W DOC AIRBUS | AMM A320F

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

TASK 24-21-51-400-803-A
Installation of the Integrated Drive Generator - IDG 1(2)

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 DURING THE REMOVAL/INSTALLATION OF THE IDG. IT WEIGHS 125.04 lb (56.72 kg) DRY WEIGHT. IF YOU LET IT FALL, INJURY AND/OR DAMAGE CAN OCCUR.
WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.
CAUTION: YOU MUST ADJUST ALL TUBES WITH NO LESS THAN 0.090 INCH (2.286 MM) CLEARANCE TO ADJACENT TUBES OR PARTS. TUBES WITH LESS CLEARANCE CAN RUB DURING ENGINE OPERATION. THIS CAN CAUSE A LEAK AND A POSSIBLE IN-FLIGHT SHUTDOWN.
ZONE: 453
ZONE: 463
FIN: 4000XU1 ** ON A/C NOT FOR ALL
FIN: 4000XU2 ** 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
1
ACCESS PLATFORM 1M(3 FT)
No specific
AR
COVER - PROTECTION
No specific
1
DRIFT - PLASTIC
No specific
1
MALLET - PLASTIC
No specific
1
PLIERS - JAWED, SOFT
No specific
Torque wrench: range to between 22 and 21 lbf.in (0.25 and 0.24 m.daN ) T
No specific
Torque wrench: range to between 180 and 120 lbf.in (2.03 and 1.36 m.daN ) T
No specific
Torque wrench: range to between 168 and 144 lbf.in (1.90 and 1.63 m.daN ) T
No specific
Torque wrench: range to between 300 and 240 lbf.in (3.39 and 2.71 m.daN ) T
No specific
Torque wrench: range to between 312 and 265 lbf.in (3.53 and 2.99 m.daN ) T
No specific
Torque wrench: range to between 420 and 300 lbf.in (4.75 and 3.39 m.daN ) T
No specific
Torque wrench: range to between 480 and 360 lbf.in (5.42 and 4.07 m.daN ) T
No specific
Torque wrench: range to between 730 and 700 lbf.in (8.25 and 7.91 m.daN ) T
No specific
Torque wrench: range to between 1050 and 1000 lbf.in (11.87 and 11.3 m.daN ) T
98D71203016000
1
IDG R/I CRADLE PW
98D71203022000
1
ADAPTER-TROLLEY R/I IDG (PW AND CFM)
 B. Consumable Materials
REFERENCE
DESIGNATION
(Material No.P03-001)
lubricant, aircraft turbine engine
(Material No.P05-005)
lint-free cotton cloth
(Material No.P06-053)
Sealing Ring Lubricant
(Material No.PU1-0027)
safety cable
 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, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 461AL, 462AR
 D. Expendable Parts
FIG.ITEM
DESIGNATION
IPC-CSN
6
PACKING
AIPC 24-21-51-51-010
5
PACKING
AIPC 24-21-51-51-020
9
PACKING
AIPC 24-24-86-01-030
10
PACKING
AIPC 24-24-86-01-060
16
PACKING
AIPC 24-24-86-01-090
13
PACKING
AIPC 24-24-86-01-120
 E. Referenced Information
REFERENCE
DESIGNATION
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
TASK 24-21-00-210-805-A
Check of the Oil Level and Oil-Filter Differential-Pressure Indicator (DPI)
TASK 24-21-00-710-803-A-01
Operational Test of the IDG Disconnect and Reconnect Function - Engine in Operation
TASK 31-60-00-860-001-A
EIS Start Procedure
TASK 49-00-00-860-008-A
APU Start by External Power
TASK 49-00-00-860-008-A-01
APU Start by Batteries
TASK 49-00-00-860-009-A
APU Shutdown by External Power (131-9(A))
TASK 49-00-00-860-009-A-01
APU Shutdown by Batteries (131-9(A))
TASK 71-00-00-860-814-A
Shutdown of the Engine
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
F IDG Shipping Plugs
F IDG Couplings
F IDG Unions
F Integrated Drive Generator
F Harnesses, tubes and the IDG Power Cables
3. Job Set-up
Subtask 24-21-51-941-062-A ** ON A/C NOT FOR ALL
A. Safety Precautions
   (1) Make sure that you did the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833).
