Aw139 MGB O/h Training Course

MAIN TRANSMISSION GEARBOX
(MGB) REPAIR & OVERHAUL

TECHNICIAN TRAINING
THIS TRAINING PUBLICATION IS ISSUED TO TRAINEES OF AGUSTAWESTLAND TRAINING ACADEMY A.MARCHETTI FOR TRAINING PURPOSE ONLY. THE INFORMATION CONTAINED IN THIS TRAINING
PUBLICATION IS NOT INTENDED TO SUBSTITUTE OR REPLACE ANY RELEVANT TECHNICAL PUBLICATION/ORDER/INSTRUCTION ISSUED BY ANY COMPETENT DESIGN AUTHORITY IN RELATION TO THE
SUBJECT MATTER HEREIN AND THE TRAINEES SHALL ALWAYS REFER TO THESE OFFICIAL DOCUMENTS WHILE PERFORMING ACTIVITIES ON THE HELICOPTER. THE INFORMATION HEREIN ARE UPDATED
AT THE DATE OF RELEASE OF THIS TRAINING PUBLICATION AND AGUSTAWESTLAND DOES NOT TAKE ANY COMMITMENT TO UPDATE THE SAME UNLESS AGUSTAWESTLAND DETERMINES AT ITS SOLE
DISCRETION TO RELEASE AN UPDATE OF THIS DOCUMENT. MOREOVER AGUSTAWESTLAND REPRESENTS THAT NO FURTHER DOCUMENT WILL BE PROVIDED TO THE TRAINEE IN ADDITION TO THE
TRAINING PUBLICATION HEREIN. INFORMATION AND DRAWINGS CONTAINED IN THIS TRAINING PUBLICATION ARE CONFIDENTIAL AND PROPERTY OF AGUSTAWESTLAND S.P.A.. TRAINEE SHALL USE SUCH
INFORMATION FOR THE TRAINING PURPOSE ONLY AND KEEP THE INFORMATION HEREIN CONFIDENTIAL AND NOT MAKE AVAILABLE OR OTHERWISE DISCLOSE SUCH INFORMATION TO ANY THIRD PARTY
WITHOUT THE PRIOR WRITTEN CONSENT OF AGUSTAWESTLAND S.P.A.. ANY UNAUTHORISED USE DISCLOSURE REPRODUCTION IN WHOLE OR IN PART OF THE INFORMATION CONTAINED IN THIS
TRAINING PUBLICATION IS FORBIDDEN AND PROSECUTED IN ACCORDANCE WITH THE APPLICABLE LAW.
DOCUMENT No.: 39-A0126-MG001-00

ISSUE: 002
ISSUE DATE: 16 April 2014
Document Name: 39-A0126-MG001-00
ISSUE DATE REMARKS

001 2013.07.25 1st Issue
002 2014.04.16 2st Issue
NOTE
All information reported in this Manual

must be considered for Training
purpose only
For Training purpose only 2 of 18

TECHNICIAN TRAINING
Chapter 1 - Introduction
1 - Introduction
The information reported in this training manual are relevant to the Repair & Overhaul
procedures described on AW139 IETP data modules for MGB P/Ns:
3G6320A00132,
3G6320A00133,
3G6320A00134,
3G6320A00135
Hereinafter is shown the Table of Contents of this manual.

1 Introduction
Table of Contents
Chapter 2 - Documentation
2.1 A/C Publication

2.2 IETP Interactive Electronic Technical Publication
2.3 AMP A/C Maintenance Publication
2.4 DMC Data Module Code
2.5 Descriptive Data Module
2.6 AMPI A/C Maintenance Planning Information
2.7 CR&OP Component Repair & Overhaul Publication
2.8 IPD Illustrated Part Data
2.9 ITEP Illustrated Tolls & Equipment Publication
2.10 RFM Rotorcraft Flight Manual
2.11 QRH Quick Reference and Handbook
2.12 MGB Log card

1 Introduction (continued)
Chapter 3 - General information
3.1 General description

3.2 MGB description
3.3 Mechanical assembly description
3.3.1 Left and Right Input Shaft Module description
3.3.2 Upper Module description
3.3.3 Hydraulic Pumps drive quills description
3.3.4 ECS compressor drive quill description
3.3.5 FAN drive quill description
3.3.6 Tail-rotor drive quill description
3.4 Lubrication system description
3.4.1 General
3.4.2 Chip detection operation
3.4.3 Pumps
3.4.4 Pressure regulation
3.4.5 Oil Filter
3.4.6 Oil Cooler
3.4.7 Sensors and Jets
3.5 Leading Particulars
3.6 Controls and Indicators
3.7 Warning, Caution Messages
3.8 Components that must be removed from the MGB before its overhaul

Chapter 4 General Procedures
4.1 Introduction
4.2 A/C Publications
4.3 AMPI A/C Maintenance Publication Information
4.4 Limits
Chapter 5 Pre-Disassembly Procedures
5.1 Safety Information

5.2 Pre-disassembly requirements
5.3 MGB Drain oil and Draining Pipe removal procedures
5.4 Anti-Torque Beam & Bottom Cover, removal procedures
5.5 Installation of the Main Case on the Support Trolley
Chapter 6 Disassembly Procedures

6.1 Left and Right Input Shaft Module and Cross Shaft, removal and disassembly
procedures
6.2 Main Case Assembly - External components (Plugs, Covers, Sensors, Filter
element, Servo Supports, Chip Detectors, Oil Level gauge, Borescope Port,
Lubrication Pumps, Check Valves, PRV,), removal procedures.
6.3 Main Case Oil Jets, removal procedures.
6.4 Upper Module, Oil Unions and Planetary Crown (fixed ring gear), removal
procedures.
6.5 Main Case, Backlash Check .
6.6 Drive Quills (LH/RH/Front Hyd. Pumps, ECS-Compressor and Fan drive
quill), removal procedures.
6.7 LH and RH Input Pinion Assembly (II stage of reduction), removal
procedures.
6.8 LH and RH Input Pinion Assy (II stage of reduction), disassembly
procedures.
6.9 Tail Rotor Drive Quill Assembly, removal procedures.
6.10 Tail Rotor Drive Quill Assembly, disassembly procedures.
6.11 Diaphragm, Oil Jets and Roller Bearing, removal procedures.
6.12 Collector Gear and Collector Bearing, removal procedures.
6.13 Main Case Assembly - Internal components (Roller Bearings, Shims and
Outer Race of the Roller bearing), removal procedures.
6.14 Left and Right Input Shaft Module, disassembly procedures Ref. doc.
6.15 Freewheel Group Assembly, removal and disassembly procedures.
6.16 Input Shaft Module, Backlash Check.
6.17 Input Shaft Module Input Drive Quill Group, removal procedures
6.18 Input Drive Quill Group, disassembly procedures.
6.19 Input Shaft Module Gear (I Stage of reduction), removal and disassembly
procedures
6.20 Upper Module, disassembly procedures
6.21 Mast-Planetary Assembly Disassembly procedures.
6.22 Planetary Gears Assembly Disassembly procedures.
6.23 LH & RH Lubrication Pumps Disassembly procedures.
6.24 ECS Compressor Drive Quill Disassembly procedures.
6.25 FAN Drive Quill Disassembly procedures.

6.26 Front Hyd. Pump Drive Quill Disassembly procedures.
6.27 LH & RH Hyd. Pump Drive Quill (No.1 and No. 2) Disassembly procedures.
Chapter 7 - Components Cleaning, Paint removal, Protection and Inspection
7.1 Introduction
7.2 Cleaning procedures
7.3 Paint removal
7.4 Protection procedures
7.5 Detailed Visual Examination
7.6 Defects definition
7.7 Surface finish protection restoration (Main Case)
7.8 Surface finish protection restoration (Upper Module)
7.9 Surface finish protection restoration (LH/RH Input Shaft Module)
7.10 Damages code list
7.11 Example of damages
7.12 Detailed visual examination, applicable Data Modules list
7.13 Main gearbox Detailed Visual Examination
7.14 Chip detectors Detailed Visual Examination
7.15 LH/RH Right Input Shaft Module Detailed Visual Examination
7.16 Freewheel Detailed Visual Examination
7.17 Upper Module Detailed Visual Examination
7.18 Mast-Planetary Assembly Detailed Visual Examination
7.19 Planetary Gears Assembly Detailed Visual Examination
7.20 LH/RH Hyd. Pump Drive Quill Detailed Visual Examination

7.21 Front Hyd. Pump Drive Quill Detailed Visual Examination
7.22 ECS Compressor Drive Quill Detailed Visual Examination
7.23 Fan Drive Quill Detailed Visual Examination
7.24 LH/RH Lubrication Pump Detailed Visual Examination
7.25 Tail Rotor Drive Quill Detailed Visual Examination
7.26 Dimensions Check
7.27 Main gearbox Dimensions check
7.28 LH/RH Input Shaft Module Dimensions check
7.29 Upper Module Dimensions Check
7.30 Mast-Planetary Assembly Dimensions check
7.31 Planetary Gears Dimensions check
7.32 LH/RH Hyd. Pump Drive Quill Dimensions check
7.33 Front Hyd. Pump Drive Quill Dimensions check
7.34 ECS Compressor Drive Quill Dimensions check
7.35 Fan Drive Quill Dimension check
7.36 LH/RH Lubrication Pump Dimensions check
7.37 Tail Rotor Drive Quill Dimensions check
7.38 Dye Penetrant Examination
7.39 General guidelines for Dye Penetrant Examination

7.40 Main gearbox Dye Penetrant Examination

7.41 LH/RH Input Shaft Module Dye penetrant Examination
7.42 Upper Module Dye Penetrant Examination
7.43 Front Hyd. Pump Drive Quill Dye Penetrant Examination
7.44 ECS Compressor Drive Quill Dye Penetrant Examination
7.45 LH/RH Hyd. Pump Drive Quill Dye Penetrant Examination
7.46 Tail Rotor Drive Quill Dye Penetrant Examination
7.47 Magnetic Particles Examination
7.48 General guidelines for Magnetic Particles Examination
7.49 Main gearbox Magnetic Particles Examination
7.50 LH/RH Input Shaft Module Magnetic Particles Examination
7.51 Upper Module Magnetic Particles Examination
7.52 Front Hyd. Pump Drive Quill Magnetic Particles Examination
7.53 ECS Compressor Drive Quill Magnetic Particles Examination
7.54 LH/RH Lubrication Pump Magnetic Particles Examination
7.55 Fan Drive Quill Magnetic Particles Examination
7.56 Mast-Planetary Assembly Magnetic Particles Examination
7.57 Planetary Gears Assembly Magnetic Particles Examination
7.58 LH/RH Hyd. Pump Drive Quill Magnetic Particles Examination
7.59 Tail Rotor Drive Quill Magnetic Particles Examination

Chapter 8 Assembly Procedures
8.1 Pre-Assembly Requirements

8.2 MGB, Assembly procedures
8.2.1 Main Case, Assembly procedures
8.2.1.1 Shims, installation.
8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing,
installation.
8.2.1.3 Diaphragm Assy, assembly.
8.2.1.4 Collector Gear Assy, assembly.
8.2.1.5 RH / LH Input Pinion Assy (II stage of reduction), assembly.
8.2.1.6 Tail Rotor Drive Quill Assy, assembly.
8.2.1.7 Left and Right Hyd. Pump Drive Quill, assembly.
8.2.1.8 Front Hyd. Pump Drive Quill, assembly.
8.2.1.9 ECS-Compressor Drive Quill, assembly.
8.2.1.10 Fan Drive Quill, assembly.
8.2.1.11 Collector Gear Assy, installation.
8.2.1.12 Diaphragm Assy, installation.
8.2.1.13 Tail Rotor Drive Quill Assy, installation.
8.2.1.14 RH / LH Input Pinion Assy (II stage of reduction), installation.
8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation.
8.2.1.16 Front Hyd. Pump Drive Quill Assy, installation.
8.2.1.17 ECS-Compressor Drive Quill Assy and Seal Cover, installation.
8.2.1.18 Fan Drive Quill Assy, installation.
8.2.1.19 Main Case, Backlash check

8.2.1.20 Fan Seal Cover, installation.
8.2.1.21 Left / Right Lubrication Pump, assembly.
8.2.1.22 Left / Right lubrication Pump, installation.
8.2.1.23 Bottom Cover, assembly.
8.2.1.24 Bottom Cover, installation.
8.2.1.25 AC Generators drive cover and plug, installation
8.2.2 Upper Module, Assembly procedure
8.2.2.1 Planetary gears assembly (mast planetary assembly), assembly.
8.2.2.2 Mast-planetary assembly (upper module), assembly.
8.2.2.3 Upper Fittings, Brackets, installation.
8.2.2.4 Mast-planetary assembly, installation.
8.2.2.5 Planetary Crown (Fixed Ring Gear), installation.
8.2.2.6 Roller Bearing and Cover seal, Installation.
8.2.2.7 Upper Cooler Adapter, installation
8.2.2.8 Four Oil jets, installation.
8.2.2.9 Oil Filler plug, Mast Chip detector, Mast Cover and Ident. Plate
installation
8.2.2.10 Unions, installation procedures
8.2.2.11 Upper Module Assy, installation procedures

8.2.3 Main Case, External components installation procedures

8.2.3.1 Oil draining Pipe, Oil Level Gauge and low Oil Level sensor,
installation.
8.2.3.2 Oil Filter Head, Oil Temperature sensor, Oil Pressure sensor and Oil
Temperature SW, installation.
8.2.3.3 Rotor Speed Sensor, installation.
8.2.3.4 Check valves and Pressure Relief Valve, installation.
8.2.3.5 Borescope Port, Two Chip Detectors, Washers, Plugs and Flange,
installation
8.2.3.6 Fifteen (from No. 1 to No. 13) Oil Jets, installation.
8.2.4 LH / RH Input Shaft Module, assembly procedures
8.2.4.2 Bearings, installation.
8.2.4.4 Gear (I stage of reduction), assembly.
8.2.4.5 Gear Assy and Diaphragm Assy, installation.
8.2.4.6 Input Drive Quill group, assembly.
8.2.4.7 Input Drive Quill group and Gimbal Assy, installation.
8.2.4.8 Input Shaft Module, Backlash check.
8.2.4.9 Freewheel Group, assembly.
8.2.4.10 Freewheel Group and Oil Jet Cover, installation.
8.2.4.11 Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation
8.2.4.12 LH/RH Input Shaft Module, installation.
8.2.5 Anti-Torque Beam, Installation procedures
Chapter 9 Functional Check

9.1 Preliminary Actions
9.1.1 Introduction
9.1.2 Description of operations of flushing
9.2 Functional Check (Test A)
9.2.1 Procedures
Chapter 10 Disassembly procedure after functional check

10.1 Introduction
10.2 MGB - Disassembly procedures, initial phase
10.3 Main Case, Backlash check
10.4 MGB - Disassembly procedure, final phase
10.5 Left / Right Input Shaft Module - Disassembly procedures, initial phase
10.6 Input Shaft Modules, Backlash check
10.7 Left / Right Input Shaft Module - Disassembly procedures, final phase
10.8 Upper module, disassembly procedures
10.9 Mast-Planetary Assy, disassembly procedures
10.10 Front Hyd. Pump drive quill, disassembly procedures
10.11 LH/RH Hyd. Pump drive quills, disassembly procedures

Chapter 11 - Inspection Criteria after Functional check

11.1 General guideline for visual examination of components after functional
check
11.2.1 Collector gear Wear Pattern Check
11.2.2 Input pinion (II stage of reduction) Wear Pattern Check
11.2.3 Gear (Hyd. Pump drive quill) Wear Pattern Check
11.3.1 Freewheel Detailed Visual Examination
11.4.1 Ring Gear Wear Pattern Check
11.5.1 Planetary Gear Assembly Wear Pattern Check
11.6.1 LH/RH Hyd. Pump Drive Quill Wear Pattern Check
11.7.1 Front Hyd. Pump Drive Quill Wear Pattern Check
11.8.1 ECS Compressor Drive Quill Wear Pattern Check
11.9.1 LH/RH Lubrication Pump Wear Pattern Check
11.10.1 Fan Drive Quill Wear Pattern Check
11.11 Tail Rotor Drive Quill Detailed Visual Examination & Wear Pattern Check
Chapter 12 Assembly procedures after Functional Check
12.1 Introduction
12.2 MGB - Assembly procedures, initial phase
12.4 MGB - Assembly procedures, intermediate phase
12.5 Mast-Planetary Assy, Assembly procedures
12.6 Upper Module, Assembly procedures
12.7 Upper Module, Installation procedures
12.8 MGB - External components installation
12.9 MGB - Oil jets installation
12.10 Left / Right Input Shaft Module - Assembly procedures, initial phase
12.12 Left / Right Input Shaft Module - Assembly procedures, final phase
12.13 Left / Right Input Shaft Module, Installation procedures
12.14 MGB Assembly procedures, final phase
Chapter 13 - Leak Check
13.1 Leak Check (Test B)
Chapter 14 - Finish after leak check
14.1 Oil Filter Element installation
14.2 Nylon setscrews installation
Chapter 15 - Painting procedures
Chapter 16 - Final Acceptance

THE END
RETURN TO LESSON SUMMARY RETURN TO COURSE MENU

TECHNICIAN TRAINING
2 - Documentation
INDEX
2.1 A/C Publication

2.2 IETP Interactive Electronic Technical Publication
2.3 AMP A/C Maintenance Publication
2.4 DMC Data Module Code
2.5 Descriptive Data Module
2.6 AMPI A/C Maintenance Planning Information
2.7 CR&OP Component Repair & Overhaul Publication
2.8 IPD Illustrated Part Data
2.9 ITEP Illustrated Tolls & Equipment Publication
2.10 RFM Rotorcraft Flight Manual
2.11 QRH Quick Reference and Handbook
2.12 MGB Log card
Documentation 2 of 57
2.1 - Aircraft Publications
IETP
Interactive Electronic Technical Publication
Maintenance Publication (AMP)
Maintenance Planning Information (AMPI)
Master Minimum Equipment List (MMEL)
Component Repair & Overhaul Publication (CR&OP)
RFM
Rotorcraft Flight Manual
Limitations
Normal and Emergency Procedures
Performance Data
Weight and Balance Data
Handling, Servicing and Maintenance Data
QRH
Quick Reference Handbook
Limitations
Normal and Emergency Procedures
2.2 - IETP Interactive Electronic Technical Publication
The AgustaWestland AW139

Interactive
Electronic
Technical
Publication
is distributed on CD-ROM
2.3 - AMP A/C Maintenance Publication
The Technical Publications are

arranged in CHAPTERS and
Sections.
Each chapter is composed of

DATA MODULES.
2.4 - DMC Data Module Code
Each Data Module is identified by a unique Data Module Code (DMC)

having the following structure:
1 2 3 4 5 6
39-A-XX-XX-XX-YXA-XXXA-A
2.4.1 Model Identification Code
1 2 3 4 5 6
39 - A - XX-XX-XX - XYA - XXXA - A
The Model Identification Code for the AW139 is 39.
1 2 3 4 5 6
39-A-XX-XX-XX-YXA-XXXA-A
2.4.2 System Difference Code
1 2 3 4 5 6

The System Difference Code is a letter (letters I and O are not used).
It is used when two or more subsystems can be installed in the A/C as alternatives to do the same function
(hereinafter is reported an example relevant to differents MGB group that can be installed on A/C).
(AMP) 39-A-63-20-00-00A-041A-A
Main gearbox group - Description of how it is made
(P/N 3G6320A00132 and subsequents P/N) with
different last two digits)
See AMP:
39-A-63-00-00-00A-000A-C
Main rotor drive - General
(AMP) 39-B-63-20-00-00A-041A-K
Main gearbox group - Description of how it is made
(P/N 4G6320A00132 and subsequents P/N) with different
last two digits)
2.4.3 Standard Numbering System (SNS) Code
1 2 3 4 5 6

The Standard Numbering System Code includes three pairs of digits which show:
SYSTEM eg: IPD 39-A-29-00-00-010-941A-A Hydraulic system Fuselage Section
SUBSYSTEM eg: AMP 39-A-29-10-00-00A-231A-A Main hydraulic system - Bleed

and SUB-SUBSYSTEM eg: AMP 39-A-29-11-00-00A-041A-A Number 1 main hydraulic system - Description of how it is made
COMPONENT eg: IPD 39-A-29-11-01-010-941A-A Number 1 Power Control Module Assy
2.4.4 Disassembly Code & Disassembly Code Variant 1/2
1 2 3 4 5 6
The Disassembly Code has two digits

The Disassembly Code Variant has one letter
The Disassembly Code in AMP shows the breakdown of a component, as follows:
- 00 - Data module for all of the helicopter, system, subsystem or component

- 01 - Data module for the first assembly that you remove from the component
- 02 - Data module for the second assembly that you remove from the component
- 03 and subsequent codes refer to the third, fourth, etc. assembly that you remove from the component
The disassembly code is also used to identify the data modules in sequence.
2.4.4 Disassembly Code & Disassembly Code Variant 2/2
1 2 3 4 5 6
The Disassembly Code Variant

A
is a letter which identifies alternative items
(letters I and O are not used)
eg: These items are different,

but the difference is too small to cause a change
in the System Difference Code.
B
2.4.5 Information Code & Information Code Variant
1 2 3 4 5 6
The Information Code has three digits and Code Definition

identifies the types of information you can find in 0XX Function, data for plans and description
1XX Operation
that data module. 2XX Servicing
3XX Examination, tests and checks
4XX Fault reports and isolation procedures
5XX Disconnect, remove and disassemble
The Information Code Variant has one letter and procedures
6XX Repairs and locally make procedures and
is used for different data modules that are applicable data
7XX Assemble, install and connect procedures
to the same component and type of operation. 8XX Storage procedures and data
9XX Miscellaneous
2.4.6 Item location code
1 2 3 4 5 6

The Item Location Code is a letter which shows where you must do the maintenance task.
Examples of location codes:
A - on the helicopter.
B - on the removed assembly/component.
C - R&O shop
D - applicable to all the locations.
2.5 - Descriptive Data Module 1/8
List of Data Modules and

Technical Publications
associated to the procedure
References
List of Tasks to be performed

before starting the procedure
Preliminary requirements
Required conditions
List of Special Tools and Support Equipment

required to do the procedure
Support Equipment
Supplies
Spares
List of Consumables and Expendables
necessary to do the procedure
List of Spares
required to complete the job
General Warnings and Cautions
Safety Conditions
Sequence of Steps and Illustrations

necessary to do the procedure
Procedure
Instructions necessary to return

the helicopter back to operation
Requirement After Job Completion
2.6 - AMPI - Maintenance Planning Information 1/16
Each one of these publications gives you all the data necessary for the
maintenance planning of the AgustaWestland AW139 helicopter as
approved by the relevant Authority.
AMPI :
Chapter 00 HELICOPTER
GENERAL
Chapter 04 AIRWORTHINESS
LIMITATIONS
Chapter 05 SCHEDULED/
UNSCHEDULED
MAINTENANCE
AMPI :
Chapter 04 AIRWORTHINESS
LIMITATIONS
04-00 AIRWORTHINESS LIMITATIONS
04-10 RETIREMENT LIVES
04-20 MANDATORY INSPECTIONS
04-30 CERTIFICATION MAINTENANCE

REQUIREMENTS
04-00 AIRWORTHINESS LIMITATIONS
04-10 RETIREMENT LIVES
04-20 MANDATORY INSPECTIONS
04-30 CERTIFICATION MAINTENANCE REQUIREMENTS
AMPI :
Chapter 05 SCHEDULED/UNSCHEDULED
MAINTENANCE
05-00 SCHEDULED/UNSCHEDULED MAINTENANCE
05-10 TIME LIMITS
05-20 COMMON SCHEDULED MAINTENANCE CHECKS
05-30 PHASED and PROGRESSIVE SCHEDULED

MAINTENANCE CHECKS
05-40 STANDARD SCHEDULED MAINTENANCE CHECKS
05-50 UNSCHEDULED MAINTENANCE CHECKS
05-00 SCHEDULED/UNSCHEDULED MAINTENANCE
05-00 SCHEDULED/UNSCHEDULED MAINTENANCE (example)
05-10 TIME LIMITS
Section 39-A-05-12-00-00A-000A-A
(Component overhaul schedule General)
Components overhaul schedule: This sub-section gives the overhaul intervals for the
components of the helicopter.
List of components: Refer to the following Table (see Note)
Ref Component Part number Overhaul interval (FH)
CO63-01 Main gearbox assembly 3G6320A00132 5000 (*)

CO63-05 Lubricating pump 3G6320V04252 2500
CO63-07 Main gearbox assembly 4G6320A00132 5000
CO63-09 Lubricating pump 3G6320A18731 2500
(*) The overhaul interval is extended to 6000 FH if the retro-mod. P/N 3G6306P01511 is applied to the MGB,
independently from the date of its application.
Note: Refer to AMPI for further and more detailed information
05-20 COMMON SCHEDULED MAINTENANCE CHECKS LIST
05-30 PHASED and PROGRESSIVE SCHEDULED MAINTENANCE CHECKS
05-40 STANDARD SCHEDULED MAINTENANCE CHECKS
05-50 UNSCHEDULED MAINTENANCE CHECKS
2.7 CR&OP Component Repair & Overhaul Publication 1/10
39-A-CR&OP-00-X
Section 00-00 Helicopter general
This section includes:
SECTION 39-A-00-00-00-00A-011E-C
Component repair and overhaul publication - List of effectivity codes
SECTION 39-A-00-00-00-00A-018E-C
Component repair and overhaul publication Introduction
SECTION 39-A-00-00-00-00A-943B-C
Illustrated parts data - List of NATO supply codes for manufacturers
SECTION 39-A-00-00-00-00A-944B-C
Illustrated parts data - List of unit of issue codes
SECTION 39-A-00-00-00-00A-945B-C
Illustrated parts data - List of abbreviations
Sec. 39-A-00-00-00-00A-011E-C : List of effectivity codes
The meaning of the effectivity codes used is as follows:
All : Helicopters AW139:
- S/N 31005 and subsequent

- S/N 41001 and subsequent
Sec. 39-A-00-00-00-00A-018E-C : Introduction

General
This publication gives you all the data necessary for the repair and the
overhaul of the components of the Agusta Westland AW139.
It includes the data that are necessary for the requisition and
identification of the spare parts at the repair/overhaul level.
Publication contents
The publication gives repair and overhaul data for:
System Title
60 Standard practices - rotors
62 Main rotor
63 Main rotor drive
64 Tail rotor
65 Tail rotor drive
67 Rotors flight control
Sec. 39-A-00-00-00-00A-018E-C : Introduction (Cont.s)
Publication layout
This publication contains:
This introduction and the general data modules (39-A-63-....)

The repair/overhaul data modules (39-A-63-......)
The illustrated parts data modules (IPD: ZG-.....Main gearbox)
Illustrated parts data modules (IPD)
General
Each Illustrated Parts Data (IPD) module includes a figure and the
related text (detailed parts list).
A code identifies each IPD module as required. Hereinafter is reported
an example.

Data Module Code (DMC)
The IPD at the repair/overhaul level refers to components of the helicopter not to
systems. Thus, data is not-chapterized.
The DMC structure is as follows: ZG-W5-....
Z - identifies that the data module is non-chapterized.

G - is the code that identifies Agusta as responsible company.
W5- .... followed by a sequential number (assigned by Agusta) identifies the project
number; see the example reported hereinafter:
01 - for the main gearbox.

02 - for the intermediate gearbox.
03 - for the tail gearbox.
For P/N : 3G
For P/N : 4G

Detailed parts list
The detailed parts list is a table. Each column of the table has a heading that gives the contents.
The columns include the information that follows:
Usable on code
assembly and model
version and
effectivity column
(UOCA MVEFFECT)
Interchangeability column Source, maintenance and
(ICY) recoverability code
column (SMR)
Quantity per next higher assembly

and unit of issue column (QNHA UI)
Repair/Overhaul data modules: 39-A-63-20-05-00A-000A-C Main gearbox - General
Repair/Overhaul data modules: 39-A-63-20-05-00A-000A-C Main gearbox General (cont.s)

Effectivity codes:
39-A-63-20-05-00A-000A-C:
- All : Main Gearboxes (MGB) P/N 3G6320A00132 and subsequents P/N with different
last two digits
- A01 : MGB P/N 3G6320A00132 and P/N 3G6320A00133
- A02 : MGB P/N 3G6320A00134 and subsequents P/N with different last two digits
- A03 : MGB P/N 3G6320A00135 and subsequents P/N with different last two digits
- A04 : MGB P/N 3G6320A00132, P/N 3G6320A00133 and P/N 3G6320A00134
- B01 : Input shaft module P/N 3K6320A00133 (installed on MGB P/N 3G6320A00132
and 3G6320A00133)
- B02 : Input shaft module P/N 3K6320A00135 (installed on MGB P/N 3G6320A00134
and 3G6320A00135)
- B03 : Input shaft module P/N 3K6320A00136 (installed on MGB P/N 3G6320A00134,
3G6320A00135, 3G6320A00132 and 3G6320A00133)
39-B-63-20-05-00A-000A-C:
- All : Main Gearboxes (MGB) P/N 4G6320A00132 and subsequents P/N with different
last two digits
Illustrated parts data modules IPD : 39-A-ZG-W5-01-010-941A-C MAIN GEARBOX ASSY
2.8 - IPD Illustrated Part Data
IPD: Section 63-20 Main gearbox group
2.9 - ITEP Illustrated Tools & Equipment Publication
2.10 -RFM Rotorcraft Flight Manual
2.11 - QRH Quick Reference Handbook
2.12 - MGB LOG CARD (Section 1)
Mxxx
XX-XXX XXXXX
XXXXX
XXXXX
XX-XXX XXXXX
2.12 - MGB LOGCARD (Section 2)
Mxxx
2.12 - MGB LOGCARD (Section 2, Cont.s)
Mxxx
THE END

TECHNICIAN TRAINING
Chapter 3 MGB General
information
3 MGB General information
INDEX

3.2 MGB description
3.3.1 Left and Right Input Shaft Module description
3.3.2 Upper Module description
3.3.3 Hydraulic Pumps drive quills description
3.3.4 ECS compressor drive quill description
3.3.5 FAN drive quill description
3.3.6 Tail-rotor drive quill description
3.4 Lubrication system description
3.4.1 General
3.4.2 Chip detection operation
3.4.3 Pumps
3.4.4 Pressure regulation
3.4.5 Oil Filter
3.4.6 Oil Cooler
3.4.7 Sensors and Jets
3.5 Leading Particulars
3.6 Controls and Indicators
3.7 Warning, Caution Messages
3.8 Components that must be removed from the MGB before its overhaul

The Main Gearbox has the primary functions to transmit the Power/Torque coming from the two
Engines to the Main Rotor Shaft (Mast), to the Tail Rotor Mast and to the Accessories installed on the
MGB. The MR and the TR rotate CCW, see Figure 1.
Tail Rotor Shaft (Mast)
Main Gearbox
Main Rotor Shaft (Mast)
Engine No. 2 Tail Gearbox
Lub. Pump FAN, Oil Cooler Unit
Rotor
Brake
Intermediate
RH Hyd. Pump (Hyd. Sys. No. 2) Gearbox
Tail Rotor Drive System (3 shafts)
AC Generator (Optional)
Lub. Pump Engine No.1

ECS Compressor
LH Hyd. Pump (Hyd. Sys. No. 1)
Front Hyd. Pump (Hyd. Sys. No. 2)
AC Generator (Optional)
Fig. 1 - Drive system

3.1 General description (Continued)
The Main Gearbox Group includes the following primary components (see Figure 2):
- The Main Gearbox (that includes a mechanical assembly and a lubrication system)
- The Oil Cooler
- The Oil Cooler Fan
Figure 2 Main Gearbox Group Continued

3.2 MGB description
Hereinafter is described the MGB, type 3G.
As already mentioned before, the Main Gearbox has the primary functions to transmit the Power/Torque
coming from the two Engines to the Main Rotor Shaft (Mast), to the Tail Rotor Mast and to the Accessories
installed on the MGB.
The Power / Torque produced by each Engine is transmitted to the MGB by means of specific Engine Drive
Shaft (EDS) equipped with Flexible couplings connected to the MGB Input drive quills. Each engine rotate
clockwise at 21000 RPM (see Figure 1). The EDS and the Torque Tube is built in Steel Alloy.
The MGB that is 5 tilted forward, drives the Main Rotor Shaft (MAST) at 296.4 RPM (CCW), the Tail Rotor
Shaft (Mast) at 1435.7 (CCW) by means of the Tail Rotor Drive System (TRDS) that includes: 3 Shafts, the
Intermediate Gearbox (IGB) and the Tail Gearbox (TGB). Furthermore, the MGB drives some accessories at
the required speeds (see from Figure 1 to Figure 5).
The MGB reduces the engine output speed to the main rotor speed by means of three reduction stages (see
Figure 1):
First and Second stage of reduction is carried out by means of spiral bevel gears
Third stage of reduction is carried out by means of an epicyclical planetary gear
Each MGB input is provided with a freewheel unit, to override each engine drive in case of engine shut-down
or failure, allowing the rotor to be continuously driven by the remaining engine.
The MGB includes a Tail Rotor Take-OFF Pinion for the Tail Rotor Drive System (TRDS). The Housing of the
Tail Rotor Take-Off Pinion also provides the support for the Rotor Brake Actuator. The Brake Calliper is
attached to the Flange that is bolted to the Main Case assembly of the MGB. The drive Flange for the Tail
Rotor Drive Shaft also permits the attachment of the Rotor Brake Disc (see Figure 2).

