 44 of 313


7.13.2 MGB - Bottom cover - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 3 and Figure 3

P/N:

S/N:.

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

Fig. 3 Bottom cover (MGB)

For Training purpose only 45 of 313


7.13.3 MGB - Seal Cover of the Fan and ECS compressor drive quills
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 4 and Figure 4

P/N:

S/N:.

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

Fig. 4 Seal covers (MGB)

For Training purpose only 46 of 313


7.13.4 - MGB - Anti-torque beam Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 5 and Figure 5

P/N:

S/N:.

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

Fig. 5 Anti-torque beam (MGB)

For Training purpose only 47 of 313


7.13.5 MGB - 17 Oil Jets (Main case)
Detailed visual examination
CR&OP Data Module:
N11
N6 N12 N7
N10 39-A-63-20-05-00A-311A-C Main gearbox - Detailed
N9
visual examination. See Para. 6 and Figure 6.
Oil Jet No. 3 (x2) Oil Jet P/N: .
Oil Jet No. 4 (x2) Oil Jet P/N: .
Oil Jet No. 5 Oil Jet P/N: .
Oil Jet No. 6 Oil Jet P/N: .
Oil Jet No. 7 Oil Jet P/N: .
Oil Jet No. 8 Oil Jet P/N: .
N3 N3 Oil Jet No. 9 Oil Jet P/N: .
Oil Jet No. 10 Oil Jet P/N: .
Oil Jet No. 11 Oil Jet P/N: .
Oil Jet No. 12 Oil Jet P/N: .
Oil Jet No. 13 Oil Jet P/N: .
Oil Jet No. 14 Oil Jet P/N: .
N 16
Oil Jet No. 15 Oil Jet P/N: .
N16 N5 Oil Jet No. 16 (x2) Oil Jet P/N: .
N8 N4 Inspection results: ..............................
N4

N13
N15 N14

Notes

1) In the MGB are installed 29 Oil Jets: N3


- 17 oil jets in the Main Case
- 4 oil jets in the Upper Module
- 3 oil jets in each Input Shaft Module (6 total)
- 1 oil jet in each Cover of each Input Shaft Module (2 total)
N3
2) Check with filtered compressed air the possible occlusion of the oil jet holes

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


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

For Training purpose only 48 of 313


7.13.6 MGB - 3 Servo-Actuator Brackets
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 7 and Figure 7

Front servo-actuator Bracket (A)


P/N:.
S/N:.

Left servo-actuator Bracket (B)


P/N:.
S/N:.

Right servo-actuator Bracket (C)


P/N:.
S/N:.

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

Fig. 7 Servo-actuator brackets (MGB)

For Training purpose only 49 of 313


7.13.7 MGB - Cross shaft (left and right) - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 8 and Figure 8

Left Cross shaft


P/N:.
S/N:.

Right Cross shaft


P/N:.
S/N:.

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

Fig. 8 Cross shaft (MGB)

For Training purpose only 50 of 313


7.13.8 MGB - Ring nuts (Input pinions II stage) -
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 9 and Figure 9

Left ring nut


P/N:.
S/N:.

Right ring nut


P/N:.
S/N:.

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

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

For Training purpose only 51 of 313


7.13.9 MGB - Pump gears - (Input pinions II stage)
- Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 10 and Figure 10

Left Pump gear


P/N:.
S/N:.

Right Pump gear


P/N:.
S/N:.

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

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

For Training purpose only 52 of 313


7.13.10 MGB - Bearing sleeves - (Input pinions II stage)
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 11 and Figure 11

Left Bearing sleeve


P/N:.
S/N:.

Right Bearing sleeve


P/N:.
S/N:.

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

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

For Training purpose only 53 of 313


7.13.11 MGB - Bearing sleeve Retaining rings (Input pinions II
stage) - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 12 and Figure 12

Left Retaining Ring


P/N:.
S/N:.

Right Retaining Ring


P/N:.
S/N:.

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

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

For Training purpose only 54 of 313


7.13.12 MGB - Input pinions II Stage
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 13 and Figure 13

Left Input Pinion


P/N:.
S/N:.

Right Input Pinion


P/N:.
S/N:.

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

Fig. 13 Input pinions II stage (MGB)

For Training purpose only 55 of 313


7.13.13 MGB - Sliding adapter (Tail rotor drive quill)
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 14 and Figure 14

P/N:.
S/N:.

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

Fig. 14 Sliding adapter (MGB)

For Training purpose only 56 of 313


7.13.14 - Collector gear Locking ring - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 15 and Figure 15

P/N:.
S/N:.

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

Fig. 15 Collector gear Locking ring (MGB)

For Training purpose only 57 of 313


7.13.15 MGB - Collector gear - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 16 and Figure 16

P/N:.
S/N:.

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

Fig. 16 Collector gear Locking ring (MGB)

For Training purpose only 58 of 313


7.13.16 MGB - Filter head and the Bypass valve
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 17 and Figure 17

Filter Head
P/N:.
S/N:.

Bypass Valve
P/N:.
S/N:.

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

Fig. 17 Filter head and Bypass valve (MGB)

For Training purpose only 59 of 313


7.13.17 MGB - Pressure relief valves - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 18 and Figure 18

LH PRV
P/N:.
S/N:.

RH PRV
P/N:.
S/N:.

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

Fig. 18 PRV (MGB)

For Training purpose only 60 of 313


7.13.18 MGB - Input-pinion II stage triplex Ball Bearings -
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 19 and Figure 19

LH triplex ball bearing


P/N:.
S/N:.

RH triplex ball bearing


P/N:.
S/N:.

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

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

For Training purpose only 61 of 313


7.13.19 MGB - Input pinion II stage Roller Bearings
Detailed visual examination

CR&OP Data Module:

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

LH Roller bearing
P/N:.
S/N:.

RH Roller bearing
P/N:.
S/N:.

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

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

For Training purpose only 62 of 313


7.13.20 MGB - Collector-gear Flanged bearing
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 21 and Figure 21

Collector-gear Flanged bearing


P/N:.
S/N:.

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

Fig. 21 Collector gear flanged bearing (MGB)

For Training purpose only 63 of 313


7.13.21 MGB - Collector gear Roller bearing
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 22 and Figure 22

Collector-gear Roller bearing


P/N:.
S/N:.

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

Fig. 22 Collector gear flanged bearing (MGB)

For Training purpose only 64 of 313


7.14 - Chip detectors - Detailed visual examination

CR&OP Data Module:


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

Nomenclature Identification No.


Container Local supply

Magnifying glass, 10-power Local supply


Sump Chip
Detector (x2) Paint brush Local supply

Supplies:
Mast Chip
Detector Nomenclature Identification No Specification references Ref. Documents

Cleaning solvent C010 P-D-680 type II (AMDI)


Mast Chip Detector (upper module) 39-A-00-50-00-09A-078A-D
P/N:. Adhesive tape C012 DEF1313 or DEF (AMDI)
S/N:. STAN75-3-1. 39-A-00-50-00-11A-078A-D
LH Chip Detector (sump)
P/N:. Procedure:
S/N:.
RH Chip Detector (sump) 1) Examine each of the chip detectors. Use a strong light and the
P/N:. Magnifying Glass. Make sure that there are no metallic particles on
S/N:. these Chip Detectors.
Inspection results: 2) If you find metallic particles on the chip detectors obey the
............................................................ instructions reported in this data module.

For Training purpose only 65 of 313


7.14.1 - Chip Detector Event Report Card

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

For Training purpose only 66 of 313


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

39-A-63-20-05-01A-311A-C Left input shaft module (main


gearbox) - Detailed visual examination

39-A-63-20-05-02A-311A-C Right input shaft module (main


gearbox) - Detailed visual examination
Safety conditions:
CAUTION

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: General Note:


The data to the a detailed visual examination
Nomenclature Identification No.
of the left-input shaft module is applicable
Magnifying glass, 10 times Local supply also to the right-input shaft module (see
CR&OP 39-A-63-20-05-02A-311A-C).

For Training purpose only 67 of 313


7.15.1 - Case Assy - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 1 and Figure 1

LH Case Assy
P/N:
S/N:.

RH Case Assy
P/N:
S/N:.

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

T11

T8
T10

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

For Training purpose only 68 of 313


7.15.2 - Input Pinion- Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 2 and Figure 2

LH Pinion
P/N:
S/N:.

RH Pinion
P/N:
S/N:.

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

T7

Fig. 2 - Pinion (Left input shaft module)

For Training purpose only 69 of 313


7.15.3 - Gear, I stage of reduction - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 3 and Figure 3

LH Gear
P/N:
S/N:.

RH Gear
P/N:
S/N:.

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

Fig. 3 - Gear (Left input shaft module)

For Training purpose only 70 of 313


7.15.4 - Input shaft - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 4 and Figure 4

LH Input Shaft
P/N:
S/N:.

RH input Shaft
P/N:
S/N:.

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

T7

Fig. 4 Input Shaft (Left input shaft module)

For Training purpose only 71 of 313


7.15.5 - Diaphragm - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 5 and Figure 5

LH Diaphragm
P/N:
S/N:.

RH Diaphragm
P/N:
S/N:.

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

T10

T10
T8

Fig. 5 Diaphragm (Left input shaft module)

For Training purpose only 72 of 313


7.15.6 - Sleeve - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 6 and Figure 6

LH Sleeve
P/N:
S/N:.

RH Sleeve
P/N:
S/N:.

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

T8

T9
T9

Fig. 6 Sleeve (Left input shaft module)

For Training purpose only 73 of 313


7.15.7 - Flange - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 7 and Figure 7

LH Flange
P/N:
S/N:.

RH Flange
P/N:
S/N:.

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

T7

T8

Fig. 7 Flange (Left input shaft module)

For Training purpose only 74 of 313


7.15.8 - Gimbal support - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 8 and Figure 8

LH Gimbal support
P/N:
S/N:.

RH Gimbal support
P/N:
S/N:.

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

T10

T10
T8

Fig. 8 Gimbal (Left input shaft module)

For Training purpose only 75 of 313


7.15.9 - Oil jet cover - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 9 and Figure 9

LH Oil Jet cover


P/N:
S/N:.

RH Oil Jet cover


P/N:
S/N:.

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

Note

Using filtered compressed air inspect the oil


jet holes for possible blockage.
T8

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

For Training purpose only 76 of 313


7.15.10 - Three oil jets - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 10 and Figure 10
Left Input Shaft module:
Oil Jet A No.
P/N:

Oil Jet B No.


P/N:

Oil Jet C No.


P/N:

Inspection results:
........................................................................
Right Input Shaft module:
Oil Jet A No.
P/N:

Oil Jet B No.


Note 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

B CR&OP Data Module:

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

A Ring nut B
P/N:
S/N:.
Inspection results:
........................................................................

Right Input Shaft module:

Ring nut A
P/N:
S/N:.

Ring nut B
P/N:
S/N:.

Fig. 11 Ring nuts (Left input shaft module)


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

For Training purpose only 78 of 313


7.15.12 - Carbon seal and Ring - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 12 and Figure 12
Left Input Shaft module:
Carbon Seal
P/N:
S/N:.

Ring
P/N:
S/N:.

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

Right Input Shaft module:


Carbon Seal
P/N:
S/N:.

Ring
P/N:
S/N:.

Inspection results:
Fig. 12 Carbon Seal and Ring (Left input shaft module) ........................................................................

For Training purpose only 79 of 313


7.15.13 - Inner Bearing - Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 13 and Figure 13

LH Inner Bearing
P/N:
S/N:.

RH Inner Bearing
P/N:
S/N:.

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

Fig. 13 Inner Bearing (Left input shaft module)

For Training purpose only 80 of 313


7.15.14 - Outer Bearing Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 14 and Figure 14

LH Outer Bearing
P/N:
S/N:.

RH Outer Bearing
P/N:
S/N:.

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

Fig. 14 Outer Bearing (Left input shaft module)

For Training purpose only 81 of 313


7.15.15 - Ball bearing (gear 1 stage of reduction)
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 15 and Figure 15

LH Ball Bearing
P/N:
S/N:.

RH Ball Bearing
P/N:
S/N:.

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

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

For Training purpose only 82 of 313


7.15.16 - Roller bearing (gear 1 stage of reduction)
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 16 and Figure 16

LH Roller Bearing
P/N:
S/N:.

RH Roller Bearing
P/N:
S/N:.

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

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

For Training purpose only 83 of 313


7.15.17 - Roller bearing (Input pinion)
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 17 and Figure 17

LH Roller Bearing
P/N:
S/N:.

RH Roller Bearing
P/N:
S/N:.

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

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

For Training purpose only 84 of 313


7.15.18 - Duplex ball bearing (input pinion)
Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) -
Detailed visual examination.
See Para. 18 and Figure 18

LH Duplex Ball Bearing


P/N:
S/N:.

RH Duplex Ball Bearing


P/N:
S/N:.

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

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

For Training purpose only 85 of 313


7.16 - Freewheel Detailed visual examination

Procedure CR&OP Data Module:


1) Do the detailed visual examination with the aid of the Magnifying
Glass, the Mirror and a strong light. Refer to Fig. 1 reported on the 39-A-63-20-05-01A-311B-C Left input
next page. shaft module (main gearbox) - Freewheel -
2) Examine the freewheel for corrosion and distress caused by the
heat. Reject it if you find one of these defects. Detailed visual examination.
3) Examine the sprags, the inner cage, the outer cage and the inner LH Freewheel
springs and the outer springs for cracks and breaks. Reject the P/N:
freewheel if you find one of these defects. S/N:.
4) Make sure that the sprags move freely in their pockets and stay in
position. Reject the freewheel if the sprags do not move freely or RH Freewheel
do not stay in position.
P/N:
5) Examine each sprag for discoloration caused by the heat, chips and
spalling and pitting. Reject the freewheel if you find one of these
S/N:.
defects. Accept the freewheel if you find small polished areas.
6) Examine the position of the wear patterns on the inner and outer Inspection results:
faces of each sprags. The wear pattern must be at a minimum ........................................................................
distance of 1.0 mm (0.04 in) from the high load corner. Reject the ........................................................................
freewheel if you do not find these conditions. ........................................................................
7) Examine each sprag for wear on the outer and inner faces. Make
sure that the wear width on the inner face is not more than 0.30 Support equipment:
mm (0.012 in) (see Detail A). Reject the freewheel if you find one
of these defects.
8) Examine the inner springs for wear. Reject the freewheel if the Nomenclature Identification No.
inner springs show important wear (approximately 30% of the
original thickness). Magnifying glass, 10-power Local supply
9) Examine the outer springs for fretting. Refer to Detail B for an
example of permitted fretting. Mirror Local supply
10) Examine the cross bars of the inner and outer cages for
straightness and uniformity. The cross bars must not be bent from
the initial shape and there must be no distortion. Reject the Note:
freewheel if you find one of these defects. The procedure reported in this D.M. is applicable for both
(LH, RH) freewheels.

For Training purpose only 86 of 313


7.16.1 - Freewheel Detailed visual examination

Fig. 1 Freewheel Detailed visual examination

For Training purpose only 87 of 313


7.17 - Upper Module (main gearbox) - Detailed visual examination

CR&OP Data Module:

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


Detailed visual examination

Safety conditions:
CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 88 of 313


7.17.1 Top case Detailed visual examination

CR&OP Data Module:

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:
........................................................................
........................................................................
........................................................................

Fig. 1 Top Case (Upper Module)

For Training purpose only 89 of 313


7.17.2 - Cooler adapter Detailed visual examination

CR&OP Data Module:

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:
........................................................................
........................................................................
........................................................................

Fig. 2 Cooler adapter (Upper Module)

For Training purpose only 90 of 313


7.17.3 - Seal cover Detailed visual examination

CR&OP Data Module:

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:
........................................................................
........................................................................
........................................................................

Fig. 3 Cooler adapter (Upper Module)

For Training purpose only 91 of 313


7.17.4 - Four Upper Fittings Detailed visual examination

CR&OP Data Module:

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)

For Training purpose only 92 of 313


7.17.5 - Four oil jets Detailed visual examination

CR&OP Data 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.