Subtask 24-21-51-865-085-A ** ON A/C NOT FOR ALL
B. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:
PANELDESIGNATIONFINLOCATION
** ON A/C NOT FOR ALL
FOR FIN: 4000XU1 (IDGENG 1)
122VUELEC/GCU/12XU1T26
122VUELEC/IDG1/DISC1XTT24
FOR FIN: 4000XU2 (IDGENG 2)
122VUELEC/GCU/22XU2T27
122VUELEC/IDG2/DISC2XTT25
Subtask 24-21-51-010-081-A ** ON A/C NOT FOR ALL
C. Get Access
   (1) Make sure that the fan cowl doors are open (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 24-21-51-040-054-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) Make sure that you did the deactivation of the thrust reverser system for ground maintenance (Ref. AMM TASK 78-30-00-040-805).
Subtask 24-21-51-010-089-A ** ON A/C NOT FOR ALL
E. Get Access
   (1) Make sure that the thrust-reverser cowl-doors (Ref. AMM TASK 78-36-00-010-802) are open:
     (a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
     (b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR
   (2) Make sure that the ACCESS PLATFORM 1M(3 FT) is in position.
   (3) Make sure that the engine protection covers are installed.
CAUTION: INSTALL PROTECTION COVERS ON ALL THE OPENINGS IMMEDIATELY TO PREVENT DAMAGE TO THE ENGINE.
     (a) Make sure that the COVER - PROTECTION are in position to prevent damage to the engine.
Subtask 24-21-51-020-122-A ** ON A/C NOT FOR ALL
F. Removal of the IDG Shipping Plugs
F IDG Shipping Plugs ** ON A/C NOT FOR ALL
   (1) If you install a new IDG:
     (a) Remove the fitting plugs (18), (19), (22) and (24) from the IDG ports and discard the packings (17), (20), (21) and (23).
Subtask 24-21-51-420-164-A ** ON A/C NOT FOR ALL
G. Installation of the Overfill Drain Valve Coupling
F IDG Couplings ** ON A/C NOT FOR ALL
   (1) If you install a new IDG:
     (a) Remove the overfill drain valve plug and discard the packing.
     (b) Make sure that the overfill drain valve coupling (8) is clean and clear.
     (c) Install the new AIPC 24-24-86-01-030 PACKING (9) on the overfill drain valve coupling (8).
       1 Install the overfill drain valve coupling (8) on the overfill drain valve port.
       2 TORQUE the overfill drain valve coupling (8) to between 300 and 240 lbf.in (3.39 and 2.71 m.daN ) T.
     (d) Install the pressure cover (7) on the overfill drain valve coupling (8).
     (e) Safety the pressure cover (7) cable to the nut on the IDG.
Subtask 24-21-51-420-167-A ** ON A/C NOT FOR ALL
H. Installation of the IDG Pressure Fill Valve Coupling
F IDG Couplings ** ON A/C NOT FOR ALL
   (1) If you install a new IDG:
     (a) Remove the pressure fill valve plug and discard the packing.
     (b) Make sure that the pressure fill valve coupling (11) is clean and clear.
     (c) Install the new AIPC 24-24-86-01-060 PACKING (10) on the pressure fill valve coupling (11).
       1 Install the pressure fill valve coupling (11) on the pressure fill valve port.
       2 TORQUE the pressure fill valve coupling (11) to between 180 and 120 lbf.in (2.03 and 1.36 m.daN ) T.
     (d) Install the pressure cover (12) on the pressure fill valve coupling (11).
     (e) Safety the pressure cover (12) cable to the nut on the IDG.
Subtask 24-21-51-420-170-A ** ON A/C NOT FOR ALL
I. Installation of the IDG Fittings
F IDG Unions ** ON A/C NOT FOR ALL
   (1) If you install a new IDG:
     (a) Make sure that the two fittings (14) and (15) are clean.
