Integrated Drive Generator (IDG) Servicing - Filling of the IDG with Oil or Addition of Oil after a Level Check

TASK 12-13-24-612-803-A
Integrated Drive Generator (IDG) Servicing - Filling of the IDG with Oil or Addition of Oil after a Level Check

WARNING: WEAR GOGGLES, INSULATED GLOVES AND OTHER PROTECTIVE CLOTHES. HOT OIL CAN BURN YOUR EYES AND SKIN. IF OIL TOUCHES YOUR EYES OR SKIN, GET MEDICAL AID.

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AFTER SHUTDOWN. THE ENGINE CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

CAUTION: DO NOT LET ENGINE OIL FALL ON THE ENGINE. UNWANTED OIL MUST BE REMOVED IMMEDIATELY. THE OIL CAN CAUSE DAMAGE TO THE SURFACE PROTECTION AND TO SOME PARTS.

CAUTION: DO NOT OPERATE THE IDG:

IF IT CONTAINS TOO MUCH OIL
IF IT DOES NOT CONTAIN ENOUGH OIL

IF YOU DO, YOU CAN CAUSE DAMAGE TO THE IDG.

CAUTION: REMOVE THE REMAINING OIL FROM THE FILLING EQUIPMENT. FILL THE EQUIPMENT ONLY WITH NEW CANS OF OIL BEFORE YOU FILL THE IDG WITH OIL OR ADD OIL TO THE IDG. THE CONTAMINATION IN THE OIL THAT STAYS IN THE FILLING EQUIPMENT CAN CAUSE FAST DETERIORATION OF THE OIL AND WILL DECREASE THE LIFE OF THE IDG.

CAUTION: USE ONLY NEW CANS OF OIL WHEN YOU FILL THE IDG WITH OIL OR ADD OIL TO THE IDG. THE CONTAMINATION IN OIL THAT STAYS IN OPEN CANS CAN CAUSE FAST DETERIORATION OF THE OIL AND WILL DECREASE THE LIFE OF THE IDG.

CAUTION: DO NOT USE SOLVENTS THAT CONTAIN CHLORINE TO CLEAN THE EQUIPMENT (PUMP, HOSES, TANK AND FUNNEL) USED TO FILL THE IDG WITH OIL. CHLORINE CONTAMINATION OF THE OIL CAN CAUSE FAST DETERIORATION OF THE OIL AND WILL DECREASE THE LIFE OF THE IDG.

CAUTION: DO NOT DO THE SERVICING OF A DISCONNECTED IDG. CONTINUED OPERATION OF A DEFECTIVE IDG CAN CAUSE DAMAGE.

CAUTION: MAKE SURE THAT YOU DO NOT USE TOOLS THAT LET AIR GO INTO THE SYSTEM DURING SERVICING. IF AIR GETS INTO THE SYSTEM, DAMAGE TO THE EQUIPMENT CAN OCCUR.

NOTE: Airbus recommends that you do not do the servicing of more than one IDG at a time.

ZONE: 453
ZONE: 463

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	CONTAINER 20L (5 USGAL)
No specific	AR	COVER - PROTECTION
No specific	1	FILLING EQUIPMENT - TANK OIL
No specific	1	FLASHLIGHT

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.P03-001)	lubricant, aircraft turbine engine
(Material No.P05-005)	lint-free cotton cloth

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
453	HOT SECTION
463	HOT SECTION
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 451AL
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 461AL

D. Referenced Information

REFERENCE	DESIGNATION
TASK 24-21-00-612-806-A	Integrated Drive Generator (IDG) Oil-Type Change
TASK 24-42-00-861-001-A	Energize the Ground Service Network from the External Power
TASK 24-42-00-862-001-A	De-energize the Ground Service Network Supplied from the External Power
TASK 71-00-00-720-809-A	Test No. 2 - Engine Motor Leak Test (Dry Method)
TASK 71-00-00-720-811-A	Test No. 3A - Idle Power Test
TASK 71-00-00-860-817-A	Motor the Engine (Dry Method)
TASK 71-00-00-860-823-A	Start the Engine (Normal Automatic Start)
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-802-A	Closing of the Fan Cowl Doors
TASK 78-30-00-040-805-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-805-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-36-00-010-802-A	Opening of the Thrust Reverser Cowl-Doors
TASK 78-36-00-410-802-A	Closing of the Thrust Reverser Cowl-Doors
AIPC 11-24-81-
IDG