3.2 MGB description (Continued)
The MGB can drive the following components (see Figure 3):
The Front Hydraulic Pump drive pinion, driven by the Collector Gear,
The ECS Compressor drive pinion, driven by the Collector Gear,
Left and Right Lubrication Pump drive pinion, driven by the Collector Gear,
Two AC Generators (optional) drive pinions, driven by the relevant Input Pinion 2^ stage of
reduction,
The Fan Cooling drive pinion, driven by the Tail Rotor Take-Off Pinion,
Left and Right Hydraulic Pump drive pinion, driven by the relevant Input Pinion 2^ stage of
reduction.
The MGB is pressure lubricated and includes a lubrication and cooling system; all the oil ducts are cored in
the MGB housings.
The lubrication and cooling system is composed by (see Figures 4a, 4b and 4c):
Two Positive Displacement Pumps (Gerotor type).
Two Pressure Relief Valves (PRV).
Two Check Valves.
An Oil Filter provided of a Disposable Filter, a By-pass Valve, an Impending bypass indicator (Pop-out)
with the relevant caution alarm switch.
An Oil Cooler and Cooling Fan.
29 oil Jets (17 located in the Main Case, 4 located in the Upper Module and 4 on each Input Shaft
Module).
An oil Level Gauge and a Low Level Sensor located on the Main Case.
An oil Filler Plug.
An oil Pressure Senor, oil Temperature Sensor and an oil Temperature Switch located on the Filter
Housing .
Two Low Pressure Switch (one located on each Input Shaft Module).
Three Chip detectors (2 located in lower side of the Main Case and 1 located on the Upper Module).

Furthermore, the MGB is provided of (see Figures 4a, 5):
One Rotor Speed Sensor (NR) located on the Main Case.

Two Bearing Temperature Sensors (one thermocouple located on each Input Shaft Module).
Three Servo-Actuator Brackets (Front, Left and Right) located on the Main Case.
The Swashplate support.
Four Attachments points (four upper fittings, located on the MGB Upper Module) and of an Anti-Torque
Beam (located on the MGB bottom side). The transmission is locked to the helicopter upper central
fuselage structure by means 4 Rods / Supports and by means 4 bolts connected to the Anti-torque
beam.

1435.7 rpm (CCW)

296.4 rpm (CCW)
Mast-Planetary Assy
Gimbal Crosshead Torque Tube
3^ stage of reduction TGB
Engine No. 2
T.R. Drive Quill Assy

IGB
RB
TRDS
Engine Drive Shaft
Input Shaft Module
Engine No.1 Crosshead

connected to
the Gimbal
2^ stage
of 1^ stage of reduction Flexible
reduction
Coupling
Input Pinion + Gear MGB Input Drive Quill
Collector Gear + Freewheel unit Connection Torque Tube
+ Input Pinion (Input Shaft Module)
Engine Drive Shaft

Fig. 1 - Drive system (EDS)

Rotor
Brake
Flange
Case
Fig. 2 Rotor Brake Assy

Collector Gear
(1355 rpm)
Fan Drive Quill
Front Hyd. Pump (16014 rpm)
Drive Quill
(7732 rpm)
Tail Rotor Take-Off

Pinion (4532 rpm)
ECS Compressor
Drive Quill (4868 rpm)
AC Gen. Drive LH / RH Hyd. Pump LH / RH Lubrication

Quill (12050 rpm) Drive Quills (9111 rpm) Pump (7302 rpm)
Input Pinion 2^ stage of

reduction (6917.6 rpm)
Fig. 3 Components driven by the MGB

Fig. 4.a Lubrication System - Components and Sensors location
OIL TEMPERATURE SWITCH
OIL TEMPERATURE SENSOR
OIL PRESSURE SENSOR
RH HYD. PUMP
drive quill
UPPER FITTING
TAIL ROTOR DRIVE

QUILL Assy
LH HYD. PUMP drive quill
AC GENERATOR LH INPUT SHAFT MODULE
drive quill SUMP CHIP DETECTORS
OIL LOW LEVEL SWITCH
UPPER MODULE
ECS COMP. drive quill
FRONT HYD. PUMP
Drive quill
OIL LEVEL GAUGE AC GENERATOR MAIN CASE

drive quill ANTI-TORQUE BEAM

Oil
Filter
PRV
CHECK
VALVES
LUB.
PUMPS
SUMP CHIP
DETECTORS
Fig. 4.b Lubrication System - Components and Sensors location

N11
N6 N12 N7
N10
N9
N3 N3
N 16
N16 N5
N8 N4
N4
N13
N15 N14
Notes
In the MGB are installed 29 Oil Jets:

- 17 oil jets in the Main Case
- 4 oil jets in the Upper Module
- 3 oil jets in each Input Shaft Module (6 total)
- 1 oil jet in each Cover of each Input Shaft Module (2 total)
Fig. 4.c Lubrication System - Components and Sensors location

FWD
Fig. 5 Mounts and Attachments

The Main Gearbox is a set of Cases which are the housings of the gears of the reduction / transmission
stages, the accessories and the other components of the main gearbox.
It is a three stages reduction gearbox.
The Main Gearbox drives the Main rotor mast, the accessories and the Tail rotor mast (and the rotor brake)
through the Tail Rotor drive quill, 3 drive shafts, an IGB and a TGB.
The Cases (made of Aluminium Alloy) of the MGB are (see Figure 1):
The two Input Shaft Modules (left input shaft module and right input shaft module)
The Main Case (*)
The Upper Module.
(*) A Bottom Cover (Al. Alloy) and an Anti-Torque Beam (Al. Alloy) are connected to the lower side of the
Main Case by means of Studs.
The Primary Internal Assy of the main gearbox are:
The Input Pinion and the Bevel Gear of the Left and Right Input Shaft Modules (first stage of reduction)
The Input Pinions and the Collector Gear of the Main Case (second stage of reduction) and the
Diaphragm.
The Mast-Planetary Gear and the Fixed Ring Gear located in the Upper module (third stage of reduction).
Through 3 reduction stages , the Main Rotor Mast will rotates (CCW) at about 296 rpm.

3.3 - Mechanical assembly description (continued)
The drive quills installed in the Main Case are (see figure 1):
the Front Hyd. Pump drive quill

the Left / Right Hyd. Pumps drive quills
the ECS Compressor drive quill
the Fan drive quill
the Tail Rotor drive quill.
the A/C Generators drive quills (optional)
Besides, LH and RH Lubrication Pumps installed on the Main Case, that are components of the
Transmission lubrication system, are driven by the Collector Gear.

3.3 - Mechanical assembly description (continued)
A/C GENERATORS
drive quills
Collector Gear (Sun gear, in view)

Planetary
MAIN CASE
Input Pinion
Bottom
Cover
Fig. 1 MGB Cases and Drive Quills

3.3.1 - Left and Right Input Shaft Module description
There are two Input Shaft Modules installed on the main gearbox, the left input shaft module and the right
input shaft module.
The two input shaft modules are interchangeable, because they have the same shape, configuration and
components.
The left and the right input shaft modules are installed on the related side of the main gearbox (studs).
The primary components of each module are (see Figure 2 and 3):
the Housing and the Cover

the Gimbal
the Input Flange
the Input Pinion Assy,
the Bevel Gear, I Stage of reduction
the Freewheel Unit .
The Housing is made of Aluminium alloy and contains the components that turn (first reduction stage).
The Gimbal has the function to hold the crosshead and the torque tube connected to the engine and is
attached to the housing with eight washers and nuts.
The Input Flange receives the torque from the Engine Drive Shaft and transmits it to the Input Pinion. The
input flange has internal splines and is installed on the splined end of the input pinion. Between the Input
Pinion and the Bevel Gear there is the first stage of reduction.
A duplex ball bearing and a roller bearing hold the input pinion and let it turn, the input pinion engages the
gear that is held in position by a ball bearing and a roller bearing.
Three oil jets are installed in each housing of the Input Shaft Module. They lubricates the pinion, the gear
and the related bearings. Furthermore, another Oil jet is installed in each Cover of each Input Shaft Module.
The freewheel unit is of the "sprag" type and the centrifugal force operates it. It is installed between the gear
and the input shaft. The freewheel has two ball bearings that hold it and let it turn. The freewheel is
lubricated through an oil jet part of the cover. (see Figure 3).
A Low Pressure switch and a Bearing Thermocouple is installed on each Input Shaft Module.
3.3.1 - Left and Right Input Shaft Module description (Continued)
Left Input
Shaft Module
Housing Oil Housing

Jet
Cover
Low Oil Pressure
Switch
Oil Jet
Cover
Gear, I Stage
of reduction
Input
Flange
Bearing
Thermocouple
Input
Pinion
Gimbal
Freewheel Assy
Unit
Figure 2 - Input Shaft Module

3.3.1 - Left and Right Input Shaft Module description (Continued)
Input Pinion (II Stage

of reduction), part of the
Main Case.
(I Stage of reduction)
EDS
Input shaft
Figure 3 Freewheel unit

3.3.2 - Upper Module description
The Upper Module of the main gearbox holds the Mast-Planetary Assy and the Fixed Ring Gear .
This module is installed above the Main Case by means of washers and nuts locked to the studs of the
main case as required.
The primary components of the upper module are (see Figure 4) :
the Top case,

the Mast-Planetary Assy,
5 Planetary Gears Assy,
the Fixed Ring Gear (Planetary crown).
The case is a light alloy (AL. Alloy) casting and is machined. In the walls of the case there are the oil ducts
for the lubrication of the components.
The collector gear (in the main case) engages, by means of the sun gear, the five planetary gears that
rotates around the planetary crown (third stage of reduction) that drive the main rotor mast.
A ball bearing an a roller bearing hold the mast in position and permits it to turn.
Four fittings are installed on the upper module, they are the attachments of the four rods of the main
gearbox and of the four Lightning conductor jumpers (see Figure 5).
These sensors / components are installed on the Upper Module (see Figure 5):
the mast chip detector,

the oil cooler adapter,
the oil temperature switch, the oil temperature sensor, the oil pressure sensor, the Pop-out and oil filter
caution alarm switch,
four oil jets,
the oil filler cap.

3.3.2 - Upper Module description (Continued)
Top Case
Upper
Module
Assembly
Mast-Planetary
assembly
5 Planetary
Gears Assy
Packing
Planetary Crown
(Fixed Ring Gear)
Figure 4 Upper module

3.3.2 - Upper Module description (Continued)
Ts Ps
Tsw
Lightning
Conductor Jumper
Pop-Out +
Caution alarm Oil Filter Head
Switch
Upper Fittings (4)

2 Oil Jets No. 1
A B
2 Oil Jets No. 2
C D
Oil Filler cap Screw +
Mast Chip
detector washer
Oil jet
filter
Oil Jets No. 1
and No. 2
Oil Cooler adapter
O-ring (Oil Filter case)
O-ring
O-ring
Figure 5 Upper module (sensors /components )

3.3.3 - Hydraulic Pumps drive quills description
Three Hyd. pump drive quills are installed in the main gearbox.
One is installed in the left side of the main case, the second is installed in the right side, in symmetrical
position while the third drive quill is installed in the front of the main case. Each of them drives one
(hydraulic) pump.
The Front pump is driven by the Collector gear while, the LH and RH pumps are driven by the relevant Input
Pinion II stage of reduction.
The drive quills are shown on Figure attached.

3.3.3 - Hydraulic Pumps drive quills description (continued)
A
A
Screw (2)
Nylon
Screw (2)
LH/ RH Hyd. Pump B
A Drive Quill
Shim
O-ring Screw (3)
Screw (3)
Shim B
Setscrew
(2)
O-ring
Screw (2) FRONT Hyd. Pump

Drive Quill
Figure 6 Hyd. Pump drive quills

3.3.4 - ECS compressor drive quill description
The ECS compressor drive quill is installed in the front of the main case of the gearbox and is driven by the
Collector Gear.
The ECS compressor drive quill is shown on the Figure attached.
C
Screw (3)
O-ring
Shim
ECS -
Compressor
Drive Quill
Screw (2)
Setscrew (3)
Figure 7 ECS Compressor drive quill

3.3.5 - FAN drive quill description
The Fan drive quill is installed in the rear of the of the main gearbox, just before and in the upper position
of the tail-rotor drive quill.
The fan drive quill is driven the Gear installed on the Tail Rotor Take-Off Pinion.
The drive quill is shown on the Figure attached.
Nut,
Washer
(3)
Seal-Cover
O-ring
Lip-Seal
V Fan Drive
Screw Quill
Shim
Figure 8 Fan drive quill

3.3.6 - Tail-rotor drive quill description
The Tail-rotor drive quill is installed in the rear of the of the main gearbox.
The primary components of the tail-rotor drive quill are shown on the Figure attached.
The pinion (Tail Rotor Take-Off Pinion) engages the collector gear (second stage of reduction) and drives
the tail rotor shaft.
A gear installed on the pinion, drives the fan drive quill.
The flanged bearing, housed in the rotor-brake case, and the roller bearing, housed in the main case,
hold the pinion.
The flanged, internal splined, engages the external spline of the pinion. The flange is the connection point
of the rotor brake disc.
The internal spline of the pinion engages the sliding adaptor that drives the tail rotor shaft.
The Retaining rings, the Locking washer and the Locking ring hold in position the pinion and the gear.

3.3.6 - Tail-rotor drive quill description (continued)
Gear
Pinion (tail rotor take
Off pinion)
Retaining ring
Locking washer
Locking ring
Ring
Flange
Nut + Retaining ring
Washer
Seal case
Seal
Rotor brake case
O-ring
Shim Nipple Retaining ring

Screw Locking washer
Flanged
bearing Locking ring
Gear
Shim
Retaining ring
Locking washer
Locking ring
Bearing inner
race (roller)
Plug O-ring
Pinion
Bearing cage
Plug
Figure 9 Tail-Rotor drive quill Figure 1 Tail-Rotor drive quill Pinion

3.4 - Lubrication system description
3.4.1 - General -
The AB/AW139 MGB lubrication system is based on the wet sump concept. With this concept, the lower
part of the MGB perform also the function of oil tank whereby the pressure pumps suck the oil for
feeding the delivery circuit.
Note:
The "dry sump" concept where the gearbox sump is maintained virtually dry by means of a scavenge pump(s) sending all the oil to a separate
oil tank, normally placed upward from which the pressure pump(s) suck the oil for feeding the distribution system.
The "wet sump" concept where the scavenge pump(s) and the external tank is eliminated leaving only the pressure pump(s) and the gearbox
housing serves also as a tank.
Another important characteristics of the MGB lubrication system design is the absence of remote
components and consequently of external pipes and fittings.
The lubrication system schematic can be seen on the attached Figure 1.
The lubrication System includes:
Two Lubrication pumps (positive displacement, Gerotor type) installed in the rear side of the Main Case.
Two Pressure Relief Valves (PRV).
Two Check Valves.
An Oil Filter Assy that includes: a Disposable Filter (10 micron), an Anti-Spill Valve, a By-Pass Valve, an
Impending bypass indicator (Pop-out) provided of a caution alarm switch (the By-pass valve, the Pop-out
and the alarm switch are located on the Oil Filter Head).
A Cooling Fan and an Oil Cooler provided of a By-pass Valve.
An Oil Pressure sensor installed on the Oil Filter Case.
An Oil Temperature sensor and an Oil Temperature switch installed on the Oil Filter Case.
29 oil Jets (17 located in the Main Case, 4 located in the Upper Module and 4 on each Input Shaft Module).
A Low Oil Pressure switch located on each Input Shaft Module.
A Low Oil Level switch located on the front side and in bottom area of the Main Case.
3 Chip Detectors (One located on the Upper Module MAST and two located in the Main Case SUMP).
A Bearing Thermocouple located on each Upper Module.
A Sight glass on the front side of the Main Case; it shows two marks: MAX and MIN.

3.4.1 General (continued)
The sump is obtained in the bottom of the MGB and is designed to contain about 18 litres of oil (MIL-PRF-
23699 if the ambient temperature is above -30C or MIL-PRF-7808L if the ambient temperature is above
-40C, the two oil types are not mixable).
From the sump the oil is sucked through the sintered mesh steel screens of the full flow Chip detectors.
These screens have the purpose of aiding the trapping or wear particles and the consequent capture by
means of the magnetic chip detectors.
The screen serves also the purpose of preventing wear or abrasive particles of significant magnitude to enter
the lubrication system and therefore causing damage to important components such as the pumps.
The overall pressure loss through the screen and the ducts will be minimized by proper sizing of flow areas
such that the pressure at the pump inlet shall be not less than about 90kPa.

3.4.1 General (continued)
MAST CHIP DETECTOR T> 109C
Oil cooler By-pass

Valve (Therm. / Diff.
Pressure)
P < 3.1 Bar P < 3.1 Bar
T> 140C
The By-Pass opens at p = 190 kPa (1.9 Bar)
T> 140C The By-Pass opens at T +80 C
Anti-Spill Valve
P = 1.7 Bar
P = 1.25 Bar
SUMP CHIP DETECTOR
SUMP CHIP DETECTOR
Figure 1 Lubrication system schematic

3.4.2 - Chip Detection Operation
The chip detector senses the unwanted ferrous particles contained in the lubricating oil of the gearbox.
The sensor is a magnet with a coil around it, this coil is electrically connected to the circuit in the sensor.
The magnetic force of the magnet pulls the ferrous particles to the magnet. When the particles go
through the magnetic field, they change the properties of the signal of the coil. The electronic circuit of
the sensor amplifies this signal and sends it to the MAU 1 and MAU 2 (Modular Avionics Units) of the
vehicle monitoring system.
If the metallic particles have a diameter lower than 0.05 mm (0.0019685 in), they can be burned by
pressing the CHIP BURNER switch on the miscellaneous control panel. See Figure 2.

3.4.2 - Chip Detection Operation (continued)
Figure 2 Chip Detection Operation

3.4.3 - Pumps
After the chip detectors the oil reaches the oil pumps. The system is based on a dual pump design with
features allowing to continue safely with only one pump operating.
The pumps are of the positive displacement, GEROTOR (see Fig. 3) type pumps with multiple
elements to optimise the rotors tip speed to avoid the risk of cavitations even under the most critical
flight conditions.
Figure 3 Gerotor pump
The basic pump characteristics are as follows :
Inlet pressure pi =47.5 kPa (approximately).

Flow Q=40.1 litre/min (NOMINAL).
Nominal driving speed n=7302 RPM (NOMINAL).
Outlet pressure p0 =700 kPa (NOMINAL)

3.4.4 - Pressure Regulation
Each pump delivery duct is provided with its own Pressure Relief Valve (PRV) which maintain the required
constant pressure inside the circuit. These valves are of the spring actuated poppet type and can easily be
adjusted at MGB acceptance testing in order to provide a gearbox with the most appropriate system
pressure.
The pressure relief valve, also called pressure regulating valve, is set at:
Outlet pressure =700 kPa (7 Bar)
However the valve is capable of being adjusted over a range allowing correct pressure regulation of the
system.
After the pressure relief valves, the Check Valves are placed. Their purpose is to exclude the oil backflow in
case of pump malfunction or blockage. In fact if one pump fails, the other pump will provide more flow to the
system and the flow will be prevented to go back to the sump through the failed pump by means of the check
valves.
The check valves are of the full flow poppet type giving very little flow resistance (about 1 kPa)
during normal operation.
After the check valves the two branches of the oil system are joined together before entering the Oil Filter.
At this stage the total system flow should have been reduced (by means of the pressure relief valves) to
about:
Flow Q=70 liters/min (NOMINAL)
Giving ample regulation margins during development and testing.

3.4.5 - Oil Filter
The oil filter is provided with a bypass valve excluding the filter in case of clogging of the filter element.
Before opening the bypass, an electrical sensor will provide advance information that the filter is being
clogged and that will be bypassed.
The by-pass opens at p=17028 kPa (1.7 Bar)

The impending bypass alarm switch actuates at p=12514 kPa (1.25 Bar)
Clean filter assembly pressure drop p=38 kPa (0.38 bar)
The filtration capacity of the filter is 10 m and the filter element is disposable.
The filter is fitted into a special housing bolted directly to the upper housing and giving interface and support
to the oil cooler.

3.4.6 - Oil Cooler
After having been filtered, the oil is delivered to the oil-air heat exchanger also called the oil cooler.
The oil cooler is simply connected to the above filter housing assembly avoiding the need of external pipes
or fittings as normally required by different, more conventional designs.
The oil cooler is provided with a by-pass valves which actuates in case of both high differential pressure
and low oil temperature :
The by-pass opens at p=190 kPa (NOMINAL) (1.9 Bar)

The by-pass opens at T < +80 2C.
The air stream to cool the oil in the heat exchanger is provided by the cooling fan. The fan is mechanically
driven at about 16014 RPM by a set of bevel gears directly connected to the MGB providing a high degree
of integrity to this assembly as compared to external units driven by shafts.
The cooling fan is of the mixed (axial/centrifugal) type delivering approximately an air flow of about 1.14
m3/sec and is provided with aluminium cast impeller and aluminium scroll housing.
The impeller is supported on independent self lubricated (grease) bearings avoiding the risk of MGB oil loss
or contamination.
The fan drive shaft is also provided with a shear section which will prevent damage to the MGB in case of
failure of the fan due to FOD or malfunction.

3.4.7 - Sensors and Jets
At the outlet of the fan the following sensors are fitted :
Oil pressure sensor

Oil temperature sensor
Oil temperature switch (actuation point T > 109C)
Oil low pressure switch (actuation point P < 3.1 Bar)
The oil is subsequently delivered to the several points of the MGB, where, by means of dedicated nozzles,
it is directed to all the lubrication points.
The oil nozzles (total: 29 Oil Jets) are of peculiar design having the following important characteristics (see
Figure 4):
Aluminum alloy construction

Removable screen filter
Each and every nozzle can be removed from the outside
Furthermore, in the system, on each Input Shaft Module a Bearing Thermocouple is installed near to
duplex ball bearing of the Input Drive Quill.

3.4.7 - Sensors and Jets (continued)
Oil Jet Screen
N11
N6 N12 N7 Filter
N10
N9
N3 N3
Example of Oil Jet
N 16
N16 N5
N8 N4
N4
N13
N15 N14
Notes
In the MGB are installed 29 Oil Jets:

Figure 4 Oil Jets

3.5 - Leading Particulars
(LH/RH)
(FRONT)
(TQ: 100% +100%)
(TQ: 110% +110%)
(TQ: 140%)
(TQ: 160%)
(18 Liters)
Note: - in AEO condition the Maximum Transient (5 sec) TQ is 121%

- in OEI condition the Maximum transient (5 sec) TO is 176%

3.6 - Controls and Indicators
The main gearbox (MGB) controls are located on the Miscellaneous Panel and on the Test Control Panel
both installed in the cockpit console (see Figure attached).
The MFD (Main and Cruise Page) displays the MGB OIL TEMP/PRESS parameters.
The MFD also provides the malfunction condition in the CAS message window No.1.
The Miscellaneous Panel provides the following function:
CHIP BURNER: ........................ when pressed a burning attempt

for the MGB CHIP MAST or MGB
CHIP SUMP is performed.
NOTE
If the MGB CHIP MAST or MGB CHIP SUMP cautions illuminate when
MGB OIL PRESS warning is illuminated the CHIP BURNER must not be activated.
The Test Control Panel provides the following function:
MGB OIL LEVEL

Push button test switch: ..... when pressed the caution MGB
OIL LOW in inverse video is
displayed in the CAS window.
NOTE
This test is operative with the A/C on ground and NR < 2%.

3.6 - Controls and Indications (continued)

3.7 - Warning, Caution Messages and Indications
MGB OIL PRESS Oil pressure below limits at one or both MGB
inputs and in MGB oil system (less than 3.1 Bar)
MGB OIL TEMP MGB Oil temp is above 109C. Reset below
97C
Audio Warning: (No Tone) + Warning Warning
1 (2) MGB OIL PRESS Associated MGB engine Input Oil Pressure low
(Less than 3.1 Bar. Reset above 3.4 bar)
Note: With both 1 and 2 Input oil press low, the warning MGB OIL PRESS
will suppresses the caution message 1-2 MGB OIL PRESS
MGB CHIP MAST Debris is detected on the Mast Chip Detector
MGB CHIP SUMP Debris is detected in one of the two Sump Chip
Detectors
CHIP MAST FAIL Sensing channel of Mast Chip Detector is faulty
CHIP SUMP FAIL Sensing channel of Sump Chip Detector is faulty
3.7 - Warning, Caution Messages and Indications (continued)
MGB OIL FILTER Differential pressure exceeds 1.25 bar
MGB OIL LOW MGB Oil level is at minimum (only active on ground)
1 (2) BRG TEMP MGB - Engine 1 (2) Input stage bearing temp is
above 140C. Resets below 135 C.
In case double bearing temp caution, 1-2 BRG TEMP will be displayed.
AVIONICS FAULT Loss of communication to single MAU is detected for
the Chip Detector Power Unit.
XMNS OVTQ During AEO TQ1>110% or TQ2>110%.

During OEI TQ >160%
CHIP DET UNIT Chip Detector Power Unit does not respond on
Power-up Test and Continuous BIT
CHIP DET TEST Chip Detector Power Unit responds on manual test.
Caution will be displayed when test switch on CDPU is
pressed and all is normal.
Note


COMPOSITE FORMAT

3.8 - Components that must be removed from the MGB before its overhaul
In order to remove the Main Gearbox group from the helicopter it is necessary to follow the instructions
reported on AMP 39-A-63-20-00-00A-520A-A.
In particular, the following preliminary actions are required:
- Observe all Warning, Caution and Note reported in the Specifics Data Module.
- The Helicopter must be safe for maintenance.
- The specific access doors and covers must be removed as required.
- The Main Rotor Head must be removed as required.
- The ECS Compressor pack must be removed as required.
- The AC Generators (1 and 2), if installed must be removed as required.
- The Swashplate must be removed as required.
- The Fan duct must be removed as required.
- The Rotor brake disc cover must be removed as required.
Then
- Disconnect the Hydraulic lines (section, pressure, drain-house and seal drain house) from each
Hydraulic Pump (LH, RH and Front).
- Disconnect the Hydraulic pressure and return lines from the Servo-actuators (1, 2 and 3).
- Remove the specific Control Rod form the relevant Servo-actuator lever (1, 2 and 3).
- Remove the all drain hoses from the Main gearbox.
- Disconnect the pressure hose from the Rotor brake caliper.
- Disconnect the electrical connector from the Rotor brake caliper and actuator.
- Disconnect all electrical connectors from the helicopter structure.
- Remove the HUMS (health and usage monitoring systems) wring harness from the box (part of the
rotor brake guard installation), if installed.
- Disconnect the No.1 Engine Drive Shaft and the No. 2 Engine Drive Shaft form their input flanges.

3.8 - Components that must be removed from the MGB before its overhaul
(continued)
- Remove the Crossheads from their Gimbals

- Disconnect the No. 1 Flexible coupling (part of the Tail Rotor Drive Shaft) from its sliding adapter located
on the gearbox.
- Install the Sling on the MAST and apply a light tension as required.
- Remove the 4 Bolts installed on the Anti-torque beam as required.
- Remove the 4 Rods that connect the gearbox to the helicopter as required.
- Carefully lift the Main gearbox from the helicopter and install the Transmission on the applicable trolley.
Then these remaining parts from the MGB:
- Remove the Oil Cooler and the Oil Cooler Fan as required.
- Remove all Hydraulic Pumps as required.
- Remove all Hydraulic Servo-actuators as required.
- Remove the Rotor Brake Disc, Actuator and Caliper as required.
- Drain the Oil as required.

Chapter 3 MGB Genaral information
THE END

TECHNICIAN TRAINING
Chapter 4 - General Procedures
4 General Procedures
INDEX
4.1 Introduction
4.2 A/C Publications
4.3 AMPI A/C Maintenance Publication Information
4.4 Limits

4.1 - Introduction
Before describing the procedure of disassembling of the MGB it is

important to know the Retirement lives, the Discard time of the
MGB components and the Overhaul intervals of the MGB and
where it is possible to find them in the IETP.
In this section will be shown the Publications, the Data Modules
and the Limits involved.
The information reported hereafter are relevant to MGB P/N:
3G6320A00132 or
3G6320A00133 or
3G6320A00134 or
3G6320A00135
NOTE
All information reported hereinafter must be considered for

Training purpose only

4.2 - Aircraft Publications
IETP
Interactive Electronic Technical Publication
Maintenance Planning Information (AMPI)
Master Minimum Equipment List (MMEL)
Component Repair & Overhaul Publication (CR&OP)

4.3 - AMPI - Maintenance Planning Information
Each one of these publications gives you all the data

necessary for the maintenance planning of the
AgustaWestland AW139 helicopter as approved by
the relevant Authority.

4.4 Limits (Part 1)
Note:
The overhaul intervals and the discard times, specified for the AgustaWestland part numbers (e.g.: 3G6310A00531, 3G3350A01811)
written in the specific table (see D.M), apply also to all successive part numbers with the same first ten digits and different last
two digits, unless specified differently.
MGB Overhaul intervals (EASA)
AMPI (EASA), Data Module Ref Component Part number Overhaul interval
39-A-05-12-00-00A-000A-A CO63-01 Main gearbox assembly 3G6320A00132 5000 FH (*)

Component overhaul Note:
schedule General The overhaul interval is
extended to 6000 FH if
the retromod P/N
3G6306P01511 is
applied to the MGB,
independently from the
date of its application. (*)
39-A-05-12-00-00A-000A-A CO63-05 Lubricating pump 3G6320V04252 2500 FH (*)
Component overhaul
schedule General
39-A-05-12-00-00A-000A-A CO63-09 Lubricating pump 3G6320A18731 2500 FH (*)
Component overhaul
schedule General
MGB Discard time (EASA)
AMPI (EASA), Data Module Ref Component Part number Discard time
39-A-05-13-00-00A-000A-A DT63-03 MGB Gimbal support 3K6320A01131 46000 FH (*)

Discard time schedule assembly
General
(*): Refer to AMPI for further and more detailed information.

4.4 Limits (Part 2)
MGB Retirement lives (EASA)
AMPI (EASA), Data Module Ref Part Part number Retirement life
39-A-04-10-00-00A-000A-A RL021 MGB Case, Top 3G6320A01033 8800 FH or 23000

Retirement lives - General Assembly landings whichever
comes first (*)
MGB Case, Top 3G6320A01035 17000 FH (*)
Assembly
39-A-04-10-00-00A-000A-A RL022 MGB Shaft, Main Rotor 3G6320A01852 15300 FH or 54000
Retirement lives - General landings whichever
comes first (*)
39-A-04-10-00-00A-000A-A RL023 MGB Case, Main 3G6320A02734 5000 FH or 27000
Retirement lives - General Assembly landings whichever
comes first (*)
MGB Case, Main 3G6320A02736 10000 FH or 77500
Assembly landings whichever
comes first (*)
39-A-04-10-00-00A-000A-A RL024 MGB Upper Fitting 3G6330A00232 95800 landings (*)
Retirement lives - General
39-A-04-10-00-00A-000A-A RL025 MGB Antitorque Beam 3G6330A00532 20000 FH or 63000
Retirement lives - General landings whichever
comes first (*)
(*): Refer to AMPI for further and more detailed information.