     (b) Install a new AIPC 24-24-86-01-120 PACKING (13) on the fitting (14).
       1 Apply a thin layer of P03-001lubricant, aircraft turbine engine to the threads of the fitting (14).
       2 Install the fitting (14) on the IDG port.
         a TORQUE the fitting (14) to between 480 and 360 lbf.in (5.42 and 4.07 m.daN ) T.
     (c) Install a new AIPC 24-24-86-01-090 PACKING (16) on the fitting (15).
       1 Apply a thin layer of P03-001lubricant, aircraft turbine engine to the threads of the fitting (15).
       2 Install the fitting (15) on the IDG port.
         a TORQUE the fitting (15) to between 420 and 300 lbf.in (4.75 and 3.39 m.daN ) T.
4. Procedure
Subtask 24-21-51-420-157-A ** ON A/C NOT FOR ALL
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.
A. Installation of the IDG (1) to Engine Gearbox
F Integrated Drive Generator ** ON A/C NOT FOR ALL
F Harnesses, tubes and the IDG Power Cables ** 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.
   (1) Prepare the IDG (1) and the Quick-Attach-Detach (QAD) as follows:
     (a) Put the lockwire in position on the QAD tension bolt but do not safety it at this time.
     (b) Apply P03-001lubricant, aircraft turbine engine on the QAD adapter and the threads of the QAD tension bolt.
     (c) Remove the grease from the IDG input shaft and the engine gearbox spline with the lint-free cotton cloth (Material No.P05-005) .
     (d) Apply Sealing Ring Lubricant (Material No.P06-053) or P03-001lubricant, aircraft turbine engine on the new AIPC 24-21-51-51-020 PACKING (5).
     (e) Install the new packing (5) in the groove of the IDG spline shaft.
     (f) Apply P03-001lubricant, aircraft turbine engine on the new AIPC 24-21-51-51-010 PACKING (6).
     (g) Install the new packing (6) in the groove of the IDG (1).
   (2) Attach the IDG (1) to the 98D71203016000 IDG R/I CRADLE PW with the detail strap. Refer to Ground Support Equipment (GSE) manufacturer's instructions.
   (3) Lift the 98D71203016000 IDG R/I CRADLE PW to the correct installation position with the 98D71203022000 ADAPTER-TROLLEY R/I IDG (PW AND CFM). Refer to the GSE manufacturer's instructions.
   (4) Put the IDG (1) at the correct installation angle with the 98D71203022000 ADAPTER-TROLLEY R/I IDG (PW AND CFM).
   (5) Turn the QAD tension bolt until the mark:
  • On the QAD adapter aligns with the mark on the QAD ring plate (removal or installation position)
  • On the QAD ring aligns with the mark on the QAD adapter plate (removal or installation position).
   (6) Operate the 98D71203022000 ADAPTER-TROLLEY R/I IDG (PW AND CFM) to align:
  • The IDG (1) with the mark on the QAD adapter plate, and
  • The pins with the pin holes.
Refer to the GSE manufacturer's instructions.
   (7) TORQUE the QAD tension bolt to between 312 and 265 lbf.in (3.53 and 2.99 m.daN ) T.
   (8) Tap around the QAD adapter Outside Diameter (OD) (at minimum three locations with equal distance between them) with the DRIFT - PLASTIC and the MALLET - PLASTIC as necessary, with the IDG (1) attached to the 98D71203016000 IDG R/I CRADLE PW.
   (9) Remove the IDG (1) from the 98D71203016000 IDG R/I CRADLE PW. Refer to the GSE manufacturer's instructions.
   (10) Lower the 98D71203022000 ADAPTER-TROLLEY R/I IDG (PW AND CFM) and remove it from the work area. Refer to the GSE manufacturer's instructions.
   (11) TORQUE the QAD tension bolt again to between 312 and 265 lbf.in (3.53 and 2.99 m.daN ) T.
   (12) Installation of the lockwire
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.
     (a) Safety the QAD tension bolt with the safety cable (Material No.PU1-0027) .
