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

TASK 24-21-51-000-040-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.

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
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	AR	CAP - BLANKING, SHIPPING
No specific	1	CONTAINER 4 L (1 USGAL)
No specific	AR	COVER - PROTECTION
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	WARNING NOTICE(S)
TMHSD10-20-00	1	HOIST-ACCESSORY,IDG R I FOR CFM56-5

B. Consumable Materials

REFERENCE	DESIGNATION
(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
436	FAN AND ACCESSORY GEARBOX
FOR [1000EM1] (ENGINE-1)
437AL, 438AR
FOR [1000EM2] (ENGINE-2)
447AL, 448AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
8	PACKING	AIPC 24-21-51-02-120
10	PACKING	AIPC 24-21-51-02-140

E. Referenced Information

REFERENCE	DESIGNATION
TASK 12-13-24-680-040-A	Draining of the Oil from the Integrated Drive Generator (IDG)
TASK 24-21-00-612-043-A	Servicing of the Integrated Drive Generator (IDG) after Oil Chemical Contamination
TASK 24-21-00-612-043-A-01	Servicing of the IDG after Oil Chemical Contamination and Extension of the Oil-Filter Differential-Pressure Indication (DPI)
TASK 24-21-49-000-040-A	Removal of the Tubings - IDG Cooling Oil
TASK 24-21-51-000-041-A	Removal of the IDG Oil Filter(s)
TASK 24-21-51-400-041-A	Installation of the IDG Oil Filter(s)
TASK 71-13-00-010-040-A	Opening of the Fan Cowl Doors
TASK 73-11-60-000-001-A	Removal of the Integrated Drive Generator (IDG) Oil Cooler Assembly
Integrated Drive Generator (IDG)
Integrated Drive Generator (IDG)

3. Job Set-up
Subtask 24-21-51-941-053-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 24-21-51-865-053-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 24-21-51-010-054-A ** ON A/C NOT FOR ALL

C. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-040):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR

4. Procedure

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.

Subtask 24-21-51-680-052-A ** ON A/C NOT FOR ALL

A. Draining of the IDG Oil
(1) Drain the IDG oil system before you remove the integrated drive generator (Ref. AMM TASK 12-13-24-680-040).

Subtask 24-21-51-210-073-A ** ON A/C NOT FOR ALL

B. Visual Inspection of Components
(1) Remove the IDG oil filter-element (Ref. AMM TASK 24-21-51-000-041).
(2) Do a visual inspection of the IDG oil 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 24-21-00-612-043).
(b) If there are no signs of metal particles, install the filter element you removed (Ref. AMM TASK 24-21-51-400-041), 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 tubings (Ref. AMM TASK 24-21-49-000-040) and clean them.
c Remove the cooler (Ref. AMM TASK 73-11-60-000-001), 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 IDG oil-cooler assembly and the clean IDG cooling-oil tubings.

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 24-21-51-400-041), 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 24-21-51-400-041).

Subtask 24-21-51-020-056-A ** ON A/C NOT FOR ALL

C. Removal of the Electrical Harnesses
(1) Disconnect the three electrical connectors (20), (21) and (22).
(2) Put CAP - BLANKING (23), (24) and (25) on the electrical receptacles and plugs.

Subtask 24-21-51-020-057-A ** ON A/C NOT FOR ALL

D. Removal of the Phase Leads
(1) Remove the screws (28), the washers (29) and the terminal block cover (27).

NOTE: Optional configuration: for easier access to the screw, operators can turn the IDG terminal-block cover.
Remove the screws (28(A)), the washers (29(A)) and the terminal block cover (27(A)).

(2) Remove the terminal nut (30) and the washer (31) from each terminal block stud.

NOTE: Alternate configuration, remove the terminal nut with captive washer (32) from each terminal block stud.

(3) Disconnect the phase leads (26).

Subtask 24-21-51-420-058-A ** ON A/C NOT FOR ALL

E. Installation of the Terminal Block Cover
(1) Install the washer (31) and the terminal nut (30), or the terminal nut with captive washer (32) on each terminal block stud.
Tighten the terminal nuts (30) or the terminal nuts with captive washer (32) by hand only.
(2) Install the terminal block cover (27) or 27(A)) with the washers (29) or (29(A)) and the screws (28) or (28(A)).
Tighten the screws (28) by hand only.