Chapter 4 - General Procedures
THE END

TECHNICIAN TRAINING
Chapter 5 - Pre-Disassembly
Procedures
5 Pre-Disassembly Procedures
INDEX

5.2 Pre-disassembly requirements
5.3 MGB Drain oil and Draining Pipe removal procedures
5.4 Anti-Torque Beam & Bottom Cover, removal procedures
5.5 Installation of the Main Case on the Support Trolley

Dangerous materials
Every time you use a dangerous material make sure you know the related safety precautions and
first aid instructions.
For more data refer to:
The label of the material container
The manufacturer safety data sheet
The local safety regulations.
Refer to CR&OP data module 39-A-60-50-00-00A-074A-C.
Critical parts
Critical parts are those parts the failure of which during ground or flight operations can have
catastrophic effects on the helicopter.
Refer to AMP data module 39-A-00-60-00-00A-010A-A.
Note
- When the disassembly of the MGB has been completed all disassembled components
must be cleaned and protected as necessary.
- Rubber glovers must be used when moving components.
- Cotton gloves must be used after cleaning to prevent component contamination.
(Conts)

5.2 - Pre-disassembly Requirements
1. Refer to CR&OP: 39-A-63-20-05-00A-531A-C (Main gearbox General guidelines for disassemble

procedures)
2. Make sure that the work area is clean.
3. Install the main gearbox on the Trolley (main gearbox support).
Support equipment: Nomenclature Identification No.
Trolley, main gearbox transport HE-04-00, or

3G6320A00131A188B, or
3G6320A00331A188E, or equivalent
4. Drain the oil from the main gearbox as required. Refer to CR&OP: 39-A-63-20-05-00A-222A-C (Main
gearbox - Drain oil).
5. Remove the beads of sealing compound from the mating edges between the components of the main
gearbox and around the nuts. To do this, use a plastic scraper.
6. After then removal of the sealing compound beads, clean the surfaces with the Cloth and the Solvent.
7. Dry the cleaned surfaces with the Cloth and the compressed air until you fully remove all solvent.
Supplies: Nomenclature Identification No Specification references Ref. Documents
Cloth, soft lint-free C011 None (AMDI) 39-A-00-50-00-10A-078A-D

Cleaning solvent C010 P-D-680 type II (AMDI) 39-A-00-50-00-09A-078A-D
(Conts)

5.2 - Pre-disassembly Requirements
8. Always keep the parts of an assembly together. Do not interchange these parts with the same parts of
other assemblies.
9. During disassembly, put the parts in applicable containers as you remove them.
10. Remove the internal Oil Draining Pipe from the gearbox. Refer to CR&OP: 39-A-63-20-05-00A-530A-C
(Main gearbox - Disassemble procedures).
11. Remove the Anti-Torque Beam, the Bottom Cover and the Slip Ring from the gearbox. Refer to CR&OP:
39-A-63-20-05-00A-530A-C (Main gearbox - Disassemble procedures).
12. At the disassembly, discard the fasteners (nuts, bolts ) and seals as required.

5.3 - MGB Drain oil and Draining Pipe removal procedures
CR&OP Data Module:
(MGB) 39-A-63-20-05-00A-222A-C
Main gearbox - Drain oil
Support Equipments:
Nomenclature Identification No.

(Filler Cap +
Breather) Trolley, main gearbox 3G6320A00131A188B
support
Adapters kit, helicopter 3G1205G00131
servicing
(Oil Filler
Neck) Hose, MGB oil draining 3G1205G00332
A
Pump, MGB oil draining E1224/30-40
Container Local supply
Draining Pipe
removal-
CR&OP Data Module:
(Coupling Half)
39-A-63-20-05-00A-530A-C
(Drain Cap) Main gearbox - Disassemble
procedures.

5.4 - Anti-Torque Beam & Bottom Cover, removal procedures
CR&OP Data Module:
39-A-63-20-05-00A-530A-C Main gearbox - Disassemble procedures
Support Equipments:
M/R Shaft (MAST) Lifting tool, main 3G6320A00131A181A

gearbox
Lifting device Local supply
MGB Assembly
Note:
During this procedure, obey the general guidelines applicable to the

disassemble procedures. Refer to 39-A-63-20-05-00A-531A-C.
Before to remove the Anti-torque Beam and the Bottom Cover from the
MGB Main case, it is necessary to disconnect the MGB assembly from its
Trolley Support .
Bottom Cover
Anti-Torque Beam
Trolley, main gearbox HE-04-00, or

transport 3G6320A00131A188B, or
3G6320A00331A188E, or
equivalent

5.4.1 - Anti-Torque Beam, removal procedures
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures.
Upper Module Support Equipments:
MGB
Lifting tool, 3G6320A00131A181A
main gearbox
Main Case
Standard
Screw
Extractors
Anti-Torque Beam removed,

Main Case Stud detail
RH
Main Case
RH
Anti-Torque Beam
Nylon Screw LH
Nylon Screw (x 2)
Washers + LH
Washers
Nut (x 23) + Nut
Anti-Torque beam, looking from the bottom view

5.4.2 - Bottom Cover , removal procedures
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Support Equipments:
Main Case
Lifting tool, main 3G6320A00131A181A
gearbox
O-ring Bottom Cover

Extractor, drive 3G6320A00331A029G removed
quill
O-ring
Bottom
Cover
Nylon
Screw Washers
(x 3) O-ring + Nut
(x 13)
Slip ring
Retaining ring
Bottom Cover

5.4.3 - Retaining ring and Slip ring, removal procedures
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Support Equipments:
Extractor tool, 3G6320A00331A023R

retaining ring
Removal tool, 3G6320A00331A023Q
slip ring
O-ring
O-ring
Bottom Cover
Nylon
Screw Washers
(x 3) O-ring + Nut
(x 13)
Slip ring
Retaining ring

5.5 - Installation of the Main Case on the Support Trolley
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Support Equipments:
Main Case
Assembly Nomenclature Identification No.
Trolley, main case maintenance 3G6320A00131A188C
Main Case
Assembly
Support
Maintenance
Trolley
Side View Front View

Chapter 5 - Pre-Disassembly Procedures
THE END

TECHNICIAN TRAINING
Chapter 6 - Disassembly
Procedures
6 MGB Disassembly Procedures
INDEX
6.1 Left and Right Input Shaft Module removal and Cross Shaft disassembly procedures
6.2 Main Case Assembly - External components (Plugs, Covers, Sensors, Filter element, Servo
Supports, Chip Detectors, Oil Level gauge, Borescope Port, Lubrication Pumps, Check Valves,
PRV,) , removal procedures.
6.3 Main Case Oil Jets, removal procedures.
6.4 Upper Module, Oil Unions and Planetary Crown (fixed ring gear), removal procedures.
6.5 Main Case, Backlash Check.
6.6 Drive Quills (LH/RH/Front Hyd. Pumps, ECS-Compressor and Fan drive quill), removal
procedures.
6.7 LH and RH Input Pinion Assembly (II stage of reduction), removal procedures.
6.8 LH and RH Input Pinion Assy (II stage of reduction), disassembly procedures.
6.9 Tail Rotor Drive Quill Assembly, removal procedures.
6.10 Tail Rotor Drive Quill Assembly, disassembly procedures.
6.11 Diaphragm, Oil Jets and Roller Bearing, removal procedures.
6.12 Collector Gear and Collector Bearing, removal procedures.
(Conts)

6 MGB, Disassembly procedures
6.13 Main Case Assembly - Internal components (Roller Bearings, Shims and Outer Race of the
Roller bearing), removal procedures.
6.14 Left and Right Input Shaft Module, disassembly procedures Ref. documentations
6.15 Freewheel Group Assembly, removal and disassembly procedures.
6.16 Input Shaft Module, Backlash Check.
6.17 Input Shaft Module Input Drive Quill Group, removal procedures
6.18 Input Drive Quill Group, disassembly procedures.
6.19 Input Shaft Module Gear (I Stage of reduction), removal and disassembly procedures
6.20 Upper Module, disassembly procedures
6.21 Mast-Planetary Assembly Disassembly procedures.
6.22 Planetary Gears Assembly Disassembly procedures.
6.23 LH & RH Lubrication Pumps Disassembly procedures.
6.24 ECS Compressor Drive Quill Disassembly procedures.
6.25 FAN Drive Quill Disassembly procedures.
6.26 Front Hyd. Pump Drive Quill Disassembly procedures.
6.27 LH & RH Hyd. Pump Drive Quill (No.1 and No. 2) Disassembly procedures.

6.1 - Left and Right Input Shaft Module Removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble procedures
Notes: The removal procedure used for LH Input Module is also applicable
for RH Input Module.
Support Equipments: Std Screw Extractors
Main Case
O-ring
Plug
Cross Shaft
LH Input Shaft Module
Union
Washers
Washers
Cross Shaft Nuts
Washers
O-rings
Bracket
Washers
Nuts NutsWashers
Washers
Bracket
+ Nuts
Bracket Set screw (Nylon)

6.1.1 - LH and RH Cross Shaft, disassembly procedures
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Cross Shaft
Support Equipments: Std Tools
Plug
Input Shaft
Module Input Shaft Module Plug
(inner side)

6.2 Main Case , External Components (Plugs, Covers, Sensors, Filter element, Servo
Supports, Chip Detectors, Oil level gauge, Lub. Pumps, Check Valves, PRV) removal
Engine 2 Inlet
(Drive Shaft) Details
A Input Shaft Module (1 & 2)

B - Hydraulic Pump (1 & 2) Drive Quills
C - ECS Compressor Drive Quill
D - Hydraulic Pump (front) Drive Quill
E - AC Generator Drive Cover (2 positions)
Engine 1 Inlet F - Oil Level Gauge
(Drive Shaft)
G - Oil Filter case
H Low Oil Level Sensor
I Draining Pipe
J Plugs
K - Rotor Speed Sensor (NR)
L Front Servo Support
M Left Servo Support
Front Side
N Right Servo support
O Borescope port
P Check Valves (2 positions)
Q Pressure Relief Valve (PRV)
R Chip Detectors (2 positions)
S Washer and Screw (3 positions)
T Plug (Flange)
U Lubrication Pump (2 positions)
V Fan Drive Quill
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Rear Side

6.2 Detail B - (No. 1 & No. 2 Hyd. Pump drive quill), external
components removal
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
B
Components removed:
B
- Nylon Screws (2 positions)
- Plug
Nylon Screw
Front Side
Hydraulic Pump Drive Quill
Plug

6.2 Detail C - (ECS Compressor drive quill), external components
removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Seal Lip
Cover Seal Components removed:
O-ring
Plug
- Plug
C - Retaining Ring
- Seal Cover + O-ring
- Lip seal
ECS Compressor Retaining Ring - Nipple or Plug (Oil drain)
Drive Quill
Support Equipments:
Removal tool, seal cover 3G6320A00731A029E
Extractor tool, lip seal 3G6320A00731A029D
Front Side

6.2 Detail D (Front Hyd. Pump drive quill), external components
removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Components removed:
D - Plug
- Nylon Screw (2 positions)
Hydraulic Pump Drive Quill Nylon Screw
Plug
Front Side

6.2 Detail E - AC Generator Drive Cover, Shim and Plug removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Support Equipments:
E
E Nomenclature Identification No.
Extractor tool, generator 3G6320A00132A029A

drive cover
Screw Shim
O-ring
Nut,
Washers
AC
O-ring
Generator
Drive Cover
Plug
Front Side

6.2 Detail F - Oil Level gauge removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Main gearbox Disassemble
procedures.
Oil level gauge disassembled
Oil level
Gauge
Nuts + Washers
Front View, LH side

6.2 Detail G - Oil filter head, Oil Filter Element, Anti-spill Valve, Oil
press. Sensor, Oil Temp. Sensor and Oil Temp. Switch removal
References:
Oil Pressure sensor CR&OP: 39-A-63-20-05-29A-520A-C Oil filter element (main gearbox) - Remove procedures
AMP: 39-A-63-41-05-00A-920A-A Oil temperature sensor Replacement
AMP: 39-A-63-41-06-00A-920A-A Oil pressure sensor - Replacement
AMP: 39-A-63-41-07-00A-920A-A Oil temperature switch - Replacement
Oil Temp. sensor

Components removed:
- Oil Filter Head

Oil Filter Head
- Oil Filter Element
Anti-Spill - Anti-spill Valve
Valve
- Oil Temp. Switch (Tsw)
Oil Filter
Oil Temp. element - Oil Temp. Sensor (Ts)
Sw
- Oil Press. Sensor (Ps)
Oil Filter Case
OUT Oil
IN Cooler
Pop-Out + Caution
alarm Switch
Ts Ps
Tsw
Oil Filter Head

6.2 Detail H - Low Oil Level Sensor removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Low Oil Level Sensor
Front View, RH side

6.2 Detail J - Plugs removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
J Main gearbox - Disassemble procedures
Plug
Plug

6.2 Detail K - Rotor Speed Sensor (NR) removal
K CR&OP Data Module:
39-A-63-20-05-00A-530A-C
O-ring
Washer
Nut
Rotor Speed Sensor
Front View, LH side

6.2 Details L, M, N - Front Servo Support, Left Servo Support and
Right Servo Support removal
CR&OP Data Module:

N 39-A-63-20-05-00A-530A-C Main gearbox - Disassemble
procedures.
M Nomenclature Identification No.

Support Equipments:
Extractor tool, servo 3G6320A00331A029N
L support
Screw + Washer(4)
Front Servo
L L
Support L
Setscrew (2)
LH Servo RH Servo
M Support Support N L

6.2 Detail O - Borescope Port removal
O
CR&OP Data Module:
O-ring
39-A-63-20-05-00A-530A-C Main
Washers gearbox - Disassemble procedures.
Screws
Borescope Port
Rear View, LH side

6.2 Detail P - Check Valves removal
CR&OP Data Module:

39-A-63-20-05-00A-530A-C Main gearbox -
Disassemble procedures.
P P
Check Valve Plug

O-ring Rear View
P
O-ring
Check Valve
Retaining ring

6.2 Detail Q - Pressure Relief Valves removal
CR&OP Data Module:

Q
PRV Disassemble procedures.
O-ring PRV
O-ring
Q Q
Rear View
Rear View
6.2 Detail R - Chip Detectors removal
CR&OP Data Module:

R
Chip Detector
O-ring
Chip Detector Valve
O-ring
Chip Detector
Chip Detector Valve
Rear View
R R

6.2 Details S, T - Washers, Screws and Flange removal
CR&OP Data Module:

S
S
Flange
S T
Rear View LH side Rear View RH side

Nylon Screw
S Nut
T Flange
Flange
O-ring
Washer
+ Screw
Washer
S
Washer S S
Rear View Rear View LH side Rear View RH side

6.2 Detail U - LH and RH Lubrication Pump removal
CR&OP Data Module:

U
Support Equipments:
Extractor, drive quill 3G6320A00331A029G
Rear View
RH Lubrication Pump removal
Washers + Nut
Nylon Screw (3)
O-rings Lub. Pump
Rear View RH Lubrication Pump

Extractor tool installation
Rear View LH Lubrication Pump Rear View RH Lubrication Pump

6.2 Detail V - (Fan Drive quill), external components removal
CR&OP Data Module:

V
39-A-63-20-05-00A-530A-C
Components removed:
- Plug
- Seal Cover
Support Equipments:
Extractor tool, seal cover 3G6320A00331A029L
Rear View

6.3 - Fifteen (from No. 1 to No. 13) Oil Jets removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Components removed:
- Filter
- Oil Jet
- O-ring
- Screw + Washer
Support Equipments:
Top View Nomenclature Identification No.
applicable plastic Local supply

scraper
Oil Jets Oil Jets

Filter Filter
O-ring O-ring
Screw
Screw
+
+
Washer
Washer
Rear View
O-ring
O-ring
O-ring O-ring
O-ring

6.4 - Upper Module, Oil Unions and Fixed ring Gear Assy removal
Oil Union CR&OP Data Module:

A (x4) D Upper Module
Assy 39-A-63-20-05-00A-530A-C
Oil Union C
B Main gearbox - Disassemble
procedures.
B
Support Equipments:
A / A1
Nylon Screw (x 3) Nomenclature Identification No.
Planetary Lifting tool, main 3G6320A00131A181A

Crown gearbox
Main Case Side View (Fixed Ring Lifting device Local supply
Gear)
Details Trolley, upper module 3G6320A00231A188B
A / A1 B support
Nut
Nut
Washer Washer
Bracket Bracket
6 pos. 1 pos.
C Nut D
Nut
Washer
Bracket Washers
1 pos. 22 pos.
Top View

6.4.1 - Oil Unions removal
CR&OP Data Module:

Planetary
Crown 39-A-63-20-05-00A-530A-C
(Fixed Ring Main gearbox - Disassemble
Oil Union Gear)
procedures.
A (x4)
Support Equipments:
Oil Union
B
Extractor tool, oil union 3G6320A00131A029A

A
A
A
Main Case
A
A
Oil Union
(5 positions)

6.4.2 - Planetary Crown (Fixed Ring Gear) removal
Planetary Crown Planetary Crown

(external view) (Removal)
Collector Gear
Diaphragm
Tool installation
Planetary Crown
(inner view)
Support Equipments
Disassembly tool, 3G6320A00231A029F

planetary crown

6.5 - Main Case, Backlash check
Backlash check required

RH Input Pinion II
Stage Check of the backlash CR&OP Data Module:
between:
Collector Gear and the Input 39-A-63-20-05-00A-713A-C
Collector Gear Pinions (LH/RH) II Stage Main gearbox - Backlash/gear
Hyd. Pump Main Case pattern check, Para. 2

Fan Drive Quill
No. 2 Collector Gear and Tail-Rotor 39-A-63-20-05-00A-713A-C
Tail-Rotor Drive Quill Main gearbox - Backlash/gear
Drive Quill pattern check, Para. 3
Collector Gear and ECS- 39-A-63-20-05-00A-713A-C

Compressor Drive Quill Main gearbox - Backlash/gear
pattern check, Para. 4
Hyd. Pump Collector Gear and Front Hyd. 39-A-63-20-05-00A-713A-C

No. 1 Pump Drive Quill Main gearbox - Backlash/gear
Left/Right Input Pinion II Stage 39-A-63-20-05-00A-713A-C

ECS and Left/Right Pump Drive Quill Main gearbox - Backlash/gear
Compressor (Hyd. Pump No. 1 & No. 2) pattern check, Para. 6
Drive Quill
Tail-Rotor Drive Quill and Fan 39-A-63-20-05-00A-713A-C
Drive Quill Main gearbox - Backlash/gear
LH Input Pinion II
Front Hyd. Pump Stage

6.5.1 - Main Case, Backlash tool (Collector gear) installation
CR&OP Data Module: Nomenclature Identification No.
39-A-63-20-05-00A-713A-C Backlash tool, 3G6320A00331A676L

collector gear
Main gearbox - Backlash/gear
pattern check, Para. 1 Dial gauge Local supply
Support Equipments: Legend:

Item No. Nomenclature
1 Dial Gauge Support (3)
2 Tool Top section
3 Knobs (4)
4 Bolt
5 Nylon Split Ring
6 Bolts (4)
7 Registers (2)
8 Retainers
9 Bolts (2)
10 Wrench (Torque application

point)
11 Expander
12 Tool Bottom Section
13 Torque application point
14 Collector Gear

6.5.2 - MGB (Collector gear) Top Tool Section installation
1 7
Register
Expander,
installation
Wrench
2
Retainer
Tool Top
Section,
installation
Nylon Split
Ring Bolts
5
4
Collector
Gear
Knobs

6.5.3 MGB, (Collector gear) Tool Bottom Section installation
10

6.5.4 MGB, Backlash tool (Collector gear), torque wrench
application and Collector Gear levelness check
Top Section 11 13
Bolts
Register
(2 positions)
Dial gauges
(3 positions)
Bottom Section
Note: 12 Note:
Lock the Collector Gear with the Use the two Registers to adjust the
Expander as required. levelness as required.
Tighten the Bolts as required.
Note:
Push the tool bottom section

up as required.

6.5.5 - Backlash check between the Collector Gear and the Input pinions
CR&OP Data Module:

Input Pinion
Backlash/gear pattern check, Para. 2
Support Equipments:
Backlash tool, input pinions 3G6320A00331A676B

Dial gauge Local supply
Note:
- Lock the tool expander.

Input Pinion
Backlash Tool - Pull the input pinion externally as required.
installation - Measure and record the backlash in three
positions, 120 apart.
- Perform this action on both Input pinions.
LH Input Pinion II Stage, RH Input Pinion II Stage,

Backlash Backlash
Tool installation Tool installation

6.5.6 - Backlash check between the Collector Gear and the Tail-Rotor Drive Quill
Tail Rotor Drive Quill,

Backlash Tool
CR&OP Data Module:
installation
39-A-63-20-05-00A-713A-C
Support Equipments:
Backlash tool, tail rotor 3G6320A00331A676C

drive quill
Output Pinion Tail Rotor

Drive Quill
Note:

- Push the pinion internally as required.
- Measure and record the backlash in three

6.5.7 - Backlash check between the Collector Gear and the ECS-Compressor Drive
Quill
CR&OP Data Module:

ECS Compressor 39-A-63-20-05-00A-713A-C
Drive Quill
Support Equipments:
Backlash tool, ECS- 3G6320A00331A676E

compressor drive quill
ECS Compressor
Drive Quill, Dial gauge Local supply
Backlash Tool
installation
Note:

6.5.8 - Backlash check between the Collector Gear and the Front Hyd.
Pump drive quill
CR&OP Data Module:
Front Hyd. Pump 39-A-63-20-05-00A-713A-C

Drive Quill
Support Equipments:
Backlash tool, front 3G6320A00331A676H

Front Hyd. Pump,
pump drive quill
Backlash Tool
installation Dial gauge Local supply
Note:

6.5.9 - Backlash check between the Left/Right Input Pinion II Stage and
the Left/Right Pump (Hyd. Pump No. 1 & No. 2) Drive Quill
CR&OP Data Module:

Support Equipments:
Left/Right Pump
(Hyd. Pump No. 1
and No. 2)
Drive Quill,
Backlash tool, left and right pump drive quill 3G6320A00331A676D
Backlash Tool Dial gauge Local supply
Note:
Left/Right Pump - Pull the pinion externally as required.
(Hyd. Pump No. 1 - Measure and record the backlash in
and No. 2) three positions, 120 apart.
Drive Quill
- Perform this action on both Hyd. Pumps.
Left Pump (Hyd. Right Pump (Hyd.

Pump No. 1) Pump No. 2)
Drive Quill Drive Quill

6.5.10 - Backlash check between the Tail-Rotor Drive Quill and the Fan Drive
Quill
CR&OP Data Module:

Support Equipments:
Backlash tool, fan drive quill 3G6320A00331A676F
Fan Drive Quill,

Backlash Tool Note:
- Pull the pinion externally as required.
Fan Drive Quill - Measure and record the backlash in
three positions, 120 apart.

6.6 - Drive Quills (Hyd. Pumps, ECS- Compressor and Fan) removal
Engine 2 Inlet
B - LH/RH Hydraulic Pump Drive Quills

D - Front Hydraulic Pump Drive Quill
V - Fan Drive Quill
Engine 1 Inlet
(Drive Shaft)
CR&OP Data Module:
39-A-63-20-05-00A-530A-C

6.6.1 - Hydraulic Pump (No. 1 & No. 2) Drive Quill removal
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
B
B
Screw (2)
Nylon Support equipment:
Screw (2)
Hyd. Pump Nomenclature Identification No. Shim
B Drive Quill Extractor, drive quill 3G6320A00331A029G
3
O-ring
Screw (3)
Shim
2
1
Extractors
installation
Screws removal
6.6.2 - ECS-Compressor Drive Quill removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
C
Screw (3)
Support equipment:
O-ring
C Extractor, drive quill 3G6320A00331A029G
Shim
Screw (2)
ECS- Compressor
Setscrew (3) Drive Quill
Extractors
installation

6.6.3 - Front Hyd. Pump Drive Quill removal
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
D
Support equipment:
Shim
Screw (3) Nomenclature Identification No.
Extractor, drive quill 3G6320A00331A029G

D
Setscrew
(2)
O-ring
Screw (2) Hyd. Pump

Drive Quill
Extractors
installation

6.6.4 - Fan Drive Quill removal
CR&OP Data Module:

V
39-A-63-20-05-00A-530A-C
Nut, Main gearbox - Disassemble procedures
Washer
(3)
Seal-Cover Support equipment:
O-ring
Lip-Seal Nomenclature Identification No.
V Extractor, drive quill 3G6320A00331A029G
Screw
Shim
Fan Drive
Quill
1 2

6.6.5 - Drive Quills removed
LH Hyd. RH Hyd. Front Hyd. ECS- Compressor Fan

Pump Pump Pump Drive Quill Drive Quill
Drive Quill Drive Quill Drive Quill

6.7 - LH & RH Input Pinion Assembly (II Stage of reduction),
removal
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Bearing Support equipment:

Sleeve
V incision Main Case Nomenclature Identification No.
Extractor, input pinions 3G6320A00331A029F

O-ring Input Pinion II
Stage
Bearings 1
Spacer
Pump
Nuts, Washers gear
Pump Retaining Ring
(parts to be
removed) gear
Retaining Locking Ring
Ring Locking
Washer Nuts, Washers
Input Pinion Assembly

installed inside the Main Case
(RH Side)
2
LH and RH Input Pinion
Assembly removed
6.8 - LH & RH Input Pinion Assembly (II Stage), Disassembly
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Bearing Support equipment:

Sleeve
V incision Main Case Nomenclature Identification No.
Installation tool, input 3G6320A00331A023W

O-ring
Input Pinion II pinions
Stage Removal tool, pump gear 3G6320A00331A029R
Bearings
Spacer Removal tool, pinion 3G6320A00331A029O
Removal tool, bearings 3G6320A00331A029P

Nuts, Washers
Pump Retaining Ring
gear
Retaining Locking Ring Note
Ring
Locking
Washer Details of the Input Pinion Assembly
disassembled are available on the next
page.

6.8.1 - Details of the Input Pinion Assy disassembled
Inner side of External side

the Pinion of the Pinion
O-ring
Bearings
Input Pinion II Bearing Input Pinion II
Stage Sleeve Stage
Spacers
Pump
gear
Retaining Ring

6.9 - Tail-Rotor Drive Quill Assembly, removal
CR&OP Data Module:

39-A-63-20-05-00A-530A-C
Nut + Washer
Nylon Screw (8)
(3)
Support equipment:
Rotor Nomenclature Identification No.

Main Brake
Case Housing Trolley, main case 3G6320A00131A188C
maintenance
Tail Rotor Drive
Quill Assembly Extractor, tail rotor drive 3G6320A00331A029I
quill
2
Lifting tool, pinion 3G6320A00331A026M
assembly
TRDQ
Main Case Tools Assembly
rotated installation removed

6.10 - Tail-Rotor Drive Quill Assembly, disassembly procedures
CR&OP Data Module:

39-A-63-20-05-28A-530A-C Tail
rotor drive quill (main gearbox) -
Disassemble procedures
Retaining ring
Locking washer
Support equipment:
Locking ring
Ring Nomenclature Identification No.
Flange
Nut + Retaining ring Reaction tool, pinion 3G6320A00331A023Z
Washer
O-rings Seal case
Extractor tool, locking 3G6320A00431A029C
Seal
washer
Rotor brake case
O-ring Wrench 3G6320A00331A026F
Shim Nipple Retaining ring Removal tool, flange 3G6320A00331A028A

Flanged
bearing Locking ring Removal tool, seal cover 3G6320A00331A029Y
(spherical) O-rings Gear
Shim Extractor tool, lip seal 3G6320A00331A029W
Retaining ring
Locking washer
Removal tool, rotor brake 3G6320A00331A029U
case
Locking ring
Bearing inner Removal tool, flanged 3G6320A00331A029V
race (roller) bearing
Plug O-ring Wrench 3G6320A00331A026B
Pinion
Removal tool, gear 3G6320A00331A029T

Bearing cage
Wrench 3G6320A00331A026A
Plug
Pinion Removal tool, bearing 3G6320A00331A029S

6.10.1 - Tail-Rotor Drive Quill Assembly , disassembly procedures Step 1
STEP 1
Put the Tail-Rotor Drive Quill on the

Reaction Tool attached to an applicable
work table.
Support equipment:
Reaction tool, pinion 3G6320A00331A023Z

6.10.2 - Tail-Rotor Drive Quill Ass. , disassembly procedures Steps 2 7
Pinion STEPS 2 7
2 - Remove the Retaining Ring (1) from the

pinion.
3 - Remove the Locking Washer (2) from the
Retaining ring pinion. Use the Extractor Tool No.
Locking washer 3G6320A00431A029C (see Detail A)
Locking ring 4 - Remove the Locking Ring (3) from the
Ring
Flange
pinion. Use the Wrench No.
Retaining ring 3G6320A00331A026F (see Detail B).
Seal cover 5 - Remove the Ring (4) from the pinion.
6 - Remove the Flange (5) from the pinion
and from the Seal Cover (7). Use the
Removal Tool No. 3G6320A00331A028A
(see Detail C).
(3G6320A00331A026F)
7 - Remove the assembled pinion from the
(3G6320A00431A029C) Reaction Tool No. 3G6320A00331A023Z.
Removal Tool
(3G6320A00331A028A)
Detail A Detail B
Detail C

Pinion STEPS 8 13
8 - Remove the Retaining Ring (6) from the
Rotor-Brake Case (11).
9 - Remove the Seal Case (7) from the Rotor-
Brake Case (11). Use the Removal Tool No.
G6320A00331A029Y (see Detail D).
10 Remove the O-rings (8) and (9) from the
Seal Case (7).
Retaining ring 11 - Remove the Lip Seal (10) from the Seal
Nut +
Seal case case (7). Use the Extractor Tool No.
Washer
O-rings
3G6320A00331A029W (see Detail E).
Lip Seal
12 - Remove the six Nuts (15) and the six
Rotor brake case Washers (16).
O-ring
13 - Remove the Rotor-Brake Case (11) from
Shim Nipple the Flanged bearing (17). Use the Removal
Screw Tool No. 3G6320A00331A029U as required
Flanged Extractor Tool
(G6320A00331A029W) (see Detail F).
bearing
(spherical)
Removal Tool
Removal Tool
(G6320A00331A029U)
(G6320A00331A029Y)
Detail D Detail E Detail F

Pinion
STEPS 14 16
14 - Remove the three Screws (14A) and the Shim
(14) from the Rotor Brake Case (11).
15 - Remove the Nipple (13) and the O-ring (12)
from the Rotor Brake Case (11).
16 - Remove the Flanged Bearing (17) from the
pinion. Use the Removal Tool No.
3G6320A00331A029V with Press (locally supply) as
Nut + required. See Detail G.
Washer
Rotor brake case

O-ring Removal Tool
(G6320A00331A029V)
Shim Nipple
Screw
Flanged
bearing
(spherical)
Detail G

STEPS 17 20
Retaining ring 17 - Remove the retaining ring (18) and the
Locking washer locking washer (19) from the Pinion (30) or
Locking ring (30A). Use the Extractor Tool No.
Gear 3G6320A00431A029C (see Detail H).
Shim 18 - Remove the Locking Ring (20) from the
Pinion (30) or (30A). Use the Wrench No.
3G6320A00331A026B (see Detail I).
19 - Remove the Gear (21) from the Pinion
(30) or (30A). Use the Removal Tool No.
3G6320A00331A029T (see Detail J).
Pinion 20 - Remove the Shim (22) from the Pinion
(30) or (30A).
Removal Tool
(3G6320A00331A029T)
Pinion
(3G6320A00431A029C)
(3G6320A00331A026B)
Detail H Detail I Detail J

6.10.6 -Tail-Rotor Drive Quill Ass., disassembly procedures Steps 21 26
STEPS 21 26
21 - (Main gearbox P/N 3G6320A00132). Remove the
Bearing Inner Race (28) from the Pinion (30) as
follows:
21.1 Remove the Retaining Ring (23) and the Locking

O-rings Washer (24) from the Pinion (30). Use the Extractor
Tool No. 3G6320A00431A029C (see Detail K).
Retaining ring 21.2 Remove the Locking Ring (25) from the pinion
Locking washer (30). Use the Wrench No. 3G6320A00331A026A (see
Locking ring Detail L).
Bearing inner
21.3 Remove the Bearing Inner Race (28) from the
race (roller) Pinion (30). Use the Removal Tool No.
Plug
3G6320A00331A029S (see Detail M).
Pinion O-ring 21.4 Remove the Pinion (30) from the Reaction Tool.
Bearing cage
Plug
22 (Main gearboxes P/N 3G6320A00133 and
subsequent P/N with different last two digits). Remove
the Bearing Cage (28A) from the pinion (30A).
23 Remove the O-rings (31) and (32) from the pinion
Pinion (30) or (30A).
(3G6320A00431A029C) 24 (Main gearbox P/N 3G6320A00132). Remove the

Tool Plug (29) from the Pinion (30).
(G6320A00331A026A)
the Plug (29A) from the Pinion (30A).
the O-ring (33) from the Plug (29A).
Removal Tool
(3G6320A00331A029S)
Detail K Detail L
Detail M

6.11 - Diaphragm, Oil Jets and Roller Bearing removal
Nuts,
Washers
Screws (14) CR&OP Data Module:
Diaphragm
39-A-63-20-05-00A-530A-C Main
Roller Bearing gearbox - Disassemble procedures.
Bolts
Collector Gear
Oil Jets pre-mod.

