Removal of the Integrated Drive Generator -IDG 1(2)

TASK 24-21-51-000-010-A
Removal of the Integrated Drive Generator -IDG 1(2)

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: DO NOT LET ENGINE OIL STAY ON YOUR SKIN FOR A LONG TIME. FLUSH THE OIL FROM YOUR SKIN WITH WATER. THE OIL IS POISONOUS AND CAN GO THROUGH YOUR SKIN AND INTO YOUR BODY.

WARNING: BE CAREFUL DURING THE REMOVAL/INSTALLATION OF THE IDG. IT WEIGHS 124lb (60kg). DRY WEIGHT.

CAUTION: DO NOT LET ENGINE FUEL OR OIL FALL ON THE ENGINE. UNWANTED FUEL OR OIL MUST BE REMOVED IMMEDIATELY WITH A CLEAN LINT FREE CLOTH. THE FUEL OR OIL CAN CAUSE DAMAGE TO THE SURFACE PROTECTION AND TO SOME PARTS.

CAUTION: DO NOT USE THE IDG CABLES FOR A HAND HOLD. IF THE IDG CABLES ARE PULLED LOOSE IT CAN CAUSE DAMAGE TO THE CABLES OR TO THE ENGINE.

ZONE: 436
ZONE: 453
ZONE: 463
FIN: 4000XU ** ON A/C NOT FOR ALL

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

REFERENCE	QTY	DESIGNATION
No specific	AR	BAG - PLASTIC
No specific	AR	CAP - BLANKING
No specific	1	CONTAINER 10 L(2 1/2 USGAL)
No specific	AR	COVER - PROTECTION
No specific	AR	PLUG - BLANKING
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	WARNING NOTICE(S)
TMHSD09-60-00	1	IDG R/I

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
436	FAN AND ACCESSORY GEARBOX
453	HOT SECTION
463	HOT SECTION
FOR [1000EM1] (ENGINE-1)
437AL, 438AR, 451AL, 452AR
FOR [1000EM2] (ENGINE-2)
447AL, 448AR, 461AL, 462AR

C. Referenced Information

REFERENCE	DESIGNATION
TASK 12-13-24-680-010-A	Draining of the Oil from the Integrated Drive Generator (IDG)
TASK 24-21-00-612-044-A	Servicing of the Integrated Drive Generator (IDG) after Oil Chemical Contamination
TASK 24-21-00-612-044-A-01	Servicing of the IDG after Oil Chemical Contamination and Extension of the Oil-Filter Differential-Pressure Indicator (DPI)
TASK 24-21-42-000-010-B	Removal of the Fuel-Cooled IDG Oil-Cooler
TASK 24-21-49-000-041-A	Removal of the Tubings - IDG Cooling Oil
TASK 24-21-51-000-011-A	Removal of the IDG Oil Filter(s)
TASK 24-21-51-400-011-A	Installation of the IDG Oil Filter(s)
TASK 71-13-00-010-010-A	Opening of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 78-32-00-010-010-A	Opening of the Thrust Reverser Halves
Integrated Drive Generator (IDG)
Integrated Drive Generator (IDG)
Integrated Drive Generator (IDG)
Integrated Drive Generator (IDG)
Integrated Drive Generator (IDG)

3. Job Set-up
Subtask 24-21-51-941-050-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) On the center pedestal, on the ENG panel 115VU:
(a) Put a WARNING NOTICE(S) to tell persons not to start the engine.
(2) Make sure that the engine 1(2) shutdown occurred not less than 5 minutes before you do this procedure.
(3) On the overhead maintenance panel 50VU:
(a) Make sure that the ON legend of the ENG/FADEC GND PWR/1(2) pushbutton switch is off.
(b) Put a WARNING NOTICE(S) to tell persons not to energize the FADEC 1(2).