   (13) Connect the power cables to the IDG (1) terminal block studs as follows:
     (a) Remove the bolts (3), the cover (2) and the nuts (4) from the IDG (1).
     (b) Connect the white power cable to the stud (N1) with the nut (4) and tighten it with your hand.
     (c) Connect the red power cable to the stud (T1) with the nut (4) and tighten it with your hand.
     (d) Connect the yellow power cable to the stud (T2) with the nut (4) and tighten it with your hand.
     (e) Connect the blue power cable to the stud (T3) with the nut (4) and tighten it with your hand.
     (f) TORQUE the nuts (4) to between 168 and 144 lbf.in (1.90 and 1.63 m.daN ) T.
     (g) Attach the terminal cover (2) with the bolts (3).
     (h) TORQUE the bolts (3) to between 22 and 21 lbf.in (0.25 and 0.24 m.daN ) T.
   (14) Connect the IDG oil tubes (LS01) and (LS04) as follows:
CAUTION: USE A SECOND WRENCH TO HOLD THE MATING PARTS WHEN YOU LOOSEN OR TIGHTEN THE TUBE OR HOSE NUTS. IF YOU DO NOT OBEY THIS CAUTION, YOU CAN TWIST OR CAUSE DAMAGE TO THE TUBES OR HOSES.
     (a) Apply P03-001lubricant, aircraft turbine engine on the IDG adapter threads.
     (b) Connect the tube (LS01) with your hand only.
     (c) TORQUE the B-nut to between 730 and 700 lbf.in (8.25 and 7.91 m.daN ) T.
     (d) Connect the tube (LS04) with your hand only.
     (e) TORQUE the B-nut to between 1050 and 1000 lbf.in (11.87 and 11.3 m.daN ) T.
NOTE: To prevent damage to the IDG (1), it is necessary to use two wrenches:
  • One to hold the fitting, and
  • The other one to torque the B-nut.
   (15) Connect the electrical connectors of the wiring harness to the IDG receptacles as follows:
     (a) Examine, align and engage the electrical connectors.
     (b) Lightly push the inner side of the electrical connectors while you tighten the coupling ring.
     (c) Tighten the electrical connectors against the receptacle with the PLIERS - JAWED, SOFT.
     (d) Make sure that you can feel the ratchet feature.
     (e) While you tighten the coupling ring, push the electrical connectors in the IDG receptacles from one side to the other one.
     (f) Tighten the electrical connectors until the PLIERS - JAWED, SOFT move on the electrical connector ring.
Subtask 24-21-51-612-068-A ** ON A/C NOT FOR ALL
B. Replenish or change the IDG oil (Ref. AMM TASK 12-13-24-612-803).
   (1) Examine the assembly for unwanted objects, damage and correct assembly.
Subtask 24-21-51-410-085-A ** ON A/C NOT FOR ALL
C. 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) Close the thrust-reverser cowl-doors (Ref. AMM TASK 78-36-00-410-802):
     (a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
     (b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR
Subtask 24-21-51-440-052-A ** ON A/C NOT FOR ALL
D. 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 24-21-51-410-075-A ** ON A/C NOT FOR ALL
E. 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 24-21-51-865-086-A ** ON A/C NOT FOR ALL
F. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):
PANELDESIGNATIONFINLOCATION
** ON A/C NOT FOR ALL
FOR FIN: 4000XU1 (IDGENG 1)
122VUELEC/GCU/12XU1T26
122VUELEC/IDG1/DISC1XTT24
FOR FIN: 4000XU2 (IDGENG 2)
122VUELEC/GCU/22XU2T27
122VUELEC/IDG2/DISC2XTT25
Subtask 24-21-51-710-064-A ** ON A/C NOT FOR ALL
G. Do an operational test of the IDG disconnect and reconnect (reset) function with the engine in operation (Ref. AMM TASK 24-21-00-710-803).
Subtask 24-21-51-720-065-A ** ON A/C NOT FOR ALL
H. Check for Oil Leaks and the Electrical Properties
   (1) Start engines 1 and 2 at minimum idle (Ref. AMM TASK 71-00-00-860-823).