Support equipment:
Extractor Tool 3G6320A00331A029I
Extractor tool, roller bearing 3G6320A00331A029A
Oil Jets post-mod.

6.11.1 - Diaphragm removal
1a Screws (14)
Diaphragm
3
Oil Jets pre-mod.
Roller Bearing
Collector Gear
1b
Diaphragm removed
from the Main Case
2
Oil Jets post-mod.
Extractor Tool
installation

6.11.2 Oil Jets removal
Diaphragm
Oil Jets pre-mod.
Oil Jets post-mod.

6.11.3 Roller Bearing removal
(A) Diaphragm +
Roller Bearing
Diaphragm
Roller
Bearing
(B) Roller bearing removed

Nuts,
Washers Upper side
Extractor tool, roller bearing

(3G6320A00331A029A)

6.12 - Collector Gear removal
CR&OP Data Module:

Collector Gear 39-A-63-20-05-00A-530A-C Main
gearbox - Disassemble procedures
Bolts Collector Bearing
Support equipment:
Locking Ring
Locking Washer Nomenclature Identification No.
(B) Note:
Retaining Ring
Retaining Ring installed Removal tool, collector 3G6320A00331A029E
on MGB gear
P/N 3G6320A00135 only
Collector Gear
3
2
Retaining Ring Main Case
Washers
Nuts
1

6.12.1 - Collector Bearing and Retaining Ring removal
CR&OP Data Module:

Collector Gear
39-A-63-20-05-00A-530A-C Main
gearbox - Disassemble
Collector procedures.
Main Case
Bolts Bearing
Support equipment:
Locking Ring
Locking Washer
(B) Note:
Retaining Ring Nomenclature Identification No.
Retaining Ring installed
on MGB Lifting tool, collector gear 3G6320A00331A181C
P/N 3G6320A00135 only
Removal tool, Locking ring 3G6320A00331A023D

Collector Gear
Removal tool, collector 3G6320A00331A023C
Retaining Ring bearing
Washers
Nuts Hydraulic cylinder Local supply

6.12.2 Retaining ring and Collector Bearing,
View of the removal tools
Removal tool, Locking ring 3G6320A00331A023D Removal tool, collector 3G6320A00331A023C

bearing

6.13 - Main Case Ass., Internal Components removal Step 1
Nuts + Screws CR&OP Data Module:

Shim Washers
Shim
Screws
39-A-63-20-05-00A-530A-C
Main gearbox - Disassemble
procedures. (Roller bearing
4 188), (Shim 193) and (Shim
Shim (187) 187).
Roller Support equipment:
Bearing
Extractor tool, 3G6320A00331A029C

roller bearing
Note:
1 Roller Record the thickness of the shim
Bearing
(188)
2 3
Shim
(193)
Input Pinions II Stage,

installation side Shim (193)
Roller Bearing, removal
Main Screws CR&OP Data Module: Support equipment:

Case Nuts + 39-A-63-20-05-00A-530A-C
Washers
Main gearbox - Disassemble Nomenclature Identification No.
procedures.
Extractor tool, 3G6320A00331A029D
outer race roller
bearing
Screws Shim
2 Screws
Outer Race of the
roller bearing
Tail Rotor
Drive Quill Nuts +
1 location Washers
Shim
Main Case
external view
Note:
Screws Record the thickness of the shim

Main Case Main Case
internal view external view
A
Screws
Shim
CR&OP Data Module:
39-A-63-20-05-00A-530A-C
Hyd. Pump
(No.1 and No.2) procedures.
drive quill
location
Note:
Record the thickness of the shim

Fan drive quill

A CR&OP Data Module:
location Screws
Shim
39-A-63-20-05-00A-530A-C
procedures.
Note:

CR&OP Data Module:

Shim
39-A-63-20-05-00A-530A-C
Screws
procedures.
Note:

ECS drive quill
location

CR&OP Data Module:

Shim
Screws 39-A-63-20-05-00A-530A-C
procedures.
Note:
AC Generator
drive covers
location

CR&OP Data Module:
Shim
39-A-63-20-05-00A-530A-C
Screws Main gearbox - Disassemble
procedures.
Note:

Front drive
quill (Hyd.
Pump No. 3)
location

6.14 - LH and RH Input Shaft Module, disassembly procedures
Ref. documentations
Engine 2 Inlet
(Drive Shaft) CR&OP Data Module:
Right input
shaft module 39-A-63-20-05-01A-530A-C Left input shaft
module (main gearbox) - Disassemble
procedures (Effectivity Code: B01)
Engine 1 Inlet
Or
(Drive Shaft)
39-A-63-20-05-01B-530A-C Left input shaft
Or
Left input 39-A-63-20-05-01C-530A-C Left input shaft
shaft module
Effectivity Codes: And
CR&OP Data Module: 39-A-63-20-05-00A-000A-C Main 39-A-63-20-05-02A-530A-C Right input shaft
gearbox General module (main gearbox) - Disassemble
procedures
- B01 : Input shaft module P/N 3K6320A00133 (installed on MGB
P/N 3G6320A00132 and 3G6320A00133) Note
- B02 : Input shaft module P/N 3K6320A00135 (installed on MGB
P/N 3G6320A00134 and 3G6320A00135) The disassemble procedures given for the left-
- B03 : Input shaft module P/N 3K6320A00136 (installed on MGB input shaft module are applicable to the right-
P/N 3G6320A00134, 3G6320A00135, 3G6320A00132 and input shaft module.
3G6320A00133) Refer to: [B01], [B02], [B03] as necessary.

6.15 - Freewheel Group Assy, removal and disassembly procedures
Action No. 1 : Install the Input Module on the applicable Stand
LH Input Shaft
Module CR&OP Data Module:
Thermocouple
39-A-63-20-05-01A-530A-C Left input
Freewheel shaft module (main gearbox) -
Group
Support equipment:

Oil Pressure
Switch Stand, backlash check 3K6320A00131A676A
Plastic Caps/Plugs
Cotton gloves
Oil Jet
Oil Jet Note
Cover Perform this action on both Input Shaft Modules.
Use the specific Data Module
Oil Jet Oil Pressure
Cover Switch
Thermocouple
RH Input Shaft
Module
Action No. 2 : Remove the Sealant and Clean the mating areas
CR&OP Data Module:
39-A-63-20-05-01A-530A-C
Oil Pressure
Switch Left input shaft module (main
gearbox) - Disassemble procedures.
Support equipment:

Oil Jets
Plastic scraper Local supply
Supplies:
Cloth, soft lint free C011

Oil Jet
Cover Solvent, cleaning C010 (P-D-680 type II)
RH Input Shaft
Module Note
Perform this action on both Input Shaft Modules.

Action No. 3 : Oil Jets, Thermocouple and Oil Pressure Switch removal
Screw + Washer
LH Input Shaft
Module CR&OP Data Module:
Thermocouple
39-A-63-20-05-01A-530A-C
Left input shaft module (main
O-ring
Screw
Oil Pressure Thermocouple
Switch
Washer
Oil Jet
O-ring
Oil Pressure
Switch
Note
RH Input Shaft
Module
Action No. 4 : Oil Jet Cover removal
LH Input Shaft CR&OP Data Module:
Module
39-A-63-20-05-01A-530A-C
Left input shaft module (main gearbox) - Disassemble
Freewheel procedures.
Group
Support equipment:
Jackscrew, MGB 3G6005G00531
Note
O-ring Use the specific Data Module
Oil Jet
Cover Nuts +
Washers
1 2 3

Action No. 5 : Freewheel Group removed and disassembled
Note
LH Input Shaft CR&OP Data Module: Perform this action on both Input Shaft Modules.
Module
Freewheel Use the specific Data Module
39-A-63-20-05-01A-530A-C
Group
Left input shaft module (main gearbox) - Disassemble
Inner Bearing procedures.
Oil Vane
Input Shaft Support equipment:
Freewheel
Outer Bearing Nomenclature Identification No.
O-ring
Spacer Tool, clutch removal 3K6320A00131A029D
O-ring
Tool, inner/outer bearing 3K6320A00131A029G
removal
Arbor press Local supply
Retaining ring
Freewheel Group
disassembled

6.16 - Input shaft module Backlash check
Left Input CR&OP Data Module:

Shaft Module
39-A-63-20-05-01A-713A-C
Left input shaft module (main gearbox) -
Backlash/gear pattern check
Note

Use the specific Data Module.
Gear, I Stage Record the backlash found between the Input Pinion and the Gear.
of reduction
Support equipment:
Flange Nomenclature Identification No.
Stand, backlash check 3K6320A00131A676A
Stopper, gear 3K6320A00131A023L
Backlash tool, input drive quill 3K6320A00131A676B

Input
Pinion

6.16.1 Input shaft module (main gearbox) Backlash check, Procedures
Left Input Shaft Procedure:

A
A Module (1),
Input side 1 - Put the left input module (1) on the Stand.
2 - Install the Gear Stopper on the Stand.
3 - Lock the gear (2) in the left input module (1) with the Stopper.
4 - Install the Backlash Tool on the input side of the left input module (1).
Stand 5 - Lock the Backlash Tool to the flange (3).
(3K6320A00131A676A) 6 - Do a check of the backlash between the gear (2) and the input pinion (4) as
follows as required. Perform in phases, first by pulling and turning the Input pinion
and second by pushing and turning the Input pinion.
Stopper, gear Note

(3K6320A00131A023L) Measure these value in three position at 120 to each other. Calculate for each
condition the average value and then record these values are required.
B Backlash tool, installation
Note
(3K6320A00131A676B) Perform this action on both Input Shaft Modules.
Flange (3)
C D
Gear, 1 Stage
of reduction (2)
Input
Pinion
(4)
Flange Dial gauge,

(3) installation Backlash check

6.17 - Input shaft module, Input Drive-Quill Group removal
CR&OP Data Module:

Input Drive-Quill
39-A-63-20-05-01A-530A-C
Group Left input shaft module (main gearbox) -
Keys Disassemble procedures.
Plug Note
Input
Bolt Pinion
Roller
Bearing Sleeve
Washer Bearing
Nut O-ring Support equipment:
Duplex Ball Nomenclature Identification No.

Bearing
Heat gun Local supply
+
Washers
Nuts
Plug Nuts Jackscrew, MGB 3G6005G00531
Retaining
Gimbal Spring
Input Drive-
O-ring
Quill Group
O-ring Locknut removal
Carbon
Seal Flange
LH Input Shaft Bushings
Module Ring Note
O-ring
Fitting Use the Heat Gun and
increase the temperature
Carbon Seal (6070C) of the LH Input
Module locally in the
housing area of the Input
Pinion.
Spacer

6.18 - Input drive-quill group - Disassembly procedures
Action No. 1: Locknut, Flange, Gimbal, Bushing, Carbon Seal Assy removal
Bushings
A Locknut CR&OP Data Module:
(already Plug Retaining
removed) Spring
Gimbal
O-ring 39-A-63-20-05-01A-530A-C
O-ring Locknut gearbox) - Disassemble procedures.
Carbon
Seal Flange
Support Equipment:
Ring Bushings
Gimbal Flange Retaining Spring
O-ring Reaction, locknut removal 3K6320A00131A023F
Fitting
Wrench 3K6320A00131A023P
Pinion Tool, pinion support 3K6320A00131A023B

Mating Ring
Tool, flange removal 3K6320A00131A029E
Bearing Sleeve
Spacer Tool, Gimbal removal 3K6320A00131A029F
Tool, carbon seal removal 3K6320A00131A023T

B Note
Perform this action on both Input Shaft Modules. Tool, bushing removal EA6305G630-041
Puller, mating ring GJ-06-01
C
D E Pinion
Locknut
removal
Bearing
Gimbal Sleeve
removal Carbon Seal
removal Ring removal

Action No. 2: Bushings removal
CR&OP Data Module:
39-A-63-20-05-01A-530A-C
Support Equipment:
Tool, bushing removal EA6305G630-041

Action No. 3: Pinion, Duplex Ball Bearing and Bearing Sleeve disassembly
CR&OP Data Module:
Two 39-A-63-20-05-01A-530A-C
Keys Left input shaft module (main gearbox) - Disassemble
procedures.
Plug
Pinion Duplex Ball
Support Equipment:
Bearing
Bearing Sleeve
O-ring Tool, bearing sleeve removal 3K6320A00131A029B
1 Bearing race removal 3K6320A00131A029A
Bearing Sleeve + Bearings
Procedure
Disassemble the input drive-quill group. To do this obey the instructions that follow:
Items - Remove the input pinion (60) from the duplex ball bearing (49) and bearing sleeve
disassembled (47) group. Use the Tool No. 3K6320A00131A029B.
Keys
- Remove the plug (60A) from the input pinion (60).
Remove the duplex ball bearing (49) from the bearing sleeve (47) as required. Use
tool P/N 3K6320A00131A029A and the Arbor Press as necessary.
Note
3 Perform this action on both Input Shaft Modules.

Action No. 4: Roller Bearing Removal
Bolt
CR&OP Data Module:
Washer Roller Bearing 39-A-63-20-05-01A-530A-C
Nut Left input shaft module (main
gearbox) - Disassemble procedures
Support Equipment:
Tool, roller bearing removal 3K6320A00131A029M
Note
LH Input Shaft
Module
Left Input Shaft Module, Input side

6.18 - Input shaft module
Action No. 5 : Shim (input side) removal
CR&OP Data Module:
Shim Screw 39-A-63-20-05-01A-530A-C

Note
LH Input Shaft
Module

6.19 - Input Shaft Module Gear (I Stage of reduction).
Removal and disassembly procedures
Bolts + Washers
Flanged Roller
Bearing Diaphragm
CR&OP Data Module:
Bolts
39-A-63-20-05-01A-530A-C
gearbox) - Disassemble procedures
Oil dam
Nuts +
O-ring
Washers
Support Equipment:
Gear, 1 Stage Diaphragm, standard extractor Locally supply

of reduction
Nuts + Reaction, lock nut removal 3K6320A00131A023H
Washers (see next page)
Wrench 3K6320A00131A023I
(see next page)
Pusher 3K6320A00131A029C
Tool, gear support 3K6320A00131A023D
Flanged Ball Puller, oil dam 3K6320H02331

Shim
Bearing
Bolts Note
Screws Lock ring Use the specific Data Module
Lock nut

6.19.1 Input Shaft Module Gear (I Stage of reduction).
DWG of the Reaction, Wrench and Pusher tools used

6.19.2 - Input Shaft Module Gear (I Stage of reduction).
View of the parts removed
6 7 Flanged ball Bearing 12

1
Gear
Tools installation, Shim
Lock nut removal Lock ring & Lock nut removed
Diaphragm Assembly removal
2 Bearing
5
8
11
Gear, 1 Stage of reduction Outer Race of the

Lock ring Lock nut Gear, 1 Stage of reduction
looking from the base of the ISM Flanged Bearing
3 9 10
4
Diaphragm & Bearing removed Roller Bearing removal

Oil dam & O-ring removed from the Gear
6.20 - Upper Module, disassembly procedures
(Main Components)
CR&OP Data Module:

Top Case
39-A-63-20-05-03A-530A-C
Upper module (main gearbox) -
Upper
Module
Assembly
Mast-Planetary
assembly
Note
Planetary Crown (Fixed

Ring Gear) already
removed.
Packing
Planetary Crown
(Fixed Ring Gear)

Action No. 1: Make sure that Upper Module is installed on the Support
CR&OP Data Module:
39-A-63-20-05-03A-530A-C
Support equipment:
Support trolley 3G6320A00231A188B

Action No. 2: Ident. Plate, Cond. Jumper, Mast Cover removal
CR&OP Data Module:

Mast Cover
39-A-63-20-05-03A-530A-C
Packing Upper module (main gearbox) -
Upper
Module Mast-Planetary
Identification assembly Support equipment:
plate
Blade, sharp (for Id. Plate) Local supply
Extractor (For Mast Cover) 3G6320A00231A029E
Lifting tool (Upper fittings ) 3G6320A00231A181B
Lifting tool (Gear Ring) 3G6320A00131A181A

Lightning
Conductor Jumper Work trolley 3G6320A00231A188A
Supplies:

Cloth, soft lint free C011
Upper Fittings (4)
Solvent, cleaning C010 (P-D-680 type II)

Action No. 3: Chip Detector Valve and Oil Filler Neck removal
CR&OP Data Module:
39-A-63-20-05-03A-530A-C
Oil Filler plug
Chip Detector O-ring
Oil Filler Neck

O-ring O-ring
Chip Det. Valve
O-ring
Oil drain cup

Action No. 4: Four Oil Jets removal
CR&OP Data Module:
39-A-63-20-05-03A-530A-C Upper
procedures.
2 Oil Jets No. 1

A B
2 Oil Jets No. 2
C D
Screw +
washer
Oil jet
filter
Oil Jets No. 1
and No. 2
O-ring
O-ring
O-ring
Oil Jets No. 1
and No. 2
removed

Action No. 5: Upper Cooler Adapter and Oil Ducts removal
C
CR&OP Data Module:
39-A-63-20-05-03A-530A-C
Upper module (main
gearbox) - Disassemble
procedures.
Upper Cooler
Adapter
removed
A A B
Top Oil Duct
O-ring Nuts +
(q.ty 4)
Washers
(q.ty 5)
O-ring
Upper Cooler
Adapter
O-ring
Main Oil Duct (q.ty 1)

O-ring
Rear View Side View

Action No. 6: Seal Cover and Lip Seal removal
Mast-Planetary
assembly CR&OP Data Module:
A
39-A-63-20-05-03A-530A-C Upper
procedures.
Support equipment:
Removal tool, lip seal 3G6320A00231A029C

Nylon Screw A
(Q.ty 2)
Nuts +
Washers
Seal Cover +
Lip Seal
O-ring
O-ring
Top Case

Action No. 7.1: Ring Gear, Mast-Planetary Ass., Roller Bearing removal
Action A
Nuts +
Washers CR&OP Data Module:
E
Roller 39-A-63-20-05-03A-530A-C Upper

Bearing Top Case
module (main gearbox) -
O-ring
Support equipment:
D
Mast-
Work trolley 3G6320A00231A188A
Planetary
Assembly Clamp 3G6320A00231A023M
Lifting tool, gear ring 3G6320A00231A181A

Ball Bearing
Planetary Gear
Assembly Removal tool, mast- 3G6320A00231A029A
planetary assembly
B Packing
Hydraulic jack Local supply
Nuts + C
Washers Lifting tool, mast- 3G6320A00231A181C
Ring Gear
planetary assembly
Work trolley, mast- 3G6320A07231A188A

planetary assembly
Note
Removal tool, roller 3G6320A00231A029B
Ring Gear already removed. bearing

Action No. 7.2: Details A, B and C
A: Temporary
install two Nuts
and two Washers
(33,34) on the
Roller Bearing.
Note: in this photo
the seal cover is
yet installed.
View of the
Mast-Planetary
Assembly (4)
B: Remove the installed in the
Nuts and the TOP Case
Washers (44, 45,
46) from the Top
Case and the
flanged Outer
race of the Ball
Bearing.
Detail B C: Packing
(42), removal

Action No. 7.3: Detail D of the Mast-Planetary Assembly removed from the TOP Case

Mast-
D1
Planetary Assembly,
installed on the
Work trolley
Mast-Planetary
Assembly, TOP Case
D5 inner view
lifting tool installation.
Lifting tool, mast- 3G6320A00231A181C D3

planetary assembly
D2
D4
Work trolley, 3G6320A07231A188A

Mast-Planetary mast-planetary
Assembly, removed assembly
from the TOP Case

Action No. 8: Upper Fittings removal
Details A,B,C and D are relevant to the

Upper Fittings (Item 49)
CR&OP Data Module:
39-A-63-20-05-03A-530A-C Upper
module (main gearbox) -
Top Case Support equipment:

Lifting tool, mast 3G6320A00231A181B
Work bench Local supply

Bolts
Plastic scraper Local supply
Screw Washers Adapter, MGB upper 3G6305G10931
fitting removal
Brackets
Grease gun Local supply
Upper
Fitting
Note
Install the Adapter in the threaded hole of the
upper fitting (49).
Connect the Grease Gun filled with Grease to
the Adapter Tool (code C009: Aeroshell 22).
Operate the Grease Gun and slowly remove
the upper fitting (49) from the top case.
Do this action on each position.

Action No. 8.1: View of the Upper Fittings removed and the tools used
7
5
3

6.21 - Mast-Planetary assembly, disassembly procedures
Action No. 1: Ret. springs removal from the Ring Nuts and inst. of the M-P Ass. on the React. tool
Retaining 1 CR&OP Data Module:

ring
Lock
39-A-63-20-05-13A-530A-C Mast-planetary
washer assembly (upper module) - Disassemble
Ring Nut
procedures.
Support equipment:
Ball
bearing Nomenclature Identification No.
Retaining springs
Oil removal
collector Reaction tool 3G6320A07231A023E
2 Lifting tool 3G6320A00131A181A
Mast Lifting device Local supply
Bolts Work table Local supply

Lock
Retaining
washers
springs
Bushings
Ring nuts
Ring nut
Flange (upper view)
Planetary
Gear Assy. Pins
Spacers 3
Plate
Bushings
Pins
Lock washers
Bolts
4

6.21 - Mast-Planetary assembly , disassembly procedures
Action No. 2: Installation of the M.-P. Assembly on the Reaction tool assembly

Action No. 3: Retaining ring (1) and Lock washer (2) removal from the Ring nut.
Retaining CR&OP Data Module:

ring
Lock
39-A-63-20-05-13A-530A-C Mast-planetary
Ring Nut
procedures.
Retaining ring, Support equipment:
Ball removal
1
Oil Work table Local supply
collector Reaction tool 3G6320A07231A023E
Mast
Lock washer,
Bolts
removal
Lock
Retaining
washers 2
springs
Bushings
Ring nuts
Flange
Planetary Pins
Gear Assy.
Spacers
Plate
Bushings Ring Nut
Pins
Lock washers
Bolts

Action No. 4: Ring nut (3) removal from the Mast.
Retaining CR&OP Data Module:

ring
Lock 39-A-63-20-05-13A-530A-C Mast-planetary
Ring Nut
procedures.
Support equipment:
Ball
Oil Work table Local supply
collector
Reaction tool 3G6320A07231A023E
Ring nut, 3G6320A07231A023G

Mast rem./inst. tool
Bolts Servo-multiplier Sweeney 8200

Lock Lifting tool 3G6320A00131A181A
Retaining
washers
springs Lifting device Local supply
Bushings
Ring nuts
Flange
Planetary
Pins
Gear Assy.
Spacers
Plate
Bushings
Pins
Lock washers
Bolts

Action No. 5: Ring nut (3) removal , Tools installation sequence
1 6
Ring nut, rem./inst. tool

7
2 Ring Nut,
5
location
8 Ring Nut,
3 removed
4
Ball
bearing
Servo-multiplier

Action No. 6: Ball bearing (4) and Oil collector (5) removal
Retaining
ring
CR&OP Data Module:
Lock 39-A-63-20-05-13A-530A-C Mast-planetary assembly
washer (upper module) - Disassemble procedures.
Ring Nut
Support equipment:
Ball
bearing
Oil Nomenclature Identification No.
collector Work table Local supply
Lifting tool 3G6320A00131A181A
Bolts Reaction tool 3G6320A07231A023D

assembly
Lock
Retaining (adapter, spacer)
washers
springs Removal tool 3G6320A07231A029C
Bushings
Ring nuts assembly
Flange Removal tool 3G6320A07231A023F

assembly (plunger)
Planetary Jack Enerpack RC-252
Gear Assy.
Pins
Spacers
Plate
Bushings
Pins
Lock washers
Bolts

Action No. 7: Ball bearing (4) and Oil collector (5) removal, tools installation
(3G6320A07231A023D) (3G6320A07231A029C)
(3G6320A00131A181A)
(Enerpack RC-252)
(3G6320A07231A023F)
Ball
bearing
Oil
collector
Work Table
(3G6320A07231A023D)

Action No. 8: Ring nuts (20) removal, tools installation
Retaining
ring
CR&OP Data Module:
Ring Nut
3 Ring nut,
Ball Support equipment: removed
bearing
Oil
Reaction tool 3G6320A07231A023D
assembly
Mast (Wrench)
Bolts
Lock
Retaining 1
washers
springs
Bushings
Ring nuts
2
Flange
Planetary
Gear Assy. Pins
Spacers
Plate
Bushings
Pins
Lock washers
Bolts

Action No. 9: Pins (17), Items 6 and Planetary gear assemblies (19) removal
Retaining
ring
CR&OP Data Module:
Ring Nut
Support equipment:
Ball
bearing
Oil Nomenclature Identification No.

Bolts
Work trolley (turn the 3G6320A07231A188A
Lock
Retaining Mast 180)
washers
springs Bushing removal tool 3G6320A07131A023B
Bushings
Ring nuts
Planetary gear removal 3G6320A07131A029A
Flange tool
Planetary Jack (planetary gear RCH-121H

Gear Assy. Pins removal)
Spacers
Plate
Bushings
Pins
Lock washers
Bolts

Action No. 10: Pins (17), Items 6 and Planetary gear assemblies (19), details
Flange (11)
Pins (17) Planetary disassembled,
Gear Assy. Planetary gear
Plate (19) Assy (19)
Spacers (18)
(13) removed
partially removed
from the Planetary
gear Assy
Plate (13)
removal
Items 6,
details

6.22 - Planetary gears assembly, disassembly procedures
CR&OP Data Module:
39-A-63-20-05-14A-530A-C
Planetary gear assembly
(mast planetary assembly) -
Planetary Support equipment:
Gears Assy.
Rollers removal 3G6320A07231A029D

tool
Top-inner
bearing race Procedure
Roller cage
Put the planetary gear assembly (1) on an applicable work table.
Rollers
Note
Identify and record the installation position of the top and
bottom-inner bearing race (2) and (8) on the planetary gear
Gear
(outer bearing
assembly (1). This is to put them again in their correct
race) position during the assembly.
Disassemble the planetary gear assembly (1). Obey the

Rollers instructions that follow:
Bottom-inner Roller cage
bearing race
- Remove the rollers (4), the top-inner bearing race (2) and the
roller cage (3) from the gear (5). Always keep these parts
together. Do not interchange the rollers (4) with the rollers (6).
- Remove the rollers (6), the bottom-inner bearing race (8) and
the roller cage (7) from the gear (5). Always keep these parts
together. Do not interchange the rollers (6) with the rollers (4).

6.22.1 - Planetary gears disassembled, details
Gear
(outer bearing
Rollers removal tool 3G6320A07231A029D
A race)
B
Bottom-inner
Bottom-inner bearing race
Top-inner
bearing race bearing race Roller cage
Roller cage Roller cage
Rollers
Rollers Rollers
Roller cage
Bottom side F
Inner Bearing
race
Rollers
Inner Bearing
race
E
Top side Roller cage

6.23 - LH & RH Lubrication Pumps, disassembly procedures
Gear Ring
nut Retaining ring CR&OP Data Module:
Lubrication Key
pump 39-A-63-20-05-06A-530A-C Left lubrication
pump (main gearbox)- Disassemble procedures
Lock washer
39-A-63-20-05-24A-530A-C Right lubrication
pump (main gearbox) - Disassemble procedures
A
Shaft
Support equipment:
Retaining ring Reaction tool 3G6305G00931
Removal tool, lock washer 3G6305G01431
Wrench, ring nut 3G6305G01051
Lubrication
B Vice
pumps,
disassembled
Lock washer Ring Key Shaft
nut
C D E F G

6.24 - ECS Compressor drive quill, disassembly procedures
Action No. 1: Retaining ring and Locking washer removal
CR&OP Data Module:
39-A-63-20-05-05A-530A-C ECS compressor drive

quill (main gearbox) - Disassemble procedures.
Locking
ring Support equipment:
Pinion
ECS-compressor Nomenclature Identification No.
Case drive quill
Flanged washer
bearing
Retaining Locking Nuts +

ring washer Washers
ECS-compressor
drive quill
Vice
Retaining
ring,
removal

Action No. 2: remove the Locking ring from the Pinion
CR&OP Data Module:

Locking
ring
Pinion
Support equipment:
Case Nomenclature Identification No.

