Servicing of the Integrated Drive Generator (IDG) after Oil Chemical Contamination

TASK 24-21-00-612-807-A
Servicing of the Integrated Drive Generator (IDG) after Oil Chemical Contamination

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE SHUTDOWN. USE APPLICABLE THERMAL GLOVES. THE ENGINE PARTS CAN STAY HOT FOR ONE HOUR AFTER SHUTDOWN AND CAN BURN YOU.

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 USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

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: 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: 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.

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

ZONE: 435
ZONE: 436
ZONE: 445
ZONE: 446

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 10 L(2 1/2 USGAL)
No specific	1	FILLING EQUIPMENT - TANK OIL
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 75 and 55 lbf.in (0.85 and 0.62 m.daN )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.CP8001)	lockwire 0.032 in. (0.8 mm) dia.
(Material No.CP8002)	lockwire 0.032 in. (0.8 mm) dia
(Material No.03ABA1)	Synthetic base Lubricating Oil-Turbine Engine - -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
435	FAN AND ACCESSORY GEARBOX
436	FAN AND ACCESSORY GEARBOX
445	FAN AND ACCESSORY GEARBOX
446	FAN AND ACCESSORY GEARBOX
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
1	PREFORMED PACKING	AIPC 24-21-51-61-150

E. Referenced Information

REFERENCE	DESIGNATION
TASK 12-13-24-612-804-A	Integrated Drive Generator (IDG) Servicing - Filling of the IDG with Oil or Addition of Oil after a Level Check
TASK 20-11-11-911-001-A	Safetying with Lockwire
TASK 24-21-51-000-810-A	Removal of the IDG Oil Charge and Scavenge Filter-Elements
TASK 24-21-51-400-810-A	Installation of the IDG Oil Charge and Scavenge Filter-Elements
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 71-00-00-860-827-A	Start the Engine (Normal Automatic Start)
TASK 71-00-00-860-829-A	Engine Shutdown
TASK 71-13-00-010-803-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-803-A	Closing of the Fan Cowl Doors
TASK 20-34-00-00	LIST OF MATERIALS REQUIRED FOR IDG SERVICE AND MAINTENANCE - DESCRIPTION AND OPERATION
Servicing of the IDG after Oil Contamination

3. Job Set-up
Subtask 24-21-00-861-081-A

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

Subtask 24-21-00-941-102-A

B. Safety Precautions
(1) On the center pedestal, on ENG panel 115VU:
(a) Make sure that the ENG/MODE selector switch is in the NORM position.
(b) Make sure that the ENG/MASTER 1(2) control switch was in the OFF position not less than five minutes before you do this procedure.
(c) Put WARNING NOTICE(S) in position to tell persons not to operate the ENG/MODE selector switch and the ENG/MASTER 1(2) control switch.
(2) On the ENG section of maintenance panel 50VU:
(a) Make sure that the ON legend of the FADEC GND PWR/1(2) pushbutton switch is off.
(b) Put a WARNING NOTICE(S) in position to tell persons not to energize FADEC 1(2).

Subtask 24-21-00-010-131-A

C. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR

4. Procedure
Subtask 24-21-00-864-068-A

A. Depressurization of the IDG Case
(1) Let the IDG temperature decrease to 120 DEG.F (49 DEG.C) or less before you drain the oil.
(2) Put the CONTAINER 10 L(2 1/2 USGAL) (5) below the overflow drain half-coupling on the IDG.
(3) Remove the overflow drain blanking-cap from the overflow drain half-coupling.
(4) Install the overflow drain hose (4):

WARNING: POINT THE OVERFLOW DRAIN HOSE INTO A CONTAINER WHEN YOU CONNECT THE HOSE TO THE OVERFLOW DRAIN HALF-COUPLING. THIS WILL PREVENT BURNS FROM THE HOT OIL SPRAY. HOT OIL CAN CAUSE BURNS TO EYES AND SKIN.

CAUTION: MAKE SURE YOU CONNECT THE HOSE OF THE OVERFLOW DRAIN HALF- COUPLING CORRECTLY. THIS HOSE LETS THE OIL IN THE IDG DRAIN TO THE CORRECT LEVEL. IF THERE IS TOO MUCH OIL IN THE IDG THE IDG WILL BECOME TOO HOT.

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 HALF-COUPLING SEAT.

(a) Put the end of the overflow drain hose (4) in the empty CONTAINER 10 L(2 1/2 USGAL) (5).
(b) Depressurize the IDG case as follows:
1 Connect the overflow drain hose (4) to the overflow drain half-coupling.

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

NOTE: The function of the overflow drain hose is to release the pressure from the IDG oil system during the draining procedure.

Subtask 24-21-00-680-073-A

B. Draining of the IDG Oil

WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

(1) Cut and discard the lockwire from the case drain plug (2).

NOTE: Approximately between 3.8 l (1.00 USgal) and 5.7 l (1.51 USgal) of oil will flow into the CONTAINER 10 L(2 1/2 USGAL).