Subtask 24-21-51-020-058-A ** ON A/C NOT FOR ALL

F. Removal of the Overflow Drain Half-coupling
(1) Remove the dust cap (4).
(2) Remove the overflow drain half-coupling (3) from the overflow drain-port and retain for installation.
(3) Discard the packing (2).

Subtask 24-21-51-640-053-A ** ON A/C NOT FOR ALL

G. Lubrication of the New Packing
(1) Lubricate the new AIPC 24-21-51-02-120 PACKING (8) with the Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) .

Subtask 24-21-51-420-060-A ** ON A/C NOT FOR ALL

H. Installation of the Overflow Drain Plug
(1) Install the new packing (8) on the overflow drain plug (9).
(2) Install the overflow drain plug (9) in the overflow drain-port.
(3) Torque the overflow drain plug (9) by hand.
(4) Safety the overflow drain plug (9) with CP8002lockwire 0.032 in. (0.8 mm) dia.

Subtask 24-21-51-020-059-A ** ON A/C NOT FOR ALL

I. Removal of the Pressure Fill Half-Coupling
(1) Remove the dust cap (7).
(2) Remove the pressure-fill half-coupling (6) from the pressure fill-port and retain for subsequent use.
(3) Discard the packing (5).

Subtask 24-21-51-640-054-A ** ON A/C NOT FOR ALL

J. Lubricate the new AIPC 24-21-51-02-140 PACKING (10) with the Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) .

Subtask 24-21-51-420-061-A ** ON A/C NOT FOR ALL

K. Installation of the Pressure Fill Plug
(1) Install the new packing (10) on the pressure fill plug (11).
(2) Install the pressure fill plug (11) in the pressure fill-port.
(3) Torque the pressure fill plug (11) by hand.
(4) Safety the pressure fill plug (11) with CP8002lockwire 0.032 in. (0.8 mm) dia.

Subtask 24-21-51-020-060-A ** ON A/C NOT FOR ALL

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

CAUTION: USE TWO WRENCHES TO HOLD THE FITTINGS WHEN YOU TORQUE THE OIL-IN AND OIL-OUT LINES. IF NOT YOU CAN TRANSMIT TOO MUCH TORQUE TO THE IDG FITTINGS AND CAUSE DAMAGE TO THE IDG BOSSES.

(1) Put a CONTAINER 4 L (1 USGAL) below the oil-in (13) and the oil-out (12) lines.
(2) Remove the oil-in (13) and the oil-out (12) lines from the integrated drive generator (IDG) (1).
(3) Let the oil drain out.
(4) Remove the unions (14) and (16) from IDG, and retain for subsequent use.
(5) Discard the packings (17) and (15).
(6) Install the COVER - PROTECTION on the oil-in (13) and oil-out (12) lines.
(7) Install the CAP - BLANKING, SHIPPING (19) and (18) on the oil-in and oil-out bosses.
(8) Tighten the shipping plugs.

Subtask 24-21-51-480-051-A ** ON A/C NOT FOR ALL

M. Installation of the IDG Removal/Installation Tool
(1) Use a TMHSD10-20-00 HOIST-ACCESSORY,IDG R I FOR CFM56-5, support the IDG.
(2) Make sure that none of the weight is on the Quick Attach/Detach (QAD) adapter or the input shaft.

NOTE: The IDG weighs approximately 56 kg (123.4588 lb) in weight.

Subtask 24-21-51-020-061-A ** ON A/C NOT FOR ALL

N. Removal of the IDG from Engine Gearbox

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

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 tension bolt.
(2) Loosen the QAD tension bolt (43) until:

the screw head touches the lug on the QAD ring or,
the stripe marks on the QAD ring (46) and the housing of the integrated drive generator align.

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 does not turn the QAD ring to the aligned/open position:

turn the QAD ring by hand or,
lightly tap the ring until aligned.

(4) Hold the IDG with the hoisting mechanism and disconnect the IDG from the gearbox.
(5) Discard O-rings (42) and (44).
(6) Install the COVER - PROTECTION on the IDG interface side of the gearbox.
(7) Protect the IDG (1) with a BAG - PLASTIC.

[Rev.10 from 2021] 2026.03.31 23:21:16 UTC