Flanged
bearing Removal/installation 3G6320A00731A023C
tool, locking ring
ring washer Washers
Locking ring,
removal

Action No. 3: remove the Pinion from the Case
CR&OP Data Module:

Locking quill (main gearbox) - Disassemble procedures.
ring
Pinion
Support equipment:
Case
Flanged
Removal tool, pinion 3G6320A00731A029B
ring washer Washers
IN OUT

Action No. 4: remove the Flanged Bearing from the Case
CR&OP Data Module:

Locking quill (main gearbox) - Disassemble procedures.
ring
Pinion
Support equipment:
Case
Flanged
bearing
ring washer Washers Arbor press Local supply
Removal tool, 3G6320A00731A029A
flanged bearing
IN
OUT

6.25 - Fan drive quill, disassembly procedures
Action No. 1: Retaining ring and Locking Washer removal from the pinion
CR&OP Data Module:

Fan drive quill
39-A-63-20-05-07A-530A-C Fan drive quill (main

Support equipment:
Work table
Tightening tool 3G6320A00931A023B

Pinion washer
Flanged
bearing
Locking
ring
Locking
Retaining washer
ring
Vice

6.25 - Fan drive quill, disassembly procedures
Act. No. 2: Locking Ring removal from the Pinion and Pinion removal from the Flanged bearing
CR&OP Data Module:

Fan drive quill

Pinion
Flanged Support equipment:

bearing
Locking Nomenclature Identification No.
ring
Work table Local supply
Locking
washer Tightening tool, 3G6320A00931A023B
Retaining
ring
Tightening tool 3G6320A00931A023B
(wrench)

pinion
PINION
(REF.)
IN OUT

6.26 - Front Hyd. Pump Drive Quill, disassembly procedures
CR&OP Data Module:

Pinion
39-A-63-20-05-04A-530A-C Front pump drive
Pump
case quill (main gearbox) - Disassemble procedures
Support equipment:
Front Hyd. Plug
pump drive Nomenclature Identification No.
quill O-ring O-ring

Fitting
Removal tool, lip 3G6320A00431A029E
seal cover
Extractor tool, lip 3G6320A00431A029D

Flanged seal
bearing
Washers + Nuts locking washer
Locking ring
Locking washer Removal/installa 3G6320A00531A023B
Retaining ring
tion tool, locking
ring
Packing
Lip seal pinion
Seal cover
Retaining ring

flanged bearing

Action No.1: Items 15,14,13,12,11,10 and 9 removal from the Pump Case
CR&OP Data Module:
Pinion
Pump
case
Support equipment:
Front Hyd. Plug

pump drive Work table Local supply
quill O-ring O-ring
seal cover
Fitting
Extractor tool, lip 3G6320A00431A029D
seal
Flanged
bearing
Washers + Nuts Pump

case
Locking ring
Locking washer
Retaining ring
Packing
Lip seal
Seal cover
Retaining ring
Seal cover

Action No.2: Items 8, 7 and 6 removal from the Pinion
CR&OP Data Module:
Pinion
Pump
case
Support equipment:
Front hyd. Plug
Work table and Vice Local supply
pump drive
quill O-ring O-ring
Extractor tool, locking washer 3G6320A00431A029C
Removal/installation tool, locking ring 3G6320A00531A023B
Fitting
(wrench)
Flanged
bearing
Washers + Nuts
Locking ring
Locking washer
Retaining ring
Packing
Lip seal
Seal cover
Retaining ring

Action No.3: Items 2, 5, 4 and 3 removal from the Pump Case
CR&OP Data Module:
Pinion
Pump
case
Support equipment:
Front hyd. Plug
pump drive
quill O-ring O-ring
Removal tool, pinion 3G6320A00531A029A
Fitting
Removal tool, flanged bearing 3G6320A00431A029A
Flanged
bearing
Washers + Nuts
Locking ring
Locking washer Pump
Retaining ring case
Packing
Lip seal
Seal cover
Retaining ring

6.27 LH/RH Hyd. Pump Drive Quill (No.1 and No. 2), disassembly procedures
Retaining ring CR&OP Data Module:
Seal cover 39-A-63-20-05-27A-530A-C Left/right pump drive

quill (main gearbox) - Disassemble procedures
Lip seal
Support equipment:
Packing
Left/right pump Retaining ring Nomenclature Identification No.

drive quill (Hyd.
Locking washer
pump No.1 and Work table Local supply
N0.2 drive quill) Locking ring
seal cover
Flanged
bearing+ Extractor tool, lip 3G6320A00431A029D
Washers seal
and Nuts
Plug
locking washer
O-ring O-ring
Removal/installa 3G6320A00431A023C
tion tool, locking
Fitting Pump
case
ring
Removal tool, 3G6320A00431A029B
pinion

Pinion

flanged bearing

6.27 - LH/RH Hyd. Pump Drive Quill (No.1 and No. 2), disassembly procedures
Action No. 1: items 12, 13, 16, 2, 3, 4 and 8 removal from the Pump Case.
Retaining ring
CR&OP Data Module:
39-A-63-20-05-27A-530A-C Left/right pump drive

Seal cover
Lip seal Support equipment:

Packing
Retaining ring
Removal tool, lip seal cover 3G6320A00431A029E
Locking washer
Locking ring Extractor tool, lip seal 3G6320A00431A029D
Flanged
bearing+
Washers
and Nuts
Plug
O-ring O-ring
Fitting Pump
case
Seal cover
Pinion
Pump
case

6.27 - LH/RH Hyd. Pump Drive Quill (No. 1 and No. 2), disassembly procedures
Action No. 2: items 5, 6 and 7 removal from the Pinion.
Retaining ring
CR&OP Data Module:
Seal cover

Packing
Retaining ring Work table and Vice Local supply
Locking washer Extractor tool, 3G6320A00431A029C

Locking ring
locking washer
Removal/installation 3G6320A00431A023C
Flanged tool, locking ring
bearing+ (Wrench)
Washers
and Nuts
Plug
O-ring O-ring
Fitting Pump
case
Pinion

6.27 - LH/RH Hyd. Pump Drive Quill (No.1 and No. 2), disassembly procedures
Action No. 3: items 15, 9, 10 and 11 removal from the Pump case.
Retaining ring
CR&OP Data Module:
Seal cover

Packing
Retaining ring Work table Local supply
Locking washer Removal tool, 3G6320A00431A029B

Locking ring
pinion

Flanged
bearing+
Washers Removal tool, 3G6320A00431A029A
and Nuts flanged bearing
Plug
O-ring O-ring
Pump
Pump case
Fitting
case
Pinion

Chapter 6 - Disassembly Procedures
THE END

TECHNICIAN TRAINING
Ch. 7: Components Cleaning, Paint
removal, Protection and
Inspection
7 Components Cleaning, Paint removal, Protection and Inspection
INDEX
7.1 Introduction
7.2 Cleaning procedures
7.3 Paint removal
7.4 Protection procedures
7.5 Detailed Visual Examination
7.6 Defects definition
7.7 Surface finish protection restoration (Main Case)
7.8 Surface finish protection restoration (Upper Module)
7.9 Surface finish protection restoration (LH/RH Input Shaft Module)
7.10 Damage codes list
7.11 Example of damage general information
7.12 Detailed visual examination, applicable Data Modules list
7.14 Chip detectors Detailed Visual Examination
7.16 Freewheel Detailed Visual Examination
7.19 Planetary Gears Assembly Detailed Visual Examination
7.25 Tail Rotor Drive Quill Detailed Visual Examination
(Conts)
7.26 Dimensions Check

7.27 Main gearbox Dimensions check
7.28 LH/RH Input Shaft Module Dimensions check
7.29 Upper Module Dimensions Check
7.30 Mast-Planetary Assembly Dimensions check
7.31 Planetary Gears Dimensions check
7.32 LH/RH Hyd. Pump Drive Quill Dimensions check
7.33 Front Hyd. Pump Drive Quill Dimensions check
7.34 ECS Compressor Drive Quill Dimensions check
7.35 Fan Drive Quill Dimension check
7.36 LH/RH Lubrication Pump Dimensions check
7.37 Tail Rotor Drive Quill Dimensions check
7.38 Dye Penetrant Examination
7.40 Main gearbox Dye Penetrant Examination
7.41 LH/RH Input Shaft Module Dye penetrant Examination
7.42 Upper Module Dye Penetrant Examination
7.43 Front Hyd. Pump Drive Quill Dye Penetrant Examination
7.44 ECS Compressor Drive Quill Dye Penetrant Examination
7.45 LH/RH Hyd. Pump Drive Quill Dye Penetrant Examination
7.46 Tail Rotor Drive Quill Dye Penetrant Examination
(Conts)

7.47 Magnetic Particles Examination

7.49 Main gearbox Magnetic Particles Examination
7.50 LH/RH Input Shaft Module Magnetic Particles Examination
7.51 Upper Module Magnetic Particles Examination
7.52 Front Hyd. Pump Drive Quill Magnetic Particles Examination
7.53 ECS Compressor Drive Quill Magnetic Particles Examination
7.54 LH/RH Lubrication Pump Magnetic Particles Examination
7.55 Fan Drive Quill Magnetic Particles Examination
7.56 Mast-Planetary Assembly Magnetic Particles Examination
7.57 Planetary Gears Assembly Magnetic Particles Examination
7.58 LH/RH Hyd. Pump Drive Quill Magnetic Particles Examination
7.59 Tail Rotor Drive Quill Magnetic Particles Examination

7.1 - Introduction
Hereinafter will be shown:

Cleaning procedures
Paint removal with Abrasive blast and with Paint remover
Surface protection (after cleaning procedures)
Detailed Visual Examination (damage codes list, example of damages, procedures)
Surface finish protection restoration (on repaired area)
Dimensions Check
Dye Penetrant Inspection
Magnetic Inspection
NOTE
All information reported hereinafter must be considered for Training purpose only.
Refer to CR&OP as required

7.2 - Cleaning procedures
Clean the disassembled metal components of the MGB as required.

Refer to CR&OP: 39-A-60-10-01-00A-251A-C
Supplies
Nomenclature Identification No Specification references Ref. Documents
Solvent C133 ASTM D4080-00 (AMDI)

(Trichloroethylene) 39-A-00-50-00-24A-078B-D
Safety conditions
WARNINGS
1. The Solvent (C133) is a dangerous material. Before you do this procedure, make sure that
you know all the safety precautions and first aid instructions for the solvent.
Refer to CR&OP: 39-A-60-50-00-00A-074A-C; in particular refer to:
- The label of the material container,
- The manufacturer safety data sheet,
- The local safety regulations,
- Perform the cleaning operations in a well-ventilated area.
2. You must use rubber gloves when you move the components during cleaning.
CAUTION
After cleaning, do not touch the metal components with bare hands. Put on clean, lint-free
cotton gloves before you touch the metal components. Contamination from your bare hands
will cause corrosion of the metal components.

7.3 - Paint removal
- with abrasive blast
In order to remove the paint layer from the MGB metal components use the Blasting Equipment
(Schlick Stripmaster 4S or equivalent) and the Abrasive plastic (C280) equivalent to MIL-PRF-85891 A.
WARNING
Make sure you obey all applicable precautions when you use the blasting equipment.
CAUTIONS
The procedure described in this Data Module is not permitted on:
Plated Aluminium surfaces.

Aluminium sheets less than 0.8 mm (0.03 in) thick, without an applicable support.
Composite material surfaces (tell the Manufacturer for an authorization).
Only approved personnel can use the Blasting Equipment and the procedure described in this Data
Module.
Procedure
The procedure described in this Data Module permit to remove all paint, sealing compound and
adhesive from the metal components.
When operates the blasting equipment observe the following notes:
Blast pressure: 2.8 bar (41 lbf/in)

Distance from the surface: 100 mm (4 in)
Angle of impact: 45 to 60
Dwell time: less than 1 second.

7.3 - Paint removal
- with paint remover
As alternative procedure a paint remover can be used. In this case refer to the following CR&OP data
module: 39-A-60-10-01-00A-659A-C Disassembled metal components - Paint removal with paint
remover - Other processes to remove material
Supplies
Solvent C005 TT-M-261 (AMDI) 39-A-00-50-00-04A-078A-D
Paint remover C348 MIL-PRF-25134 (AMDI) 39-A-00-50-00-10D-078A-D

Paint remover C349 MIL-R-81294 Type I and II (AMDI) 39-A-00-50-00-11D-078A-D
Cleaner, alkaline C255 None (AMDI) 39-A-00-50-00-23C-078A-D
Oil, protective C256 None (AMDI) 39-A-00-50-00-24C-078A-D
Procedure
Refer to the instructions reported in the D.M.

Note
The Paint Removers must not be used on composite parts and adhesive bonded structures.

7.4 - Protection procedures
If it is not possible to examine the components immediately after clean procedure, apply
protection to their surfaces. Refer to CR&OP: 39-60-10-01-00A-259A-C.
Supplies
Cloth, soft lint-free C011 None (AMDI) 39-A-00-50-00-10A-078A-D
Cleaning solvent C010 P-D-680 type II (AMDI) 39-A-00-50-00-09A-078A-D
Corrosion preventative C150 MIL-C-15074 (AMDI) 39-A-00-50-00-16B-078A-D
Oil C008 DOD-L-85734 (AMDI) 39-A-00-50-00-07A-078A-D
For Warning and Procedure refer to the applicable D.M.
Note
Before you examine the component, clean it with the Cloth and the Cleaning Solvent.

7.5 - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination
Safety conditions:
CAUTION
During this procedure, do not touch the components made of metal with bare hands.
Put on applicable cotton gloves before you touch the components.
Contamination from your bare hands will cause corrosion of the metals.
Procedure
To make an estimate of the damage, use the damage codes on the tables of the detailed visual
examination figures and refer to Data Module CR&OP: 39-A-63-20-05-00A-913A-C for the
acceptability / rejection criteria.
Support equipment:
Magnifying glass, 10 times Local supply

7.6 - Defects definition
Defects definition :
Small
It's a defect that will not have unwanted effects on the component life or on the overhaul
period.
Moderate
Its a defect that does not cause the component to become unserviceable. This defect can
decrease the component life and overhaul period.
Bad
Its a defect that causes the life of the component to decrease.
Note
When required, restore the surface finish protection on the repaired area in accordance with
CR&OP: 39-A-63-20-05-00A-640A-C (Main gearbox - Disassembled metal
components - Change the surface finish of materials)

7.7 Surface finish protection restoration (MGB - Main Case)
CR&OP Data Module:
39-A-63-20-05-00A-640A-C
Main gearbox - Disassembled metal components -
Change the surface finish of materials
Procedure
Refer to Para. 1
Apply to the components shown in Fig 1 the chromate conversion coating (C237: Alodine1200)
Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C
Apply to the components shown in Fig 2 the surface finishes that follow:
The chromate conversion coating (C237) . Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C.
The epoxy primer (C042: MIL-P-23377) . Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.
Apply to the components shown in Fig 3 the cadmium plating finish (C282 or C183 as required).
Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C.
On the pages reported hereinafter are shown the fig.1, 2 and 3.

7.7.1 - Main Case components Surface finishes - Fig. 1
On these components apply the chromate

conversion coating (C237: Alodine1200) .
Refer to data module CR&OP: 39-A-60-10-01-
00A-644A-C

7.7.2 Main Case components Surface finishes - Fig. 2
On these components apply the surface finishes that follow:

The chromate conversion coating (C237, Alodine 1200) . Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C.

7.7.3 Main Case components Surface finishes - Fig. 3
On these components apply the cadmium

plating finish (C282 or C183 as required).
Refer to data module CR&OP: 39-A-60-10-01-
00A-647A-C.

7.8 - Surface finish protection restoration (MGB - Upper Module)
CR&OP Data Module:
39-A-63-20-05-00A-640A-C
Procedure
Refer to Para. 2
The chromate conversion coating (C237: Alodine 1200). Refer to data module CR&OP: 39-A-60-10-01-
00A-644A-C
The cadmium plating (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A-
647A-C
On next page are shown the fig. 4 and fig. 5.

7.8.1 - Upper Module components Surface finishes, Fig. 4 and Fig. 5
The chromate conversion coating (C237: Alodine 1200). The cadmium plating (C282 or C183 as required).
Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C
The epoxy primer (C042: MIL-P-23377) . The epoxy primer (C042: MIL-P-23377) .
Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C. Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.
Figure 4 Figure 5

7.9 - Surface finish protection restoration
(MGB - LH/RH Input Shaft Module)
CR&OP Data Module:
39-A-63-20-05-00A-640A-C
Procedure
Refer to Para. 3
The chromate conversion coating (C237: Alodine 1200). Refer to data module CR&OP: 39-A-60-10-01-
00A-644A-C
The cadmium plating (C282 or C183 as required). Refer to data module CR&OP: 39-A-60-10-01-00A-
647A-C
On next page are shown the fig. 6 and fig. 7.

7.9.1 LH/RH Input Shaft Module comp. Surface finishes, Fig. 6 and 7
The chromate conversion coating (C237: Alodine 1200). The cadmium plating (C282 or C183 as required).
Refer to data module CR&OP: 39-A-60-10-01-00A-644A-C Refer to data module CR&OP: 39-A-60-10-01-00A-647A-C
The epoxy primer (C042: MIL-P-23377) . The epoxy primer (C042: MIL-P-23377) .
Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C. Refer to data module CR&OP: 39-A-63-20-05-00A-257A-C.
Figure 6 Figure 7

7.10 - Damage codes list
Sheet 1 of 9
Visual examination of Bearings

Damage Area of Acceptable damage Not-acceptable damage
Code Inspection
T1 Balls and Smearing. Accept the part if you find small smearing. Pitting, spalling, corrosion, heat
Rollers Staining. Accept the part if the staining is not related to pitting or discoloration, continuous
overheating. circumferential indentation,
Indentation that you can see only with a light reflection. Accept the part. brinelling, seizure and cracks.
Reject the part if you find one of
these defects.
T1 Bearing Smearing. Accept the part if you find small smearing. Pitting, spalling, heat discoloration,
races Staining. Accept the part if the staining is not related to pitting or brinelling, seizure, corrosion and
overheating. cracks.
Indentation that you can see only with a light reflection. Accept the part. Reject the part if you find one of
these defects.
T1 Not active Staining. Accept the part if the staining is not related to pitting or Bad circumferential scoring,
surfaces of overheating. spinning marks, cracks, heat
the bearings Corrosion. Accept the part if you find small corrosion that you can repair discoloration, bad fretting and
with a Scotchbrite pad or Number 600 abrasive paper. seizure.
Fretting. Accept the part if you find small fretting that you can repair with Reject the part if you find one of
a Scotchbrite pad or Number 600 abrasive paper. Make sure that the these defects.
fretting is not more than 10% of the working surface. Moderate and bad Reject the part if you find rusting.
fretting areas, usually, have the typical brown colour.
Scratches. Accept the part if you find small or moderate scratches.
T1 Cages Polishing. Accept the part if you find polishing. Corrosion, heat discoloration,
Staining. Accept the part if the staining is not related to pitting or seizure, pocket deformation,
overheating. peeling of the plated surface and
cracks.
Reject the part if you find one of
these defects.

Sheet 2 of 9
Visual examination of Gears (sheet 1 of 2)

Code Inspection
T2 Teeth Wear of abrasive type. Accept the part if you find small worn areas Scores, flaking, pitting, spalling,
caused by small particles that go through the gear mesh. peening, heat discoloration and
Polishing. Accept the part if you find polishing. cracks.
Scratches. Accept the part if you find small scratches caused by burrs Reject the part if you find one of
that go through the gear mesh. these defects.
Interference wear. Accept the part if you find small interference wear. Reject the part if you find rusting.
Corrosion. Accept the part if you find small corrosion that you can
repair with a Scotch-brite pad or Number 600 abrasive paper.
Staining. Accept the part if the staining is not related to pitting or
overheating.
Indentation that you can see only with a light reflection. Accept the
part.
T3 Bearing Polishing. Accept the part if you find polishing. Pitting, spalling, heat discoloration,
races Staining. Accept the part if the staining is not related to pitting or brinelling and seizure.
overheating. Reject the part if you find one of
Scratches. Accept the part if you find small scratches caused by burrs these defects.
that go through the roller elements. Reject the part if you find moderate
Indentation that you can see only with a light reflection. Accept the and bad circumferential marks.
part. Reject the part if you find rusting.
Corrosion. Accept the part if you find small corrosion that you can
repair with a Scotch-brite pad.

Sheet 3 of 9
Visual examination of Gears (sheet 2 of 2)

Code Inspection
T4 Journals Staining. Accept the part if the staining is not related to pitting or Bad circumferential scores,
overheating. spinning marks, flaking, heat
Corrosion. Accept the part if you find small corrosion that you can repair discoloration and seizure.
with a Scotchbrite pad or Number 600 abrasive paper. Reject the part if you find one of
Fretting. Accept the part if you find small fretting that you can repair with these defects.
a Scotchbrite pad or Number 600 abrasive paper. Make sure that the Reject the part if you find rusting.
fretting is not more than 10% of the working surface. Usually, the areas
that show fretting have a different colour from the surfaces that do not
show fretting. Moderate and bad fretting areas, usually, have the typical
brown colour.
T5 Shoulders Staining. Accept the part if the staining is not related to pitting or Moderate or bad wear, heat
overheating. discoloration, seizure and cracks.
Corrosion. Accept the part if you find small corrosion that you can repair Reject the part if you find one of
with a Scotchbrite pad or Number 600 abrasive paper. these defects.
Fretting. Accept the part if you find small fretting that you can repair with Reject the part if you find rusting.
a Scotchbrite pad or Number 600 abrasive paper. Make sure that the
fretting is not more than 10% of the working surface. Usually, the areas
brown colour.
Scratches. Accept the part if you find small scratches that are not more
than 10% of the working surface.
Polishing. Accept the part if you find polishing.
T6 Interface Small fretting. Accept the part if you find small fretting that you can Bad fretting and cracks.
planes repair with a Scotchbrite pad or Number 600 abrasive paper. Reject the part if you find one of
these defects.

7.10 - Damage code list
Sheet 4 of 9
Visual examination of Splines

Code Inspection
T7 Teeth Wear of abrasive type. Accept the part if you find small worn areas Pitting, spalling, cracks and bad
caused by small particles that go through the gear mesh. fretting.
Polishing. Accept the part if you find polishing. Reject the part if you find one of
Corrosion. Accept the part if you find small corrosion that you can repair these defects.
with a Scotchbrite pad or Number 600 abrasive paper. Reject the part if you find rusting.
Staining. Accept the part if the staining is not related to pitting or
overheating.
Fretting. Accept the part if you find small fretting that you can repair with
a Scotchbrite pad or Number 600 abrasive paper. Usually, the areas that
show fretting have a different colour from the surfaces that do not show
fretting. Moderate and bad fretting areas, usually, have the typical brown
colour.

Sheet 5 of 9
Visual examination of Casting

Code Inspection
T8 Interface Fretting. Accept the part if you find small fretting that you can repair with Bad fretting and cracks. Reject the
planes a Scotchbrite pad or Number 600 abrasive paper. part if you find one of these defects.
T9 Liners Polishing. Accept the part if you find polishing. Heat discoloration, seizure, cracks,
Corrosion. Accept the part if you find small corrosion that you can repair moderate and bad circumferential
with a Scotchbrite pad or Number 600 abrasive paper. scores, spinning marks and
Staining. Accept the part if the staining is not related to overheating. moderate and bad fretting.
Fretting. Accept the part if you find small fretting that you can repair with Reject the part if you find one of
a Scotchbrite pad or Number 600 abrasive paper. Make sure that the these defects.
fretting is not more than 10% of the working surface. Usually, the areas Reject the part if you find rusting.
brown colour.
T10 Sleeve Polishing. Accept the part if you find polishing. Bad fretting and seizure. Reject the
seats part if you find one of these defects.

Sheet 6 of 9
Criteria of acceptability for an indentation noted on the surface of the Casting (sheet 1 of 3)
Damage Area of Acceptable damage Examples of indentation
Code Inspection
T10 Surface of Indentation (Nick)
the casting INDENTATION
Accept the part if:
The indentation has a dimension of approximately 2.5 x 2.5 mm with a

depth of 0.25 mm without paint removal. Refer to photo No. 1.
INDENTATION
Photo No.1

Sheet 7 of 9
Damage Area of Acceptable Examples of indentation
Code Inspection damage
the casting
Accept the part if:
INDENTATION
The indentation has INDENTATION
a dimension of
approximately 2.5 x
2.5 mm with a
depth of 0.25 mm
with paint INDENTATION
removal. Refer to
photos No. 2, 3 and
4.
INDENTATION INDENTATION
INDENTATION
Photo No.2 Photo No.3 Photo No.4

Sheet 8 of 9
Damage Area of Acceptable damage Examples of indentation

Code Inspection
the casting INDENTATION
Accept the part if:
The indentation is on the corner (high thickness) and

has a dimension of approximately 4.0 x 4.0 mm with a
depth of 0.5 mm with paint removal. Refer to photo No.
5.
The indentation is on the corner (low thickness) and
has a dimension of approximately 4.0 x 4.0 mm with a
depth of 0.2 mm with paint removal. Refer to photo No.
6. Picture No.5
- Blend the sharp corners.

- Apply the paint finish as required.39-A-60-10-01- INDENTATION
00A-257A-C
Picture No.6

Sheet 9 of 9
Visual examination of Threads

Code Inspection
T11 Bolt threads, Mechanical damage. Corrosion, seizure, distortion and cracks.
Threaded Reject the part if you find one of these defects.
shafts, Accept the part if the mechanical damage is limited to
Nuts . one thread pitch at the input. If you find that a stud is damaged, you must
replace it. Refer to CR&OP: 39-A-60-30-02-
Damage must not be more than of the threaded 00A-921A-C.
depth after repair.

7.11 - Example of damage General information
(Note: Photos reported below are not related to the Transmission of the AW139)
Sheet 1 of 9
Damage Definition Example

Smearing Smearing is a
phenomenon where
minute seizure is
concentrated on the
rolling surface.
In smearing, the
surface is partially
melted by heat of
high temperature Searing on Inner Ring raceway surface
generated by friction;
and on some parts,
the surface damaged Smearing on roller rolling surface of
becomes significantly Cylindrical Roller Bearing
rough.
Searing on Outer Ring raceway surface
Smearing on outer ring raceway surface Smearing on ball surface

of Cylindrical Roller Bearing

Sheet 2 of 9
Discoloration Discoloration is a
(Staining) phenomenon in which
the bearing surface is
discoloured by staining
or heat generated
during operation.
Discoloration on inner ring and roller of Roller Bearing

(Staining)
Heat It is a phenomenon in
Discoloration which the bearing
surface is heavy
discoloured by
overheating generated
during operation.
Heat Discoloration on inner ring Surface overheated

Sheet 3 of 9
Flaking Flaking is a
phenomenon in which
the bearing surface
turns scaly and peels
off due to contact load
repeatedly received on
the raceway and
rolling surface during Flaking on inner ring of Cylindrical Roller Bearing
Flaking on inner ring of Deep Groove Ball Bearing
rotation.
Fretting Fretting is a
phenomenon which
occurs when slight
sliding is
repeatedly caused on
the contact surface.
On the fitting surface,
fretting corrosion
occurs, generating a
rust like powder Fretting on inner ring bore surface of Tapered Roller Fretting on outer ring O.D. surface of Deep
Bearing Groove Ball Bearing

Sheet 4 of 9
Indentation A depression in a
(Nick) surface, normally
having sharp edges and
bottom, generally
caused by an impact
with a sharp object
and/or having an
hardness higher than
the part Hardness
(FOD)
Seizure The seizure described

in this section is the
kind in which bearing
parts are melted and
adhere to one another
due to abnormal heat or
the rolling surface
becoming rough;
as a result, the bearing
can no longer rotate.
Seizure of Tapered Roller Bearing

(Heat is generated on roller end face and Example of seizure on roller bearing
inner ring rib face)

sheet 5 of 9
Pitting Pitting corrosion is a

corrosion phenomenon in which Heavy corrosion
on gear
the bearing surface
is partially melted by
sparks generated when
electric current
enters the bearing and
passes through an
extremely thin oil
film at the rolling Pitting on
contact point. Cylindrical Roller
Bearing inner ring
Depressions like craters
can be observed when
pitting is magnified,
indicating that the
surface has been
melted by sparks.
Example of pitting
corrosion

Sheet 6 of 9

Crack Separation of material
visible to naked eye.
Cracks include slight
cracks, splitting and
fracture.
Crack very heavy Crack in outer ring of Roller Bearing

on Cast Housing
Scratch A linear depression

with a sharp bottom
caused by the contact
and/or handling.
Or
A scratch is a relatively
shallow flaw caused by
sliding contact.
Scratch on roller rolling surface of Roller Bearing

Scratch
- Scratch occurring in circumference direction -
Medium Precision Surface

Sheet 7 of 9

Brinelling Brinelling is
depressions created on
the part of the raceway
surface which comes
into contact with the
rolling element, and is
due to plastic
deformation.
Brinelling is also small
depressions on the
rolling surface caused
by contamination by
solid foreign matters.
Brinelling on outer ring Brinelling on inner ring
raceway surface of Ball raceway surface
Bearing of Roller Bearing
Dent A depression in a
(Brinelling) surface , normally
having round edges
and bottom, generally
caused by an impact
with an object of round
shape and/or having
an hardness lower than
the part Hardness
Dent Dent
Heavy - Gear teeth Heavy Roller Bearing Race

Sheet 8 of 9

Rust Rust is a film of oxide, Rust on roller rolling
hydroxide, or carbonate surface of Cylindrical Roller
produced on a metallic Bearing
surface by chemical action.
Rust on outer ring raceway

surface
of Roller Bearing
Failure of 1) Cracks and Chips Distortion of Cylindrical

Cage If a seriously cracked Roller Bearing cage
bearing is used under
heavy operating conditions,
it will fail.
2) Distortion
Since cages are made from
soft material, they tend to
be damaged or become
distorted by external forces Crack of Roller Bearing cage
or from contact with other
parts.
3) Rust / Corrosion
If rust or corrosion is found
on cages, it can be
assumed that it is also
occurring on the bearing
ring and rolling element. Rust on Roller bearing cage

Sheet 9 of 9
Spalling Spalling is similar to
destructive pitting except
that the pits are usually
large diameter and quite
shallow. Often the damaged
area does not have uniform
diameter.

7.12 - Detailed visual examination, applicable Data Modules list
Hereinafter are shown the CR&OP Data Modules required to perform a DV Examination:
7.13) 39-A-63-20-05-00A-311A-C 7.20) 39-A-63-20-05-27A-311A-C
Main gearbox - Detailed visual examination Left/right pump drive quill (main gearbox) - Detailed
visual examination
7.14) 39-A-63-20-05-00A-311B-C
Main gearbox - Chip detectors - Detailed visual 7.21) 39-A-63-20-05-04A-311A-C
examination Front pump drive quill (main gearbox) - Detailed visual
examination
7.15) 39-A-63-20-05-01A-311A-C
Left input shaft module (main gearbox) - Detailed visual 7.22) 39-A-63-20-05-05A-311A-C
examination ECS compressor drive quill (main gearbox) - Detailed
visual examination
7.15) 39-A-63-20-05-02A-311A-C
Right input shaft module (main gearbox) - Detailed visual 7.23) 39-A-63-20-05-07A-311A-C
examination Fan drive quill (main gearbox) - Detailed visual
examination
7.16) 39-A-63-20-05-01A-311B-C
Left input shaft module (main gearbox) - Freewheel - 7.24) 39-A-63-20-05-06A-311A-C
Detailed visual examination Left lubrication pump (main gearbox) - Detailed visual
examination
7.17) 39-A-63-20-05-03A-311A-C
Upper module (main gearbox) - Detailed visual 7.24) 39-A-63-20-05-24A-311A-C
examination Right lubrication pump (main gearbox) - Detailed visual
examination
7.18) 39-A-63-20-05-13A-311A-C
Mast-planetary assembly (upper module) - Detailed visual 7.25) 39-A-63-20-05-28A-311A-C
examination Tail rotor drive quill (main gearbox) - Detailed visual
examination
7.19) 39-A-63-20-05-14A-311A-C
Planetary gear assembly (mast-planetary assembly) -
Detailed visual examination
7.13 MGB - Main Case - Detailed visual examination (Sheet 1 of 5)
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Main gearbox - Detailed visual examination.
See Para. 1 and Figure 1 (Sheet 1 of 5)
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
General Safety conditions:
CAUTION
During this procedure, do not touch the components made

of metal with bare hands.
Put on applicable cotton gloves before you touch the
components.
Contamination from your bare hands will cause corrosion
of the metals.
Procedure
To make an estimate of the damage, use the damage codes

on the tables of the detailed visual examination figures
and refer to CR&OP: 39-A-63-20-05-00A-913A-C for the
Fig. 1 - Main case MGB (sheet 1 of 5)

CR&OP Data Module:
39-A-63-20-05-00A-311A-C
See Para. 1 and Figure 1 (Sheet 2 of 5).
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................

7.13 - Main Case - Detailed visual examination (Sheet 3 of 5)
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................

7.13 - Main Case - Detailed visual examination (Sheet 4 of 5)
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................

CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................

7.13.1 MGB - Diaphragm - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
See Para. 2 and Figure 2
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 2 Diaphragm (MGB)

7.13.2 MGB - Bottom cover - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 3 Bottom cover (MGB)

7.13.3 MGB - Seal Cover of the Fan and ECS compressor drive quills
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 4 Seal covers (MGB)

7.13.4 - MGB - Anti-torque beam Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 5 Anti-torque beam (MGB)

7.13.5 MGB - 17 Oil Jets (Main case)
CR&OP Data Module:
N11
N6 N12 N7
N10 39-A-63-20-05-00A-311A-C Main gearbox - Detailed
N9
visual examination. See Para. 6 and Figure 6.
Oil Jet No. 3 (x2) Oil Jet P/N: .
Oil Jet No. 4 (x2) Oil Jet P/N: .
Oil Jet No. 5 Oil Jet P/N: .
N3 N3 Oil Jet No. 9 Oil Jet P/N: .
N 16
N16 N5 Oil Jet No. 16 (x2) Oil Jet P/N: .
N8 N4 Inspection results: ..............................
N4
N13
N15 N14
Notes
1) In the MGB are installed 29 Oil Jets: N3

N3
2) Check with filtered compressed air the possible occlusion of the oil jet holes
Fig. 6 Oil Jets (MGB) Sheet 2 of 2

Fig. 6 Oil Jets (MGB) Sheet 1 of 2

7.13.6 MGB - 3 Servo-Actuator Brackets
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Front servo-actuator Bracket (A)

P/N:.
S/N:.
Left servo-actuator Bracket (B)

P/N:.
S/N:.
Right servo-actuator Bracket (C)

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 7 Servo-actuator brackets (MGB)

7.13.7 MGB - Cross shaft (left and right) - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Left Cross shaft

P/N:.
S/N:.
Right Cross shaft

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 8 Cross shaft (MGB)

7.13.8 MGB - Ring nuts (Input pinions II stage) -
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Left ring nut

P/N:.
S/N:.
Right ring nut

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 9 Ring nuts - Input pinion II stage (MGB)

7.13.9 MGB - Pump gears - (Input pinions II stage)
- Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Left Pump gear

P/N:.
S/N:.
Right Pump gear

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 10 Pump gears - Input pinion II stage (MGB)

7.13.10 MGB - Bearing sleeves - (Input pinions II stage)
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Left Bearing sleeve

P/N:.
S/N:.
Right Bearing sleeve

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 11 Bearing sleeve - Input pinion II stage (MGB)

7.13.11 MGB - Bearing sleeve Retaining rings (Input pinions II
stage) - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Left Retaining Ring

P/N:.
S/N:.
Right Retaining Ring

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 12 Bearing sleeve Retaining Rings - Input pinion II stage (MGB)

7.13.12 MGB - Input pinions II Stage
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Left Input Pinion

P/N:.
S/N:.
Right Input Pinion

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 13 Input pinions II stage (MGB)

7.13.13 MGB - Sliding adapter (Tail rotor drive quill)
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 14 Sliding adapter (MGB)

7.13.14 - Collector gear Locking ring - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 15 Collector gear Locking ring (MGB)

7.13.15 MGB - Collector gear - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 16 Collector gear Locking ring (MGB)

7.13.16 MGB - Filter head and the Bypass valve
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Filter Head
P/N:.
S/N:.
Bypass Valve
P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 17 Filter head and Bypass valve (MGB)

7.13.17 MGB - Pressure relief valves - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
LH PRV
P/N:.
S/N:.
RH PRV
P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 18 PRV (MGB)

7.13.18 MGB - Input-pinion II stage triplex Ball Bearings -
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
LH triplex ball bearing

P/N:.
S/N:.
RH triplex ball bearing

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 19 Triplex ball bearings Input Pinion II stage (MGB)

7.13.19 MGB - Input pinion II stage Roller Bearings
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
LH Roller bearing
P/N:.
S/N:.
RH Roller bearing
P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 20 Roller Bearings Input pinion II stage (MGB)

7.13.20 MGB - Collector-gear Flanged bearing
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Collector-gear Flanged bearing

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 21 Collector gear flanged bearing (MGB)

7.13.21 MGB - Collector gear Roller bearing
CR&OP Data Module:
39-A-63-20-05-00A-311A-C
Collector-gear Roller bearing

P/N:.
S/N:.
Inspection results:
...................................................................................
...................................................................................
...................................................................................
Fig. 22 Collector gear flanged bearing (MGB)

7.14 - Chip detectors - Detailed visual examination
CR&OP Data Module:

MGB
39-A-63-20-05-00A-311B-C Main gearbox -
Chip detectors - Detailed visual examination
Support equipment:

Container Local supply
Magnifying glass, 10-power Local supply

Sump Chip
Detector (x2) Paint brush Local supply
Supplies:
Mast Chip
Detector Nomenclature Identification No Specification references Ref. Documents
Cleaning solvent C010 P-D-680 type II (AMDI)

Mast Chip Detector (upper module) 39-A-00-50-00-09A-078A-D
P/N:. Adhesive tape C012 DEF1313 or DEF (AMDI)
S/N:. STAN75-3-1. 39-A-00-50-00-11A-078A-D
LH Chip Detector (sump)
P/N:. Procedure:
S/N:.
RH Chip Detector (sump) 1) Examine each of the chip detectors. Use a strong light and the
P/N:. Magnifying Glass. Make sure that there are no metallic particles on
S/N:. these Chip Detectors.
Inspection results: 2) If you find metallic particles on the chip detectors obey the
............................................................ instructions reported in this data module.

