Installation of the Integrated Drive Generator (IDG) Cooler Hoses

TASK 24-21-55-400-802-A
Installation of the Integrated Drive Generator (IDG) Cooler Hoses

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS NECESSARY.

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AND THE ADJACENT COMPONENTS AFTER ENGINE SHUTDOWN. THE ENGINE, THE ENGINE OIL AND THE ADJACENT COMPONENTS 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.

WARNING: REFER TO THE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIAL INFORMATION. THIS INCLUDES HAZARDOUS INGREDIENTS, PHYSICAL AND CHEMICAL CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, AND USE OF CONTROL MEASURES.

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

CAUTION: USE TWO WRENCHES TO REMOVE OR INSTALL THE HOSE NUTS. USE ONE WRENCH TO HOLD THE FITTING AND ONE WRENCH TO LOOSEN OR TIGHTEN THE HOSE NUT. IF YOU DO NOT DO THIS, DAMAGE TO THE COMPONENTS CAN OCCUR.

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	COVER - PROTECTION
No specific	Torque wrench: range to between 420 and 300 lbf.in (4.75 and 3.39 m.daN )
No specific	Torque wrench: range to between 480 and 360 lbf.in (5.42 and 4.07 m.daN )
No specific	Torque wrench: range to between 700 and 650 lbf.in (7.91 and 7.35 m.daN )
No specific	Torque wrench: range to between 730 and 700 lbf.in (8.25 and 7.91 m.daN )
No specific	Torque wrench: range to between 1000 and 900 lbf.in (11.30 and 10.17 m.daN )
No specific	Torque wrench: range to between 1050 and 1000 lbf.in (11.87 and 11.3 m.daN )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.PU1-0001)	lint-free cotton cloth
(Material No.PU2-0002)	acetone
(Material No.PU3-0025)	sealant, tamper proof
(Material No.PU6-0005)	lubrication oil

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
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
5	PREFORMED PACKING	AIPC 24-24-86-01-090
4	PREFORMED 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 24-21-00-210-806-A	Visual Inspection of the Integrated Drive Generator (IDG) for Oil Leaks and Check of the Electrical Circuits
TASK 24-21-00-210-806-A-01	Visual Inspection of the Integrated Drive Generator (IDG) for Oil Leakage Engine Static and Check of the Electrical Circuits
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
AC Generator Oil Tubes

3. Job Set-up
Subtask 24-21-55-941-052-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 24-21-55-865-052-A ** ON A/C NOT FOR ALL

B. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

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

Subtask 24-21-55-010-053-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 24-21-55-040-051-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 24-21-55-010-054-A ** ON A/C NOT FOR ALL

E. Get Access
(1) Make sure that the thrust-reverser cowl-doors are open (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR
(2) Installation of the engine protection covers

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

(a) Make sure that all the necessary COVER - PROTECTION to prevent damage to the engine are installed.

4. Procedure

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

Subtask 24-21-55-420-051-A ** ON A/C NOT FOR ALL

A. Installation of the IDG Cooler Hoses

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) If you removed the fitting (6), install it again as follows:
(a) Install a new AIPC 24-24-86-01-090 PREFORMED PACKING (5) on the fitting (6).
(b) Apply a thin layer of lubrication oil (Material No.PU6-0005) to the threads of the fitting (6).
(c) Install the fitting (6) on the IDG.
(d) TORQUE the fitting (6) to between 420 and 300 lbf.in (4.75 and 3.39 m.daN )

.
(e) Clean the surface of the fitting (6) and the adjacent surface with a clean lint-free cotton cloth (Material No.PU1-0001) made moist with acetone (Material No.PU2-0002) . Clean until you remove all the contamination.
(f) Clean the surface of the fitting (6) and the adjacent surface with a clean lint-free cotton cloth (Material No.PU1-0001) made moist with acetone (Material No.PU2-0002) . Remove the solvent with a clean lint-free cotton cloth (Material No.PU1-0001) before it dries.
(g) Clean the surface of the fitting (6) and the adjacent surface one more time with a clean lint-free cotton cloth (Material No.PU1-0001) .
(h) Apply the torque stripe on the fitting (6) and the adjacent surface with PU3-0025sealant, tamper proof.
(2) If you removed the fitting (3), install it again as follows:
(a) Install a new AIPC 24-24-86-01-120 PREFORMED PACKING (4) on the fitting (3).
(b) Apply a thin layer of lubrication oil (Material No.PU6-0005) to the threads of the fitting (3).
(c) Install the fitting (3) on the IDG.
(d) TORQUE the fitting (3) to between 480 and 360 lbf.in (5.42 and 4.07 m.daN )