Oil Jet (A) No. 1


P/N:

Oil Jet (B) No. 1


P/N:

Oil Jet (C) No. 2


P/N:

Oil Jet (D) No. 2


P/N:

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

Fig. 5 Oil Jets (Upper Module)

For Training purpose only 93 of 313


7.17.6 - Ring gear Detailed visual examination

CR&OP Data Module:

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:
........................................................................
........................................................................
........................................................................

Fig. 6 Ring Gear (Upper Module)

For Training purpose only 94 of 313


7.17.7 -Roller bearing Detailed visual examination

CR&OP Data Module:

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:
........................................................................
........................................................................
........................................................................

Fig. 7 Roller bearing (Upper Module)

For Training purpose only 95 of 313


7.17.8 - Components Detailed visual inspection

CR&OP Data Module:

39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 8 and Figure 8.

Mast cover P/N:


Chip detector P/N:..
Oil filler neck P/N:
Oil scupper P/N:...
Union P/N:..
Unions P/N:
Washers P/N:.
Brackets P/N:.

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

Do the detailed visual examination of the following components for corrosion,


wear and damage:
The mast cover (1)
The chip detector (2)
The oil filler neck (3)
The oil scupper (4)
The unions (5) (five items)
The washers (6) (four items)
Fig. 8 Components (Upper Module) The brackets (7) (two items).

For Training purpose only 96 of 313


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

39-A-63-20-05-13A-311A-C Mast-planetary assembly


(upper module) - Detailed visual examination

Safety conditions:
CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 97 of 313


7.18.1 - Main rotor shaft (MAST) Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 1 and Figure 1.

Main rotor shaft (Mast)

P/N:
S/N:..

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

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

For Training purpose only 98 of 313


7.18.2 Spider plate Detailed visual examination

CR&OP Data Module:

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:
.......................................................................

Fig. 2 Spider plate (Mast-Planetary Assembly)

For Training purpose only 99 of 313


7.18.3 - Ring nut Detailed visual examination

CR&OP Data Module:

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:
.......................................................................

Fig. 3 Ring nut (Mast-Planetary Assembly)

For Training purpose only 100 of 313


7.18.4 - Ball bearing Detailed visual examination

CR&OP Data Module:

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:
.......................................................................

Fig. 4 Ball bearing (Mast-Planetary Assembly)

For Training purpose only 101 of 313


7.18.5 - Five planetary gear ring nuts Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 5 and Figure 5.

Planetary gear ring nut


P/N:
S/N:..

Planetary gear ring nut


P/N:
S/N:..

Planetary gear ring nut


P/N:
S/N:..

Planetary gear ring nut


P/N:
S/N:..

Planetary gear ring nut


P/N:
S/N:..

Fig. 5 Planetary gear ring nut (Mast-Planetary Assembly)


Inspection results:
.......................................................................
For Training purpose only 102 of 313
7.18.6 - Five planetary pins Detailed visual examination

CR&OP Data Module:

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:..

Fig. 6 Planetary pin (Mast-Planetary Assembly) Inspection results:


.......................................................................
For Training purpose only 103 of 313
7.18.7 - Five planetary gear spacers Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 7 and Figure 7.

Planetary gear spacer


P/N:
S/N:..

Planetary gear spacer


P/N:
S/N:..

Planetary gear spacer


P/N:
S/N:..

Planetary gear spacer


P/N:
S/N:..

Planetary gear spacer


P/N:
S/N:..

Fig. 7 Planetary gear spacer (Mast-Planetary Assembly)


Inspection results:
.......................................................................
For Training purpose only 104 of 313
7.18.8 - Five spider plate spacers Detail visual examination

CR&OP Data Module:

39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Detailed visual examination.
See Para. 8 and Figure 8.

Spider plate spacer


P/N:

Spider plate spacer


P/N:

Spider plate spacer


P/N:

Spider plate spacer


P/N:

Spider plate spacer


P/N:

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

Fig. 8 Spider plate spacer pin (Mast-Planetary Assembly)

For Training purpose only 105 of 313


7.18.9 - Components Detailed visual examination

CR&OP Data Module:

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

Do the detailed visual examination of the following


components for corrosion, wear and damage:
The retaining ring (1)
The oil collector (2)
The nut spring (3) (five items)
Fig. 9 Components (Mast-Planetary Assembly)
The spider bolts (4) (ten items)
The spacer bush (5) (ten items).

For Training purpose only 106 of 313


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

39-A-63-20-05-14A-311A-C Planetary gear assembly


(mast-planetary assembly) - Detailed visual
examination
Safety conditions:
CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 107 of 313


7.19.1 - Gear Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-14A-311A-C Planetary
gear assembly (mast-planetary
assembly) - Detailed visual
examination. See Para.1 and Figure 1

Planetary Gear Assy


P/N:
S/N:

Planetary Gear Assy


P/N:
S/N:

Planetary Gear Assy


P/N:
S/N:

Planetary Gear Assy


P/N:
S/N:

Planetary Gear Assy


P/N:
S/N:

Fig. 1 Gear (Planetary-Gear Assembly)


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

For Training purpose only 108 of 313


7.19.2 - Inner bearing race Detailed visual examination

CR&OP Data Module:

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

Inner bearing race


Relevant to Planetary gear assy
P/N:
S/N:
Inner bearing race
Relevant to Planetary gear assy
P/N:
S/N:
Inner bearing race
Relevant to Planetary gear assy
P/N:
S/N:
Inner bearing race
Relevant to Planetary gear assy
P/N:
Fig. 2 inner bearing race (Planetary-Gear Assembly) S/N:
Inner bearing race
Relevant to Planetary gear assy
P/N:
S/N:

Inspection results:
.......................................................................
For Training purpose only 109 of 313
7.19.3 - Rollers and Cages Detailed visual examination

CR&OP Data Module:

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

Rollers and Cages


Relevant to Planetary gear assy
P/N:
S/N:
Rollers and Cages
Relevant to Planetary gear assy
P/N:
S/N:
Rollers and Cages
Relevant to Planetary gear assy
P/N:
S/N:
Rollers and Cages
Relevant to Planetary gear assy
P/N:
S/N:
Rollers and Cages
Relevant to Planetary gear assy
Fig. 3 Rollers and Cages (Planetary-Gear Assembly) P/N:
S/N:

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:

39-A-63-20-05-27A-311A-C Left/right pump drive


quill (main gearbox) - Detailed visual examination

Safety conditions:
CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 111 of 313


7.20.1 - Pinion Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right
pump drive quill (main gearbox) -
Detailed visual examination.
See Para.1 and Figure 1.

Left pinion
P/N:
S/N:

Right pinion
P/N:
S/N:

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

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

For Training purpose only 112 of 313


7.20.2 - Locking ring and Seal cover Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right
pump drive quill (main gearbox) -
Detailed visual examination.
See Para.2, 3 and Figure 2.

Left pump drive quill

Locking ring
P/N:

Seal Cover
P/N:
S/N:

Right pump drive quill

Locking ring
P/N:

Seal Cover
P/N:
S/N:

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

For Training purpose only 113 of 313


7.20.3 - Pump case Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right
pump drive quill (main gearbox) -
Detailed visual examination.
See Para.4 and Figure 3.

Left Pump case


P/N:
S/N:

Right Pump case


P/N:
S/N:

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

T8

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

For Training purpose only 114 of 313


7.20.4 - Flanged bearing Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-27A-311A-C Left/right
pump drive quill (main gearbox) -
Detailed visual examination.
See Para.5 and Figure 4.

Left Flanged bearing


P/N:
S/N:

Right Flanged bearing


P/N:
S/N:

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

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

For Training purpose only 115 of 313


7.20.5 - Components Detailed visual examination

CR&OP Data Module:

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

For Training purpose only 116 of 313


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

39-A-63-20-05-04A-311A-C Front pump drive quill


(main gearbox) - Detailed visual examination

Safety conditions:
CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 117 of 313


7.21.1 - Pinion Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-04A-311A-C Front pump


drive quill (main gearbox) - Detailed
visual examination.
See Para. 1 and Figure1.

Pinion
P/N:
S/N:.......................................

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

Fig. 1 Pinion (Front pump drive quill)

For Training purpose only 118 of 313


7.21.2 - Locking ring and Seal cover Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-04A-311A-C Front pump


drive quill (main gearbox) - Detailed
visual examination.
See Para. 2, 3 and Figure 2.

Locking ring
P/N:

Seal Cover
P/N:
S/N:

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

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

For Training purpose only 119 of 313


7.21.3 - Pump case Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-04A-311A-C Front pump


drive quill (main gearbox) - Detailed
visual examination.
See Para. 4 and Figure 3.

Pump case
P/N:
S/N:

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

Fig. 3 Pump Case (Front pump drive quill)

For Training purpose only 120 of 313


7.21.4 - Flanged bearing Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-04A-311A-C Front pump


drive quill (main gearbox) - Detailed
visual examination.
See Para. 5 and Figure 4.

Flanged bearing
P/N:
S/N:

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

Fig. 4 Flanged bearing (Front pump drive quill)

For Training purpose only 121 of 313


7.21.5 - Components Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-04A-311A-C Front pump


drive quill (main gearbox) - Detailed
visual examination. See Para. 6.

Plug
Procedure P/N:

Do the detailed visual examination of the following Locking washer


components for corrosion, wear and damage: P/N:.......................................

The plug Inspection results:


......................................................................
The locking washer

For Training purpose only 122 of 313


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

39-A-63-20-05-05A-311A-C ECS compressor drive


quill (main gearbox) - Detailed visual examination

Safety conditions:
CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 123 of 313


7.22.1 - Pinion Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-05A-311A-C ECS
compressor drive quill (main gearbox) -
Detailed visual examination.
See Para.1 and Figure 1.

Pinion
P/N:
S/N:.......................................

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

Fig. 1 Pinion (ECS compressor drive quill)

For Training purpose only 124 of 313


7.22.2 - Locking ring Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-05A-311A-C ECS
compressor drive quill (main gearbox) -
Detailed visual examination.
See Para.2 and Figure 2.

Locking ring
P/N:

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

Fig. 2 Locking ring (ECS compressor drive quill)

For Training purpose only 125 of 313


7.22.3 - Case Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-05A-311A-C ECS
compressor drive quill (main gearbox) -
Detailed visual examination.
See Para.3 and Figure 3.

Case
P/N:
S/N:.......................................

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

Fig. 3 Case (ECS compressor drive quill)

For Training purpose only 126 of 313


7.22.4 - Flanged bearing Detailed visual examination

CR&OP Data Module:

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

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

Fig. 4 Flanged bearing (ECS compressor drive quill)

For Training purpose only 127 of 313


7.22.5 - Locking washer Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-05A-311A-C ECS
compressor drive quill (main gearbox) -
Detailed visual examination.
See Para.5.

Locking washer
P/N:

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

Procedure

Do the detailed visual examination of the


locking washer for corrosion, wear and damage.

For Training purpose only 128 of 313


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

39-A-63-20-05-07A-311A-C Fan drive quill (main


gearbox) - Detailed visual examination

Safety conditions:
CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 129 of 313


7.23.1 - Pinion Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-07A-311A-C Fan drive


quill (main gearbox) - Detailed visual
examination.
See Para.1 and Figure 1.

Pinion
P/N:
S/N:.......................................

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

Fig. 1 Pinion (Fan drive quill)

For Training purpose only 130 of 313


7.23.2 - Locking ring Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-07A-311A-C Fan drive


quill (main gearbox) - Detailed visual
examination.
See Para.2 and Figure 2.

Locking ring
P/N:

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

Fig. 2 Locking ring (Fan drive quill)

For Training purpose only 131 of 313


7.23.3 - Flanged bearing Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-07A-311A-C Fan drive


quill (main gearbox) - Detailed visual
examination.
See Para.3 and Figure 3.

Flanged bearing
P/N:
S/N:

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

Fig. 3 Flanged bearing (Fan drive quill)

For Training purpose only 132 of 313


7.23.4 - Locking washer Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-07A-311A-C Fan drive


quill (main gearbox) - Detailed visual
examination.
See Para.4.

Locking washer
P/N:

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

Procedure

Do the detailed visual examination of the


locking washer for corrosion, wear and damage.

For Training purpose only 133 of 313


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

39-A-63-20-05-06A-311A-C Left lubrication pump


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

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:

The data to do a detailed visual examination of the left


Nomenclature Identification No.
lubrication pump is applicable also to the right
Magnifying glass, 10 times Local supply lubrication pump.
Refer to 39-A-63-20-05-24A-311A-C.

For Training purpose only 134 of 313


7.24.1 - Gear Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-06A-311A-C Left
lubrication pump (main gearbox) -
Detailed visual examination.
See Para. 1 and Figure 1.

Left Gear
P/N:
S/N:

Right Gear
P/N:
S/N:

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

Fig. 1 Gear (Left lubrication pump)

For Training purpose only 135 of 313


7.24.2 - Locking ring Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-06A-311A-C Left
lubrication pump (main gearbox) -
Detailed visual examination.
See Para. 2 and Figure 2.

Left Locking ring


P/N:
S/N:

Right Locking ring


P/N:
S/N:

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

Fig. 2 Locking ring (Left lubrication pump)

For Training purpose only 136 of 313


7.24.3 -Locking washer Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-06A-311A-C Left
lubrication pump (main gearbox) -
Detailed visual examination.
See Para. 3.

Left Locking washer


P/N:

Right Locking washer


P/N:

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

Do the detailed visual examination of the


locking washer for corrosion, wear and damage.

For Training purpose only 137 of 313


7.25 - Tail rotor drive quill (main gearbox)
Detailed visual examination
CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor drive quill


(main gearbox) - Detailed visual examination

Safety conditions:
CAUTION

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

Procedure

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

Support equipment:

Nomenclature Identification No.

Magnifying glass, 10 times Local supply

For Training purpose only 138 of 313


7.25.1 - Rotor brake case Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor


drive quill (main gearbox) - Detailed
visual examination.
See Para.1 and Figure 1

Rotor Brake Case


P/N:
S/N:.......................................

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

Fig. 1 case (Tail rotor drive quill)

For Training purpose only 139 of 313


7.25.2 - Pinion Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor


drive quill (main gearbox) - Detailed
visual examination.
See Para.2 and Figure 2

Pinion
P/N:
S/N:.......................................

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

T4

Fig. 2 Pinion (Tail rotor drive quill)

For Training purpose only 140 of 313


7.25.3 - Fan gear Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor


drive quill (main gearbox) - Detailed
visual examination.
See Para.3 and Figure 3

Fan gear
P/N:
S/N:.......................................

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

Fig. 3 Fan gear (Tail rotor drive quill)

For Training purpose only 141 of 313


7.25.4 - Flange Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor


drive quill (main gearbox) - Detailed
visual examination.
See Para.4 and Figure 4

Flange
P/N:
S/N:.......................................

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

Fig. 4 Flange (Tail rotor drive quill)

For Training purpose only 142 of 313


7.25.5 - Three locking rings Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor


drive quill (main gearbox) - Detailed
visual examination.
See Para.5 and Figure 5

Locking ring
P/N:
S/N:.......................................

Locking ring
P/N:
S/N:.......................................

Locking ring
P/N:
S/N:.......................................

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

Fig. 5 Locking rings (Tail rotor drive quill)

For Training purpose only 143 of 313


7.25.6 - Roller bearing Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor


drive quill (main gearbox) - Detailed
visual examination.
See Para.6 and Figure 6

Roller bearing
P/N:
S/N:.......................................

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

Fig. 6 Roller bearing (Tail rotor drive quill)

For Training purpose only 144 of 313


7.25.7 - Flanged ball bearing Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor


drive quill (main gearbox) - Detailed
visual examination.
See Para.7 and Figure 7

Flanged ball bearing


P/N:
S/N:.......................................

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

Fig. 7 Flanged ball bearing (Tail rotor drive quill)

For Training purpose only 145 of 313


7.25.8 - Components Detailed visual examination

CR&OP Data Module:

39-A-63-20-05-28A-311A-C Tail rotor


drive quill (main gearbox) - Detailed
visual examination. See Para. 8
Retaining ring (flange)
P/N:
Spacer (flange)
P/N:
Shim (case)
P/N:
Retaining ring (gear)
P/N:
Shim (gear)
P/N:
Nipple
P/N:
Retaining ring (roller bearing)
P/N:

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

Procedure:

Check the components reported above for corrosion,


wear and damage.