7.14.1 - Chip Detector Event Report Card
Procedure:
As reported on CR&OP 39-A-63-20-05-00A-311B-C apply
the tape strip with the relevant metallic particle on the
applicable box of the Drive System Chip detector Event
Report Card. See Card attached.
Compile the Card as required.
Send the form to the laboratory for analysis and inform
AgustaWestland Costumer Support.

7.15 - Left and right Input Shaft Module (main gearbox)
- Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C Left input shaft module (main

gearbox) - Detailed visual examination
39-A-63-20-05-02A-311A-C Right input shaft module (main

Safety conditions:
CAUTION
Procedure
Support equipment: General Note:

The data to the a detailed visual examination
of the left-input shaft module is applicable
Magnifying glass, 10 times Local supply also to the right-input shaft module (see
CR&OP 39-A-63-20-05-02A-311A-C).

7.15.1 - Case Assy - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
Detailed visual examination.
LH Case Assy
P/N:
S/N:.
RH Case Assy
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
T11
T8
T10
Fig. 1 - Case assy (Left input shaft module)

7.15.2 - Input Pinion- Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Pinion
P/N:
S/N:.
RH Pinion
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
T7
Fig. 2 - Pinion (Left input shaft module)

7.15.3 - Gear, I stage of reduction - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Gear
P/N:
S/N:.
RH Gear
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 3 - Gear (Left input shaft module)

7.15.4 - Input shaft - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Input Shaft
P/N:
S/N:.
RH input Shaft
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
T7
Fig. 4 Input Shaft (Left input shaft module)

7.15.5 - Diaphragm - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Diaphragm
P/N:
S/N:.
RH Diaphragm
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
T10
T10
T8
Fig. 5 Diaphragm (Left input shaft module)

7.15.6 - Sleeve - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Sleeve
P/N:
S/N:.
RH Sleeve
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
T8
T9
T9
Fig. 6 Sleeve (Left input shaft module)

7.15.7 - Flange - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Flange
P/N:
S/N:.
RH Flange
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
T7
T8
Fig. 7 Flange (Left input shaft module)

7.15.8 - Gimbal support - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Gimbal support
P/N:
S/N:.
RH Gimbal support
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
T10
T10
T8
Fig. 8 Gimbal (Left input shaft module)

7.15.9 - Oil jet cover - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Oil Jet cover

P/N:
S/N:.
RH Oil Jet cover

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Note
Using filtered compressed air inspect the oil

jet holes for possible blockage.
T8
Fig. 9 Oil jet cover (Left input shaft module)

7.15.10 - Three oil jets - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
Left Input Shaft module:
Oil Jet A No.
P/N:
Oil Jet B No.

P/N:
Oil Jet C No.

P/N:
Inspection results:
........................................................................
Right Input Shaft module:
Oil Jet A No.
P/N:
Oil Jet B No.

Note P/N:
Check with filtered compressed air the possible occlusion of the oil jet holes Oil Jet C No.
P/N:
Fig. 10 Oil jets (Left input shaft module)
Inspection results:
........................................................................
7.15.11 - Two locking ring nuts - Detailed visual examination
B CR&OP Data Module:
39-A-63-20-05-01A-311A-C
Ring nut A
P/N:
S/N:.
A Ring nut B
P/N:
S/N:.
Inspection results:
........................................................................
Ring nut A
P/N:
S/N:.
Ring nut B
P/N:
S/N:.
Fig. 11 Ring nuts (Left input shaft module)

Inspection results:
........................................................................

7.15.12 - Carbon seal and Ring - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
Carbon Seal
P/N:
S/N:.
Ring
P/N:
S/N:.
Inspection results:
........................................................................

Carbon Seal
P/N:
S/N:.
Ring
P/N:
S/N:.
Inspection results:
Fig. 12 Carbon Seal and Ring (Left input shaft module) ........................................................................

7.15.13 - Inner Bearing - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Inner Bearing
P/N:
S/N:.
RH Inner Bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 13 Inner Bearing (Left input shaft module)

7.15.14 - Outer Bearing Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Outer Bearing
P/N:
S/N:.
RH Outer Bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 14 Outer Bearing (Left input shaft module)

7.15.15 - Ball bearing (gear 1 stage of reduction)
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Ball Bearing
P/N:
S/N:.
RH Ball Bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 15 Ball Bearing of the Input gear 1 stage of reduction - (Left input shaft module)

7.15.16 - Roller bearing (gear 1 stage of reduction)
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Roller Bearing
P/N:
S/N:.
RH Roller Bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 16 Roller Bearing of the Input gear 1 stage of reduction - (Left input shaft module)

7.15.17 - Roller bearing (Input pinion)
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Roller Bearing
P/N:
S/N:.
RH Roller Bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 17 Roller Bearing of the Input pinion - (Left input shaft module)

7.15.18 - Duplex ball bearing (input pinion)
CR&OP Data Module:
39-A-63-20-05-01A-311A-C
LH Duplex Ball Bearing

P/N:
S/N:.
RH Duplex Ball Bearing

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 18 Duplex Ball Bearing of the Input pinion - (Left input shaft module)

7.16 - Freewheel Detailed visual examination
Procedure CR&OP Data Module:

1) Do the detailed visual examination with the aid of the Magnifying
Glass, the Mirror and a strong light. Refer to Fig. 1 reported on the 39-A-63-20-05-01A-311B-C Left input
next page. shaft module (main gearbox) - Freewheel -
2) Examine the freewheel for corrosion and distress caused by the
heat. Reject it if you find one of these defects. Detailed visual examination.
3) Examine the sprags, the inner cage, the outer cage and the inner LH Freewheel
springs and the outer springs for cracks and breaks. Reject the P/N:
freewheel if you find one of these defects. S/N:.
4) Make sure that the sprags move freely in their pockets and stay in
position. Reject the freewheel if the sprags do not move freely or RH Freewheel
do not stay in position.
P/N:
5) Examine each sprag for discoloration caused by the heat, chips and
spalling and pitting. Reject the freewheel if you find one of these
S/N:.
defects. Accept the freewheel if you find small polished areas.
6) Examine the position of the wear patterns on the inner and outer Inspection results:
faces of each sprags. The wear pattern must be at a minimum ........................................................................
distance of 1.0 mm (0.04 in) from the high load corner. Reject the ........................................................................
freewheel if you do not find these conditions. ........................................................................
7) Examine each sprag for wear on the outer and inner faces. Make
sure that the wear width on the inner face is not more than 0.30 Support equipment:
mm (0.012 in) (see Detail A). Reject the freewheel if you find one
of these defects.
8) Examine the inner springs for wear. Reject the freewheel if the Nomenclature Identification No.
inner springs show important wear (approximately 30% of the
original thickness). Magnifying glass, 10-power Local supply
9) Examine the outer springs for fretting. Refer to Detail B for an
example of permitted fretting. Mirror Local supply
10) Examine the cross bars of the inner and outer cages for
straightness and uniformity. The cross bars must not be bent from
the initial shape and there must be no distortion. Reject the Note:
freewheel if you find one of these defects. The procedure reported in this D.M. is applicable for both
(LH, RH) freewheels.

7.16.1 - Freewheel Detailed visual examination
Fig. 1 Freewheel Detailed visual examination

7.17 - Upper Module (main gearbox) - Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-03A-311A-C Upper module (main gearbox) -

Safety conditions:
CAUTION
Procedure
Support equipment:

7.17.1 Top case Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-03A-311A-C Upper
module (main gearbox) - Detailed
visual examination.
See Para. 1 and Figure 1.
Top case
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 1 Top Case (Upper Module)

7.17.2 - Cooler adapter Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-03A-311A-C Upper
visual examination.
Cooler adapter
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 2 Cooler adapter (Upper Module)

7.17.3 - Seal cover Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-03A-311A-C Upper
visual examination.
Seal cover
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 3 Cooler adapter (Upper Module)

7.17.4 - Four Upper Fittings Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-03A-311A-C Upper
visual examination.
Upper Fitting
P/N:
S/N:.
Upper Fitting
P/N:
S/N:.
Upper Fitting
P/N:
S/N:.
Upper Fitting
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 4 Upper Fittings (Upper Module)

7.17.5 - Four oil jets Detailed visual examination
CR&OP Data Module:
C D
A B
39-A-63-20-05-03A-311A-C Upper
visual examination.
Oil Jet (A) No. 1

P/N:
Oil Jet (B) No. 1

P/N:
Oil Jet (C) No. 2

P/N:
Oil Jet (D) No. 2

P/N:
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 5 Oil Jets (Upper Module)

7.17.6 - Ring gear Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-03A-311A-C Upper
visual examination.
Ring gear
P/N:
S/N:
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 6 Ring Gear (Upper Module)

7.17.7 -Roller bearing Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-03A-311A-C Upper
visual examination.
Roller Bearing
P/N:
S/N:
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 7 Roller bearing (Upper Module)

7.17.8 - Components Detailed visual inspection
CR&OP Data Module:
39-A-63-20-05-03A-311A-C Upper
visual examination.
Mast cover P/N:

Chip detector P/N:..
Oil filler neck P/N:
Oil scupper P/N:...
Union P/N:..
Unions P/N:
Washers P/N:.
Brackets P/N:.
Inspection results:
.......................................................................
Procedure
Do the detailed visual examination of the following components for corrosion,

wear and damage:
The mast cover (1)
The chip detector (2)
The oil filler neck (3)
The oil scupper (4)
The unions (5) (five items)
The washers (6) (four items)
Fig. 8 Components (Upper Module) The brackets (7) (two items).

7.18 - Mast-planetary assembly (upper module)
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-planetary assembly

(upper module) - Detailed visual examination
Safety conditions:
CAUTION
Procedure
Support equipment:

7.18.1 - Main rotor shaft (MAST) Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
planetary assembly (upper module) -
Main rotor shaft (Mast)
P/N:
S/N:..
Inspection results:
.......................................................................
Fig. 1 Main rotor shaft (Mast-Planetary Assembly)

7.18.2 Spider plate Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
Spider plate
P/N:
S/N:..
Inspection results:
.......................................................................
Fig. 2 Spider plate (Mast-Planetary Assembly)

7.18.3 - Ring nut Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
Ring nut
P/N:
S/N:..
Inspection results:
.......................................................................
Fig. 3 Ring nut (Mast-Planetary Assembly)

7.18.4 - Ball bearing Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
Ball bearing
P/N:
S/N:..
Inspection results:
.......................................................................
Fig. 4 Ball bearing (Mast-Planetary Assembly)

7.18.5 - Five planetary gear ring nuts Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
Planetary gear ring nut

P/N:
S/N:..

P/N:
S/N:..

P/N:
S/N:..

P/N:
S/N:..

P/N:
S/N:..
Fig. 5 Planetary gear ring nut (Mast-Planetary Assembly)

Inspection results:
.......................................................................
7.18.6 - Five planetary pins Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
Planetary pin
P/N:
S/N:..
Planetary pin
P/N:
S/N:..
Planetary pin
P/N:
S/N:..
Planetary pin
P/N:
S/N:..
Planetary pin
P/N:
S/N:..
Fig. 6 Planetary pin (Mast-Planetary Assembly) Inspection results:

.......................................................................
7.18.7 - Five planetary gear spacers Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
Planetary gear spacer

P/N:
S/N:..

P/N:
S/N:..

P/N:
S/N:..

P/N:
S/N:..

P/N:
S/N:..
Fig. 7 Planetary gear spacer (Mast-Planetary Assembly)

Inspection results:
.......................................................................
7.18.8 - Five spider plate spacers Detail visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
Spider plate spacer

P/N:
Spider plate spacer

P/N:
Spider plate spacer

P/N:
Spider plate spacer

P/N:
Spider plate spacer

P/N:
Inspection results:
.......................................................................
Fig. 8 Spider plate spacer pin (Mast-Planetary Assembly)

7.18.9 - Components Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-13A-311A-C Mast-
Retaining ring
P/N:
Oil Collector
P/N:
Nut springs
P/N:
Spider bolts
P/N:
Spacer bush
P/N:
Inspection results:
.......................................................................
Procedure
Do the detailed visual examination of the following

components for corrosion, wear and damage:
The retaining ring (1)
The oil collector (2)
The nut spring (3) (five items)
Fig. 9 Components (Mast-Planetary Assembly)
The spider bolts (4) (ten items)
The spacer bush (5) (ten items).

7.19 - Planetary gear assembly (mast-planetary assembly) -
CR&OP Data Module:
39-A-63-20-05-14A-311A-C Planetary gear assembly

(mast-planetary assembly) - Detailed visual
examination
Safety conditions:
CAUTION
Procedure
Support equipment:

7.19.1 - Gear Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-14A-311A-C Planetary
gear assembly (mast-planetary
assembly) - Detailed visual
examination. See Para.1 and Figure 1
Planetary Gear Assy

P/N:
S/N:
Planetary Gear Assy

P/N:
S/N:
Planetary Gear Assy

P/N:
S/N:
Planetary Gear Assy

P/N:
S/N:
Planetary Gear Assy

P/N:
S/N:
Fig. 1 Gear (Planetary-Gear Assembly)

Inspection results:
.......................................................................

7.19.2 - Inner bearing race Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-14A-311A-C Planetary
Inner bearing race

Relevant to Planetary gear assy
P/N:
S/N:
Inner bearing race
P/N:
S/N:
Inner bearing race
P/N:
S/N:
Inner bearing race
P/N:
Fig. 2 inner bearing race (Planetary-Gear Assembly) S/N:
Inner bearing race
P/N:
S/N:
Inspection results:
.......................................................................
7.19.3 - Rollers and Cages Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-14A-311A-C Planetary
Rollers and Cages

P/N:
S/N:
Rollers and Cages
P/N:
S/N:
Rollers and Cages
P/N:
S/N:
Rollers and Cages
P/N:
S/N:
Rollers and Cages
Fig. 3 Rollers and Cages (Planetary-Gear Assembly) P/N:
S/N:
Inspection results:
.......................................................................
7.20 - Left/Right hyd. pump drive quill (main gearbox)
CR&OP Data Module:

quill (main gearbox) - Detailed visual examination
Safety conditions:
CAUTION
Procedure
Support equipment:

7.20.1 - Pinion Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-27A-311A-C Left/right
pump drive quill (main gearbox) -
See Para.1 and Figure 1.
Left pinion
P/N:
S/N:
Right pinion
P/N:
S/N:
Inspection results:
.......................................................................
Fig. 1 Pinion (left/right pump drive quill)

7.20.2 - Locking ring and Seal cover Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-27A-311A-C Left/right
See Para.2, 3 and Figure 2.
Left pump drive quill
Locking ring
P/N:
Seal Cover
P/N:
S/N:
Right pump drive quill
Locking ring
P/N:
Seal Cover
P/N:
S/N:
Inspection results:
Fig. 2 Locking ring and Seal cover (left/right pump drive quill)
.......................................................................

7.20.3 - Pump case Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-27A-311A-C Left/right
Left Pump case

P/N:
S/N:
Right Pump case

P/N:
S/N:
Inspection results:
.......................................................................
T8
Fig. 3 Pump case (left/right pump drive quill)

7.20.4 - Flanged bearing Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-27A-311A-C Left/right
Left Flanged bearing

P/N:
S/N:
Right Flanged bearing

P/N:
S/N:
Inspection results:
.......................................................................
Fig. 4 Flanged bearing (left/right pump drive quill)

CR&OP Data Module:
39-A-63-20-05-27A-311A-C Left/right
See Para.6
Left pump drive quill
Procedure
Plug
Do the detailed visual examination of the following P/N:
components for corrosion, wear and damage: Fitting
P/N:.......................................
The plug Locking washer
P/N:.......................................
The fitting
The locking washer Right pump drive quill
Plug
P/N:
Fitting
P/N:.......................................
Locking washer
P/N:.......................................
Inspection results:
......................................................................

7.21 - Front hyd. pump drive quill (main gearbox)
CR&OP Data Module:
39-A-63-20-05-04A-311A-C Front pump drive quill

(main gearbox) - Detailed visual examination
Safety conditions:
CAUTION
Procedure
Support equipment:

CR&OP Data Module:
39-A-63-20-05-04A-311A-C Front pump

drive quill (main gearbox) - Detailed
visual examination.
See Para. 1 and Figure1.
Pinion
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 1 Pinion (Front pump drive quill)

7.21.2 - Locking ring and Seal cover Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-04A-311A-C Front pump

visual examination.
See Para. 2, 3 and Figure 2.
Locking ring
P/N:
Seal Cover
P/N:
S/N:
Inspection results:
......................................................................
Fig. 2 Locking ring and Seal cover (Front pump drive quill)

7.21.3 - Pump case Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-04A-311A-C Front pump

visual examination.
Pump case
P/N:
S/N:
Inspection results:
......................................................................
Fig. 3 Pump Case (Front pump drive quill)

CR&OP Data Module:
39-A-63-20-05-04A-311A-C Front pump

visual examination.
Flanged bearing
P/N:
S/N:
Inspection results:
......................................................................
Fig. 4 Flanged bearing (Front pump drive quill)

CR&OP Data Module:
39-A-63-20-05-04A-311A-C Front pump

visual examination. See Para. 6.
Plug
Procedure P/N:
Do the detailed visual examination of the following Locking washer

components for corrosion, wear and damage: P/N:.......................................
The plug Inspection results:

......................................................................
The locking washer

7.22 - ECS compressor drive quill (main gearbox)
CR&OP Data Module:

quill (main gearbox) - Detailed visual examination
Safety conditions:
CAUTION
Procedure
Support equipment:

CR&OP Data Module:
39-A-63-20-05-05A-311A-C ECS
compressor drive quill (main gearbox) -
Pinion
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 1 Pinion (ECS compressor drive quill)

7.22.2 - Locking ring Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-05A-311A-C ECS
Locking ring
P/N:
Inspection results:
......................................................................
Fig. 2 Locking ring (ECS compressor drive quill)

7.22.3 - Case Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-05A-311A-C ECS
Case
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 3 Case (ECS compressor drive quill)

CR&OP Data Module:
39-A-63-20-05-05A-311A-C ECS
Flanged bearing
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 4 Flanged bearing (ECS compressor drive quill)

7.22.5 - Locking washer Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-05A-311A-C ECS
See Para.5.
Locking washer
P/N:
Inspection results:
......................................................................
Procedure
Do the detailed visual examination of the

locking washer for corrosion, wear and damage.

7.23 - Fan drive quill (main gearbox)
CR&OP Data Module:

Safety conditions:
CAUTION
Procedure
Support equipment:

CR&OP Data Module:
39-A-63-20-05-07A-311A-C Fan drive

quill (main gearbox) - Detailed visual
examination.
Pinion
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 1 Pinion (Fan drive quill)

CR&OP Data Module:
39-A-63-20-05-07A-311A-C Fan drive

examination.
Locking ring
P/N:
Inspection results:
......................................................................
Fig. 2 Locking ring (Fan drive quill)

CR&OP Data Module:
39-A-63-20-05-07A-311A-C Fan drive

examination.
Flanged bearing
P/N:
S/N:
Inspection results:
......................................................................
Fig. 3 Flanged bearing (Fan drive quill)

7.23.4 - Locking washer Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-07A-311A-C Fan drive

examination.
See Para.4.
Locking washer
P/N:
Inspection results:
......................................................................
Procedure


7.24 - Left/Right lubrication pump (main gearbox)
CR&OP Data Module:
39-A-63-20-05-06A-311A-C Left lubrication pump

39-A-63-20-05-24A-311A-C Right lubrication pump
Safety conditions:
CAUTION
Procedure
Support equipment:
Note:
The data to do a detailed visual examination of the left

lubrication pump is applicable also to the right
Magnifying glass, 10 times Local supply lubrication pump.
Refer to 39-A-63-20-05-24A-311A-C.

7.24.1 - Gear Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-06A-311A-C Left
lubrication pump (main gearbox) -
Left Gear
P/N:
S/N:
Right Gear
P/N:
S/N:
Inspection results:
......................................................................
Fig. 1 Gear (Left lubrication pump)

CR&OP Data Module:
39-A-63-20-05-06A-311A-C Left
Left Locking ring

P/N:
S/N:
Right Locking ring

P/N:
S/N:
Inspection results:
......................................................................
Fig. 2 Locking ring (Left lubrication pump)

7.24.3 -Locking washer Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-06A-311A-C Left
See Para. 3.
Left Locking washer

P/N:
Right Locking washer

P/N:
Inspection results:
......................................................................
Procedure


7.25 - Tail rotor drive quill (main gearbox)
CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor drive quill

Safety conditions:
CAUTION
Procedure
Support equipment:

7.25.1 - Rotor brake case Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor

visual examination.
See Para.1 and Figure 1
Rotor Brake Case

P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 1 case (Tail rotor drive quill)

CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor

visual examination.
Pinion
P/N:
S/N:.......................................
Inspection results:
......................................................................
T4
Fig. 2 Pinion (Tail rotor drive quill)

7.25.3 - Fan gear Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor

visual examination.
Fan gear
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 3 Fan gear (Tail rotor drive quill)

7.25.4 - Flange Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor

visual examination.
Flange
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 4 Flange (Tail rotor drive quill)

7.25.5 - Three locking rings Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor

visual examination.
Locking ring
P/N:
S/N:.......................................
Locking ring
P/N:
S/N:.......................................
Locking ring
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 5 Locking rings (Tail rotor drive quill)

7.25.6 - Roller bearing Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor

visual examination.
Roller bearing
P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 6 Roller bearing (Tail rotor drive quill)

7.25.7 - Flanged ball bearing Detailed visual examination
CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor

visual examination.
Flanged ball bearing

P/N:
S/N:.......................................
Inspection results:
......................................................................
Fig. 7 Flanged ball bearing (Tail rotor drive quill)

CR&OP Data Module:
39-A-63-20-05-28A-311A-C Tail rotor

visual examination. See Para. 8
Retaining ring (flange)
P/N:
Spacer (flange)
P/N:
Shim (case)
P/N:
Retaining ring (gear)
P/N:
Shim (gear)
P/N:
Nipple
P/N:
Retaining ring (roller bearing)
P/N:
Inspection results:
......................................................................
Procedure:
Check the components reported above for corrosion,

wear and damage.

7.26 - Dimensions check
Hereinafter are shown the CR&OP Data Modules required to perform the Dimensions check:
7.27) 39-A-63-20-05-00A-361A-C 7.33) 39-A-63-20-05-04A-361A-C

Main gearbox - Dimensions check Front pump drive quill (main gearbox) - Dimensions
check
7.28) 39-A-63-20-05-01A-361A-C
Left input shaft module (main gearbox) - 7.34) 39-A-63-20-05-05A-361A-C
Dimensions check ECS compressor drive quill (main gearbox) -
Dimensions check
7.28) 39-A-63-20-05-02A-361A-C
Right input shaft module (main gearbox) - 7.35) 39-A-63-20-05-07A-361A-C
Dimensions check Fan drive quill (main gearbox) - Dimensions check
7.29) 39-A-63-20-05-03A-361A-C 7.36) 39-A-63-20-05-24A-361A-C

Upper module (main gearbox) - Dimensions check Right lubrication pump (main gearbox) - Dimensions
check
7.30) 39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper module) - 7.36) 39-A-63-20-05-06A-361A-C
Dimensions check Left lubrication pump (main gearbox) - Dimensions
check
7.31) 39-A-63-20-05-14A-361A-C
Planetary gear (mast-planetary assembly) - 7.37) 39-A-63-20-05-28A-361A-C
Dimensions check Tail rotor drive quill (main gearbox) - Dimensions
check
7.32) 39-A-63-20-05-27A-361A-C
Left/right pump drive quill (main gearbox)
Dimensions check

7.27 - Main gearbox (Main case) Dimensions check
CR&OP Data Module:
39-A-63-20-05-00A-361A-C
Main gearbox - Dimensions check
Safety conditions:
CAUTION

7.27.1 - Collector gear Dimensions check
CR&OP Data Module:

(MGB A04) 39-A-63-20-05-00A-361A-C Main gearbox -
Dimensions check. See Para. 1 and Figure 1
Collector gear
P/N:
S/N:.
Inspection results:
........................................................................
(MGB A03)
Fig. 1 Collector gear (Main gearbox)

7.27.2 - Diaphragm Dimensions check
CR&OP Data Module:

Dimensions check.
Diaphragm
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 2 Diaphragm (Main gearbox)

7.27.3 - Housing of the collector-gear ball bearing
Dimensions check
CR&OP Data Module:

Dimensions check.
Housing of the collector-gear ball bearing,

Main Case
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 3 Housing of the collector gear ball bearing (Main gearbox)

7.27.4 - Collector-gear ball bearing
Dimensions check
CR&OP Data Module:

Dimensions check.
Collector-gear ball bearing

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 4 Collector gear ball bearing (Main gearbox)

7.27.5 - Collector-gear roller bearing
Dimensions check
CR&OP Data Module:

Dimensions check.
Collector-gear roller bearing

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 5 Collector gear roller bearing (Main gearbox)

7.27.6 Housing of the tail rotor drive quill
Dimensions check
CR&OP Data Module:

Dimensions check.
Housing of the tail rotor drive quill,

Main Case
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
178.030 / 7.0090
Fig. 6 Housing of the tail rotor drive quill (Main gearbox)

7.27.7 - Housing of the fan drive quill
Dimensions check
CR&OP Data Module:

Dimensions check.
Housing of the fan drive quill,

Main Case
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 7 Housing of the fan drive quill (Main gearbox)

7.27.8 - Sliding adaptor Dimensions check
CR&OP Data Module:

Dimensions check.
Sliding adaptor
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 8 Sliding adaptor (Main gearbox)

7.27.9 - Cross shafts (left and right input pinion shaft module)
Dimensions check
CR&OP Data Module:

Dimensions check.
Left Cross shaft

P/N:
S/N:.
Right Cross shaft

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 9 Cross shaft (left and right input pinion)

7.27.10 - Left and right input pinion (II stage) Dimensions check
CR&OP Data Module:

Dimensions check.
Left input pinion

P/N:
S/N:.
Right input pinion

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 10 Input pinion (left and right)

7.27.11 - Left and right pump gear Dimensions check
CR&OP Data Module:

Dimensions check.
Left pump gear

P/N:
S/N:.
Right pump gear

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 11 Pump gear (left and right Input pinion)

7.27.12 - Left and right bearing sleeve
Dimensions check
CR&OP Data Module:

Dimensions check.
Left bearing sleeve

P/N:
S/N:.
Right bearing sleeve

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 12 Bearing sleeve (left and right Input pinion)

7.27.13 - Housing of the left and right input pinion bearings (main
case) Dimensions check
CR&OP Data Module:

Dimensions check.
Housing of the left and right input pinion

bearings, Main case:
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 13 Housing of the left and right input pinion bearings

(main case)

7.27.14 - Triplex bearing (left and right input pinion)
Dimensions check
CR&OP Data Module:

Dimensions check.
Left triplex ball bearing

P/N:
S/N:.
Right triplex ball bearing

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 14 Ttriplex bearing (left and right input pinion)

7.27.15 - Roller bearing (left and right input pinion)
Dimensions check
CR&OP Data Module:

Dimensions check.
Left roller bearing

P/N:
S/N:.
Right roller bearing

P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 15 Roller bearing (left and right input pinion)

7.27.16 - Housing of the diaphragm Dimensions check
CR&OP Data Module:

Dimensions check.
Housing of the diaphragm, Main case:
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 16 Housing of the diaphragm (main case)

7.27.17 - Housing of the left and right pump drive quill
Dimensions check
CR&OP Data Module:

Dimensions check.
Housings of the left and right pump drive

quill, Main case:
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 17 Housings of the left and right pump drive quill

(Main case)

7.27.18 - Housing of the front pump drive quill
Dimensions check
CR&OP Data Module:

Dimensions check.
Housing of the front pump drive quill,

Main case:
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 18 Housing of the front pump drive quill

(Main case)

7.27.19 - Housing of the ECS drive quill
Dimensions check
CR&OP Data Module:

Dimensions check.
Housing of the ECS drive quill,

Main case:
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 19 Housing of the ECS drive quill

(Main case)

7.27.20 - Housings of the left and right lubrication pump
Dimensions check
CR&OP Data Module:

Dimensions check.
Housings of the left and right lubrication

pimp, Main case:
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 20 Housings of the left and right lubrication pump

(Main case)

7.27.21 - Housing of the servo actuators brackets
Dimensions check
CR&OP Data Module:

Dimensions check.
Housing of the servo actuators brackets,

Main case:
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 21 Housings of the servo actuators brackets

(Main case)

7.27.22 - Anti-torque beam Dimensions check
CR&OP Data Module:

Dimensions check.
Anti-torque beam
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Note:
If the internal diameter of one of the four bushings of the

anti-torque beam does not obey the permitted dimension
written in Fig 22, you must replace the bushing (or the
bushings). Refer to CR&OP 39-A-63-20-05-40A-921A-C.
(This task is not part of this course). Contact the
Manufacturer.
Fig. 22 Anti-torque beam

7.28 - Left and Right input shaft module (main gearbox) -
Dimensions check
CR&OP Data Module:
39-A-63-20-05-01A-361A-C
Dimensions check
39-A-63-20-05-02A-361A-C
Right input shaft module (main gearbox) -
Dimensions check
Safety conditions:
CAUTION
General note
The data to do a dimension check of the left-input shaft

module is applicable also to the right-input shaft module
(see CR&OP 39-A-63-20-05-02A-361A-C)

7.28.1 - Case assy Dimensions check
CR&OP Data Module:
39-A-63-20-05-01A-361A-C Left input shaft

module (main gearbox) - Dimensions check
LH Case Assy
P/N:
S/N:.
RH Case Assy
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 1 Case Assy (left input shaft module)

7.28.2 - Input Pinion Dimensions check
CR&OP Data Module:

(MGB A01) 39-A-63-20-05-01A-361A-C Left input shaft module (main
gearbox) - Dimensions check. See Para. 2 and Figure 2
(MGB A02) LH Pinion

P/N:
S/N:
RH Pinion
P/N:
S/N:
Inspection results:
....................................................
Fig. 2 Input pinion (left input shaft module)

7.28.3 - Gear, I stage of reduction
Dimensions check
CR&OP Data Module:

LH Gear
P/N:
S/N:.
RH Gear
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 3 Gear (left input shaft module)

7.28.4 - Input shaft Dimensions check
CR&OP Data Module:

LH Input shaft
P/N:
S/N:.
D
RH Input shaft
P/N:
S/N:.
D
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 4 Input shaft (left input shaft module)

7.28.5 - Diaphragm Dimensions check
CR&OP Data Module:

LH Diaphragm
P/N:
S/N:.
RH Diaphragm
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 5 Diaphragm (left input shaft module)

7.28.6 - Sleeve Dimensions check
CR&OP Data Module:

LH Sleeve
P/N:
S/N:.
RH Sleeve
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 6 Sleeve (left input shaft module)

7.28.7 - Flange Dimensions check
CR&OP Data Module:

LH Flange
P/N:
S/N:.
D
RH Flange
P/N:
S/N:.
D
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 7 Flange (left input shaft module)

7.28.8 Gimbal support Dimensions check
CR&OP Data Module:

LH Gimbal support
P/N:
S/N:.
RH Gimbal support
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 8 Gimbal support (left input shaft module)

7.28.9 - Inner bearing Dimensions check
CR&OP Data Module:

LH Inner bearing
P/N:
S/N:.
RH Inner bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 9 Inner bearing (left input shaft module)

7.28.10 - Outer bearing Dimensions check
CR&OP Data Module:

LH Outer bearing
P/N:
S/N:.
RH Outer bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 10 Outer bearing (left input shaft module)

7.28.11 - Ball bearing (gear, I stage of reduction)
Dimensions check
CR&OP Data Module:

LH Ball bearing
P/N:
S/N:.
RH Ball bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 11 Ball bearing (left input shaft module)

7.28.12 - Roller bearing (gear, I stage of reduction)
Dimensions check
CR&OP Data Module:

LH Roller bearing
P/N:
S/N:.
RH Roller bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Roller bearing OD
Fig. 12 Roller bearing (left input shaft module)

7.28.13 - Roller bearing (Input pinion) Dimensions check
CR&OP Data Module:

LH Roller bearing
P/N:
S/N:.
RH Roller bearing
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 13 Roller bearing (left input shaft module)

7.28.14 - Duplex ball bearing (Input pinion) Dimensions check
CR&OP Data Module:

(MGB A01)
39-A-63-20-05-01A-361A-C Left input shaft module (main
gearbox) - Dimensions check. See Para. 14 and Figure 14
LH Duplex ball bearing

(MGB A02)
P/N:
S/N:
RH Duplex ball bearing
P/N:
S/N:
Inspection results:
...............................................
Fig. 14 Duplex ball bearing (left input shaft module)

7.29 - Upper module (main gearbox)
Dimensions check
CR&OP Data Module:
39-A-63-20-05-03A-361A-C
Dimensions check
Safety conditions:
CAUTION

7.29.1 - Top Case Dimensions check
CR&OP Data Module:
39-A-63-20-05-03A-361A-C Upper module

(main gearbox) - Dimensions check
Top Case
P/N:
S/N:.
Inspection results:
........................................................................
........................................................................
........................................................................
Fig. 1 Top case (Upper module)

7.29.2 - Top-case strut attachments
Dimensions check
CR&OP Data Module:

Top-case strut attachment of the upper

fittings, Top case:
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 2 Top case strut attachments (Upper module)

7.29.3 - Ring gear Dimensions check
CR&OP Data Module:

Ring gear
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 3 Ring gear (Upper module)

7.29.4 - Roller bearing Dimensions check
CR&OP Data Module:

Roller bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 4 Roller bearing (Upper module)

7.29.5 - Four Upper Fittings Dimensions check
CR&OP Data Module:

Upper Fitting
P/N:
S/N:.
Upper Fitting
P/N:
S/N:.
Upper Fitting
P/N:
S/N:.
Upper Fitting
P/N:
S/N:.
Inspection results:
.................................................................
Note:
If required, replace the Spherical Bearing i.a.w.