.
(e) Clean the surface of the fitting (3) and the adjacent surface with a clean lint-free cotton cloth (Material No.PU1-0001) made moist with acetone (Material No.PU2-0002) . Clean until you remove all the contamination.
(f) Clean the surface of the fitting (3) and the adjacent surface with a clean lint-free cotton cloth (Material No.PU1-0001) made moist with acetone (Material No.PU2-0002) . Remove the solvent with a clean lint-free cotton cloth (Material No.PU1-0001) before it dries.
(g) Clean the surface of the fitting (3) and the adjacent surface one more time with a clean lint-free cotton cloth (Material No.PU1-0001) .
(h) Apply the torque stripe on the fitting (3) and the adjacent surface with PU3-0025sealant, tamper proof.
(3) Install the IDG cooler hose (1):
(a) Apply a thin layer of lubrication oil (Material No.PU6-0005) to the threads of the fitting (6) on the thermal management-system module.
(b) Connect the IDG cooler hose (1) to the thermal management-system module. Do not torque the nut of the IDG cooler hose (1) at this time.
(c) Apply a thin layer of lubrication oil (Material No.PU6-0005) to the threads of the fitting (6).
(d) Connect the IDG cooler hose (1) to the fitting (6) on the IDG. Do not torque the nut of the IDG cooler hose (1) at this time.
(e) Adjust the IDG cooler hose (1) to keep the preload to a minimum.
(f) Make sure that there are no kinks on the IDG cooler hose (1).
(g) Hold the fitting (6) on the thermal management-system module with the applicable wrench and TORQUE the nut of the IDG cooler hose (1) to between 700 and 650 lbf.in (7.91 and 7.35 m.daN )

.
(h) Hold the fitting (6) on the IDG with the applicable wrench and TORQUE the nut of the IDG cooler hose (1) to between 730 and 700 lbf.in (8.25 and 7.91 m.daN )

NOTE: It is necessary to use two wrenches. One to hold the fitting and the other to torque the nut. This will prevent damage to the IDG.

(i) Clean the surface of the IDG cooler hose (1) nut with a clean lint-free cotton cloth (Material No.PU1-0001) made moist with acetone (Material No.PU2-0002) . Clean until you remove all the contamination.
(j) Clean the surface of the IDG cooler hose (1) nut with a clean lint-free cotton cloth (Material No.PU1-0001) made moist with acetone (Material No.PU2-0002) . Remove the solvent with a clean lint-free cotton cloth (Material No.PU1-0001) before it dries.
(k) Clean the surface of the IDG cooler hose (1) nut one more time with a clean lint-free cotton cloth (Material No.PU1-0001) .
(l) Apply the torque stripe on the IDG cooler hose (1) nut and the adjacent fitting (6) with PU3-0025sealant,tamper proof.
(4) Install the IDG cooler hose (2):
(a) Apply a thin layer of lubrication oil (Material No.PU6-0005) to the threads of the fitting (3) on the thermal management-system module.
(b) Connect the IDG cooler hose (2) to the thermal management-system module. Do not torque the nut of the IDG cooler hose (2) at this time.
(c) Apply a thin layer of lubrication oil (Material No.PU6-0005) to the threads of the fitting (3).
(d) Connect the IDG cooler hose (2) to the fitting (3) on the IDG. Do not torque the nut of the IDG cooler hose (2) at this time.
(e) Adjust the IDG cooler hose (2) to keep the preload to a minimum.
(f) Make sure that there are no kinks on the IDG cooler hose (2).
(g) Make sure that the primary bend on the IDG cooler hose (2) is below the fitting (3) on the IDG

AC Generator Oil Tubes ** ON A/C NOT FOR ALL

View B.
(h) Hold the fitting (3) on the thermal management-system module with the applicable wrench and TORQUE the nut of the IDG cooler hose (2) to between 1000 and 900 lbf.in (11.30 and 10.17 m.daN )

.
(i) Hold the fitting (3) on the IDG with the applicable wrench and TORQUE the nut of the IDG cooler hose (2) to between 1050 and 1000 lbf.in (11.87 and 11.3 m.daN )

NOTE: It is necessary to use two wrenches. One to hold the fitting and the other to torque the nut. This will prevent damage to the IDG.

(j) Clean the surface of the IDG cooler hose (2) nut with a clean lint-free cotton cloth (Material No.PU1-0001) made moist with acetone (Material No.PU2-0002) . Clean until you remove all the contamination.
(k) Clean the surface of the IDG cooler hose (2) nut with a clean lint-free cotton cloth (Material No.PU1-0001) made moist with acetone (Material No.PU2-0002) . Remove the solvent with a clean lint-free cotton cloth (Material No.PU1-0001) before it dries.
(l) Clean the surface of the IDG cooler hose (2) nut one more time with a clean lint-free cotton cloth (Material No.PU1-0001) .
(m) Apply the torque stripe on the IDG cooler hose (2) nut and the adjacent fitting (3) with PU3-0025sealant,tamper proof.

Subtask 24-21-55-612-051-A ** ON A/C NOT FOR ALL

B. Test
(1) Do an addition of oil and do an IDG oil level inspection at the sight glass (Ref. AMM TASK 12-13-24-612-803).
(2) Do an oil leak test at the IDG and the IDG cooler hoses (1) and (2) (Ref. AMM TASK 24-21-00-210-806).
(a) Leaks are not permitted.

5. Close-up
Subtask 24-21-55-410-051-A ** ON A/C NOT FOR ALL

A. Close Access

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

(1) Remove all the COVER - PROTECTION to prevent damage to the engine.
(2) Make sure that the work area is clean and clear of tools and other items.
(3) 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 24-21-55-440-050-A ** ON A/C NOT FOR ALL

B. Do the reactivation of the thrust reverser system after ground maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 24-21-55-410-052-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 24-21-55-865-053-A ** ON A/C NOT FOR ALL

D. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

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

[Rev.10 from 2021] 2026.03.31 23:21:44 UTC