For Training purpose only 146 of 313


7.26 - Dimensions check

Hereinafter are shown the CR&OP Data Modules required to perform the Dimensions check:

7.27) 39-A-63-20-05-00A-361A-C 7.33) 39-A-63-20-05-04A-361A-C


Main gearbox - Dimensions check Front pump drive quill (main gearbox) - Dimensions
check
7.28) 39-A-63-20-05-01A-361A-C
Left input shaft module (main gearbox) - 7.34) 39-A-63-20-05-05A-361A-C
Dimensions check ECS compressor drive quill (main gearbox) -
Dimensions check
7.28) 39-A-63-20-05-02A-361A-C
Right input shaft module (main gearbox) - 7.35) 39-A-63-20-05-07A-361A-C
Dimensions check Fan drive quill (main gearbox) - Dimensions check

7.29) 39-A-63-20-05-03A-361A-C 7.36) 39-A-63-20-05-24A-361A-C


Upper module (main gearbox) - Dimensions check Right lubrication pump (main gearbox) - Dimensions
check
7.30) 39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper module) - 7.36) 39-A-63-20-05-06A-361A-C
Dimensions check Left lubrication pump (main gearbox) - Dimensions
check
7.31) 39-A-63-20-05-14A-361A-C
Planetary gear (mast-planetary assembly) - 7.37) 39-A-63-20-05-28A-361A-C
Dimensions check Tail rotor drive quill (main gearbox) - Dimensions
check
7.32) 39-A-63-20-05-27A-361A-C
Left/right pump drive quill (main gearbox)
Dimensions check

For Training purpose only 147 of 313


7.27 - Main gearbox (Main case) Dimensions check

CR&OP Data Module:

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.

For Training purpose only 148 of 313


7.27.1 - Collector gear Dimensions check

CR&OP Data Module:


(MGB A04) 39-A-63-20-05-00A-361A-C Main gearbox -
Dimensions check. See Para. 1 and Figure 1
Collector gear
P/N:
S/N:.

Inspection results:
........................................................................
(MGB A03)

Fig. 1 Collector gear (Main gearbox)

For Training purpose only 149 of 313


7.27.2 - Diaphragm Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 2 and Figure 2

Diaphragm
P/N:
S/N:.

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

Fig. 2 Diaphragm (Main gearbox)

For Training purpose only 150 of 313


7.27.3 - Housing of the collector-gear ball bearing
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 3 and Figure 3

Housing of the collector-gear ball bearing,


Main Case

P/N:
S/N:.

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

Fig. 3 Housing of the collector gear ball bearing (Main gearbox)

For Training purpose only 151 of 313


7.27.4 - Collector-gear ball bearing
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 4 and Figure 4

Collector-gear ball bearing


P/N:
S/N:.

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

Fig. 4 Collector gear ball bearing (Main gearbox)

For Training purpose only 152 of 313


7.27.5 - Collector-gear roller bearing
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 5 and Figure 5

Collector-gear roller bearing


P/N:
S/N:.

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

Fig. 5 Collector gear roller bearing (Main gearbox)

For Training purpose only 153 of 313


7.27.6 Housing of the tail rotor drive quill
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 6 and Figure 6

Housing of the tail rotor drive quill,


Main Case

P/N:
S/N:.

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

178.030 / 7.0090

Fig. 6 Housing of the tail rotor drive quill (Main gearbox)

For Training purpose only 154 of 313


7.27.7 - Housing of the fan drive quill
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 7 and Figure 7

Housing of the fan drive quill,


Main Case

P/N:
S/N:.

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

Fig. 7 Housing of the fan drive quill (Main gearbox)

For Training purpose only 155 of 313


7.27.8 - Sliding adaptor Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 8 and Figure 8

Sliding adaptor

P/N:
S/N:.

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

Fig. 8 Sliding adaptor (Main gearbox)

For Training purpose only 156 of 313


7.27.9 - Cross shafts (left and right input pinion shaft module)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 9 and Figure 9

Left Cross shaft


P/N:
S/N:.

Right Cross shaft


P/N:
S/N:.

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

Fig. 9 Cross shaft (left and right input pinion)

For Training purpose only 157 of 313


7.27.10 - Left and right input pinion (II stage) Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 10 and Figure 10

Left input pinion


P/N:
S/N:.

Right input pinion


P/N:
S/N:.

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

Fig. 10 Input pinion (left and right)

For Training purpose only 158 of 313


7.27.11 - Left and right pump gear Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 11 and Figure 11

Left pump gear


P/N:
S/N:.

Right pump gear


P/N:
S/N:.

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

Fig. 11 Pump gear (left and right Input pinion)

For Training purpose only 159 of 313


7.27.12 - Left and right bearing sleeve
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 12 and Figure 12

Left bearing sleeve


P/N:
S/N:.

Right bearing sleeve


P/N:
S/N:.

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

Fig. 12 Bearing sleeve (left and right Input pinion)

For Training purpose only 160 of 313


7.27.13 - Housing of the left and right input pinion bearings (main
case) Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 13 and Figure 13

Housing of the left and right input pinion


bearings, Main case:

P/N:
S/N:.

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

Fig. 13 Housing of the left and right input pinion bearings


(main case)

For Training purpose only 161 of 313


7.27.14 - Triplex bearing (left and right input pinion)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 14 and Figure 14

Left triplex ball bearing


P/N:
S/N:.

Right triplex ball bearing


P/N:
S/N:.

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

Fig. 14 Ttriplex bearing (left and right input pinion)

For Training purpose only 162 of 313


7.27.15 - Roller bearing (left and right input pinion)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 15 and Figure 15

Left roller bearing


P/N:
S/N:.

Right roller bearing


P/N:
S/N:.

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

Fig. 15 Roller bearing (left and right input pinion)

For Training purpose only 163 of 313


7.27.16 - Housing of the diaphragm Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 16 and Figure 16

Housing of the diaphragm, Main case:

P/N:
S/N:.

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

Fig. 16 Housing of the diaphragm (main case)

For Training purpose only 164 of 313


7.27.17 - Housing of the left and right pump drive quill
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 17 and Figure 17

Housings of the left and right pump drive


quill, Main case:

P/N:
S/N:.

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

Fig. 17 Housings of the left and right pump drive quill


(Main case)

For Training purpose only 165 of 313


7.27.18 - Housing of the front pump drive quill
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 18 and Figure 18

Housing of the front pump drive quill,


Main case:

P/N:
S/N:.

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

Fig. 18 Housing of the front pump drive quill


(Main case)

For Training purpose only 166 of 313


7.27.19 - Housing of the ECS drive quill
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 19 and Figure 19

Housing of the ECS drive quill,


Main case:

P/N:
S/N:.

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

Fig. 19 Housing of the ECS drive quill


(Main case)

For Training purpose only 167 of 313


7.27.20 - Housings of the left and right lubrication pump
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 20 and Figure 20

Housings of the left and right lubrication


pimp, Main case:

P/N:
S/N:.

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

Fig. 20 Housings of the left and right lubrication pump


(Main case)

For Training purpose only 168 of 313


7.27.21 - Housing of the servo actuators brackets
Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 21 and Figure 21

Housing of the servo actuators brackets,


Main case:

P/N:
S/N:.

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

Fig. 21 Housings of the servo actuators brackets


(Main case)

For Training purpose only 169 of 313


7.27.22 - Anti-torque beam Dimensions check

CR&OP Data Module:

39-A-63-20-05-00A-361A-C Main gearbox -


Dimensions check.
See Para. 22 and Figure 22

Anti-torque beam

P/N:
S/N:.

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

Note:

If the internal diameter of one of the four bushings of the


anti-torque beam does not obey the permitted dimension
written in Fig 22, you must replace the bushing (or the
bushings). Refer to CR&OP 39-A-63-20-05-40A-921A-C.
(This task is not part of this course). Contact the
Manufacturer.
Fig. 22 Anti-torque beam

For Training purpose only 170 of 313


7.28 - Left and Right input shaft module (main gearbox) -
Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C
Left input shaft module (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

The data to do a dimension check of the left-input shaft


module is applicable also to the right-input shaft module
(see CR&OP 39-A-63-20-05-02A-361A-C)

For Training purpose only 171 of 313


7.28.1 - Case assy Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 1 and Figure 1

LH Case Assy

P/N:
S/N:.

RH Case Assy

P/N:
S/N:.

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

Fig. 1 Case Assy (left input shaft module)

For Training purpose only 172 of 313


7.28.2 - Input Pinion Dimensions check

CR&OP Data Module:


(MGB A01) 39-A-63-20-05-01A-361A-C Left input shaft module (main
gearbox) - Dimensions check. See Para. 2 and Figure 2

(MGB A02) LH Pinion


P/N:
S/N:
RH Pinion
P/N:
S/N:
Inspection results:
....................................................

Fig. 2 Input pinion (left input shaft module)

For Training purpose only 173 of 313


7.28.3 - Gear, I stage of reduction
Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 3 and Figure 3

LH Gear

P/N:
S/N:.

RH Gear

P/N:
S/N:.

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

Fig. 3 Gear (left input shaft module)

For Training purpose only 174 of 313


7.28.4 - Input shaft Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 4 and Figure 4

LH Input shaft

P/N:
S/N:.

D
RH Input shaft

P/N:
S/N:.

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

Fig. 4 Input shaft (left input shaft module)

For Training purpose only 175 of 313


7.28.5 - Diaphragm Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 5 and Figure 5

LH Diaphragm

P/N:
S/N:.

RH Diaphragm

P/N:
S/N:.

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

Fig. 5 Diaphragm (left input shaft module)

For Training purpose only 176 of 313


7.28.6 - Sleeve Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 6 and Figure 6

LH Sleeve

P/N:
S/N:.

RH Sleeve

P/N:
S/N:.

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

Fig. 6 Sleeve (left input shaft module)

For Training purpose only 177 of 313


7.28.7 - Flange Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 7 and Figure 7

LH Flange

P/N:
S/N:.
D

RH Flange

P/N:
S/N:.

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

Fig. 7 Flange (left input shaft module)

For Training purpose only 178 of 313


7.28.8 Gimbal support Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 8 and Figure 8

LH Gimbal support

P/N:
S/N:.

RH Gimbal support

P/N:
S/N:.

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

Fig. 8 Gimbal support (left input shaft module)

For Training purpose only 179 of 313


7.28.9 - Inner bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 9 and Figure 9

LH Inner bearing

P/N:
S/N:.

RH Inner bearing

P/N:
S/N:.

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

Fig. 9 Inner bearing (left input shaft module)

For Training purpose only 180 of 313


7.28.10 - Outer bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 10 and Figure 10

LH Outer bearing

P/N:
S/N:.

RH Outer bearing

P/N:
S/N:.

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

Fig. 10 Outer bearing (left input shaft module)

For Training purpose only 181 of 313


7.28.11 - Ball bearing (gear, I stage of reduction)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 11 and Figure 11

LH Ball bearing

P/N:
S/N:.

RH Ball bearing

P/N:
S/N:.

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

Fig. 11 Ball bearing (left input shaft module)

For Training purpose only 182 of 313


7.28.12 - Roller bearing (gear, I stage of reduction)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 12 and Figure 12

LH Roller bearing

P/N:
S/N:.

RH Roller bearing

P/N:
S/N:.

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

Roller bearing OD

Fig. 12 Roller bearing (left input shaft module)

For Training purpose only 183 of 313


7.28.13 - Roller bearing (Input pinion) Dimensions check

CR&OP Data Module:

39-A-63-20-05-01A-361A-C Left input shaft


module (main gearbox) - Dimensions check
See Para. 13 and Figure 13

LH Roller bearing

P/N:
S/N:.

RH Roller bearing

P/N:
S/N:.

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

Fig. 13 Roller bearing (left input shaft module)

For Training purpose only 184 of 313


7.28.14 - Duplex ball bearing (Input pinion) Dimensions check

CR&OP Data Module:


(MGB A01)
39-A-63-20-05-01A-361A-C Left input shaft module (main
gearbox) - Dimensions check. See Para. 14 and Figure 14

LH Duplex ball bearing


(MGB A02)
P/N:
S/N:

RH Duplex ball bearing

P/N:
S/N:

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

Fig. 14 Duplex ball bearing (left input shaft module)

For Training purpose only 185 of 313


7.29 - Upper module (main gearbox)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-03A-361A-C
Upper module (main gearbox) -
Dimensions check

Safety conditions:

CAUTION

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.

For Training purpose only 186 of 313


7.29.1 - Top Case Dimensions check

CR&OP Data Module:

39-A-63-20-05-03A-361A-C Upper module


(main gearbox) - Dimensions check
See Para. 1 and Figure 1

Top Case

P/N:
S/N:.

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

Fig. 1 Top case (Upper module)

For Training purpose only 187 of 313


7.29.2 - Top-case strut attachments
Dimensions check

CR&OP Data Module:

39-A-63-20-05-03A-361A-C Upper module


(main gearbox) - Dimensions check
See Para. 2 and Figure 2

Top-case strut attachment of the upper


fittings, Top case:

P/N:
S/N:.

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

Fig. 2 Top case strut attachments (Upper module)

For Training purpose only 188 of 313


7.29.3 - Ring gear Dimensions check

CR&OP Data Module:

39-A-63-20-05-03A-361A-C Upper module


(main gearbox) - Dimensions check
See Para. 3 and Figure 3

Ring gear

P/N:
S/N:.

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

Fig. 3 Ring gear (Upper module)

For Training purpose only 189 of 313


7.29.4 - Roller bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-03A-361A-C Upper module


(main gearbox) - Dimensions check
See Para. 4 and Figure 4

Roller bearing

P/N:
S/N:.

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

Fig. 4 Roller bearing (Upper module)

For Training purpose only 190 of 313


7.29.5 - Four Upper Fittings Dimensions check

CR&OP Data Module:

39-A-63-20-05-03A-361A-C Upper module


(main gearbox) - Dimensions check
See Para. 5 and Figure 5

Upper Fitting
P/N:
S/N:.

Upper Fitting
P/N:
S/N:.

Upper Fitting
P/N:
S/N:.

Upper Fitting
P/N:
S/N:.

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

If required, replace the Spherical Bearing i.a.w.


CR&OP 39-A-63-20-05-00A-921A-C.
(This task is not part of this course). Contact the
Manufacturer.
Fig. 5 Upper Fitting (Upper module)

For Training purpose only 191 of 313


7.30 - Mast-planetary assembly (upper module)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper
module) - Dimensions check

Safety conditions:

CAUTION

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.

For Training purpose only 192 of 313


7.30.1 - Main rotor shaft (MAST) Dimensions check

CR&OP Data Module:

39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper module) -
Dimensions check
See Para. 1 and Figure 1

Main rotor shaft (mast)

P/N:
S/N:.

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

Fig. 1 Main rotor shaft (Mast planetary assembly)

For Training purpose only 193 of 313


7.30.2 - Spider plate Dimension check

CR&OP Data Module:

39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper module) -
Dimensions check
See Para. 2 and Figure 2

Spider plate

P/N:
S/N:.

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

Fig. 2 Spider plate (Mast planetary assembly)

For Training purpose only 194 of 313


7.30.3 - Planetary pin Dimension check

CR&OP Data Module:

39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper module) -
Dimensions check
See Para. 3 and Figure 3

Planetary Pin
P/N:
S/N:.

Planetary Pin
P/N:
S/N:.

Planetary Pin
P/N:
S/N:.

Planetary Pin
P/N:
S/N:.

Planetary Pin
P/N:
S/N:.

Inspection results:
Fig. 3 Planetary pin (Mast planetary assembly)
.........................................................................
.........................................................................
......................................................................
For Training purpose only 195 of 313
7.30.4 - Ball bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper module) -
Dimensions check
See Para. 4 and Figure 4

Ball bearing

P/N:
S/N:.

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

Fig. 4 Ball bearing (Mast planetary assembly)

For Training purpose only 196 of 313


7.31 - Planetary gear (mastplanetary assembly) -
Dimensions check

CR&OP Data Module:

39-A-63-20-05-14A-361A-C
Planetary gear (mast-planetary
assembly) - Dimensions check

Safety conditions:

CAUTION

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.