CR&OP 39-A-63-20-05-00A-921A-C.
(This task is not part of this course). Contact the
Manufacturer.
Fig. 5 Upper Fitting (Upper module)

Dimensions check
CR&OP Data Module:
39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper
module) - Dimensions check
Safety conditions:
CAUTION

7.30.1 - Main rotor shaft (MAST) Dimensions check
CR&OP Data Module:
39-A-63-20-05-13A-361A-C
Mast-planetary assembly (upper module) -
Dimensions check
Main rotor shaft (mast)
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 1 Main rotor shaft (Mast planetary assembly)

7.30.2 - Spider plate Dimension check
CR&OP Data Module:
39-A-63-20-05-13A-361A-C
Dimensions check
Spider plate
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 2 Spider plate (Mast planetary assembly)

7.30.3 - Planetary pin Dimension check
CR&OP Data Module:
39-A-63-20-05-13A-361A-C
Dimensions check
Planetary Pin
P/N:
S/N:.
Planetary Pin
P/N:
S/N:.
Planetary Pin
P/N:
S/N:.
Planetary Pin
P/N:
S/N:.
Planetary Pin
P/N:
S/N:.
Inspection results:
Fig. 3 Planetary pin (Mast planetary assembly)
.........................................................................
.........................................................................
......................................................................
7.30.4 - Ball bearing Dimensions check
CR&OP Data Module:
39-A-63-20-05-13A-361A-C
Dimensions check
Ball bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 4 Ball bearing (Mast planetary assembly)

7.31 - Planetary gear (mastplanetary assembly) -
Dimensions check
CR&OP Data Module:
39-A-63-20-05-14A-361A-C
Planetary gear (mast-planetary
assembly) - Dimensions check
Safety conditions:
CAUTION

7.31.1 - Inner bearing race Dimensions check
CR&OP Data Module:
39-A-63-20-05-14A-361A-C
Planetary gear (mast-planetary assembly) -
Dimensions check
Inner bearing race,
part of the Planetary gear assy
P/N:
S/N:.
Inner bearing race,
P/N:
S/N:.
Inner bearing race,
P/N:
S/N:.
Inner bearing race,
P/N:
S/N:.
Inner bearing race,
P/N:
S/N:.
Inspection results:
Fig. 1 Planetary gear (Mast planetary assembly)
.........................................................................
.........................................................................
7.32 - Left/right hyd. pump drive quill (main gearbox)
Dimensions check
CR&OP Data Module:
39-A-63-20-05-27A-361A-C
Left/right pump drive quill (main
gearbox) - Dimensions check
Safety conditions:
CAUTION

7.32.1 - Pinion Dimensions check
CR&OP Data Module:
39-A-63-20-05-27A-361A-C Left/right pump

drive quill (main gearbox) - Dimensions
check
Left pinion
P/N:
S/N:.
Right pinion
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 1 Pinion (left/right pump drive quill)

7.32.2 - Pump case Dimensions check
CR&OP Data Module:

check
Left pump case

P/N:
S/N:.
Right pump case

P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 2 Pump case (left/right pump drive quill)

7.32.3 - Flanged bearing Dimensions check
CR&OP Data Module:

check
Left Flanged bearing

P/N:
S/N:.
Right Flanged bearing

P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 3 Flanged bearing (left/right pump drive quill)

Dimensions check
CR&OP Data Module:
39-A-63-20-05-04A-361A-C
Front pump drive quill (main
Safety conditions:
CAUTION

CR&OP Data Module:

quill (main gearbox) - Dimensions check
Pinion
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 1 Pinion (Front pump drive quill)

7.33.2 - Pump Case Dimensions check
CR&OP Data Module:

Pump Case
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 2 Pump Case (Front pump drive quill)

CR&OP Data Module:

Flanged bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 3 Flanged bearing (Front pump drive quill)

Dimensions check
CR&OP Data Module:
39-A-63-20-05-05A-361A-C
ECS compressor drive quill (main
Safety conditions:
CAUTION

CR&OP Data Module:
39-A-63-20-05-05A-361A-C
ECS compressor drive quill (main gearbox) -
Dimensions check.
Pinion
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 1 Pinion (ECS compressor drive quill)

7.34.2 - Case Dimensions check
CR&OP Data Module:
39-A-63-20-05-05A-361A-C
Dimensions check.
Case
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 2 Case (ECS compressor drive quill)

CR&OP Data Module:
39-A-63-20-05-05A-361A-C
Dimensions check.
Flanged bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 3 Flanged bearing (ECS compressor drive quill)

7.35 - Fan drive quill (main gearbox)
Dimensions check
CR&OP Data Module:
39-A-63-20-05-07A-361A-C
Fan drive quill (main gearbox) -
Dimensions check
Safety conditions:
CAUTION

CR&OP Data Module:
39-A-63-20-05-07A-361A-C
Fan drive quill (main gearbox) - Dimensions
check.
Pinion
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 1 Pinion (Fan drive quill)

CR&OP Data Module:
39-A-63-20-05-07A-361A-C
Fan drive quill (main gearbox) - Dimensions
check.
Flanged bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 2 Flanged bearing (Fan drive quill)

7.36 - Left /Right lubrication pump (main gearbox)
Dimensions check
CR&OP Data Module:
39-A-63-20-05-06A-361A-C
Left lubrication pump (main
39-A-63-20-05-24A-361A-C
Right lubrication pump (main
Safety conditions:
CAUTION
Note:
The data to do the dimensions check of the left

lubrication pump is applicable also to the right lubrication
pump. See 39-A-63-20-05-24A-361A-C.

7.36.1 - Gear Dimensions check
CR&OP Data Module:
39-A-63-20-05-06A-361A-C
Left lubrication pump (main gearbox) -
Dimensions check.
Left Gear
P/N:
S/N:.
Right Gear
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 1 Gear (Left Lubrication Pump)

7.36.2 - Pump shaft Dimensions check
CR&OP Data Module:
39-A-63-20-05-06A-361A-C
Dimensions check.
Left Pump
P/N:
S/N:.
Right Pump
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 2 Pump shaft (Left Lubrication Pump)

7.37 - Tail rotor drive quill (main gearbox) Dimensions check
CR&OP Data Module:
39-A-63-20-05-28A-361A-C
Tail rotor drive quill (main gearbox) -
Dimensions check
Safety conditions:
CAUTION

7.37.1 - Pinion Dimensions check (sheet 1 of 2)
CR&OP Data Module:
39-A-63-20-05-28A-361A-C Tail rotor drive

Pinion (for MGB P/N 3G6320A00132)

P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 1 Pinion (Tail rotor drive quill) Sheet 1 of 2

7.37.1 - Pinion Dimensions check (sheet 2 of 2)
CR&OP Data Module:

Pinion
(for MGB P/N 3G6320A00133 and

subsequent P/N with different two last
digits)
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 1 Pinion (Tail rotor drive quill) Sheet 2 of 2

7.37.2 - Fan gear Dimensions check
CR&OP Data Module:

Fan gear
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 2 Fan gear (Tail rotor drive quill)

7.37.3 - Flange Dimensions check
CR&OP Data Module:

Flange
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 3 Flange (Tail rotor drive quill)

7.37.4 - Rotor brake case Dimensions check
CR&OP Data Module:

Rotor brake case
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 4 Rotor brake case (Tail rotor drive quill)

CR&OP Data Module:

Flanged bearing
P/N:
S/N:.
Inspection results:
.........................................................................
.........................................................................
......................................................................
Fig. 5 Flanged bearing (Tail rotor drive quill)

7.37.6 - Roller bearing Dimensions check (sheet 1 of 2)
CR&OP Data Module:

Roller bearing (for MGB P/N 3G6320A00132)
P/N:
S/N:.
Inspection results:
..................................................................................
..................................................................................
....................................................
Fig. 6 Roller bearing (Tail rotor drive quill) sheet 1 of 2

7.37.6 - Roller bearing Dimensions check (sheet 2 of 2)
CR&OP Data Module:

Roller bearing
(for MGB P/N 3G6320A00133 and subsequent

P/N with different two last digits)
P/N:
S/N:.
Inspection results:
..................................................................................
..................................................................................
....................................................
Fig. 6 Roller bearing (Tail rotor drive quill) sheet 2 of 2

7.38 - Dye penetrant Examination
Hereinafter are shown the CR&OP Data Modules required to perform the
dye penetrant examination on the MGB components:
7.39) 39-A-60-20-01-00A-351A-C 7.43) 39-A-63-20-05-04A-351A-C

Disassembled metal components Front pump drive quill (main gearbox)
Tests for surface cracks with dye penetrant Tests for surface cracks with dye penetrant
(General guidelines for Dye Penetrant Examination)
7.44) 39-A-63-20-05-05A-351A-C
7.40) 39-A-63-20-05-00A-351A-C ECS compressor drive quill (main gearbox)
Main gearbox Tests for surface cracks with dye penetrant
Tests for surface cracks with dye penetrant
7.45) 39-A-63-20-05-27A-351A-C
7.41) 39-A-63-20-05-01A-351A-C Left/right pump drive quill (main gearbox)
Left input shaft module (main gearbox) Tests for surface cracks with dye penetrant
7.46) 39-A-63-20-05-28A-351A-C
7.41) 39-A-63-20-05-02A-351A-C Tail rotor drive quill (main gearbox)
Right input shaft module (main gearbox) Tests for surface cracks with dye penetrant
7.42) 39-A-63-20-05-03A-351A-C
Upper module (main gearbox)

CR&OP Data Module:
39-A-60-20-01-00A-351A-C
Disassembled metal components - Tests for surface cracks
with dye penetrant
Safety conditions:
WARNINGS
You must be careful when you do the penetrant inspection. Make sure you know the safety precaution given in standard practices for
liquid penetrant examination (ASTM-E1417).
Wear protective goggles when you use the compressed air. Dust and particles can cause injury to your eyes.
CAUTION
Only approved personnel are permitted to do this procedure.
Procedure
1 ) Unpainted component. Clean the component. Refer to CR&OP 39-A-60-10-01-00A-251A-C.
2) Painted component. Remove the paint finish from the component as applicable, refer to: CR&OP: 39-A-60-10-01-00A-651A-C or to -
659A-C or to -659B-C as necessary.
3) Do a penetrant inspection of the component to find cracks. Obey the standard practices for liquid penetrant examination (ASTM-
E1417).
Note
Refer to QPL-AMS-2644-1 for a list of the qualified products for the liquid penetrant examination.
NDT Type
Type I, Method D, Sensitivity Level 2 or Level 3 penetrant (refer to the data module of the applicable component).

7.40 - Main gearbox Tests for surface cracks with dye penetrant
CR&OP Data Module:
39-A-63-20-05-00A-351A-C
Main gearbox - Tests for surface cracks with
dye penetrant
Procedure
To do the test of metal components for surface

cracks with dye penetrant.
Refer to CR&OP: 39-A-60-20-01-00A-351A-C for

general guideline.

7.40.1 - Main case, Bottom cover, Anti-torque beam, Diaphragm
CR&OP Data Module:
Diaphragm
39-A-63-20-05-00A-351A-C
dye penetrant. See form Para. 1 to Para. 4
and Figure 1 (sheet 1 of 4)
1) Main case
P/N:
S/N:.
2) Bottom cover
Main Case P/N:
S/N:.
3) Anti-torque beam
P/N:
S/N:.
Bottom
4) Diaphragm
Cover
P/N:
S/N:.
Dye Penetrant Classification :

Anti-torque
beam
Type I (Fluorescent dye), Method D (methods of
excess penetrant removal), Level 2 (Sensitivity
level: Medium).
Fig. 1 Main gearbox (sheet 1 of 4) Inspection results: ..................................

7.40.2 - Seal cover of the Fan & ECS compressor drive quills
CR&OP Data Module:
39-A-63-20-05-00A-351A-C
dye penetrant. See Paragraphs 5,6 and
Figure 1 (sheet 2 of 4)
5) Seal cover of the Fan drive quill
Seal cover P/N:

(Fan drive quill) S/N:.
Seal cover 6) Seal cover of the ECS compressor

(ECS compressor) drive quill
P/N:
S/N:.

level: Medium).
Inspection results: ..................................
Fig. 1 Main gearbox (sheet 2 of 4)

7.40.3 - Servo-actuator brackets - Tests for surface cracks with dye
penetrant
CR&OP Data Module:
39-A-63-20-05-00A-351A-C
dye penetrant. See Para. 7 and Figure 1
(sheet 3 of 4)
7) Front servo-actuator Bracket (A)
P/N:
S/N:.
8) Left servo-actuator Bracket (B)

P/N:
S/N:.
Servo-actuators 9) Right servo-actuator Bracket (C)
Brackets P/N:
S/N:.

level: High).

7.40.4 - Left and Right input pinions locking rings, collector-gear
locking ring - Tests for surface cracks with dye penetrant
CR&OP Data Module:
39-A-63-20-05-00A-351A-C
dye penetrant. See Para. 8 and Figure 1
(sheet 4 of 4)
10) Left ring nut
P/N:
S/N:.
10) Right ring nut

P/N:
S/N:.
11) Collector-gear locking ring

P/N:
S/N:.
Type I (Fluorescent dye), Method D

(methods of excess penetrant removal),
Collector-gear Level 3 (Sensitivity level: High).
Locking ring Ring nut

7.41 - Left and right input shaft module (main gearbox)
CR&OP Data Module:

module (main gearbox) - Tests for surface
cracks with dye penetrant
39-A-63-20-05-02A-351A-C Right input shaft

module (main gearbox) - Tests for surface
cracks with dye penetrant
Procedure

general guideline.
Nota
The data to do a test for surface cracks with dye

penetrant of the left-input shaft module are
applicable also to the right-input shaft module (see
CR&OP 39-A-63-20-05-02A-351A-C).

7.41.1 - Case assy, Oil jet cover, Diaphragm
Diaphragm CR&OP Data Module:

Case Assy 39-A-63-20-05-01A-351A-C
See Paragraphs 1, 2, 3 and Figure 1
1) LH Case Assy
P/N:
Oil Jet Cover S/N:.
1) RH Case Assy
P/N:
S/N:.
2) LH Oil jet cover

P/N:
S/N:.
2) RH Oil jet cover

P/N:
Fig. 1 left input shaft module (MGB)
S/N:.
3) LH Diaphragm
P/N:
Dye Penetrant Classification : S/N:.
3) RH Diaphragm
Type I (Fluorescent dye), Method D P/N:
(methods of excess penetrant removal), S/N:.
Level 2 (Sensitivity level: Medium),
Time: 30.

7.42 - Upper module (main gearbox)
CR&OP Data Module:
39-A-63-20-05-03A-351A-C
Upper module (main gearbox) - Tests for
surface cracks with dye penetrant
Procedure

general guideline.

7.42.1 - Top case, Cooler adapter and Seal cover -
CR&OP Data Module:
39-A-63-20-05-03A-351A-C
Seal cover surface cracks with dye penetrant.
See Para. 1, 2, 4 and Figure 1 (sheet 1 of 2)
1) Top Case
P/N:
S/N:.
2) Cooler adapter
P/N:
S/N:.
3) Seal cover
P/N:
S/N:.
Top case

Cooler adapter Level 2 (Sensitivity level: Medium).
Fig. 1 Upper module (MGB) sheet 1 of 2

7.42.2 - Four Upper Fittings -
CR&OP Data Module:
39-A-63-20-05-03A-351A-C
surface cracks with dye penetrant.
See Para. 3 and Figure 1 (sheet 2 of 2)
Upper Fitting (A)
P/N:
S/N:.
Upper Fitting (B)

P/N:
S/N:.
Upper Fitting (C)

P/N:
S/N:.
Upper Fitting (D)

Upper Fitting
P/N:
S/N:.

Level 3 (Sensitivity level: High).
Fig. 1 Upper module (MGB) sheet 2 of 2

CR&OP Data Module:
39-A-63-20-05-04A-351A-C
Front pump drive quill (main gearbox) - Tests
for surface cracks with dye penetrant
Procedure

general guideline.

7.43.1 - Pump Case, Seal Cover
CR&OP Data Module:
39-A-63-20-05-04A-351A-C
for surface cracks with dye penetrant.
See Para. 1 and 2, Figure 1
Pump Case
P/N:
S/N:.
Seal Cover
P/N:
S/N:.
Pump case Dye Penetrant Classification :
Seal Cover Type I (Fluorescent dye), Method D

Level 2 (Sensitivity level: Medium).
Fig. 1 Front pump drive quill (MGB)

CR&OP Data Module:
39-A-63-20-05-05A-351A-C
Procedure

general guideline.

7.44.1 - Case - Tests for surface cracks with dye penetrant
CR&OP Data Module:
39-A-63-20-05-05A-351A-C
Case
P/N:
S/N:.

Case Inspection results: ..................................
Fig. 1 ECS compressor drive quill (MGB)

7.45 - Left/right hyd. pump drive quill (main gearbox)
CR&OP Data Module:
39-A-63-20-05-27A-351A-C
Left/right pump drive quill (main gearbox) -
Procedure

general guideline.

7.45. 1 - Pump Case and Seal Cover
CR&OP Data Module:
39-A-63-20-05-27A-351A-C
Tests for surface cracks with dye penetrant.
See Para. 1 and 2, Figure 1
Left Pump Case
P/N:
S/N:.
Left Seal Cover
P/N:
S/N:.
Right Pump Case

P/N:
S/N:.
Right Seal Cover
Pump Case P/N:
S/N:.
Seal Cover Dye Penetrant Classification :

Fig. 1 Left/right pump drive quill (MGB) Inspection results: ..................................

7.46 - Tail rotor drive quill (main gearbox)
CR&OP Data Module:
39-A-63-20-05-28A-351A-C
Tail rotor drive quill (main gearbox) - Tests
for surface cracks with dye penetrant
Procedure

general guideline.

7.46.1 - Rotor brake case, Seal case and Locking rings
Locking ring CR&OP Data Module:

Rotor brake
Case 39-A-63-20-05-28A-351A-C
Seal Case
Tail rotor drive quill (main gearbox)
Tests for surface cracks with dye penetrant.
See from Para. 1 to Para. 5, Figure 1
3) Rotor brake Case
P/N:
S/N:.
Locking ring
2) Seal Case
P/N:
Locking ring S/N:.
1) Locking ring
P/N:
S/N:.
4) Locking ring
P/N:
S/N:.
5) Locking ring (*)

P/N:
S/N:.

Fig. 1 Tail rotor drive quill (MGB) Type I (Fluorescent dye), Method D
Level 2 (items 2, 3) Level 3 (items 1, 4, 5).

7.47 - Magnetic particles examination
Hereinafter are shown the CR&OP Data Modules required to perform the Magnetic particles examination :
7.48) 39-A-60-20-01-00A-352A-C 7.54) 39-A-63-20-05-06A-352A-C
Disassembled metal components Left lubrication pump (main gearbox)
Tests for surface cracks with magnetic particles Tests for surface cracks with magnetic particles
(General guidelines for Magnetic Particles Examination)
7.54) 39-A-63-20-05-24A-352A-C
7.49) 39-A-63-20-05-00A-352A-C Right lubrication pump (main gearbox)
Main gearbox for surface cracks with magnetic particles
Tests for surface cracks with magnetic particles
7.55) 39-A-63-20-05-07A-352A-C
7.50) 39-A-63-20-05-01A-352A-C Fan drive quill (main gearbox)
Left input shaft module (main gearbox) Tests for surface cracks with magnetic particles
7.56) 39-A-63-20-05-13A-352A-C
7.50) 39-A-63-20-05-02A-352A-C Mast-planetary assembly (upper module)
Right input shaft module (main gearbox) Tests for surface cracks with magnetic particles
7.57) 39-A-63-20-05-14A-352A-C
7.51) 39-A-63-20-05-03A-352A-C Planetary gear assembly (upper module)
Upper module (main gearbox) Tests for surface cracks with magnetic particles
7.58) 39-A-63-20-05-27A-352A-C
7.52) 39-A-63-20-05-04A-352A-C Left/right hyd. pump drive quill (main gearbox)
Front hyd. pump drive quill (main gearbox) Tests for surface cracks with magnetic particles
7.59) 39-A-63-20-05-28A-352A-C
7.53) 39-A-63-20-05-05A-352A-C Tail rotor drive quill (main gearbox)
ECS compressor drive quill (main gearbox) Tests for surface cracks with magnetic particles
CR&OP Data Module:
39-A-60-20-01-00A-352A-C
Disassembled metal components - Tests for surface cracks
with magnetic particles
Safety conditions:
WARNING
You must be careful when you do the magnetic particle inspection. Make sure you know the safety precaution given in standard practices
for magnetic particle inspection (ASTM-E1444).
CAUTION
Only approved personnel are permitted to do this procedure.
Procedure
1) Unpainted component. Clean the component. Refer to CR&OP 39-A-60-10-01-00A-251A-C.
2) Painted component. Remove the paint finish from the component. Refer to 39-A-60-10-01-00A-252A-C (this Data Module is in
preparation).
3) Do a magnetic particle inspection of the component to find cracks. Obey the standard practices for magnetic particle inspection
(ASTM-E1444).
4) Use the products that follow (or approved alternatives):
Particles Ardrox 8515 or Magnaflux Magnaglo 14A

Liquid carrier Ardrox Fluxal.
5) Clean the component. Refer to Step 1.
6) Put the component in an applicable container. Make sure the component has sufficient protection against environmental condition.

7.49 - Main gearbox (Main case) Magnetic Particles Test
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Procedure

cracks with magnetic particles.
Refer to CR&OP 39-A-60-20-01-00A-352A-C for

general guideline.

7.49.1 - MGB (Main case) components involved for the Magnetic
Particles Test
The components involved are:
CR&OP Data Module:
1) Collector gear
P/N:
39-A-63-20-05-00A-352A-C S/N:.
2) Sliding Adapter
magnetic particles. Refer to Figure 1 P/N:
S/N:.
3) Collector gear Locking ring

P/N:
S/N:.
4) LH and RH Input Pinions (II stage)

P/N:
S/N:.
5) LH and RH Cross Shafts

P/N:
S/N:
6) LH and RH input pinions Locking

Rings
P/N:
S/N:
7) LH and RH Pump gears

P/N:.
S/N:
8) and 9) LH and RH Retaining Rings

P/N:.
S/N:
10) LH and RH Pinion Bearing Sleeves

P/N:
S/N:
Fig. 1 Main gearbox Components for magnetic particles test

7.49.2 - Collector gear Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Refer to Para.1 and to Figure 2
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 2 Collector gear Magnetic Particles Test Procedure

7.49.3 - Left and right Input pinions
Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 Input Pinion Magnetic Particles Test Procedure

7.49.4 - Left and right Pump Gears
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 4 Pump gear Magnetic Particles Test Procedure

7.49.5 - Sliding Adapter - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 5 Sliding Adapter Magnetic Particles Test Procedure

7.49.6 - Left and right input Pinions Bearing Sleeves
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 6 Input Pinion Bearing Sleeve Magnetic Particles Test Procedure

7.49.7 - Left and right input pinions Locking Rings
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 7 Input Pinion Locking ring Magnetic Particles Test Procedure

7.49.8 - Collector gear Locking Ring
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Refer to Para. 7 and to Figure 8
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 8 Collector gear Locking ring Magnetic Particles Test Procedure

7.49.9 - Left and right Cross Shafts
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 9 Cross shaft Magnetic Particles Test Procedure

7.49.10 - Left and right Retaining Rings (8) and (9)
CR&OP Data Module:
39-A-63-20-05-00A-352A-C
magnetic particles
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Item 9 Item 8
Fig. 10 Retaining rings Magnetic Particles Test Procedure

7.50 - Left and right Input Shaft Module (main gearbox)
Magnetic Particles Test
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) - Tests for surface cracks
39-A-63-20-05-02A-352A-C
Right input shaft module (main gearbox) - Tests for surface cracks
Procedure


general guideline.
General Note
The data to do a test for surface cracks with magnetic particles of the left-input shaft
module are applicable also to the right-input shaft module.
See CR&OP 39-A-63-20-05-02A-352A-C.

7.50.1 - Input Shaft Module Components involved for the Magnetic
Particles Test
CR&OP Data Module:

39-A-63-20-05-01A-352A-C
Left input shaft module (main gearbox) - 1) LH and RH Gimbal
P/N:
Tests for surface cracks with magnetic S/N:.
particles. Refer to Figure 1
2) LH and RH Flange
P/N:
S/N:.
3) LH and RH Pinion Locking Ring

P/N:
S/N:.
4) LH and RH Gear Locking Ring

P/N:
S/N:.
5) LH and RH Input Shaft

P/N:
S/N:
6) LH and RH Input Pinion

P/N:
S/N:
7) LH and RH Sleeve
P/N:.
S/N:
8) LH and RH Gear (I stage)

P/N:.
S/N:
Fig. 1 Input Shaft Module Components for magnetic particles test

7.50.2 - Gimbal - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Tests for surface cracks with magnetic
particles. Refer to Para. 1 and Figure 2
Inspection results:
...............................................................................
...............................................................................
TBD ...............................................................................
Fig. 2 Gimbal Magnetic Particles Test Procedure

7.50.3 - Input Pinion - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 Pinion Magnetic Particles Test Procedure

7.50.4 - Gear (I stage of reduction)
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 4 Gear Magnetic Particles Test Procedure

7.50.5 - Input shaft - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 5 Input Shaft Magnetic Particles Test Procedure

7.50.6 - Sleeve - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 6 Sleeve Magnetic Particles Test Procedure

7.50.7 - Flange - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 7 Flange Magnetic Particles Test Procedure

7.50.8 - Gear Locking ring - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 8 - Gear locking ring Magnetic Particles Test Procedure

7.50.9 - Pinion locking ring - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-01A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 9 - Pinion locking ring Magnetic Particles Test Procedure

7.51 - Upper Module (main gearbox) - Magnetic Particles Test
CR&OP Data Module:
39-A-63-20-05-03A-352A-C
Upper module (main gearbox) Tests for
surface cracks with magnetic particles
Procedure


general guideline.

7.51.1 - Upper module (main gearbox) Components involved for
the Magnetic Particles Test
CR&OP Data Module:

39-A-63-20-05-03A-352A-C
Upper module (main gearbox) Tests for 1) Ring gear
P/N:
surface cracks with magnetic particles. Refer S/N:.
to Figure 1
2) Locking ring
P/N:
S/N:.
Fig. 1 Upper Module Components for magnetic particles test

7.51.2 - Ring gear - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-03A-352A-C
surface cracks with magnetic particles.
Refer to Para. 1 and to Figure 2.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 2 Ring gear Magnetic Particles Test Procedure

7.51.3 - Locking ring - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-03A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 Locking ring Magnetic Particles Test Procedure

CR&OP Data Module:
39-A-63-20-05-04A-352A-C
for surface cracks with magnetic particles
Procedure


general guideline.

7.52.1 - Front pump drive quill (main gearbox) Components
involved for the Magnetic Particles Test
CR&OP Data Module:

39-A-63-20-05-04A-352A-C
Front pump drive quill (main gearbox) - Tests 1) Pinion
P/N:
for surface cracks with magnetic particles. S/N:.
Refer to Figure 1.
2) Locking ring
P/N:
S/N:.
Fig. 1 Front pump drive quill (main gearbox) Components for magnetic particles test

7.52.2 - Pinion - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-04A-352A-C
Front pump drive quill (main gearbox) -
particles. Refer to Para. 1 and to Figure 2.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 2 Pinion - Magnetic Particles Test Procedure

CR&OP Data Module:
39-A-63-20-05-04A-352A-C
Front pump drive quill (main gearbox) -
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 Locking ring - Magnetic Particles Test Procedure

CR&OP Data Module:
39-A-63-20-05-05A-352A-C
particles
Procedure


general guideline.

7.53.1 - ECS compressor drive quill (main gearbox) Components
CR&OP Data Module:

39-A-63-20-05-05A-352A-C ECS compressor
drive quill (main gearbox) - Tests for surface 1) Pinion
P/N:
cracks with magnetic particles. S/N:.
Refer to Figure 1.
2) Locking ring
P/N:
S/N:.
Fig. 1 ECS Compressor drive quill (main gearbox) Components for magnetic particles test

CR&OP Data Module:
39-A-63-20-05-05A-352A-C
ECS compressor drive quill (main gearbox)
- Tests for surface cracks with magnetic
Inspection results:
...............................................................................
...............................................................................
...............................................................................

7.53.3 - Locking ring
CR&OP Data Module:
39-A-63-20-05-05A-352A-C
ECS compressor drive quill (main gearbox)
Inspection results:
...............................................................................
...............................................................................
...............................................................................

7.54 - Left and Right Lubrication Pump - Magnetic Particles Test
CR&OP Data Module:
39-A-63-20-05-06A-352A-C
Left lubrication pump (main gearbox) - Tests for surface cracks with
magnetic particles
39-A-63-20-05-24A-352A-C
Right lubrication pump (main gearbox) - Tests for surface cracks
Procedure


general guideline.
General Note
The tests for surface cracks with magnetic particles given for the right lubrication
pump are applicable to the left lubrication pump.
See CR&OP 39-A-63-20-05-24A-352A-C.

7.54.1 - Lubrication pump (main gearbox) components involved for
the Magnetic Particles Test
CR&OP Data Module:

39-A-63-20-05-06A-352A-C Left lubrication
pump (main gearbox) - Tests for surface 1) Gear
P/N:
cracks with magnetic particles. S/N:.
Refer to Figure 1.
2) Locking ring
P/N:
S/N:.
Fig. 1 Left lubrication pump (main gearbox) Components for magnetic particles test

7.54.2 - Gear - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-06A-352A-C
particles.
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 2 Gear - Magnetic Particles Test Procedure

CR&OP Data Module:
39-A-63-20-05-06A-352A-C
particles.
Inspection results:
...............................................................................
...............................................................................
...............................................................................