3. Job Set-up
Subtask 12-13-24-861-062-A ** ON A/C NOT FOR ALL

A. Energize the ground service network
(Ref. AMM TASK 24-42-00-861-001)

Subtask 12-13-24-941-071-A ** ON A/C NOT FOR ALL

B. Safety Precautions
(1) Do the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833).

Subtask 12-13-24-010-067-A ** ON A/C NOT FOR ALL

C. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR.

Subtask 12-13-24-040-056-A ** ON A/C NOT FOR ALL

D. Deactivation of the Thrust Reverser System for Ground Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Do the deactivation of the thrust reverser system for ground maintenance (Ref. AMM TASK 78-30-00-040-805).

Subtask 12-13-24-010-068-A ** ON A/C NOT FOR ALL

E. Get Access
(1) Open the left thrust reverser cowl-door (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL.
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL.
(2) Installation of the engine protection covers:

CAUTION: INSTALL PROTECTION COVERS ON ALL THE OPENINGS IMMEDIATELY TO PREVENT DAMAGE TO THE ENGINE.

(a) Install all the necessary COVER - PROTECTION to prevent damage to the engine.

4. Procedure
Subtask 12-13-24-612-080-A ** ON A/C NOT FOR ALL

A. Check of the IDG Oil Brand on the Placard

CAUTION: USE ONLY APPROVED TYPES/BRANDS OF LUBRICANTS. DO NOT MIX TYPES//BRANDS OF LUBRICANTS.

(1) Do a check of the IDG oil brand on the placard:
(a) If the IDG does not have a placard, install the applicable IDG oil-brand placard AIPC 11-24-81-.
(b) If you do not use the same oil brand that is given on the placard, do this procedure (Ref. AMM TASK 24-21-00-612-806).
(c) If you use the same oil brand that is given on the placard, continue this procedure.

Subtask 12-13-24-612-071-A ** ON A/C NOT FOR ALL

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

CAUTION: USE ONLY APPROVED TYPES/BRANDS OF LUBRICANTS. DO NOT MIX TYPES//BRANDS OF LUBRICANTS.

B. Filling of the IDG with Oil

NOTE: In rain, fog or wet conditions, it is important to prevent water contamination of the IDG oil during the filling procedure.

(1) Find the IDG on the left rear side of the main gearbox.
(2) Find the IDG overfill drain-valve on the rear side of the IDG.
(3) Remove the dust covers from the IDG overfill drain-valve and the IDG pressure fill-valve.
(4) Put the CONTAINER 20L (5 USGAL) below the IDG overfill drain-valve.
(5) Install the overflow drain hose:

WARNING: YOU MUST PUT THE OVERFLOW DRAIN HOSE INTO A CONTAINER BEFORE YOU CONNECT THE DRAIN HOSE TO THE IDG OVERFILL DRAIN VALVE. MAKE SURE THAT THE DRAIN HOSE HANGS DOWN VERTICALLY AND THE END OF THE HOSE IS ABOVE THE OIL LEVEL IN THE CONTAINER. WHEN YOU CONNECT THE OVERFLOW DRAIN HOSE TO THE IDG, YOU RELEASE THE PRESSURE IN THE IDG OIL SYSTEM AND OIL WILL SPRAY FROM THE DRAIN HOSE. THIS WILL PREVENT BURNS FROM THE HOT OIL SPRAY. HOT OIL CAN CAUSE BURNS TO EYES AND SKIN.

CAUTION: DO NOT USE DEVICES OTHER THAN THE APPROVED OVERFLOW DRAIN-HOSE FITTING. HARD METAL OBJECTS SUCH AS SCREWDRIVERS CAN CAUSE DAMAGE TO THE OVERFLOW DRAIN SEAT.

(a) Put the free end of the overflow drain hose in the empty CONTAINER 20L (5 USGAL).
(b) Connect the other end of the overflow drain hose with the OMP 2505-3 coupling to the IDG overfill drain-valve.