For Training purpose only 197 of 313


7.31.1 - Inner bearing race Dimensions check

CR&OP Data Module:

39-A-63-20-05-14A-361A-C
Planetary gear (mast-planetary assembly) -
Dimensions check
See Para. 1 and Figure 1
Inner bearing race,
part of the Planetary gear assy
P/N:
S/N:.
Inner bearing race,
part of the Planetary gear assy
P/N:
S/N:.
Inner bearing race,
part of the Planetary gear assy
P/N:
S/N:.
Inner bearing race,
part of the Planetary gear assy
P/N:
S/N:.
Inner bearing race,
part of the Planetary gear assy
P/N:
S/N:.

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

CR&OP Data Module:

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.

For Training purpose only 199 of 313


7.32.1 - Pinion Dimensions check

CR&OP Data Module:

39-A-63-20-05-27A-361A-C Left/right pump


drive quill (main gearbox) - Dimensions
check
See Para. 1 and Figure 1

Left pinion
P/N:
S/N:.

Right pinion
P/N:
S/N:.

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

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

For Training purpose only 200 of 313


7.32.2 - Pump case Dimensions check

CR&OP Data Module:

39-A-63-20-05-27A-361A-C Left/right pump


drive quill (main gearbox) - Dimensions
check
See Para. 2 and Figure 2

Left pump case


P/N:
S/N:.

Right pump case


P/N:
S/N:.

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

Fig. 2 Pump case (left/right pump drive quill)

For Training purpose only 201 of 313


7.32.3 - Flanged bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-27A-361A-C Left/right pump


drive quill (main gearbox) - Dimensions
check
See Para. 3 and Figure 3

Left Flanged bearing


P/N:
S/N:.

Right Flanged bearing


P/N:
S/N:.

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

Fig. 3 Flanged bearing (left/right pump drive quill)

For Training purpose only 202 of 313


7.33 - Front hyd. pump drive quill (main gearbox)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-04A-361A-C
Front pump drive quill (main
gearbox) - Dimensions check

Safety conditions:

CAUTION

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.

For Training purpose only 203 of 313


7.33.1 - Pinion Dimensions check

CR&OP Data Module:

39-A-63-20-05-04A-361A-C Front pump drive


quill (main gearbox) - Dimensions check
See Para. 1 and Figure 1

Pinion
P/N:
S/N:.

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

Fig. 1 Pinion (Front pump drive quill)

For Training purpose only 204 of 313


7.33.2 - Pump Case Dimensions check

CR&OP Data Module:

39-A-63-20-05-04A-361A-C Front pump drive


quill (main gearbox) - Dimensions check
See Para. 2 and Figure 2

Pump Case
P/N:
S/N:.

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

Fig. 2 Pump Case (Front pump drive quill)

For Training purpose only 205 of 313


7.33.3 - Flanged bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-04A-361A-C Front pump drive


quill (main gearbox) - Dimensions check
See Para. 3 and Figure 3

Flanged bearing
P/N:
S/N:.

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

Fig. 3 Flanged bearing (Front pump drive quill)

For Training purpose only 206 of 313


7.34 - ECS compressor drive quill (main gearbox)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-05A-361A-C
ECS compressor drive quill (main
gearbox) - Dimensions check

Safety conditions:

CAUTION

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.

For Training purpose only 207 of 313


7.34.1 - Pinion Dimensions check

CR&OP Data Module:

39-A-63-20-05-05A-361A-C
ECS compressor drive quill (main gearbox) -
Dimensions check.
See Para. 1 and Figure 1

Pinion
P/N:
S/N:.

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

Fig. 1 Pinion (ECS compressor drive quill)

For Training purpose only 208 of 313


7.34.2 - Case Dimensions check

CR&OP Data Module:

39-A-63-20-05-05A-361A-C
ECS compressor drive quill (main gearbox) -
Dimensions check.
See Para. 2 and Figure 2

Case
P/N:
S/N:.

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

Fig. 2 Case (ECS compressor drive quill)

For Training purpose only 209 of 313


7.34.3 - Flanged bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-05A-361A-C
ECS compressor drive quill (main gearbox) -
Dimensions check.
See Para. 3 and Figure 3

Flanged bearing
P/N:
S/N:.

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

Fig. 3 Flanged bearing (ECS compressor drive quill)

For Training purpose only 210 of 313


7.35 - Fan drive quill (main gearbox)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-07A-361A-C
Fan drive quill (main gearbox) -
Dimensions check

Safety conditions:

CAUTION

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.

For Training purpose only 211 of 313


7.35.1 - Pinion Dimensions check

CR&OP Data Module:

39-A-63-20-05-07A-361A-C
Fan drive quill (main gearbox) - Dimensions
check.
See Para. 1 and Figure 1

Pinion
P/N:
S/N:.

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

Fig. 1 Pinion (Fan drive quill)

For Training purpose only 212 of 313


7.35.2 - Flanged bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-07A-361A-C
Fan drive quill (main gearbox) - Dimensions
check.
See Para. 2 and Figure 2

Flanged bearing
P/N:
S/N:.

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

Fig. 2 Flanged bearing (Fan drive quill)

For Training purpose only 213 of 313


7.36 - Left /Right lubrication pump (main gearbox)
Dimensions check

CR&OP Data Module:

39-A-63-20-05-06A-361A-C
Left lubrication pump (main
gearbox) - Dimensions check

39-A-63-20-05-24A-361A-C
Right lubrication pump (main
gearbox) - Dimensions check

Safety conditions:

CAUTION

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

Note:

The data to do the dimensions check of the left


lubrication pump is applicable also to the right lubrication
pump. See 39-A-63-20-05-24A-361A-C.

For Training purpose only 214 of 313


7.36.1 - Gear Dimensions check

CR&OP Data Module:

39-A-63-20-05-06A-361A-C
Left lubrication pump (main gearbox) -
Dimensions check.
See Para. 1 and Figure 1

Left Gear
P/N:
S/N:.

Right Gear
P/N:
S/N:.

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

Fig. 1 Gear (Left Lubrication Pump)

For Training purpose only 215 of 313


7.36.2 - Pump shaft Dimensions check

CR&OP Data Module:

39-A-63-20-05-06A-361A-C
Left lubrication pump (main gearbox) -
Dimensions check.
See Para. 2 and Figure 2

Left Pump
P/N:
S/N:.

Right Pump
P/N:
S/N:.

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

Fig. 2 Pump shaft (Left Lubrication Pump)

For Training purpose only 216 of 313


7.37 - Tail rotor drive quill (main gearbox) Dimensions check

CR&OP Data Module:

39-A-63-20-05-28A-361A-C
Tail rotor drive quill (main gearbox) -
Dimensions check

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.

For Training purpose only 217 of 313


7.37.1 - Pinion Dimensions check (sheet 1 of 2)

CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive


quill (main gearbox) - Dimensions check
See Para. 1 and Figure 1

Pinion (for MGB P/N 3G6320A00132)


P/N:
S/N:.

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

Fig. 1 Pinion (Tail rotor drive quill) Sheet 1 of 2

For Training purpose only 218 of 313


7.37.1 - Pinion Dimensions check (sheet 2 of 2)

CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive


quill (main gearbox) - Dimensions check
See Para. 1 and Figure 1

Pinion

(for MGB P/N 3G6320A00133 and


subsequent P/N with different two last
digits)

P/N:
S/N:.

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

Fig. 1 Pinion (Tail rotor drive quill) Sheet 2 of 2

For Training purpose only 219 of 313


7.37.2 - Fan gear Dimensions check

CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive


quill (main gearbox) - Dimensions check
See Para. 2 and Figure 2

Fan gear

P/N:
S/N:.

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

Fig. 2 Fan gear (Tail rotor drive quill)

For Training purpose only 220 of 313


7.37.3 - Flange Dimensions check

CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive


quill (main gearbox) - Dimensions check
See Para. 3 and Figure 3

Flange

P/N:
S/N:.

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

Fig. 3 Flange (Tail rotor drive quill)

For Training purpose only 221 of 313


7.37.4 - Rotor brake case Dimensions check

CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive


quill (main gearbox) - Dimensions check
See Para. 4 and Figure 4

Rotor brake case

P/N:
S/N:.

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

Fig. 4 Rotor brake case (Tail rotor drive quill)

For Training purpose only 222 of 313


7.37.5 - Flanged bearing Dimensions check

CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive


quill (main gearbox) - Dimensions check
See Para. 5 and Figure 5

Flanged bearing

P/N:
S/N:.

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

Fig. 5 Flanged bearing (Tail rotor drive quill)

For Training purpose only 223 of 313


7.37.6 - Roller bearing Dimensions check (sheet 1 of 2)

CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive


quill (main gearbox) - Dimensions check
See Para. 6 and Figure 6

Roller bearing (for MGB P/N 3G6320A00132)

P/N:
S/N:.

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

Fig. 6 Roller bearing (Tail rotor drive quill) sheet 1 of 2

For Training purpose only 224 of 313


7.37.6 - Roller bearing Dimensions check (sheet 2 of 2)

CR&OP Data Module:

39-A-63-20-05-28A-361A-C Tail rotor drive


quill (main gearbox) - Dimensions check
See Para. 6 and Figure 6

Roller bearing

(for MGB P/N 3G6320A00133 and subsequent


P/N with different two last digits)

P/N:
S/N:.

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

Fig. 6 Roller bearing (Tail rotor drive quill) sheet 2 of 2

For Training purpose only 225 of 313


7.38 - Dye penetrant Examination

Hereinafter are shown the CR&OP Data Modules required to perform the
dye penetrant examination on the MGB components:

7.39) 39-A-60-20-01-00A-351A-C 7.43) 39-A-63-20-05-04A-351A-C


Disassembled metal components Front pump drive quill (main gearbox)
Tests for surface cracks with dye penetrant Tests for surface cracks with dye penetrant
(General guidelines for Dye Penetrant Examination)
7.44) 39-A-63-20-05-05A-351A-C
7.40) 39-A-63-20-05-00A-351A-C ECS compressor drive quill (main gearbox)
Main gearbox Tests for surface cracks with dye penetrant
Tests for surface cracks with dye penetrant
7.45) 39-A-63-20-05-27A-351A-C
7.41) 39-A-63-20-05-01A-351A-C Left/right pump drive quill (main gearbox)
Left input shaft module (main gearbox) Tests for surface cracks with dye penetrant
Tests for surface cracks with dye penetrant
7.46) 39-A-63-20-05-28A-351A-C
7.41) 39-A-63-20-05-02A-351A-C Tail rotor drive quill (main gearbox)
Right input shaft module (main gearbox) Tests for surface cracks with dye penetrant
Tests for surface cracks with dye penetrant

7.42) 39-A-63-20-05-03A-351A-C
Upper module (main gearbox)
Tests for surface cracks with dye penetrant

For Training purpose only 226 of 313


7.39 General guidelines for Dye Penetrant Examination

CR&OP Data Module:

39-A-60-20-01-00A-351A-C
Disassembled metal components - Tests for surface cracks
with dye penetrant
Safety conditions:
WARNINGS

You must be careful when you do the penetrant inspection. Make sure you know the safety precaution given in standard practices for
liquid penetrant examination (ASTM-E1417).
Wear protective goggles when you use the compressed air. Dust and particles can cause injury to your eyes.

CAUTION

Only approved personnel are permitted to do this procedure.

Procedure

1 ) Unpainted component. Clean the component. Refer to CR&OP 39-A-60-10-01-00A-251A-C.

2) Painted component. Remove the paint finish from the component as applicable, refer to: CR&OP: 39-A-60-10-01-00A-651A-C or to -
659A-C or to -659B-C as necessary.

3) Do a penetrant inspection of the component to find cracks. Obey the standard practices for liquid penetrant examination (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).

For Training purpose only 227 of 313


7.40 - Main gearbox Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-00A-351A-C
Main gearbox - Tests for surface cracks with
dye penetrant

Procedure

To do the test of metal components for surface


cracks with dye penetrant.

Refer to CR&OP: 39-A-60-20-01-00A-351A-C for


general guideline.

For Training purpose only 228 of 313


7.40.1 - Main case, Bottom cover, Anti-torque beam, Diaphragm
Tests for surface cracks with dye penetrant

CR&OP Data Module:

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:.

Dye Penetrant Classification :


Anti-torque
beam
Type I (Fluorescent dye), Method D (methods of
excess penetrant removal), Level 2 (Sensitivity
level: Medium).

Fig. 1 Main gearbox (sheet 1 of 4) Inspection results: ..................................

For Training purpose only 229 of 313


7.40.2 - Seal cover of the Fan & ECS compressor drive quills
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-00A-351A-C
Main gearbox - Tests for surface cracks with
dye penetrant. See Paragraphs 5,6 and
Figure 1 (sheet 2 of 4)

5) Seal cover of the Fan drive quill

Seal cover P/N:


(Fan drive quill) S/N:.

Seal cover 6) Seal cover of the ECS compressor


(ECS compressor) drive quill

P/N:
S/N:.

Dye Penetrant Classification :

Type I (Fluorescent dye), Method D (methods of


excess penetrant removal), Level 2 (Sensitivity
level: Medium).

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

Fig. 1 Main gearbox (sheet 2 of 4)

For Training purpose only 230 of 313


7.40.3 - Servo-actuator brackets - Tests for surface cracks with dye
penetrant

CR&OP Data Module:

39-A-63-20-05-00A-351A-C
Main gearbox - Tests for surface cracks with
dye penetrant. See Para. 7 and Figure 1
(sheet 3 of 4)
7) Front servo-actuator Bracket (A)
P/N:
S/N:.

8) Left servo-actuator Bracket (B)


P/N:
S/N:.
Servo-actuators 9) Right servo-actuator Bracket (C)
Brackets P/N:
S/N:.

Dye Penetrant Classification :

Type I (Fluorescent dye), Method D (methods of


excess penetrant removal), Level 3 (Sensitivity
level: High).

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

Fig. 1 Main gearbox (sheet 3 of 4)

For Training purpose only 231 of 313


7.40.4 - Left and Right input pinions locking rings, collector-gear
locking ring - Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-00A-351A-C
Main gearbox - Tests for surface cracks with
dye penetrant. See Para. 8 and Figure 1
(sheet 4 of 4)
10) Left ring nut
P/N:
S/N:.

10) Right ring nut


P/N:
S/N:.

11) Collector-gear locking ring


P/N:
S/N:.

Dye Penetrant Classification :

Type I (Fluorescent dye), Method D


(methods of excess penetrant removal),
Collector-gear Level 3 (Sensitivity level: High).
Locking ring Ring nut
Inspection results: ..................................

Fig. 1 Main gearbox (sheet 4 of 4)

For Training purpose only 232 of 313


7.41 - Left and right input shaft module (main gearbox)
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-01A-351A-C Left input shaft


module (main gearbox) - Tests for surface
cracks with dye penetrant

39-A-63-20-05-02A-351A-C Right input shaft


module (main gearbox) - Tests for surface
cracks with dye penetrant

Procedure

To do the test of metal components for surface


cracks with dye penetrant.
Refer to CR&OP: 39-A-60-20-01-00A-351A-C for
general guideline.

Nota

The data to do a test for surface cracks with dye


penetrant of the left-input shaft module are
applicable also to the right-input shaft module (see
CR&OP 39-A-63-20-05-02A-351A-C).

For Training purpose only 233 of 313


7.41.1 - Case assy, Oil jet cover, Diaphragm
Tests for surface cracks with dye penetrant

Diaphragm CR&OP Data Module:


Case Assy 39-A-63-20-05-01A-351A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with dye penetrant
See Paragraphs 1, 2, 3 and Figure 1
1) LH Case Assy
P/N:
Oil Jet Cover S/N:.

1) RH Case Assy
P/N:
S/N:.

2) LH Oil jet cover


P/N:
S/N:.

2) RH Oil jet cover


P/N:
Fig. 1 left input shaft module (MGB)
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.

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

For Training purpose only 234 of 313


7.42 - Upper module (main gearbox)
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-03A-351A-C
Upper module (main gearbox) - Tests for
surface cracks with dye penetrant

Procedure

To do the test of metal components for surface


cracks with dye penetrant.
Refer to CR&OP: 39-A-60-20-01-00A-351A-C for
general guideline.