(2) Remove the case drain plug (2)
(3) Remove and discard the packing (1).
(4) Drain the oil.
(5) Remove the pressure fill blanking-cap from the pressure fill half-coupling.
(6) Connect the pressure fill hose (3) of the FILLING EQUIPMENT - TANK OIL to the pressure fill half-coupling.
(7) Use the FILLING EQUIPMENT - TANK OIL to fill the IDG with new Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) and drain the used oil:
(a) Make sure that the filling pressure is not more than 2.41 bar (34.95 psi).
(8) Continue to fill the IDG with Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) until 1.85 l (0.49 USgal) of oil flows out of the case drain.
(9) Stop the FILLING EQUIPMENT - TANK OIL.
(10) Let the oil drain from the case drain until the flow of oil decreases to drops.
(11) Disconnect the pressure fill hose (3) of the FILLING EQUIPMENT - TANK OIL from the pressure fill half-coupling.
(12) Install the pressure fill blanking-cap on the pressure fill half-coupling.

Subtask 24-21-00-920-062-A

C. Removal of the IDG Oil Filter-Elements
(1) Replace the IDG oil scavenge-filter-element with its new packing (Ref. AMM TASK 24-21-51-000-810) and (Ref. AMM TASK 24-21-51-400-810).
(a) Install the new packing into the cap of the IDG oil scavenge-filter-element.
(b) Install the cap of the IDG oil scavenge-filter-element.
(2) Remove and discard the IDG oil charge-filter-element and its packing (Ref. AMM TASK 24-21-51-000-810). Do not install a new IDG oil charge-filter-element and its packing.
(a) Install the new packing into the cap of the IDG oil charge-filter-element (Ref. AMM TASK 24-21-51-400-810).
(b) Install the cap of the IDG oil charge-filter-element (Ref. AMM TASK 24-21-51-400-810).

Subtask 24-21-00-170-055-A

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

D. Flushing of the IDG

NOTE: Approximately 3.8 l (1.00 USgal) to 5.7 l (1.51 USgal) of oil will flow into the CONTAINER 10 L(2 1/2 USGAL).

NOTE: The (Ref. AMM D/O 20-34-00-00) gives a list of approved oil-brand names for the IDG.

(1) Remove the blanking cap from the pressure fill half-coupling.
(2) Connect the pressure fill hose (3) of the FILLING EQUIPMENT - TANK OIL to the pressure fill half-coupling.
(a) Fill the IDG with Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) until:

The color of the oil that flows out of the case drain is the same as the color of the oil that you put into the IDG, or
You collect approximately 3.8 l (1.00 USgal) to 5.7 l (1.51 USgal) of oil from the case drain.

Subtask 24-21-00-640-069-A

E. Lubrication of the Expendable Part
(1) Apply Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) to a new AIPC 24-21-51-61-150 PREFORMED PACKING (1) of the case drain plug (2).

Subtask 24-21-00-420-098-A

F. Installation of the Case Drain Plug on the IDG
(1) Install the packing (1) on the case drain plug (2).
(2) Install the case drain plug (2) on the IDG.
(3) Tighten the case drain plug (2) by hand only.

Subtask 24-21-00-612-101-A

G. Filling of the IDG with Oil
(1) Fill the IDG with oil (Ref. AMM TASK 12-13-24-612-804).

Subtask 24-21-00-410-132-A

H. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR

Subtask 24-21-00-710-077-A

I. Operation of the Engine
(1) Start the related engine (Ref. AMM TASK 71-00-00-860-827) and let it operate until the temperature of the IDG oil is 175 deg.F (79.44 deg.C).
(a) Read the oil temperature on the ELEC page of the lower ECAM DU.
(2) Stop the engine (Ref. AMM TASK 71-00-00-860-829).

Subtask 24-21-00-010-136-A

J. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR

Subtask 24-21-00-680-074-A

K. Depressurization of the IDG Case, Draining of the Oil, Replacement of the IDG Oil Scavenge-Filter-Element, Lubrication of the Expendable Part and Installation of the Case Drain Plug
(1) Depressurize the case and drain the oil from the IDG.
(a) Do Steps 4.A. and 4.B. again.
(2) Replace the IDG oil scavenge-filter-element (Ref. AMM TASK 24-21-51-000-810) and (Ref. AMM TASK 24-21-51-400-810).
(a) Install a new IDG oil charge-filter-element (Ref. AMM TASK 24-21-51-400-810), the new packing and the cap.
(3) Lubrication of the expendable part and installation of the case drain plug (2) on the IDG.
(a) Do Step 4.E. again.
(b) Install the new packing (1) on the case drain plug (2).
(c) Install the case drain plug (2) on the IDG.
(d) TORQUE the case drain plug (2) to between 75 and 55 lbf.in (0.85 and 0.62 m.daN )

.
(e) Safety the case drain plug with lockwire

1 Safety the case drain plug (2) with CP8001lockwire 0.032 in. (0.8 mm) dia. or CP8002lockwire 0.032 in. (0.8 mm) dia, (Ref. AMM TASK 20-11-11-911-001).

Subtask 24-21-00-612-102-A

L. Fill the IDG with oil (Ref. AMM TASK 12-13-24-612-804).

5. Close-up
Subtask 24-21-00-410-127-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR
(3) Remove the WARNING NOTICE(S).

Subtask 24-21-00-862-081-A

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

[Rev.10 from 2021] 2026.03.31 23:19:59 UTC