NOTE: The IDG oil flows through the overflow drain hose during the draining procedure.

NOTE: Some hot pressurized oil can come out of the overflow drain hose when it is connected.

(6) Connect the pressure fill hose with the OMP 2506-3 coupling from the FILLING EQUIPMENT - TANK OIL to the IDG pressure fill-valve.
(7) Fill the IDG with filtered P03-001lubricant, aircraft turbine engine with the FILLING EQUIPMENT - TANK OIL set at a maximum pressure of 35 psi (2.41 bar).

NOTE: AMM 20-34-00 gives the list of approved oil brands for the IDG servicing.

(8) Continue to fill the IDG with P03-001lubricant, aircraft turbine engine until a minimum of 0.95 l (0.25 USgal) of oil flows out of the overflow drain hose.
(9) Collect the oil in the CONTAINER 20L (5 USGAL).

Subtask 12-13-24-080-065-A ** ON A/C NOT FOR ALL

C. Removal of the Hoses
(1) Disconnect the pressure fill hose.
(2) Drain the oil.

CAUTION: DO NOT DISCONNECT THE OVERFLOW DRAIN HOSE UNTIL THE FLOW DECREASES TO SINGLE DROPS.

(3) Disconnect the overflow drain hose.
(4) Install the dust caps on the IDG overfill drain-valve and IDG pressure fill-valve.

Subtask 12-13-24-710-060-A ** ON A/C NOT FOR ALL

D. If you replaced a component of the oil system (filter, external system component or drain plug), do the tests that follow for leak check before inspection:

An idle power test (recommended procedure) (Ref. AMM TASK 71-00-00-720-811), or
A dry motoring (alternative procedure) (Ref. AMM TASK 71-00-00-720-809).

Subtask 12-13-24-210-058-A ** ON A/C NOT FOR ALL

E. Inspection of the Oil Level
(1) To fill the external oil system to its maximum level before the oil level check, it is necessary to:

Operate the engine at minimum idle (recommended procedure) (Ref. AMM TASK 71-00-00-860-823), or
Do the dry motoring of the engine (alternative procedure) (Ref. AMM TASK 71-00-00-860-817).

(2) Wait for a minimum of five minutes after the engine shutdown or 30 minutes after the dry motoring of the engine and do a visual check of the IDG oil level as follows:
(a) Use the FLASHLIGHT to find the IDG oil-level sight-glass on the rear side of the IDG.
(b) Clean the IDG oil-level sight-glass with the lint-free cotton cloth (Material No.P05-005) .

NOTE: The IDG oil temperature is shown on the ECAM "ELEC SD" page. If the oil temperature is less than 49 DEG.C (120 DEG.F), the oil is cold. If the oil temperature is equal to or more than 49 DEG.C (120 DEG.F), the oil is hot.

(c)

IDG ** ON A/C NOT FOR ALL

(3) After the IDG oil servicing, do a reset of the oil level sensor:
(a) Release and then push the related GEN pushbutton switch.

NOTE: After the oil level correction, no more dry motoring of the engine or idle power test is necessary.

NOTE: We recommend that you do the visual inspection again to make sure that there are no oil leaks at the IDG oil-filter cover. You can do this inspection the next time that you operate the engine at minimum idle.

5. Close-up
Subtask 12-13-24-410-067-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Removal of the engine protection covers:

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

(a) Remove all the COVER - PROTECTION.
(2) Make sure that the work area is clean and clear of tools and other items.
(3) Close the left thrust reverser cowl-door (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL.

Subtask 12-13-24-440-057-A ** ON A/C NOT FOR ALL

B. Reactivation of the Thrust Reverser System after Ground Maintenance
(1) Do the reactivation of the thrust reverser system after ground maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 12-13-24-410-068-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR.
(2) Remove the WARNING NOTICE(S).

Subtask 12-13-24-862-062-A ** ON A/C NOT FOR ALL

D. De-energize the ground service network
(Ref. AMM TASK 24-42-00-862-001).

[Rev.10 from 2021] 2026.04.01 03:57:21 UTC