For Training purpose only 235 of 313


7.42.1 - Top case, Cooler adapter and Seal cover -
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-03A-351A-C
Upper module (main gearbox) - Tests for
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 :

Type I (Fluorescent dye), Method D


(methods of excess penetrant removal),
Cooler adapter Level 2 (Sensitivity level: Medium).

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

Fig. 1 Upper module (MGB) sheet 1 of 2

For Training purpose only 236 of 313


7.42.2 - Four Upper Fittings -
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-03A-351A-C
Upper module (main gearbox) - Tests for
surface cracks with dye penetrant.
See Para. 3 and Figure 1 (sheet 2 of 2)
Upper Fitting (A)
P/N:
S/N:.

Upper Fitting (B)


P/N:
S/N:.

Upper Fitting (C)


P/N:
S/N:.

Upper Fitting (D)


Upper Fitting
P/N:
S/N:.

Dye Penetrant Classification :

Type I (Fluorescent dye), Method D


(methods of excess penetrant removal),
Level 3 (Sensitivity level: High).

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

Fig. 1 Upper module (MGB) sheet 2 of 2

For Training purpose only 237 of 313


7.43 - Front hyd. pump drive quill (main gearbox)
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-04A-351A-C
Front pump drive quill (main gearbox) - Tests
for surface cracks with dye penetrant

Procedure

To do the test of metal components for surface


cracks with dye penetrant.
Refer to CR&OP: 39-A-60-20-01-00A-351A-C for
general guideline.

For Training purpose only 238 of 313


7.43.1 - Pump Case, Seal Cover
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-04A-351A-C
Front pump drive quill (main gearbox) - Tests
for surface cracks with dye penetrant.
See Para. 1 and 2, Figure 1

Pump Case
P/N:
S/N:.

Seal Cover
P/N:
S/N:.

Pump case Dye Penetrant Classification :

Seal Cover Type I (Fluorescent dye), Method D


(methods of excess penetrant removal),
Level 2 (Sensitivity level: Medium).

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

Fig. 1 Front pump drive quill (MGB)

For Training purpose only 239 of 313


7.44 - ECS compressor drive quill (main gearbox)
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-05A-351A-C
ECS compressor drive quill (main gearbox) -
Tests for surface cracks with dye penetrant

Procedure

To do the test of metal components for surface


cracks with dye penetrant.
Refer to CR&OP: 39-A-60-20-01-00A-351A-C for
general guideline.

For Training purpose only 240 of 313


7.44.1 - Case - Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-05A-351A-C
ECS compressor drive quill (main gearbox) -
Tests for surface cracks with dye penetrant
See Para. 1 and Figure 1

Case
P/N:
S/N:.

Dye Penetrant Classification :

Type I (Fluorescent dye), Method D


(methods of excess penetrant removal),
Level 2 (Sensitivity level: Medium).

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

Fig. 1 ECS compressor drive quill (MGB)

For Training purpose only 241 of 313


7.45 - Left/right hyd. pump drive quill (main gearbox)
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-27A-351A-C
Left/right pump drive quill (main gearbox) -
Tests for surface cracks with dye penetrant

Procedure

To do the test of metal components for surface


cracks with dye penetrant.
Refer to CR&OP: 39-A-60-20-01-00A-351A-C for
general guideline.

For Training purpose only 242 of 313


7.45. 1 - Pump Case and Seal Cover
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-27A-351A-C
Left/right pump drive quill (main gearbox) -
Tests for surface cracks with dye penetrant.
See Para. 1 and 2, Figure 1
Left Pump Case
P/N:
S/N:.
Left Seal Cover
P/N:
S/N:.

Right Pump Case


P/N:
S/N:.
Right Seal Cover
Pump Case P/N:
S/N:.

Seal Cover Dye Penetrant Classification :

Type I (Fluorescent dye), Method D


(methods of excess penetrant removal),
Level 2 (Sensitivity level: Medium).

Fig. 1 Left/right pump drive quill (MGB) Inspection results: ..................................

For Training purpose only 243 of 313


7.46 - Tail rotor drive quill (main gearbox)
Tests for surface cracks with dye penetrant

CR&OP Data Module:

39-A-63-20-05-28A-351A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with dye penetrant

Procedure

To do the test of metal components for surface


cracks with dye penetrant.
Refer to CR&OP: 39-A-60-20-01-00A-351A-C for
general guideline.

For Training purpose only 244 of 313


7.46.1 - Rotor brake case, Seal case and Locking rings
Tests for surface cracks with dye penetrant

Locking ring CR&OP Data Module:


Rotor brake
Case 39-A-63-20-05-28A-351A-C
Seal Case
Tail rotor drive quill (main gearbox)
Tests for surface cracks with dye penetrant.
See from Para. 1 to Para. 5, Figure 1
3) Rotor brake Case
P/N:
S/N:.
Locking ring
2) Seal Case
P/N:
Locking ring S/N:.

1) Locking ring
P/N:
S/N:.

4) Locking ring
P/N:
S/N:.

5) Locking ring (*)


P/N:
S/N:.

Dye Penetrant Classification :


Fig. 1 Tail rotor drive quill (MGB) Type I (Fluorescent dye), Method D
(methods of excess penetrant removal),
Level 2 (items 2, 3) Level 3 (items 1, 4, 5).

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

For Training purpose only 245 of 313


7.47 - Magnetic particles examination

Hereinafter are shown the CR&OP Data Modules required to perform the Magnetic particles examination :
7.48) 39-A-60-20-01-00A-352A-C 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

CR&OP Data Module:

39-A-60-20-01-00A-352A-C
Disassembled metal components - Tests for surface cracks
with magnetic particles

Safety conditions:
WARNING
You must be careful when you do the magnetic particle inspection. Make sure you know the safety precaution given in standard practices
for magnetic particle inspection (ASTM-E1444).
CAUTION
Only approved personnel are permitted to do this procedure.

Procedure
1) Unpainted component. Clean the component. Refer to CR&OP 39-A-60-10-01-00A-251A-C.

2) Painted component. Remove the paint finish from the component. Refer to 39-A-60-10-01-00A-252A-C (this Data Module is in
preparation).

3) Do a magnetic particle inspection of the component to find cracks. Obey the standard practices for magnetic particle inspection
(ASTM-E1444).

4) Use the products that follow (or approved alternatives):

Particles Ardrox 8515 or Magnaflux Magnaglo 14A


Liquid carrier Ardrox Fluxal.

5) Clean the component. Refer to Step 1.

6) Put the component in an applicable container. Make sure the component has sufficient protection against environmental condition.

For Training purpose only 247 of 313


7.49 - Main gearbox (Main case) Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 248 of 313


7.49.1 - MGB (Main case) components involved for the Magnetic
Particles Test
The components involved are:
CR&OP Data Module:
1) Collector gear
P/N:
39-A-63-20-05-00A-352A-C S/N:.
Main gearbox - Tests for surface cracks with
2) Sliding Adapter
magnetic particles. Refer to Figure 1 P/N:
S/N:.

3) Collector gear Locking ring


P/N:
S/N:.

4) LH and RH Input Pinions (II stage)


P/N:
S/N:.

5) LH and RH Cross Shafts


P/N:
S/N:

6) LH and RH input pinions Locking


Rings
P/N:
S/N:

7) LH and RH Pump gears


P/N:.
S/N:

8) and 9) LH and RH Retaining Rings


P/N:.
S/N:

10) LH and RH Pinion Bearing Sleeves


P/N:
S/N:
Fig. 1 Main gearbox Components for magnetic particles test

For Training purpose only 249 of 313


7.49.2 - Collector gear Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para.1 and to Figure 2

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

Fig. 2 Collector gear Magnetic Particles Test Procedure

For Training purpose only 250 of 313


7.49.3 - Left and right Input pinions
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para.2 and to Figure 3

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

Fig. 3 Input Pinion Magnetic Particles Test Procedure

For Training purpose only 251 of 313


7.49.4 - Left and right Pump Gears
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para.3 and to Figure 4

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

Fig. 4 Pump gear Magnetic Particles Test Procedure

For Training purpose only 252 of 313


7.49.5 - Sliding Adapter - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para.4 and to Figure 5

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

Fig. 5 Sliding Adapter Magnetic Particles Test Procedure

For Training purpose only 253 of 313


7.49.6 - Left and right input Pinions Bearing Sleeves
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para.5 and to Figure 6

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

Fig. 6 Input Pinion Bearing Sleeve Magnetic Particles Test Procedure

For Training purpose only 254 of 313


7.49.7 - Left and right input pinions Locking Rings
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para.6 and to Figure 7

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

Fig. 7 Input Pinion Locking ring Magnetic Particles Test Procedure

For Training purpose only 255 of 313


7.49.8 - Collector gear Locking Ring
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para. 7 and to Figure 8

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

Fig. 8 Collector gear Locking ring Magnetic Particles Test Procedure

For Training purpose only 256 of 313


7.49.9 - Left and right Cross Shafts
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para. 8 and to Figure 9

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

Fig. 9 Cross shaft Magnetic Particles Test Procedure

For Training purpose only 257 of 313


7.49.10 - Left and right Retaining Rings (8) and (9)
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-00A-352A-C
Main gearbox - Tests for surface cracks with
magnetic particles
Refer to Para. 9 and to Figure 10

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

Item 9 Item 8

Fig. 10 Retaining rings Magnetic Particles Test Procedure

For Training purpose only 258 of 313


7.50 - Left and right Input Shaft Module (main gearbox)
Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) - Tests for surface cracks
with magnetic particles

39-A-63-20-05-02A-352A-C
Right input shaft module (main gearbox) - Tests for surface cracks
with magnetic particles
Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

General Note

The data to do a test for surface cracks with magnetic particles of the left-input shaft
module are applicable also to the right-input shaft module.
See CR&OP 39-A-63-20-05-02A-352A-C.

For Training purpose only 259 of 313


7.50.1 - Input Shaft Module Components involved for the Magnetic
Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) - 1) LH and RH Gimbal
P/N:
Tests for surface cracks with magnetic S/N:.
particles. Refer to Figure 1
2) LH and RH Flange
P/N:
S/N:.

3) LH and RH Pinion Locking Ring


P/N:
S/N:.

4) LH and RH Gear Locking Ring


P/N:
S/N:.

5) LH and RH Input Shaft


P/N:
S/N:

6) LH and RH Input Pinion


P/N:
S/N:

7) LH and RH Sleeve
P/N:.
S/N:

8) LH and RH Gear (I stage)


P/N:.
S/N:

Fig. 1 Input Shaft Module Components for magnetic particles test

For Training purpose only 260 of 313


7.50.2 - Gimbal - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 1 and Figure 2

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

Fig. 2 Gimbal Magnetic Particles Test Procedure

For Training purpose only 261 of 313


7.50.3 - Input Pinion - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 2 and Figure 3

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

Fig. 3 Pinion Magnetic Particles Test Procedure

For Training purpose only 262 of 313


7.50.4 - Gear (I stage of reduction)
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 3 and Figure 4

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

Fig. 4 Gear Magnetic Particles Test Procedure

For Training purpose only 263 of 313


7.50.5 - Input shaft - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 4 and Figure 5

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

Fig. 5 Input Shaft Magnetic Particles Test Procedure

For Training purpose only 264 of 313


7.50.6 - Sleeve - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 5 and Figure 6

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

Fig. 6 Sleeve Magnetic Particles Test Procedure

For Training purpose only 265 of 313


7.50.7 - Flange - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 6 and Figure 7

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

Fig. 7 Flange Magnetic Particles Test Procedure

For Training purpose only 266 of 313


7.50.8 - Gear Locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 7 and Figure 8

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

Fig. 8 - Gear locking ring Magnetic Particles Test Procedure

For Training purpose only 267 of 313


7.50.9 - Pinion locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 8 and Figure 9

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

Fig. 9 - Pinion locking ring Magnetic Particles Test Procedure

For Training purpose only 268 of 313


7.51 - Upper Module (main gearbox) - Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-03A-352A-C
Upper module (main gearbox) Tests for
surface cracks with magnetic particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 269 of 313


7.51.1 - Upper module (main gearbox) Components involved for
the Magnetic Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-03A-352A-C
Upper module (main gearbox) Tests for 1) Ring gear
P/N:
surface cracks with magnetic particles. Refer S/N:.
to Figure 1
2) Locking ring
P/N:
S/N:.

Fig. 1 Upper Module Components for magnetic particles test

For Training purpose only 270 of 313


7.51.2 - Ring gear - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-03A-352A-C
Upper module (main gearbox) Tests for
surface cracks with magnetic particles.
Refer to Para. 1 and to Figure 2.

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

Fig. 2 Ring gear Magnetic Particles Test Procedure

For Training purpose only 271 of 313


7.51.3 - Locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-03A-352A-C
Upper module (main gearbox) Tests for
surface cracks with magnetic particles.
Refer to Para. 2 and to Figure 3.

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

Fig. 3 Locking ring Magnetic Particles Test Procedure

For Training purpose only 272 of 313


7.52 - Front hyd. pump drive quill (main gearbox)
Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-04A-352A-C
Front pump drive quill (main gearbox) - Tests
for surface cracks with magnetic particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 273 of 313


7.52.1 - Front pump drive quill (main gearbox) Components
involved for the Magnetic Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-04A-352A-C
Front pump drive quill (main gearbox) - Tests 1) Pinion
P/N:
for surface cracks with magnetic particles. S/N:.
Refer to Figure 1.
2) Locking ring
P/N:
S/N:.

Fig. 1 Front pump drive quill (main gearbox) Components for magnetic particles test

For Training purpose only 274 of 313


7.52.2 - Pinion - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-04A-352A-C
Front pump drive quill (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 1 and to Figure 2.

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

Fig. 2 Pinion - Magnetic Particles Test Procedure

For Training purpose only 275 of 313


7.52.3 - Locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-04A-352A-C
Front pump drive quill (main gearbox) -
Tests for surface cracks with magnetic
particles. Refer to Para. 2 and to Figure 3.

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

Fig. 3 Locking ring - Magnetic Particles Test Procedure

For Training purpose only 276 of 313


7.53 - ECS compressor drive quill (main gearbox)
Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-05A-352A-C
ECS compressor drive quill (main gearbox) -
Tests for surface cracks with magnetic
particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 277 of 313


7.53.1 - ECS compressor drive quill (main gearbox) Components
involved for the Magnetic Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-05A-352A-C ECS compressor
drive quill (main gearbox) - Tests for surface 1) Pinion
P/N:
cracks with magnetic particles. S/N:.
Refer to Figure 1.
2) Locking ring
P/N:
S/N:.

Fig. 1 ECS Compressor drive quill (main gearbox) Components for magnetic particles test

For Training purpose only 278 of 313


7.53.2 - Pinion - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-05A-352A-C
ECS compressor drive quill (main gearbox)
- Tests for surface cracks with magnetic
particles. Refer to Para. 1 and to Figure 2.

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

Fig. 2 Pinion - Magnetic Particles Test Procedure

For Training purpose only 279 of 313


7.53.3 - Locking ring
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-05A-352A-C
ECS compressor drive quill (main gearbox)
- Tests for surface cracks with magnetic
particles. Refer to Para. 2 and to Figure 3.

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

Fig. 3 Locking ring - Magnetic Particles Test Procedure

For Training purpose only 280 of 313


7.54 - Left and Right Lubrication Pump - Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-06A-352A-C
Left lubrication pump (main gearbox) - Tests for surface cracks with
magnetic particles

39-A-63-20-05-24A-352A-C
Right lubrication pump (main gearbox) - Tests for surface cracks
with magnetic particles
Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

General Note

The tests for surface cracks with magnetic particles given for the right lubrication
pump are applicable to the left lubrication pump.
See CR&OP 39-A-63-20-05-24A-352A-C.

For Training purpose only 281 of 313


7.54.1 - Lubrication pump (main gearbox) components involved for
the Magnetic Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-06A-352A-C Left lubrication
pump (main gearbox) - Tests for surface 1) Gear
P/N:
cracks with magnetic particles. S/N:.
Refer to Figure 1.
2) Locking ring
P/N:
S/N:.