   (2) Make sure that IDG operates correctly:
     (a) Do the EIS start procedure (upper ECAM DU and lower ECAM DU only) (Ref. AMM TASK 31-60-00-860-001).
     (b) On the ECAM control panel, push the ELEC key to get the ELEC page on the lower ECAM DU:
  • Make sure that the voltage of the IDG is 115VAC.
  • Make sure that the frequency of the IDG is 400Hz plus or minus 5Hz.
NOTE: If the IDG was removed after an IDG 1(2) disconnection, do a GCU 1(2) reset at the first engine start at idle. To do this, push, then release the related ELEC/GEN pushbutton switch.
   (3) Do the switching test that follows:
ACTION
RESULT
1.On the APU section of the overhead control and indication panel 25VU:
  • Make sure that the APU MASTER SW pushbutton switch is released.
On the APU section of the overhead control and indication panel 25VU:
  • The ON legend of the APU MASTER SW pushbutton switch is off.
2.On the ELEC control panel 35VU:
  • Release the GEN1 pushbutton switch.
On the ELEC control panel 35VU:
  • The OFF legend of the GEN1 pushbutton switch comes on.
3.Wait for three minutes.


On the lower ECAM DU, on the ELEC page, make sure that there is a green line between:
  • The GEN2 and the AC2 busbar
  • The AC2 and the AC1 busbars, and
  • The AC1 and the AC ESS busbars.
4.On the ELEC control panel 35VU:
  • Push the GEN1 pushbutton switch.
On the ELEC control panel 35VU:
  • The OFF legend of the GEN1 pushbutton switch goes off.
5.On the ELEC control panel 35VU:
  • Release the GEN2 pushbutton switch.
On the ELEC control panel 35VU:
  • The OFF legend of the GEN2 pushbutton switch comes on.
6.Wait for three minutes.


On the lower ECAM DU, on the ELEC page, make sure that there is a green line between:
  • The GEN1 and the AC1 busbar
  • The AC1 and the AC2 busbar, and
  • The AC1 and the AC ESS busbars.
7.Start and operate the APU:
For the GTCP 36-300 (Ref. AMM D/O 49-00-00-86)
For the APS 3200 (Ref. AMM D/O 49-00-00-86)
For the 131-9(A) (Ref. AMM TASK 49-00-00-860-008)
On the lower ECAM DU, on the ELEC page:
Make sure that there is a green line between:
  • The AC ESS and the AC1 busbars
  • The APU GEN and the AC2 busbar, and
    Make sure that the parameters that follow are corrects:
  • AC LOAD Percent shown in green,
  • AC V = 115 + or - 5V,
  • FRQ HZ = 400 + or - 10HZ.
8.On the ELEC control panel 35VU:
  • Push the GEN2 pushbutton switch.
On the ELEC control panel 35VU:
  • The OFF legend of the GEN2 pushbutton switch goes off.
   (4) Stop engines 1 and 2 (Ref. AMM TASK 71-00-00-860-814).
   (5) In the cockpit, on the ELEC panel 35VU:
     (a) Make sure that the EXT PWR pushbutton switch is pushed (OFF legend goes off).
   (6) Stop the APU:
For the GTCP 36-300 (Ref. AMM D/O 49-00-00-86)
For the APS 3200 (Ref. AMM D/O 49-00-00-86)
For the 131-9(A) (Ref. AMM TASK 49-00-00-860-009).
   (7) Make sure that there are no oil leaks.
   (8) Do a check of the oil level at the sight glass of the IDG (Ref. AMM TASK 24-21-00-210-805).
5. Close-up
Subtask 24-21-51-410-080-A ** ON A/C NOT FOR ALL
A. Put the aircraft back to its initial configuration.
   (1) Remove the WARNING NOTICE(S).
   (2) Remove the access platform(s).
   (3) Make sure that the work area is clean and clear of tools and other items.
[Rev.10 from 2021] 2026.04.01 05:42:27 UTC
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