Subtask 24-21-51-865-050-A ** ON A/C NOT FOR ALL

B. Open, safety and tag this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
FOR FIN: 4000XU (IDG) FOR FIN: 1000EM1 (ENGINE1)
122VU	ELEC/GCU/1	2XU1	T26
122VU	ELEC/IDG1/DISC	1XT	T24
FOR FIN: 4000XU (IDG) FOR FIN: 1000EM2 (ENGINE2)
122VU	ELEC/GCU/2	2XU2	T27
122VU	ELEC/IDG2/DISC	2XT	T25

Subtask 24-21-51-010-050-A ** ON A/C NOT FOR ALL

C. Get Access
(1) Open the fan cowls (Ref. AMM TASK 71-13-00-010-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR
(2) Open the reverser cowls (Ref. AMM TASK 78-32-00-010-010):
(a) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(b) FOR [1000EM2] (ENGINE-2)
461AL 462AR

4. Procedure
Subtask 24-21-51-680-050-A ** ON A/C NOT FOR ALL

A. Draining of the Oil from the IDG System before you remove the Integrated Drive Generator
(1) Drain the IDG oil (Ref. AMM TASK 12-13-24-680-010).

Subtask 24-21-51-210-075-A ** ON A/C NOT FOR ALL

B. Visual Inspection of Components
(1) Remove the IDG oil-scavenge filter-element (Ref. AMM TASK 24-21-51-000-011).
(2) Do a visual inspection of the IDG oil-scavenge filter-element.
(a) If you smell fuel from the filter element or the filter cover, do the servicing of the IDG after oil chemical contamination (Ref. AMM TASK 24-21-00-612-044).
(b) If there are no signs of metal particles, install the filter element you removed (Ref. AMM TASK 24-21-51-400-011) and go to Para. C. of this procedure.
(c) If there are bright metal particles and:
1 The filter element or/and the O-rings is (are) damaged (there is a risk of particles in the external circuit):
a Discard the damaged filter element or/and the O-rings.
b Remove the IDG cooling-oil tubes (Ref. AMM TASK 24-21-49-000-041) and clean them.
c Remove the fuel-cooled IDG oil-cooler (Ref. AMM TASK 24-21-42-000-010), send it back to the overhaul facility and go to Para. C. of this procedure.

NOTE: Before you install a new IDG, install a new fuel-cooled IDG oil-cooler and the clean IDG cooling-oil tubes.

2 The filter element and the O-rings are not damaged (no risk of particles in the external circuit):

Install the filter element you removed (Ref. AMM TASK 24-21-51-400-011) and go to Para. C. of this procedure.

NOTE: If you install the same IDG, install a new IDG oil scavenge-filter (Ref. AMM TASK 24-21-51-400-011).

Subtask 24-21-51-020-051-A ** ON A/C NOT FOR ALL

C. Removal of the Electrical Harnesses
(1) Disconnect the three electrical connectors (38)
(2) Put the CAP-BLANKING on each disconnected electrical connector and receptacle.

Subtask 24-21-51-020-052-B ** ON A/C NOT FOR ALL

D. Removal of the Phase Leads
(1) Remove the two bolts (33), the washers (32) and the cover (31) from the terminal block (37).
(2) Remove the four captive washer nuts (34).
(3) Disconnect the four phase cables (39) from the IDG (1).
(4) Use temporary ties and safety the four phase cables (39) and the three electrical connectors (38) away from the IDG (1).

Subtask 24-21-51-020-053-A ** ON A/C NOT FOR ALL

E. Removal of the Oil-in and Oil-out Lines

Integrated Drive Generator (IDG) ** ON A/C NOT FOR ALL

CAUTION: MAKE SURE THAT THE COUPLINGS DO NOT TWIST. DAMAGE TO THE IDG BOSSES CAN OCCUR IF YOU DO NOT HOLD THE COUPLINGS.

CAUTION: MAKE SURE THAT THE TUBES CANNOT TWIST. DAMAGE TO THE TUBES CAN OCCUR IF THEY DO TWIST.