Fig. 1 Left lubrication pump (main gearbox) Components for magnetic particles test

For Training purpose only 282 of 313


7.54.2 - Gear - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-06A-352A-C
Left lubrication pump (main gearbox) -
Tests for surface cracks with magnetic
particles.
Refer to Para. 1 and to Figure 2.
Inspection results:
...............................................................................
...............................................................................
...............................................................................

Fig. 2 Gear - Magnetic Particles Test Procedure

For Training purpose only 283 of 313


7.54.3 - Locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-06A-352A-C
Left lubrication pump (main gearbox) -
Tests for surface cracks with magnetic
particles.
Refer to Para. 2 and to Figure 3.

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

Fig. 3 Locking ring - Magnetic Particles Test Procedure

For Training purpose only 284 of 313


7.55 - Fan drive quill (main gearbox) Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-07A-352A-C
Fan drive quill (main gearbox) - Tests for
surface cracks with magnetic particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 285 of 313


7.55.1 - Fan drive quill (main gearbox) components involved for the
Magnetic Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-07A-352A-C Fan drive quill
(main gearbox) - Tests for surface cracks with 1) Pinion
P/N:
magnetic particles. S/N:.
Refer to Figure 1.
2) Locking ring
P/N:
S/N:.

Fig. 1 Fan drive quill (main gearbox) Components for magnetic particles test

For Training purpose only 286 of 313


7.55.2 - Pinion - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-07A-352A-C
Fan drive quill (main gearbox) - Tests for
surface cracks with magnetic particles.
Refer to Para. 1 and to Figure 2.

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

Fig. 2 Pinion - Magnetic Particles Test Procedure

For Training purpose only 287 of 313


7.55.3 - Locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-07A-352A-C
Fan drive quill (main gearbox) - Tests for
surface cracks with magnetic particles.
Refer to Para. 2 and to Figure 3.

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

Fig. 3 Locking ring - Magnetic Particles Test Procedure

For Training purpose only 288 of 313


7.56 - Mast-planetary assembly (upper module)
Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) -
Tests for surface cracks with magnetic
particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 289 of 313


7.56.1 - Mast-planetary assembly (upper module) components
involved for the Magnetic Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) - 1) Main Rotor Shaft (Mast)
P/N:
Tests for surface cracks with magnetic S/N:.
particles. Refer to Figure 1.
2) Planetary Gear Spacers (5 items)
P/N:

3) Spider Plate
P/N:
S/N:.

4) Planetary Pins (5 items)


P/N:
S/N:.

5) Spider Plate Spacers (5 items)


P/N:
S/N:.

6) Ring Nuts (5 items)


P/N:
S/N:.

Fig. 1 Mast Planetary assembly Components for magnetic particles test

For Training purpose only 290 of 313


7.56.2 - Main Rotor Shaft (Mast)
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) -
Tests for surface cracks with magnetic
particles. Refer to Para. 1 and to Figure 2.

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

Fig. 2 Main Rotor Shaft - Magnetic Particles Test Procedure

For Training purpose only 291 of 313


7.56.3 - Spider Plate - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) -
Tests for surface cracks with magnetic
particles. Refer to Para. 2 and to Figure 3.

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

Fig. 3 - Spider Plate - Magnetic Particles Test Procedure

For Training purpose only 292 of 313


7.56.4 - Planetary Pins (five items)
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) -
Tests for surface cracks with magnetic
particles. Refer to Para. 3 and to Figure 4.

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

Fig. 4 Planetary Pins - Magnetic Particles Test Procedure

For Training purpose only 293 of 313


7.56.5 - Ring Nuts (five items)
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) -
Tests for surface cracks with magnetic
particles. Refer to Para. 4 and to Figure 5.

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

Fig. 5 Ring Nuts - Magnetic Particles Test Procedure

For Training purpose only 294 of 313


7.56.6 - Spider plate spacers (five items)
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) -
Tests for surface cracks with magnetic
particles. Refer to Para. 5 and to Figure 6.

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

Fig. 6 Spider plate spacer - Magnetic Particles Test Procedure

For Training purpose only 295 of 313


7.56.7 - Planetary gear spacers (five items)
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) -
Tests for surface cracks with magnetic
particles. Refer to Para. 6 and to Figure 7.

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

Fig. 7 Planetary gear spacer - Magnetic Particles Test Procedure

For Training purpose only 296 of 313


7.57 - Planetary gear assembly (upper module)
Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-14A-352A-C
Planetary gear assembly (upper module) -
Tests for surface cracks with magnetic
particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 297 of 313


7.57.1 - Planetary gear assembly (upper module) components
involved for the Magnetic Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-14A-352A-C
Planetary gear assembly (upper module) -
Tests for surface cracks with magnetic Planetary Gear Assy (5 items)
particles. Refer to Figure 1. P/N:
S/N:.

1) Gear

2) Inner Bearing Race

Fig. 1 Planetary gear assembly Components for magnetic particles test

For Training purpose only 298 of 313


7.57.2 - Gear - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-14A-352A-C
Planetary gear assembly (upper module) -
Tests for surface cracks with magnetic
particles. Refer to Para. 1 and to Figure 2.

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

Fig. 2 Gear (planetary gear assembly) - Magnetic Particles Test Procedure

For Training purpose only 299 of 313


7.57.3 - Inner bearing race - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-14A-352A-C
Planetary gear assembly (upper module) -
Tests for surface cracks with magnetic
particles. Refer to Para. 2 and to Figure 3.

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

Fig. 3 Inner Bearing Race (planetary gear assembly) - Magnetic Particles Test
Procedure

For Training purpose only 300 of 313


7.58 - Left/Right hyd. pump drive quill (main gearbox)
Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-27A-352A-C
Left/right pump drive quill (main gearbox) -
Tests for surface cracks with magnetic
particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 301 of 313


7.58.1 - Left/right pump drive quill (main gearbox) components
involved for the Magnetic Particles Test

CR&OP Data Module:


The components involved are:
39-A-63-20-05-27A-352A-C
Left/right pump drive quill (main gearbox) - 1) Pinion (LH & RH)
P/N:
Tests for surface cracks with magnetic S/N:.
particles. Refer to Figure 1.
2) Locking ring (LH & RH)
P/N:

Fig. 1 Left/right pump drive quill Components for magnetic particles test

For Training purpose only 302 of 313


7.58.2 - Pinion - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-27A-352A-C
Left/right pump drive quill (main gearbox)
- Tests for surface cracks with magnetic
particles. Refer to Para. 1 and to Figure 2.

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

Fig. 2 Pinion (Left/right pump drive quill) - Magnetic Particles Test


Procedure

For Training purpose only 303 of 313


7.58.3 - Locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-27A-352A-C
Left/right pump drive quill (main gearbox)
- Tests for surface cracks with magnetic
particles. Refer to Para. 2 and to Figure 3.

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

Fig. 3 Locking ring (Left/right pump drive quill) - Magnetic Particles Test
Procedure

For Training purpose only 304 of 313


7.59 - Tail rotor drive quill (main gearbox) Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles

Procedure

To do the test of metal components for surface


cracks with magnetic particles.

Refer to CR&OP 39-A-60-20-01-00A-352A-C for


general guideline.

For Training purpose only 305 of 313


7.59.1 - Tail rotor drive quill (main gearbox) components involved
for the Magnetic Particles Test

CR&OP Data Module:

39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Figure 1.

The components involved are:


1) Flange
P/N:
S/N:.

2) Locking Ring
P/N:
S/N:.

3) Fan gear
P/N:
S/N:.

4) Locking ring
P/N:
S/N:.

5) and 6) Pinion
P/N:
S/N:.

Fig. 1 Tail rotor drive quill Components for magnetic particles test

For Training purpose only 306 of 313


7.59.2 - Pinion (Main gearbox P/N 3G6320A00132) -
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 1 and to Figure 2.

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

Fig. 2 Pinion (Tail rotor drive quill) - Magnetic Particles Test Procedure

For Training purpose only 307 of 313


7.59.3 - Pinion (Main gearboxes P/N 3G6320A00133 and subsequent P/N
with different two last digits) - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 6 and to Figure 7.

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

Fig. 7 Pinion (Tail rotor drive quill) - Magnetic Particles Test Procedure

For Training purpose only 308 of 313


7.59.4 - Fan gear - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 2 and to Figure 3.

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

Fig. 3 Fan gear (Tail rotor drive quill) - Magnetic Particles Test Procedure

For Training purpose only 309 of 313


7.59.5 - Flange - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 3 and to Figure 4.

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

Fig. 4 Flange (Tail rotor drive quill) - Magnetic Particles Test Procedure

For Training purpose only 310 of 313


7.59.6 - Locking ring (Main gearbox P/N 3G6320A00132) -
Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 4 and to Figure 5.

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

Fig. 5 locking ring (Tail rotor drive quill) - Magnetic Particles Test
Procedure

For Training purpose only 311 of 313


7.59.7- Locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:

39-A-63-20-05-28A-352A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with magnetic particles.
Refer to Para. 5 and to Figure 6.

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

Fig. 6 locking ring (Tail rotor drive quill) - Magnetic Particles Test
Procedure

For Training purpose only 312 of 313


Chapter 7 Components Cleaning, Paint removal, Protection and Inspection

THE END

RETURN TO LESSON SUMMARY RETURN TO COURSE MENU


For Training purpose only 313 of 313
MAIN TRANSMISSION GEARBOX
(MGB) REPAIR & OVERHAUL
TECHNICIAN TRAINING
Chapter 8 - Assembly
Procedures
8 Assembly Procedure

INDEX

8.1 Pre-Assembly Requirements


8.2 MGB, Assembly procedures
8.2.1 Main Case, Assembly procedures
8.2.2 Upper Module, Assembly procedures
8.2.3 Main Case, External components installation procedures
8.2.4 LH / RH Input Shaft Module, assembly procedures
8.2.5 Anti-Torque Beam, Installation procedures

(Conts)

For Training purpose only 2 of 152


8.1 Pre-Assembly Requirements

During this phase there are conditions and actions that must be carried out i.a.w. the current issue of the
IETP, these are:

1. 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

Nomenclature Identification No Specification references Ref. Documents

Solvent, cleaning C010 P-D-680 type II (AMDI) 39-A-00-50-00-09A-078A-D


Grease C115 Parker super O-lube. (AMDI) 39-A-00-50-00-08A-078B-D
Grease (NS-3913-G1) C147 None (AMDI) 39-A-00-50-00-13B-078A-D
Oil C006 MIL-PRF-7808L (AMDI) 39-A-00-50-00-05A-078A-D

For Training purpose only 3 of 152


8.2 MGB, Assembly procedures

During the MGB assembly procedure perform the following actions:

Record and identify the P/N and the S/N of all Components / Main assemblies used during the
MGB assembly phase.
The assembly procedure of the MGB is essentially the reverse of the disassembly procedure.

8.2.1 Main Case, Assembly procedures.

8.2.1.1 Shims, installation.


8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing, installation.
8.2.1.3 Diaphragm Assy, assembly.
8.2.1.4 Collector Gear Assy, assembly.
8.2.1.5 RH / LH Input Pinion Assy (II stage of reduction), assembly.
8.2.1.6 Tail Rotor Drive Quill Assy, assembly.
8.2.1.7 Left and Right Hyd. Pump Drive Quill, assembly.
8.2.1.8 Front Hyd. Pump Drive Quill, assembly.
8.2.1.9 ECS-Compressor Drive Quill, assembly.
8.2.1.10 Fan Drive Quill, assembly.
8.2.1.11 Collector Gear Assy, installation.
8.2.1.12 Diaphragm Assy, installation.
8.2.1.13 Tail Rotor Drive Quill Assy, installation.

(cont.s)

For Training purpose only 4 of 152


8.2 MGB, Assembly procedures
8.2.1.14 RH / LH Input Pinion Assy (II stage of reduction), installation.
8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation.
8.2.1.16 Front Hyd. Pump Drive Quill Assy, installation.
8.2.1.17 ECS-Compressor Drive Quill Assy and Seal Cover, installation.
8.2.1.18 Fan Drive Quill Assy, installation.
8.2.1.19 Main Case, Backlash check
8.2.1.20 Fan Seal Cover, installation.
8.2.1.21 Left / Right Lubrication Pump, assembly.
8.2.1.22 Left / Right lubrication Pump, installation.
8.2.1.23 Bottom Cover, assembly.
8.2.1.24 Bottom Cover, installation.
8.2.1.25 AC Generators drive cover and plug, installation

8.2.2 Upper Module, Assembly procedures


8.2.2.1 Planetary gears assembly (mast planetary assembly), assembly.
8.2.2.2 Mast-planetary assembly (upper module), assembly.
8.2.2.3 Upper Fittings, Brackets, installation.
8.2.2.4 Mast-planetary assembly, installation.
8.2.2.5 Planetary Crown (Fixed Ring Gear), installation.
8.2.2.6 Roller Bearing and Cover seal, Installation.
8.2.2.7 Upper Cooler Adapter, installation
8.2.2.8 Four Oil jets, installation.
8.2.2.9 Oil Filler plug, Mast Chip detector, Mast Cover and Ident. Plate installation
8.2.2.10 Unions, installation procedures
8.2.2.11 Upper Module Assy, installation.

(cont.s)

For Training purpose only 5 of 152


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

For Training purpose only 6 of 152


8.2.1 Main Case, Assembly procedures
Safety conditions
WARNING
The materials that follow are dangerous. Before you do this procedure, make sure that you know all the safety precautions
and first aid instructions for the materials reported hereinafter. Refer to CR&OP: 39-A-60-50-00-00A-074A-C.

Nomenclature Identification No. Specification references Ref. Documents

Solvent, cleaning C010 P-D-680 type II (AMDI) 39-A-00-50-00-09A-078A-D

Oil C006 MIL-PRF-7808L (AMDI) 39-A-00-50-00-05A-078A-D

Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M (AMDI) 39-A-00-50-00-28A-078A-D

Grease (Parker super O-lube). C115 None (AMDI) 39-A-00-50-00-08A-078B-D

Grease (Aeroshell 22) C009 MIL-PRF-81322F (AMDI) 39-A-00-50-00-08A-078A-D

Grease (Aeroshell Grease 17) C022 MIL-PRF-21164 (AMDI) 39-A-00-50-00-21A-078A-D

Grease (NS-3913-G1) C147 None (AMDI) 39-A-00-50-00-13B-078A-D

Solvent (Loctite quick clean 7031) C023 None (AMDI) 39-A-00-50-00-22A-078A-D

Sealing compound (Naftoseal MC-236 C030 AMS-S-8802B (AMDI) 39-A-00-50-00-29A-078A-D


Class B)
Compound (Dykem Steel Blue) C162 None (AMDI) 39-A-00-50-00-28B-078A-D

Adhesive (Shellac) C163 None (AMDI) 39-A-00-50-00-29B-078A-D

Sealing compound (AMS-S-8802, Class A- C164 AMS-S-8802, Class A-1/2. (AMDI) 39-A-00-50-00-30B-078A-D
1/2)

For Training purpose only 7 of 152


8.2.1 Main Case, Assembly procedures

CAUTION

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

Note 1 Refer to CR&OP data module: 39-A-63-20-05-00A-710A-C


(Main gearbox - Assemble procedures) if the Test Bench is
available.

If the Test Bench is not available, you can do the functional


check with the main gearbox installed on the helicopter.
In this case refer to CR&OP data module: 39-A-63-20-05-00A-
710B-C (Main gearbox - Assemble procedures).9
-A-63-20-05-00A-710B-C
Note 2 In this section will be described the actions reported on CR&OP
data module 39-A-63-20-05-00A-710A-C following a specific
guideline.

Note 3 - During this procedure, obey the general guidelines applicable to


the assemble procedures. Refer to CR&OP data module 39-A-
63-20-05-00A-714A-C.

For Training purpose only 8 of 152


8.2.1 Main Case, Assembly procedures
Install the Main Case assembly with the Support on the Maintenance Trolley

CR&OP data module:


1

39-A-63-20-05-00A-710A-C
Main gearbox - Assemble procedures.

Support equipments:

Identification No.
Nomenclature

Lifting tool, main case assembly 3G6320A00131A181B

Trolley, main case maintenance 3G6320A00131A188C

2 Lifting device Local supply

For Training purpose only 9 of 152


8.2.1.1 Shims Installation
Action No. 1: Shims location

Shim (102)
Shim (113)
Screw (103) x 3 CR&OP data module:
Screw (114) x 3
Shim (187)
Shim (193)
Screw (194) x 3
Screw (186) x 4 Screw (184) x 3 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

39-A-63-20-05-00A-710A-C - Main gearbox - Assemble


procedures.

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

LH Shim (193) X (mm): refer to the D.M.as necessary.

and

CG is the dimension (mm) engraved on the RH side of the Main Case.


CH is the dimension (mm) engraved on the LH side of the Main Case.

Screw (194) x 3

Main Case Left side (Input Pinion II stage of reduction)

For Training purpose only 11 of 152


8.2.1.1 Shims Installation
Action No. 2: RH Shim (193) and LH Shim (193) installation

Procedures (cont. s)

3. Measure the thickness of the shim and make sure that it is as specified in
previous Step 2. If the thickness of the shim is not in the limits, do step 3.1
or Step 3.2 as necessary. Contact the AW Customer Support as necessary.

3.1 Machine the Shim and remove material until the thickness is correct
(measure the thickness of the shim regularly while you machine it). Restore
the protection as required.

3.2 Discard the Shim and install a new item. Adjust the thickness of the new
shim and restore the protection as required.

4. Put each Shim (193) in its housing of the main case assembly.

5. Install the three Screws (194) to attach the Shim (193).

Note:

The procedure reported on Step 3 can be used for all other shims installed on the
Main Case.

For Training purpose only 12 of 152


8.2.1.1 Shims Installation
Action No. 3: Shim (177) installation

CR&OP Data Module:

39-A-63-20-05-00A-710A-C - Main
gearbox - Assemble procedures.

Procedure (TBD)
Install the Shim (177) as follows:

1. Make sure that the Shim has the same S/N


as the Main Case assembly.
2. Verify / Calculate / Record the Thickness of
the Shim with this formula:

Shim Thickness = X - CJ
where

X (mm): refer to the D.M.as necessary.


RH Shim (177)
Screw (184) x 3 and

CJ is the dimension (mm) engraved on the


Main Case.

Main Case Rear side (Tail Rotor drive quill)

For Training purpose only 13 of 152


8.2.1.1 Shims Installation
Action No. 4: Shim (187) installation
CR&OP Data Module:

39-A-63-20-05-00A-710A-C - Main
gearbox - Assemble procedures.

Procedure

Install the shim (187) as follows:

1. Make sure that the shim has the same


S/N as the main case assembly.
2. Verify / Calculate / Record the thickness
of the shim with this formula:

Screw (186) x 4 Shim Thickness = CF - X

where

CF is the dimension (mm) engraved on the


RH Shim (187)
main case, and
X (mm): refer to the D.M.as necessary.

Main Case Internal view, lower side

For Training purpose only 14 of 152


8.2.1.1 Shims Installation
Action No. 5: LH Shim (102) and RH Shim (102) installation

LH Shim (102)
CR&OP Data Module:

39-A-63-20-05-00A-710A-C - Main gearbox - Assemble


procedures.
Procedure
Install the Right and Left Shim (102) as follows:
Screw (103) x 3
1. Make sure that the Right Shim and the Left Shim have the same S/N
as the Main Case assembly.
2. Verify / Calculate / Record the Thickness of the RH Shim and LH Shim
with this formula:
Main Case LH side (LH Hyd. Pump drive quill)
RH Shim Thickness = X - CM
LH Shim Thickness = X - CP
RH Shim (102)
where

X (mm): refer to the D.M.as necessary.

CM is the dimension (mm) engraved on the RH side of the main case.


CP is the dimension (mm) engraved on the LH side of the main case.

Screw (103) x 3

Main Case RH side (RH Hyd. Pump drive quill)

For Training purpose only 15 of 152


8.2.1.1 Shims Installation
Action No. 6: Shim (113) installation

CR&OP Data Module:

39-A-63-20-05-00A-710A-C - Main gearbox -


Assemble procedures.

Shim (113) Procedure

Install the shim (113) as follows:

1. Make sure that the shim has the same serial number
as the main case assembly
2. Verify / Calculate / Record the thickness of the shim
with this formula:

Shim Thickness = X CS

Screw (114) x 3 where

X (mm): refer to the D.M.as necessary.

CS is the dimension (mm) engraved on the main


case.

Main Case Rear side (Fan drive quill)

For Training purpose only 16 of 152


8.2.1.1 Shims Installation
Action No. 7: Shim (92) installation

CR&OP Data Module:

39-A-63-20-05-00A-710A-C - Main gearbox -


Assemble procedures.

Procedure

Install the shim (92) as follows:

1. Make sure that the shim has the same serial number
as the main case assembly
2. Calculate the thickness of the shim with this formula:

Shim Thickness = X - CL
Screw (91) x 3
Where
Shim (92)
X (mm): refer to the D.M.as necessary.
CL is the dimension (mm) engraved on the main case.

Main Case Front side (ECS-Compressor drive quill)

For Training purpose only 17 of 152


8.2.1.1 Shims Installation
Action No. 8: Shim (98) installation

CR&OP Data Module:

39-A-63-20-05-00A-710A-C - Main gearbox -


Assemble procedures.
Procedure

Install the shim (98) as follows:

1. Make sure that the shim has the same serial number
as the main case assembly.

2. Verify / Calculate / Record the thickness of the shim


with this formula:

Shim Thickness = X CK
Shim (98)
Where
Screw (97) x 3

X : refer to the D.M.as necessary.


CK is the dimension (mm) engraved on the main case.

3. Measure the thickness of each shim and make sure


that it is as specified in previous Step 2. If the
Main Case Front side (Front Hyd. Pump drive quill) thickness of the shim is not in the limits, perform the
corrective action required. See page 12 for further
info.
4. Put the shim (98) in its housing of the main case
assembly.
5. Install the 3 screws (97) to attach the shim (98).

For Training purpose only 18 of 152


8.2.1.1 Shims Installation
Action No. 9: LH Shim (199K) and RH Shim (199K) installation

RH Shim (199K)
CR&OP Data Module:

39-A-63-20-05-00A-710A-C - Main gearbox -


Assemble procedures.

Procedure

Install the LH / RH Shim (199K) as follows:


Screw (199L) x 3
1. Make sure that the LH / RH shim has the same serial number
as the main case assembly.
Main Case Front side (RH AC Generator drive quill) 2. Verify / Calculate / Record the thickness of the left / right shim
with this formula:
LH Shim (199K) LH Shim Thickness = X - CR
RH Shim Thickness = X - CN

Where

X : refer to the D.M.as necessary.


CR is the dimension (mm) engraved on the main case.
CN is the dimension (mm) engraved on the main case.

3. Measure the thickness of each shim and make sure that it is as


Screw (199L) x 3 specified in previous Step 2. If the thickness of the shim is not
in the limits, perform the corrective action required. See page
12 for further info.
4. Put each shim (199K) in its housing of the main case
assembly.
Main Case Front side (LH AC Generator drive quill)
5. Install the 3 screws (199L) to attach the shim (199K).
For Training purpose only 19 of 152
8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing, installation
Action No. 1: 2 Roller bearings installation

Washer + CR&OP Data Module:


Nut x 4
39-A-63-20-05-00A-710A-C - Main gearbox -
Surfaces
Lubricated with Oil
Assemble procedures.
RH Roller Bearing Supplies:
See Detail A (next page)
Nomenclature Identification No. Specification references
Solvent, cleaning C010 P-D-680 type II
Heated area
LH Roller Bearing Oil C006 MIL-PRF-7808L

1
Support equipment:
Washer +
Nut x 4
Nomenclature Identification No.

Heat gun Local supply

Bearing installation tool 3G6320A00331A023E

2
3 4 6

For Training purpose only 20 of 152


8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing, installation
Action No. 2:Outer Race of the tail-rotor roller bearing installation

Detail A Al Washer x 3 CR&OP Data Module:


Washer x 3
39-A-63-20-05-00A-710A-C - Main gearbox -
Surfaces Nut x 3 Assemble procedures.
Lubricated with Oil
Supplies:
Heated area
Nomenclature Identification No. Specification references
Cloth, soft lint-free C011 None

Solvent, cleaning C010 P-D-680 type II


Screw x 3
Oil C006 MIL-PRF-7808L
Outer Race of the Tail-
rotor roller bearing
Support equipment:

Nomenclature Identification No.

Heat gun Local supply

Outer race installation 3G6320A00331A023F


tool, roller bearing

1 2 3 4

For Training purpose only 21 of 152


8.2.1.3 Diaphragm Assy, assembly procedures

CR&OP Data Module:


Heated area
39-A-63-20-05-00A-710A-C - Main gearbox -
Surfaces Assemble procedures.
Lubricated with Oil

Roller Bearing Supplies:

Nomenclature Identification No. Specification references


Nuts+
Cloth, soft lint-free C011 None
Washers
Oil Jets Pre-Mod. Solvent, cleaning C010 P-D-680 type II
Packing Oil C006 MIL-PRF-7808L

Grease (Parker C115 None


super O-lube).

Support equipment:
Nuts+
Washers Nomenclature Identification No.
Nuts+
Nuts+ Washers Heat gun Local supply
Washers
Bearing installation tool 3G6320A00331A023A
Packing Nuts

Oil Jets Post-Mod.

Nuts

Nuts Nuts

For Training purpose only 22 of 152


8.2.1.3 Diaphragm Assy, assembly procedures

Diaphragm + Tool + Bearing

Oil Jets Post-Mod.


installed

Heating phase

Roller Bearing installed

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:

Locking Ring Nomenclature Identification No. Specification references


Locking Washer Cloth, soft lint-free C011 None
Note:
Retaining Ring
Oil C006 MIL-PRF-7808L
Retaining Ring installed
on MGB Solvent (Loctite C023 None
P/N 3G6320A00135 only quick clean 7031)
Adhesive (Loctite C029 MIL-S-46163, Type II
222) grade M

Collector Gear Support equipment:


Retaining Ring Main Case Nomenclature Identification No.

Bearing installation tool 3G6320A00331A023C

Induction oven Local supply

Work table MS3-01300

Hydraulic cylinder BRW 104N

Lifting tool, collector 3G6320A00331A181A


gear
Lifting device Local supply

Torque tool, collector 3G6320A00331A023D


gear

For Training purpose only 24 of 152


8.2.1.4 Collector Gear Assy, assembly procedures
View of the bearing installation tool and torque tool

Bearing installation tool 3G6320A00331A023C Torque tool, collector gear 3G6320A00331A023D

For Training purpose only 25 of 152


8.2.1.4 Collector Gear Assy, assembly procedures
Collector gear assembly phase

1
4
7

For Training purpose only 26 of 152


8.2.1.4 Collector Gear Assy, assembly
Collector gear assembly phase

8
13
11

10 12

For Training purpose only 27 of 152


8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly
procedures

CR&OP Data Module:


39-A-63-20-05-00A-710A-C - Main gearbox -
Assemble procedures.

Supplies:
Heated area
Nomenclature Identification No. Specification references
V incision Main Case Cloth, soft lint-free C011 None

Oil C006 MIL-PRF-7808L


O-rings
Input Pinion II Solvent (Loctite C023 None
Bearing Stage quick clean 7031)
Sleeve
Bearings Nuts, Adhesive (Loctite C029 MIL-S-46163, Type II
222) grade M
Shim Washers
Heated area Support equipment:
Oil application Retaining Ring
(Typical for RH side) Nomenclature Identification No.
Loctite Pump gear
application Induction oven Local supply
Locking Ring
Locking Bearing installation tool 3G6320A00331A023U
Retaining
Washer Arbor press Local supply
Ring
Installation tool, sleeve 3G6320A00331A023V

Reaction tool, pinion 3G6320A00331A023W


locking ring

For Training purpose only 28 of 152


8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly proc.
Retaining Ring Step Thickness evaluation
Measure the distance between the end of the outer
race of the bearing (I2) and the flange of the bearing
sleeve (N) in three equally spaced positions. Calculate
Step the arithmetical mean between the three values, and
record it as dimension P

Calculate the thickness of the step on the retaining


ring as follows:

Thickness of step (mm) = P - (*).

(*) refer to the D.M. as necessary.

Measure the thickness of the step on the retaining ring


and make sure that it is as calculated. If the thickness
of the step is not within the limits, do the following
actions as necessary.

Machine the retaining ring and remove material


until the thickness of the step is correct (measure
the thickness of the step regularly while you
machine it), or
Discard the retaining ring and install a new item.
Retaining Adjust the thickness of the step on the new
Ring
retaining ring as necessary.

(cont.s)

For Training purpose only 29 of 152


8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly proc.
Thickness evaluation of the Shim

Measure the total height of the inner races of the


triplex bearing. Record this value as I1.

Calculate the thickness (M) of the shim with this


formula:

(RH) M = G - (H + I1 + L)
(LH) M = G - (H + I1 + L)

where

G CU is the dimension engraved on the main


case assembly (RH).
G CT is the dimension engraved on the main
case assembly (LH).
H is the dimension engraved on the pinion
I1 is the measured dimension.
Shim L is the dimension engraved on the pump gear.

Measure the thickness of the shim and make sure


that it is as calculated. If the thickness of the shim is
not in the limits, perform the actions reported
hereinafter as necessary.
Machine the shim and remove material until the
thickness is correct (measure the thickness of
the shim regularly while you machine it).
Discard the shim and install a new item. Adjust
the thickness of the new shim as necessary.

Install the Shim and the Retaining ring on the


right/left input pinion as required.

For Training purpose only 30 of 152


8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly proc.
Assembly phase step 1

5
Bearing Sleeve
1

Retaining Ring
Triplex ball bearing Pump gear
Input Pinion II stage
Bearing
installation tool

2 3
4

Inner race bearing


thickness Bearing alignment Sleeve installation
measurement tool

For Training purpose only 31 of 152


8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly proc.
Assembly phase step 2
6 Oil application 8

Pinion + Bearings

Arbor Press

For Training purpose only 32 of 152


8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly proc.
Assembly phase step 3

10 13

14

Pump Gear +
Thickness Check Locking Ring

11 12

Pinion Assy +
Supplies +
Locking Washer +
Retaining Ring

Thickness Check Retaining Ring


installation

For Training purpose only 33 of 152


8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly proc.
Assembly phase step 4

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

Locking Ring, Reaction Torque


tool + Wrench Wrench

For Training purpose only 34 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures

CR&OP Data Module:


39-A-63-20-05-28A-710A-C Tail rotor drive quill
(main gearbox) - Assemble procedures
Nylon Screw
(3) Supplies:

Nomenclature Id. No. Specification references

Main Cloth, soft lint-free C011 None


Case
Main
Case Oil C006 MIL-PRF-7808L

Solvent (Loctite quick C023 None


clean 7031)
Tail Rotor Drive
Quill Assembly Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M
Tail Rotor Drive
Quill Assembly
Safety wire C014 MS20995C32
NS-3913-G1 (Syn-Tech C147 None
Ltd)

Parker super O-lube C115 None

Nomenclature Identification No. Nomenclature Identification No.