(1) Put the CONTAINER 10 L(2 1/2 USGAL) below the oil tubes (52) and (53)
(2) Remove the nut (54), the washer(s) (55) and the bolt (58).
(3) Remove the nut (67), the washer(s) (68) and the bolt (71).
(4) Remove the nut (72), the washer(s) (73) and the bolt (76).
(5) Remove the nut (80), the washer(s) (78) and the bolt (77).
(6) Use temporary ties to hold the harness away from the two oil tubes.
(7) At the gearbox bracket (60), remove the bolts (63) and (64) and the spacers (61) and (66).

NOTE: Hold the two couplings (17) and (18) when you disconnect the oil tubes.

(8) Hold the coupling (18) and disconnect the oil inlet tube (52).
(9) Hold the coupling (17) and disconnect the oil outlet tube (53).

NOTE: Hold the tubes (51) and (50) when you loosen the connections.

(10) Hold the tube (50), disconnect and remove the oil inlet tube (52).
(11) Hold the tube (51), disconnect and remove the oil outlet tube (53).
(12) Put PLUG - BLANKING on the disconnected line ends (52) and (53).

Subtask 24-21-51-020-054-A ** ON A/C NOT FOR ALL

F. Removal of the transferable parts
(1) Make a note of the positions of the banjo couplings (17) and (18), they must be put in the same positions on installation.
(2) Remove the banjo couplings (17) and (18).
(3) Discard the seals (16) and (19).
(4) Put PLUG - BLANKING (15) and (20) on the IDG open ports.
(5) Remove the CAP - DUST from the overfill drain half-coupling (10) and the pressure fill half-coupling (11).
(6) Remove the overfill drain half-coupling (10) and the pressure fill half-coupling (11).
(7) Discard the packings (9) and (12).
(8) Put PLUG - BLANKING (13) and (14) on the IDG overfill drain and pressure fill ports.

Subtask 24-21-51-480-050-B ** ON A/C NOT FOR ALL

G. Installation of the IDG Removal/Installation Tool
(1) Put the IDG removal/installation tool TMHSD09-60-00 IDG R/I in position below the IDG.
(2) Lift the attachment cradle to the IDG with the hydraulic pump on the IDG Removal/Installation Tool.
(3) Attach the tool to the IDG.

Subtask 24-21-51-020-050-A ** ON A/C NOT FOR ALL

H. Removal of the IDG from the Engine Gearbox

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.

CAUTION: PULL THE IDG OUT IN A STRAIGHT LINE:

SO THAT THE INPUT SHAFT DOES NOT RUB
TO PREVENT DAMAGE TO THE IDG INPUT SEAL.

CAUTION: DO NOT USE EXTERNAL PARTS TO PULL OR LIFT THE IDG. IF YOU DO SO YOU CAN CAUSE DAMAGE TO THE IDG.

(1) Cut and remove the lockwire from the QAD coupling (4).
(2) Loosen the QAD tension bolt (4) until:

The screw head touches the lug on the QAD ring, or
The stripe marks on the QAD ring align with the housing of the IDG.

NOTE: The QAD kit is in the "open position" and the clamping lugs are disengaged when the stripe marks are aligned.

(3) If the tension bolt (4) does not turn the QAD ring to the aligned/open position:

Turn the QAD ring by hand, or
Lightly hit the ring up to the aligned position.

(4) Remove the IDG.

CAUTION: BE VERY CAREFUL WHEN YOU REMOVE THE IDG FROM THE ACCESSORY GEARBOX. THIS WILL HELP TO PREVENT DAMAGE TO THE ADJACENT ENGINE PARTS.

(a) Carefully pull the IDG (1) rearwards from the gearbox and remove it.
(5) Remove and discard the packings (2) and (7).
(6) Remove the container and discard all drained oil.
(7) Make sure that PLUG - BLANKING are installed on the disconnected line ends and the IDG open ports.
(8) Put the CAP-BLANKING on each disconnected electrical connector and receptacle.
(9) Install the COVER - PROTECTION on the IDG interface side of the gearbox (6).
(10) Protect the IDG (1) with a BAG - PLASTIC.

[Rev.10 from 2021] 2026.04.01 05:42:20 UTC