Oven Local supply Arbor press Local supply
Assembly tool 3G6320A00331A023Y Pusher tool, rotor brake 3G6320A00331A026D
Support equipment: Reaction tool, pinion 3G6320A00331A023Z case assembly

Wrench 3G6320A00331A026A Installation tool, lip seal 3G6320A00331A026E

Wrench 3G6320A00331A026B Wrench 3G6320A00331A026F

Installation tool, flanged 3G6320A00331A026C Work table MS3-01300


bearing

For Training purpose only 35 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Action No. 1 Bearing inner race (28) installation on Pinion (30)
CR&OP Data Module:
39-A-63-20-05-28A-710A-C Tail
rotor drive quill (main gearbox) -
Assemble procedures.
Retaining ring
Locking washer Note: This procedure is applicable only to
Locking ring Main gearbox P/N : 3G6320A00132).
Ring
Flange
Nut + Retaining ring
Washer
O-rings Seal case Support equipment:
Seal Nomenclature Identification No.
Rotor brake case
O-ring Oven Local supply

Nipple Assembly tool 3G6320A00331A023Y


Shim Retaining ring
Screw Locking washer Reaction tool, pinion 3G6320A00331A023Z
Flanged
bearing Part heated Locking ring
Work table MS3-01300
Gear
Shim Wrench 3G6320A00331A026A
Oil application Retaining ring
Locking washer Supplies:
Oil Locking ring
application Bearing inner
Nomenclature Id. No. Specification references
race (roller)
Plug Cloth, soft lint-free C011 None
Pinion

Solvent (Loctite quick C023 None


Bearing cage clean 7031)
Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M
Plug
Pinion Oil C006 MIL-PRF-7808L

For Training purpose only 36 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Action No. 1 Bearing inner race (28A) installation on Pinion (30A)
CR&OP Data Module:
39-A-63-20-05-28A-710A-C Tail
rotor drive quill (main gearbox) -
Assemble procedures.
Retaining ring
Locking washer Note:
Locking ring
Ring This procedure is applicable to Main
Flange gearbox P/N: 3G6320A00133 and sub. P/N
Nut + Retaining ring
Washer with different last two digits
O-rings Seal case
Seal
Rotor brake case
O-ring Supplies:
Shim Nipple Retaining ring
Screw Locking washer
Flanged Nomenclature Id. No. Specification references
bearing Locking ring
Gear
Oil C006 MIL-PRF-7808L
Shim
Retaining ring
Locking washer
Locking ring
Bearing inner
O-ring
race (roller)
Plug
Pinion

Bearing cage

Plug
Pinion

For Training purpose only 37 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Action No. 2 Calculate the thickness of the Shim (22)

CR&OP Data Module:


39-A-63-20-05-28A-710A-C Tail rotor drive quill
(main gearbox) - Assemble procedures.
See Para. 3 for Main Gearbox P/N: 3G6320A00132 and to
Para. 4 for Main gearbox P/N: 3G6320A00133 and sub P/N
with different last two digits.
Procedure:

3. (Main gearbox P/N 3G6320A00132) Calculate and record the


thickness F of the shim (22) with this formula:

F(*) = [(C + D) - E] - (A - B) where


A = (*)
B is the dimension (mm) engraved on the pinion (30)
C is the dimension (mm) engraved on the main gearbox case
D and E are the dimensions (mm) engraved on the gear (21).
4. Main gearboxes P/N 3G6320A00133 and subsequent P/N
with different last two digits) Calculate and record the thickness F
of the shim (22) with this formula:

F(*) = [(C + D) - E] - (A - B) where

A = (*)
B is the dimension K (mm) engraved on the pinion (30A)
C = (*)
D = (*)
E is the dimension K (mm) engraved on the gear (21).

(*): Refer to the D.M. as necessary.


For Training purpose only 38 of 152
8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Action No. 3 Shim (22) and Gear (21) installation
CR&OP Data Module:
39-A-63-20-05-28A-710A-C Tail
rotor drive quill (main gearbox) -
Assemble procedures.

Support equipment:

Nomenclature Identification No.

Oven Local supply


Wrench 3G6320A00331A026B
Part heated Reaction tool, pinion 3G6320A00331A023Z

Retaining ring
Locking washer
Locking ring
Supplies:
Gear
Shim
Oil application Nomenclature Id. No. Specification references

Cloth, soft lint-free C011 None

Oil C006 MIL-PRF-7808L


Solvent (Loctite quick C023 None
clean 7031)

Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M

Oil application

For Training purpose only 39 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Action No. 4 Shim (14), Flanged bearing (17), installation on Item 11
CR&OP Data Module:
39-A-63-20-05-28A-710A-C Tail rotor drive quill
(main gearbox) - Assemble procedures.

Part heated
Note:

Calculate and record the thickness of the shim (14) with this formula:
Oil application
Thickness = X - Y where
Nut + X (mm) : refer to the D.M. as necessary.
Washer Y is the dimension (mm) engraved on the rotor brake case.

Rotor brake case Support equipment:

Shim Nomenclature Identification No.


Screw
Flanged Oven Local supply
bearing
Installation tool, flanged bearing 3G6320A00331A026C

Arbor press Local supply

Supplies:

Nomenclature Id. No. Specification references

Oil C006 MIL-PRF-7808L

Cloth, soft lint-free C011 None

Solvent (Loctite quick clean C023 None


7031)

For Training purpose only 40 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Action No. 5 Rotor Brake Case Assy (11), installation on Pinion
CR&OP Data Module:
39-A-63-20-05-28A-710A-C Tail rotor drive
quill (main gearbox).
Grease (147)
Retaining ring Support equipment:
Locking washer
Locking ring Nomenclature Identification No.
Parts heated Ring
Flange Oven Local supply
Retaining ring
Assembly tool 3G6320A00331A023Y
O-rings Seal case
Seal
Pusher tool, rotor brake 3G6320A00331A026D
case assembly
Rotor brake case
O-ring Installation tool, lip seal 3G6320A00331A026E
Nipple Wrench 3G6320A00331A026F
Arbor press Local supply
Oil application
O-ring Supplies:

Nomenclature Id. No. Specification references

Cloth, soft lint-free C011 None

Oil C006 MIL-PRF-7808L


Solvent (Loctite quick clean C023 None
Pinion 7031)
Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M

Safety wire C014 MS20995C32

Pinion NS-3913-G1 (Syn-Tech Ltd) C147 None

Parker super O-lube C115 None


For Training purpose only 41 of 152
8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Assembly phase (Main gearbox P/N 3G6320A00133), step 1

7 6
1

Flanged bearing
R.B.C. assembled installed on the R.B.C.
3 4 5

Flanged bearing + Flanged bearing


Rotor Brake Case + Shim tool installation phase
2
Bearing cage

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

Installation phase of the


Lip Seal in the Seal case
For Training purpose only 43 of 152
8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Assembly phase (Main gearbox P/N 3G6320A00133), step 3

12

14
13

Bearing cage Shim (22) Gear (21)


(28A) installation installation installation

For Training purpose only 44 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Assembly phase (Main gearbox P/N 3G6320A00133), step 4

15
17
16 18

Locking ring (20) Locking ring, Locking Washer Rotor Brake Case Assy
installation wrench and Retaining heating phase -
installation Ring installation

For Training purpose only 45 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Assembly phase (Main gearbox P/N 3G6320A00133), step 5

19 20 21

Rotor Brake Case Seal and Seal Retaining Ring


Assy installation Case installation installation

For Training purpose only 46 of 152


8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
Assembly phase (Main gearbox P/N 3G6320A00133), step 6

22 24 25

Flange (5)
installation Nipple (13)
installation
23
Locking Washer (2)
and Retaining Ring (1)
installation
26

Locking ring (3)


installation
Tail Rotor Drive Quill Assy

For Training purpose only 47 of 152


8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures

CR&OP Data Module:


Retaining ring
39-A-63-20-05-27A-710A-C Left/right pump drive
Seal cover quill (main gearbox) - Assemble procedures
C147 application
Support equipment:
Lip seal
Nomenclature Identification No.
Packing Induction oven Local supply

Retaining ring Installation tool, bearing 3G6320A00431A023A


Locking washer Arbor press Local supply
Locking ring
Installation tool, pinion 3G6320A00431A023B

Removal/installation tool, 3G6320A00431A023C


Flanged
C115 application locking ring
bearing+
Washers
Installation tool, lip seal 3G6320A00431A023D
and Nuts
Holder tool, pump case 3G6320A00431A023E
Plug

O-ring O-ring Supplies:


Pump Nomenclature Id. No. Specification references
Fitting
case
Cloth, soft lint-free C011 None

Oil C006 MIL-PRF-7808L


Solvent (Loctite quick clean 7031) C023 None
Pinion
Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M

Left/right pump drive quill NS-3913-G1 (Syn-Tech Ltd) C147 None


(Hyd. pump No.1 and N0.2
drive quill) Parker super O-lube C115 None

Safety wire C014 MS20995C32

For Training purpose only 48 of 152


8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures
Action No. 1 Installation of the Flanged bearing (11) on the Pump Case (14)

Flanged
bearing

Heated area

Pump
case

Installation tool, bearing

For Training purpose only 49 of 152


8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures
Action No. 2 Installation of Pinion (15) in the Pump Case Assy (14)

External side

Left/right pump Retaining ring


drive quill (Hyd.
Locking washer
pump No.1 and
N0.2 drive quill) Locking ring

Heated area Removal/installation tool, locking ring


Flanged
bearing+
Washers
and Nuts

Pump Inner side


case

Pinion

Installation tool, pinion

For Training purpose only 50 of 152


8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures
Action No. 3 Pump Drive Quill, final assembly

Retaining ring

Seal cover

Lip seal

Packing

Plug

O-ring O-ring

Fitting Pump
case

Installation tool, lip seal Holder tool, pump case

For Training purpose only 51 of 152


8.2.1.8 - Front Hyd. Pump Drive Quill, assembly procedures

CR&OP Data Module:


39-A-63-20-05-04A-710A-C Front pump drive quill
Pinion
(main gearbox) - Assemble procedures
Pump
case Support equipment:

Nomenclature Identification No.

Plug Induction oven Local supply


Front Hyd.
pump drive Installation tool, bearing 3G6320A00431A023A
quill O-ring O-ring
Installation tool, pinion 3G6320A00531A023A
Heated area Fitting Arbor press Local supply

C115 application Installation tool, lip seal 3G6320A00431A023D


Holder tool, pump case 3G6320A00431A023E
C147 application Front Hyd. pump
Flanged
drive quill Removal/installation tool, 3G6320A00531A023B
bearing
locking ring
Washers + Nuts
Locking ring Supplies:
Locking washer
Retaining ring Nomenclature Id. No. Specification references
Packing
Cloth, soft lint-free C011 None
Lip seal
Oil C006 MIL-PRF-7808L
Seal cover
Solvent (Loctite quick clean 7031) C023 None
Retaining ring
Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M
Note
NS-3913-G1 (Syn-Tech Ltd) C147 None
The assembly procedure
relevant to the Front Pump
are similar to the LH/RH Hyd.
Parker super O-lube C115 None
Pump previously described. Safety wire C014 MS20995C32

For Training purpose only 52 of 152


8.2.1.9 - ECS-Compressor Drive Quill, assembly procedures
Action No.1 : Flanged Bearing (4) installation
CR&OP Data Module:
39-A-63-20-05-05A-710A-C ECS compressor
Heated area drive quill (main gearbox) - Assemble
procedures Support equipment:
Locking
ring
Pinion Nomenclature Identification No.
ECS-compressor
drive quill Induction oven Local supply

Case Installation tool, bearing 3G6320A00731A023A


Flanged
Installation tool, pinion 3G6320A00731A023B
bearing
Arbor press Local supply
Retaining Locking Nuts +
ring washer Washers Removal/installation tool, 3G6320A00731A023C
locking ring

Supplies:

Specification
Nomenclature Id. No.
references
2 3 Cloth, soft lint-free C011 None

Solvent, cleaning C010 P-D-680 type II


Case
Oil C007 MIL-PRF-23699
Solvent (Loctite quick clean C023 None
7031)
Adhesive (Loctite 222) C029 MIL-S-46163, Type II
Flanged grade M
bearing

For Training purpose only 53 of 152


8.2.1.9 - ECS-Compressor Drive Quill, assembly procedures
Action No.2 : Pinion (2) installation and final assembly

Heated area
8 7

Locking
ring
Pinion

Case
Flanged
bearing
5
Retaining Locking Nuts +
ring washer Washers

Locking Retaining Removal/installation tool,


washer ring
locking ring
4

Locking
ring

Pinion
Case
Assy

Installation tool, pinion

For Training purpose only 54 of 152


8.2.1.10 - Fan Drive Quill, assembly procedures

CR&OP Data Module:

Fan drive quill


39-A-63-20-05-07A-710A-C Fan drive quill (main
Fan drive quill gearbox) - Assemble procedures
Supplies: Support equipment:
Specification Nomenclature Identification No.
Nomenclature Id. No.
references
Induction oven Local supply
Cloth, soft lint-free C011 None
Installation tool, pinion 3G6320A00931A023A
Oil C006 MIL-PRF-7808L
Heated area Arbor press Local supply
Solvent (Loctite quick C023 None
clean 7031) Removal/installation tool, 3G6320A00931A023B
Pinion locking ring
Adhesive (Loctite 222) C029 MIL-S-46163,
Type II grade M
Flanged
bearing

Locking 1 2 3
ring

Locking
Retaining washer
ring

Locking
Pinion ring

For Training purpose only 55 of 152


8.2.1.11 - Collector Gear Assy, installation procedures

CR&OP Data Module:


39-A-63-20-05-00A-710A-C
Collector Gear
Assy Main gearbox - Assemble
procedures.

Bolts
Bolts
Bolts Bolts
Bearing
Bolts
Support equipment:

Heated area Nomenclature Identification No.

Heat gun Local supply

Lifting tool, collector gear 3G6320A00331A181A


Lifting device Local supply

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

For Training purpose only 56 of 152


8.2.1.11 - Collector Gear Assy, installation procedures
Installation phases
1
4

Bolts

Heated area

Main Case Collector bearing, locked

Collector Gear
Collector Gear Assy, installed
Assy

For Training purpose only 57 of 152


8.2.1.12 - Diaphragm Assy and two Oil Jets No. 4 installation procedures

CR&OP Data Module:

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

Solvent, cleaning C010 P-D-680 type II


Oil Jet No. 4 (2) Oil C006 MIL-PRF-7808L
Grease (Parker super C115 None
O-rings O-lube).
Main Case Filter
Safety wire C014 MS20995C32

Screw
O-ring +
1 2
Washer

Note

Install the Oil Jets


No. 4 before to
install the 14
locking Screws of
the Diaphragm.

For Training purpose only 58 of 152


8.2.1.13 - Tail Rotor Drive Quill Assy, installation procedures

Note CR&OP Data Module:


Apply the Compound (C162) on the
three-equally spaced teeth of the
39-A-63-20-05-00A-710A-C
pinion of the tail-rotor drive quill Main gearbox - Assemble
procedures.
Washers + Nuts
Support equipment:
Heated area
Nomenclature Identification No.

Installation tool, tail rotor 3G6320A00331A026M


drive quill
Rotor Brake Housing Heat gun Local supply
Lifting device Local supply
Tail Rotor Drive Quill Assy

2 Supplies:
O-ring
Specification
Nomenclature Id. No.
references
1 Compound (Dykem C162 None
Steel Blue)
Solvent, cleaning C010 P-D-680 type II

Cloth, soft lint-free C011 None

Oil C006 MIL-PRF-7808L

For Training purpose only 59 of 152


8.2.1.14 - RH / LH Input Pinion Assy (II stage of reduction),
installation procedures.

Apply the CR&OP Data Module:


Compound C162
on the three-
equally spaced 39-A-63-20-05-00A-710A-C
teeth of the Heated area
pinion of the
Main gearbox - Assemble
right / left input procedures.
pinion

Support equipment:
Apply the Oil
C006 on the
Sleeve Nomenclature Identification No.

Installation tool, input pinion 3G6320A00331A023H


Apply the
grease C115 on
O-rings RH / LH Input Heat gun Local supply
Pinion Assy
Washers +
Nuts (II Stage of Supplies:
reduction)
Specification
Nomenclature Id. No.
references

Compound (Dykem C162 None


Steel Blue)

Solvent, cleaning C010 P-D-680 type II

Cloth, soft lint-free C011 None

Oil C006 MIL-PRF-7808L

Grease (Parker C115 None


super O-lube).

For Training purpose only 60 of 152


8.2.1.14 - RH / LH Input Pinion Assy (II stage of reduction),
installation procedures. Installation phases.

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

For Training purpose only 61 of 152


8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation
procedures.

CR&OP Data Module:


39-A-63-20-05-00A-710A-C
Main gearbox - Assemble
procedures.

Screws Support equipment:

RH / LH Input Nomenclature Identification No.


Apply the Oil Hydraulic
C006 on the Pump drive Installation tool, pump drive 3G6320A00331A023L
Sleeve quill
quill Assy
Heat gun Local supply

Apply the
l grease C115 on Supplies:
e the O-ring
Specification
Nomenclature Id. No.
references

Solvent, cleaning C010 P-D-680 type II


Heated area
Cloth, soft lint-free C011 None