7.55 - Fan drive quill (main gearbox) Magnetic Particles Test
CR&OP Data Module:
39-A-63-20-05-07A-352A-C
Fan drive quill (main gearbox) - Tests for
surface cracks with magnetic particles
Procedure


general guideline.

7.55.1 - Fan drive quill (main gearbox) components involved for the
CR&OP Data Module:

39-A-63-20-05-07A-352A-C Fan drive quill
(main gearbox) - Tests for surface cracks with 1) Pinion
P/N:
magnetic particles. S/N:.
Refer to Figure 1.
2) Locking ring
P/N:
S/N:.
Fig. 1 Fan drive quill (main gearbox) Components for magnetic particles test

CR&OP Data Module:
39-A-63-20-05-07A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................

CR&OP Data Module:
39-A-63-20-05-07A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................

CR&OP Data Module:
39-A-63-20-05-13A-352A-C
particles
Procedure


general guideline.

7.56.1 - Mast-planetary assembly (upper module) components
CR&OP Data Module:

39-A-63-20-05-13A-352A-C
Mast-planetary assembly (upper module) - 1) Main Rotor Shaft (Mast)
P/N:
particles. Refer to Figure 1.
2) Planetary Gear Spacers (5 items)
P/N:
3) Spider Plate
P/N:
S/N:.
4) Planetary Pins (5 items)

P/N:
S/N:.
5) Spider Plate Spacers (5 items)

P/N:
S/N:.
6) Ring Nuts (5 items)

P/N:
S/N:.
Fig. 1 Mast Planetary assembly Components for magnetic particles test

7.56.2 - Main Rotor Shaft (Mast)
CR&OP Data Module:
39-A-63-20-05-13A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 2 Main Rotor Shaft - Magnetic Particles Test Procedure

7.56.3 - Spider Plate - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-13A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 - Spider Plate - Magnetic Particles Test Procedure

7.56.4 - Planetary Pins (five items)
CR&OP Data Module:
39-A-63-20-05-13A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 4 Planetary Pins - Magnetic Particles Test Procedure

7.56.5 - Ring Nuts (five items)
CR&OP Data Module:
39-A-63-20-05-13A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 5 Ring Nuts - Magnetic Particles Test Procedure

7.56.6 - Spider plate spacers (five items)
CR&OP Data Module:
39-A-63-20-05-13A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 6 Spider plate spacer - Magnetic Particles Test Procedure

7.56.7 - Planetary gear spacers (five items)
CR&OP Data Module:
39-A-63-20-05-13A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 7 Planetary gear spacer - Magnetic Particles Test Procedure

7.57 - Planetary gear assembly (upper module)
CR&OP Data Module:
39-A-63-20-05-14A-352A-C
Planetary gear assembly (upper module) -
particles
Procedure


general guideline.

7.57.1 - Planetary gear assembly (upper module) components
CR&OP Data Module:

39-A-63-20-05-14A-352A-C
Tests for surface cracks with magnetic Planetary Gear Assy (5 items)
particles. Refer to Figure 1. P/N:
S/N:.
1) Gear
2) Inner Bearing Race
Fig. 1 Planetary gear assembly Components for magnetic particles test

7.57.2 - Gear - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-14A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 2 Gear (planetary gear assembly) - Magnetic Particles Test Procedure

7.57.3 - Inner bearing race - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-14A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 Inner Bearing Race (planetary gear assembly) - Magnetic Particles Test
Procedure

7.58 - Left/Right hyd. pump drive quill (main gearbox)
CR&OP Data Module:
39-A-63-20-05-27A-352A-C
particles
Procedure


general guideline.

7.58.1 - Left/right pump drive quill (main gearbox) components
CR&OP Data Module:

39-A-63-20-05-27A-352A-C
Left/right pump drive quill (main gearbox) - 1) Pinion (LH & RH)
P/N:
particles. Refer to Figure 1.
2) Locking ring (LH & RH)
P/N:
Fig. 1 Left/right pump drive quill Components for magnetic particles test

CR&OP Data Module:
39-A-63-20-05-27A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 2 Pinion (Left/right pump drive quill) - Magnetic Particles Test

Procedure

CR&OP Data Module:
39-A-63-20-05-27A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 Locking ring (Left/right pump drive quill) - Magnetic Particles Test
Procedure

7.59 - Tail rotor drive quill (main gearbox) Magnetic Particles Test
CR&OP Data Module:
39-A-63-20-05-28A-352A-C
for surface cracks with magnetic particles
Procedure


general guideline.

7.59.1 - Tail rotor drive quill (main gearbox) components involved
for the Magnetic Particles Test
CR&OP Data Module:
39-A-63-20-05-28A-352A-C
for surface cracks with magnetic particles.
Refer to Figure 1.

1) Flange
P/N:
S/N:.
2) Locking Ring
P/N:
S/N:.
3) Fan gear
P/N:
S/N:.
4) Locking ring
P/N:
S/N:.
5) and 6) Pinion
P/N:
S/N:.
Fig. 1 Tail rotor drive quill Components for magnetic particles test

7.59.2 - Pinion (Main gearbox P/N 3G6320A00132) -
CR&OP Data Module:
39-A-63-20-05-28A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 2 Pinion (Tail rotor drive quill) - Magnetic Particles Test Procedure

7.59.3 - Pinion (Main gearboxes P/N 3G6320A00133 and subsequent P/N
with different two last digits) - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-28A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 7 Pinion (Tail rotor drive quill) - Magnetic Particles Test Procedure

7.59.4 - Fan gear - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-28A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 3 Fan gear (Tail rotor drive quill) - Magnetic Particles Test Procedure

7.59.5 - Flange - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-28A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 4 Flange (Tail rotor drive quill) - Magnetic Particles Test Procedure

7.59.6 - Locking ring (Main gearbox P/N 3G6320A00132) -
CR&OP Data Module:
39-A-63-20-05-28A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 5 locking ring (Tail rotor drive quill) - Magnetic Particles Test
Procedure

7.59.7- Locking ring - Magnetic Particles Test Procedure
CR&OP Data Module:
39-A-63-20-05-28A-352A-C
Inspection results:
...............................................................................
...............................................................................
...............................................................................
Fig. 6 locking ring (Tail rotor drive quill) - Magnetic Particles Test
Procedure

Chapter 7 Components Cleaning, Paint removal, Protection and Inspection
THE END

TECHNICIAN TRAINING
Chapter 8 - Assembly
Procedures
8 Assembly Procedure
INDEX

8.2.2 Upper Module, Assembly procedures
(Conts)

During this phase there are conditions and actions that must be carried out i.a.w. the current issue of the
IETP, these are:
1. Refer to CR&OP : 39-A-63-20-05-00A-714A-C (Main gearbox - General guidelines for assemble procedures).
2. Make sure that the work area is cleaned.
3. Before assembly, clean all parts.
4. At assembly, use new parts (bolts, screws, nuts, lips seals, etc.......) as required
5. Select the spare parts from the Illustrated Parts Data (39-A-ZG-W5-01-010-941A-C).
6. Before assembly, apply the surface finish protection on the external surfaces of the components as required.
7. During assembly phase Lubricate the packings with Grease (C115), lip seals with Grease (C147) and Lubricate the
fasteners and the matching surfaces (where required) with the Oil (C006).
Supplies
Solvent, cleaning C010 P-D-680 type II (AMDI) 39-A-00-50-00-09A-078A-D

Grease C115 Parker super O-lube. (AMDI) 39-A-00-50-00-08A-078B-D
Grease (NS-3913-G1) C147 None (AMDI) 39-A-00-50-00-13B-078A-D
Oil C006 MIL-PRF-7808L (AMDI) 39-A-00-50-00-05A-078A-D

During the MGB assembly procedure perform the following actions:
Record and identify the P/N and the S/N of all Components / Main assemblies used during the
MGB assembly phase.
The assembly procedure of the MGB is essentially the reverse of the disassembly procedure.
8.2.1 Main Case, Assembly procedures.

8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing, installation.
8.2.1.4 Collector Gear Assy, assembly.
8.2.1.5 RH / LH Input Pinion Assy (II stage of reduction), assembly.
8.2.1.6 Tail Rotor Drive Quill Assy, assembly.
8.2.1.7 Left and Right Hyd. Pump Drive Quill, assembly.
8.2.1.8 Front Hyd. Pump Drive Quill, assembly.
8.2.1.9 ECS-Compressor Drive Quill, assembly.
8.2.1.10 Fan Drive Quill, assembly.
8.2.1.11 Collector Gear Assy, installation.
8.2.1.12 Diaphragm Assy, installation.
8.2.1.13 Tail Rotor Drive Quill Assy, installation.
(cont.s)

8.2.1.14 RH / LH Input Pinion Assy (II stage of reduction), installation.
8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation.
8.2.1.16 Front Hyd. Pump Drive Quill Assy, installation.
8.2.1.17 ECS-Compressor Drive Quill Assy and Seal Cover, installation.
8.2.1.18 Fan Drive Quill Assy, installation.
8.2.1.19 Main Case, Backlash check
8.2.1.20 Fan Seal Cover, installation.
8.2.1.21 Left / Right Lubrication Pump, assembly.
8.2.1.22 Left / Right lubrication Pump, installation.
8.2.1.23 Bottom Cover, assembly.
8.2.1.24 Bottom Cover, installation.
8.2.2 Upper Module, Assembly procedures

8.2.2.1 Planetary gears assembly (mast planetary assembly), assembly.
8.2.2.2 Mast-planetary assembly (upper module), assembly.
8.2.2.3 Upper Fittings, Brackets, installation.
8.2.2.4 Mast-planetary assembly, installation.
8.2.2.5 Planetary Crown (Fixed Ring Gear), installation.
8.2.2.6 Roller Bearing and Cover seal, Installation.
8.2.2.8 Four Oil jets, installation.
8.2.2.9 Oil Filler plug, Mast Chip detector, Mast Cover and Ident. Plate installation
8.2.2.10 Unions, installation procedures
8.2.2.11 Upper Module Assy, installation.
(cont.s)

8.2.3.1 Oil draining Pipe, Oil Level Gauge and low Oil Level sensor, installation.
8.2.3.2 Oil Filter Head, Oil Temperature sensor, Oil Pressure sensor and Oil Temperature SW, installation.
8.2.3.3 Rotor Speed Sensor, installation.
8.2.3.4 Check valves and Pressure Relief Valve, installation.
8.2.3.5 Borescope Port, Two Chip Detectors, Washers, Plugs and Flange, installation
8.2.3.6 Fifteen (from No. 1 to No. 13) Oil Jets, installation.
8.2.4.2 Bearings, installation.
8.2.4.4 Gear (I stage of reduction), assembly.
8.2.4.5 Gear Assy and Diaphragm Assy, installation.
8.2.4.6 Input Drive Quill group, assembly.
8.2.4.7 Input Drive Quill group and Gimbal Assy, installation.
8.2.4.8 Input Shaft Module, Backlash check.
8.2.4.9 Freewheel Group, assembly.
8.2.4.10 Freewheel Group and Oil Jet Cover, installation.
8.2.4.11 Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation
8.2.4.12 LH/RH Input Shaft Module, installation.

Safety conditions
WARNING
The materials that follow are dangerous. Before you do this procedure, make sure that you know all the safety precautions
and first aid instructions for the materials reported hereinafter. Refer to CR&OP: 39-A-60-50-00-00A-074A-C.
Nomenclature Identification No. Specification references Ref. Documents
Oil C006 MIL-PRF-7808L (AMDI) 39-A-00-50-00-05A-078A-D
Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M (AMDI) 39-A-00-50-00-28A-078A-D
Grease (Parker super O-lube). C115 None (AMDI) 39-A-00-50-00-08A-078B-D
Grease (Aeroshell 22) C009 MIL-PRF-81322F (AMDI) 39-A-00-50-00-08A-078A-D
Grease (Aeroshell Grease 17) C022 MIL-PRF-21164 (AMDI) 39-A-00-50-00-21A-078A-D
Grease (NS-3913-G1) C147 None (AMDI) 39-A-00-50-00-13B-078A-D
Solvent (Loctite quick clean 7031) C023 None (AMDI) 39-A-00-50-00-22A-078A-D
Sealing compound (Naftoseal MC-236 C030 AMS-S-8802B (AMDI) 39-A-00-50-00-29A-078A-D

Class B)
Compound (Dykem Steel Blue) C162 None (AMDI) 39-A-00-50-00-28B-078A-D
Adhesive (Shellac) C163 None (AMDI) 39-A-00-50-00-29B-078A-D
Sealing compound (AMS-S-8802, Class A- C164 AMS-S-8802, Class A-1/2. (AMDI) 39-A-00-50-00-30B-078A-D
1/2)

CAUTION
During this procedure, do not touch the components made of metal with
your bare hands. Put on applicable cotton gloves before you touch the
components. Contamination from your bare hands will cause corrosion of
the metals.
Procedure
Note 1 Refer to CR&OP data module: 39-A-63-20-05-00A-710A-C

(Main gearbox - Assemble procedures) if the Test Bench is
available.
If the Test Bench is not available, you can do the functional

check with the main gearbox installed on the helicopter.
In this case refer to CR&OP data module: 39-A-63-20-05-00A-
710B-C (Main gearbox - Assemble procedures).9
-A-63-20-05-00A-710B-C
Note 2 In this section will be described the actions reported on CR&OP
data module 39-A-63-20-05-00A-710A-C following a specific
guideline.
Note 3 - During this procedure, obey the general guidelines applicable to

the assemble procedures. Refer to CR&OP data module 39-A-
63-20-05-00A-714A-C.

Install the Main Case assembly with the Support on the Maintenance Trolley
CR&OP data module:

1
39-A-63-20-05-00A-710A-C
Main gearbox - Assemble procedures.
Support equipments:
Identification No.
Nomenclature
Lifting tool, main case assembly 3G6320A00131A181B
Trolley, main case maintenance 3G6320A00131A188C
2 Lifting device Local supply

8.2.1.1 Shims Installation
Action No. 1: Shims location
Shim (102)
Shim (113)
Screw (103) x 3 CR&OP data module:
Screw (114) x 3
Shim (187)
Shim (193)
Screw (194) x 3
Screw (186) x 4 Screw (184) x 3 39-A-63-20-05-00A-710A-C
Shim (177) Main gearbox - Assemble procedures
Procedure
Shim (102)
Shim (92) Screw (103) x 3
Screw (91) x 3 The shims (tot. 11) that must be installed on the
Main Case are the following:
- LH / RH Shim (193).
- Shim (177).
Shim (193) - Shim (187).
Screw (194) x 3 - LH / RH Shim (102).
Shim (98) - Shim (113).
Screw (97) x 3 - Shim (92).
Shim (199K) x 2 - Shim (98).
Screw (199L) x 3 - LH / RH Shim (199K).
AFT
RH LH
Main Case
without
FWD
Shims
Action No. 2: RH Shim (193) and LH Shim (193) installation
CR&OP Data Module:
RH Shim (193) Screw (194) x 3
39-A-63-20-05-00A-710A-C - Main gearbox - Assemble

procedures.
Procedure
Install the Right and Left Shim (193) as follows:
1. Make sure that the Right Shim and the Left Shim have the same S/N
as the Main Case assembly.
2. Verify / Calculate / Record the Thickness of the RH Shim and LH
Shim with this formula:
RH Shim Thickness = X - CG
Main Case Right side (Input Pinion II stage of reduction) LH Shim Thickness = X - CH
where
LH Shim (193) X (mm): refer to the D.M.as necessary.
and
CG is the dimension (mm) engraved on the RH side of the Main Case.

CH is the dimension (mm) engraved on the LH side of the Main Case.
Screw (194) x 3
Main Case Left side (Input Pinion II stage of reduction)

Action No. 2: RH Shim (193) and LH Shim (193) installation
Procedures (cont. s)
3. Measure the thickness of the shim and make sure that it is as specified in
previous Step 2. If the thickness of the shim is not in the limits, do step 3.1
or Step 3.2 as necessary. Contact the AW Customer Support as necessary.
3.1 Machine the Shim and remove material until the thickness is correct
(measure the thickness of the shim regularly while you machine it). Restore
the protection as required.
3.2 Discard the Shim and install a new item. Adjust the thickness of the new
shim and restore the protection as required.
4. Put each Shim (193) in its housing of the main case assembly.
5. Install the three Screws (194) to attach the Shim (193).
Note:
The procedure reported on Step 3 can be used for all other shims installed on the
Main Case.

Action No. 3: Shim (177) installation
CR&OP Data Module:
39-A-63-20-05-00A-710A-C - Main
gearbox - Assemble procedures.
Procedure (TBD)
Install the Shim (177) as follows:
1. Make sure that the Shim has the same S/N

2. Verify / Calculate / Record the Thickness of
the Shim with this formula:
Shim Thickness = X - CJ
where
X (mm): refer to the D.M.as necessary.

RH Shim (177)
Screw (184) x 3 and
CJ is the dimension (mm) engraved on the

Main Case.
Main Case Rear side (Tail Rotor drive quill)

CR&OP Data Module:
39-A-63-20-05-00A-710A-C - Main
gearbox - Assemble procedures.
Procedure
Install the shim (187) as follows:
1. Make sure that the shim has the same

S/N as the main case assembly.
2. Verify / Calculate / Record the thickness
of the shim with this formula:
Screw (186) x 4 Shim Thickness = CF - X
where
CF is the dimension (mm) engraved on the

RH Shim (187)
main case, and
Main Case Internal view, lower side

Action No. 5: LH Shim (102) and RH Shim (102) installation
LH Shim (102)
CR&OP Data Module:
39-A-63-20-05-00A-710A-C - Main gearbox - Assemble

procedures.
Procedure
Install the Right and Left Shim (102) as follows:
Screw (103) x 3
1. Make sure that the Right Shim and the Left Shim have the same S/N
2. Verify / Calculate / Record the Thickness of the RH Shim and LH Shim
with this formula:
Main Case LH side (LH Hyd. Pump drive quill)
RH Shim Thickness = X - CM
LH Shim Thickness = X - CP
RH Shim (102)
where
CM is the dimension (mm) engraved on the RH side of the main case.

CP is the dimension (mm) engraved on the LH side of the main case.
Screw (103) x 3
Main Case RH side (RH Hyd. Pump drive quill)

CR&OP Data Module:
39-A-63-20-05-00A-710A-C - Main gearbox -

Assemble procedures.
Shim (113) Procedure
1. Make sure that the shim has the same serial number
as the main case assembly
2. Verify / Calculate / Record the thickness of the shim
with this formula:
Shim Thickness = X CS
Screw (114) x 3 where
CS is the dimension (mm) engraved on the main

case.
Main Case Rear side (Fan drive quill)

CR&OP Data Module:

Procedure
as the main case assembly
2. Calculate the thickness of the shim with this formula:
Shim Thickness = X - CL
Screw (91) x 3
Where
Shim (92)
CL is the dimension (mm) engraved on the main case.
Main Case Front side (ECS-Compressor drive quill)

CR&OP Data Module:

Procedure
as the main case assembly.
2. Verify / Calculate / Record the thickness of the shim

with this formula:
Shim Thickness = X CK
Shim (98)
Where
Screw (97) x 3
X : refer to the D.M.as necessary.

CK is the dimension (mm) engraved on the main case.
3. Measure the thickness of each shim and make sure

that it is as specified in previous Step 2. If the
Main Case Front side (Front Hyd. Pump drive quill) thickness of the shim is not in the limits, perform the
corrective action required. See page 12 for further
info.
4. Put the shim (98) in its housing of the main case
assembly.
5. Install the 3 screws (97) to attach the shim (98).

Action No. 9: LH Shim (199K) and RH Shim (199K) installation
RH Shim (199K)
CR&OP Data Module:

Procedure
Install the LH / RH Shim (199K) as follows:

Screw (199L) x 3
1. Make sure that the LH / RH shim has the same serial number
as the main case assembly.
Main Case Front side (RH AC Generator drive quill) 2. Verify / Calculate / Record the thickness of the left / right shim
with this formula:
LH Shim (199K) LH Shim Thickness = X - CR
RH Shim Thickness = X - CN
Where
X : refer to the D.M.as necessary.

CR is the dimension (mm) engraved on the main case.
CN is the dimension (mm) engraved on the main case.
3. Measure the thickness of each shim and make sure that it is as

Screw (199L) x 3 specified in previous Step 2. If the thickness of the shim is not
in the limits, perform the corrective action required. See page
12 for further info.
4. Put each shim (199K) in its housing of the main case
assembly.
Main Case Front side (LH AC Generator drive quill)
5. Install the 3 screws (199L) to attach the shim (199K).
8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing, installation
Action No. 1: 2 Roller bearings installation
Washer + CR&OP Data Module:

Nut x 4
Surfaces
Lubricated with Oil
RH Roller Bearing Supplies:
See Detail A (next page)
Nomenclature Identification No. Specification references
Solvent, cleaning C010 P-D-680 type II
Heated area
LH Roller Bearing Oil C006 MIL-PRF-7808L
1
Support equipment:
Washer +
Nut x 4
Bearing installation tool 3G6320A00331A023E
2
3 4 6

8.2.1.2 Roller Bearings and Outer Race of the tail-rotor roller bearing, installation
Action No. 2:Outer Race of the tail-rotor roller bearing installation
Detail A Al Washer x 3 CR&OP Data Module:

Washer x 3
Surfaces Nut x 3 Assemble procedures.
Lubricated with Oil
Supplies:
Heated area
Cloth, soft lint-free C011 None

Screw x 3
Oil C006 MIL-PRF-7808L
Outer Race of the Tail-
rotor roller bearing
Support equipment:
Outer race installation 3G6320A00331A023F

tool, roller bearing
1 2 3 4

8.2.1.3 Diaphragm Assy, assembly procedures
CR&OP Data Module:

Heated area
Surfaces Assemble procedures.
Lubricated with Oil
Roller Bearing Supplies:

Nuts+
Washers
Oil Jets Pre-Mod. Solvent, cleaning C010 P-D-680 type II
Packing Oil C006 MIL-PRF-7808L
Grease (Parker C115 None

super O-lube).
Support equipment:
Nuts+
Washers Nomenclature Identification No.
Nuts+
Nuts+ Washers Heat gun Local supply
Washers
Bearing installation tool 3G6320A00331A023A
Packing Nuts
Oil Jets Post-Mod.
Nuts
Nuts Nuts

8.2.1.3 Diaphragm Assy, assembly procedures
Diaphragm + Tool + Bearing
Oil Jets Post-Mod.

installed
Heating phase
Roller Bearing installed
Bearing installation
8.2.1.4 Collector Gear Assy, assembly procedures
Collector Gear
CR&OP Data Module:
Surfaces Loctite application Assemble procedures.
Lubricated with Oil
Collector Bearing Supplies:
Locking Ring Nomenclature Identification No. Specification references

Locking Washer Cloth, soft lint-free C011 None
Note:
Retaining Ring
Retaining Ring installed
on MGB Solvent (Loctite C023 None
P/N 3G6320A00135 only quick clean 7031)
Adhesive (Loctite C029 MIL-S-46163, Type II
222) grade M
Collector Gear Support equipment:

Retaining Ring Main Case Nomenclature Identification No.
Bearing installation tool 3G6320A00331A023C
Induction oven Local supply
Work table MS3-01300
Hydraulic cylinder BRW 104N
Lifting tool, collector 3G6320A00331A181A

gear
Torque tool, collector 3G6320A00331A023D

gear

View of the bearing installation tool and torque tool
Bearing installation tool 3G6320A00331A023C Torque tool, collector gear 3G6320A00331A023D

Collector gear assembly phase
1
4
7

8.2.1.4 Collector Gear Assy, assembly
Collector gear assembly phase
8
13
11
10 12

8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly
procedures
CR&OP Data Module:

Supplies:
Heated area
V incision Main Case Cloth, soft lint-free C011 None

O-rings
Input Pinion II Solvent (Loctite C023 None
Bearing Stage quick clean 7031)
Sleeve
Bearings Nuts, Adhesive (Loctite C029 MIL-S-46163, Type II
222) grade M
Shim Washers
Heated area Support equipment:
Oil application Retaining Ring
(Typical for RH side) Nomenclature Identification No.
Loctite Pump gear
application Induction oven Local supply
Locking Ring
Locking Bearing installation tool 3G6320A00331A023U
Retaining
Washer Arbor press Local supply
Ring
Installation tool, sleeve 3G6320A00331A023V
Reaction tool, pinion 3G6320A00331A023W

locking ring

8.2.1.5 RH / LH Input Pinion (II Stage of reduction), assembly proc.
Retaining Ring Step Thickness evaluation
Measure the distance between the end of the outer
race of the bearing (I2) and the flange of the bearing
sleeve (N) in three equally spaced positions. Calculate
Step the arithmetical mean between the three values, and
record it as dimension P
Calculate the thickness of the step on the retaining

ring as follows:
Thickness of step (mm) = P - (*).
(*) refer to the D.M. as necessary.
Measure the thickness of the step on the retaining ring

and make sure that it is as calculated. If the thickness
of the step is not within the limits, do the following
actions as necessary.
Machine the retaining ring and remove material

until the thickness of the step is correct (measure
the thickness of the step regularly while you
machine it), or
Discard the retaining ring and install a new item.
Retaining Adjust the thickness of the step on the new
Ring
retaining ring as necessary.
(cont.s)

Thickness evaluation of the Shim
Measure the total height of the inner races of the

triplex bearing. Record this value as I1.
Calculate the thickness (M) of the shim with this

formula:
(RH) M = G - (H + I1 + L)
(LH) M = G - (H + I1 + L)
where
G CU is the dimension engraved on the main

case assembly (RH).
G CT is the dimension engraved on the main
case assembly (LH).
H is the dimension engraved on the pinion
I1 is the measured dimension.
Shim L is the dimension engraved on the pump gear.
Measure the thickness of the shim and make sure

that it is as calculated. If the thickness of the shim is
not in the limits, perform the actions reported
hereinafter as necessary.
Machine the shim and remove material until the
thickness is correct (measure the thickness of
the shim regularly while you machine it).
Discard the shim and install a new item. Adjust
the thickness of the new shim as necessary.
Install the Shim and the Retaining ring on the

right/left input pinion as required.

Assembly phase step 1
5
Bearing Sleeve
1
Retaining Ring
Triplex ball bearing Pump gear
Input Pinion II stage
Bearing
installation tool
2 3
4
Inner race bearing

thickness Bearing alignment Sleeve installation
measurement tool

6 Oil application 8
Pinion + Bearings
Arbor Press

10 13
14
Pump Gear +
Thickness Check Locking Ring
11 12
Pinion Assy +
Supplies +
Locking Washer +
Retaining Ring
Thickness Check Retaining Ring

installation

20
15
21
17
Retaining installation
19
Locking Ring,
Reaction tool Locking Ring, Reaction
tool + Wrench Locking washer
installation Input Pinion II stage Assy
16
18
Locking Ring, Reaction Torque

tool + Wrench Wrench

8.2.1.6 Tail Rotor Drive Quill Assy, assembly procedures
CR&OP Data Module:

(main gearbox) - Assemble procedures
Nylon Screw
(3) Supplies:
Nomenclature Id. No. Specification references
Main Cloth, soft lint-free C011 None

Case
Main
Case Oil C006 MIL-PRF-7808L
Solvent (Loctite quick C023 None

clean 7031)
Tail Rotor Drive
Quill Assembly Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M
Tail Rotor Drive
Quill Assembly
Safety wire C014 MS20995C32
NS-3913-G1 (Syn-Tech C147 None
Ltd)
Parker super O-lube C115 None
Nomenclature Identification No. Nomenclature Identification No.

Oven Local supply Arbor press Local supply
Assembly tool 3G6320A00331A023Y Pusher tool, rotor brake 3G6320A00331A026D
Support equipment: Reaction tool, pinion 3G6320A00331A023Z case assembly
Wrench 3G6320A00331A026A Installation tool, lip seal 3G6320A00331A026E
Wrench 3G6320A00331A026B Wrench 3G6320A00331A026F
Installation tool, flanged 3G6320A00331A026C Work table MS3-01300

bearing

Action No. 1 Bearing inner race (28) installation on Pinion (30)
CR&OP Data Module:
39-A-63-20-05-28A-710A-C Tail
Retaining ring
Locking washer Note: This procedure is applicable only to
Locking ring Main gearbox P/N : 3G6320A00132).
Ring
Flange
Washer
O-rings Seal case Support equipment:
Seal Nomenclature Identification No.
Rotor brake case
O-ring Oven Local supply
Nipple Assembly tool 3G6320A00331A023Y

Shim Retaining ring
Screw Locking washer Reaction tool, pinion 3G6320A00331A023Z
Flanged
bearing Part heated Locking ring
Work table MS3-01300
Gear
Shim Wrench 3G6320A00331A026A
Oil application Retaining ring
Locking washer Supplies:
Oil Locking ring
application Bearing inner
race (roller)
Plug Cloth, soft lint-free C011 None
Pinion

Bearing cage clean 7031)
Adhesive (Loctite 222) C029 MIL-S-46163, Type II grade M
Plug
Pinion Oil C006 MIL-PRF-7808L

Action No. 1 Bearing inner race (28A) installation on Pinion (30A)
CR&OP Data Module:
39-A-63-20-05-28A-710A-C Tail
Retaining ring
Locking washer Note:
Locking ring
Ring This procedure is applicable to Main
Flange gearbox P/N: 3G6320A00133 and sub. P/N
Washer with different last two digits
O-rings Seal case
Seal
Rotor brake case
O-ring Supplies:
Shim Nipple Retaining ring
Flanged Nomenclature Id. No. Specification references
bearing Locking ring
Gear
Shim
Retaining ring
Locking washer
Locking ring
Bearing inner
O-ring
race (roller)
Plug
Pinion
Bearing cage
Plug
Pinion

Action No. 2 Calculate the thickness of the Shim (22)
CR&OP Data Module:

(main gearbox) - Assemble procedures.
See Para. 3 for Main Gearbox P/N: 3G6320A00132 and to
Para. 4 for Main gearbox P/N: 3G6320A00133 and sub P/N
with different last two digits.
Procedure:
3. (Main gearbox P/N 3G6320A00132) Calculate and record the

thickness F of the shim (22) with this formula:
F(*) = [(C + D) - E] - (A - B) where

A = (*)
B is the dimension (mm) engraved on the pinion (30)
C is the dimension (mm) engraved on the main gearbox case
D and E are the dimensions (mm) engraved on the gear (21).
4. Main gearboxes P/N 3G6320A00133 and subsequent P/N
with different last two digits) Calculate and record the thickness F
of the shim (22) with this formula:
F(*) = [(C + D) - E] - (A - B) where
A = (*)
B is the dimension K (mm) engraved on the pinion (30A)
C = (*)
D = (*)
E is the dimension K (mm) engraved on the gear (21).
(*): Refer to the D.M. as necessary.

Action No. 3 Shim (22) and Gear (21) installation
CR&OP Data Module:
39-A-63-20-05-28A-710A-C Tail
Support equipment:
Oven Local supply

Wrench 3G6320A00331A026B
Part heated Reaction tool, pinion 3G6320A00331A023Z
Retaining ring
Locking washer
Locking ring
Supplies:
Gear
Shim
Oil application Nomenclature Id. No. Specification references

clean 7031)
Oil application

Action No. 4 Shim (14), Flanged bearing (17), installation on Item 11
CR&OP Data Module:
Part heated
Note:
Calculate and record the thickness of the shim (14) with this formula:
Oil application
Thickness = X - Y where
Nut + X (mm) : refer to the D.M. as necessary.
Washer Y is the dimension (mm) engraved on the rotor brake case.
Rotor brake case Support equipment:
Shim Nomenclature Identification No.

Screw
Flanged Oven Local supply
bearing
Installation tool, flanged bearing 3G6320A00331A026C
Supplies:
Solvent (Loctite quick clean C023 None

7031)

Action No. 5 Rotor Brake Case Assy (11), installation on Pinion
CR&OP Data Module:
quill (main gearbox).
Grease (147)
Retaining ring Support equipment:
Locking washer
Locking ring Nomenclature Identification No.
Parts heated Ring
Flange Oven Local supply
Retaining ring
Assembly tool 3G6320A00331A023Y
O-rings Seal case
Seal
Pusher tool, rotor brake 3G6320A00331A026D
case assembly
Rotor brake case
O-ring Installation tool, lip seal 3G6320A00331A026E
Nipple Wrench 3G6320A00331A026F
Oil application
O-ring Supplies:

Pinion 7031)
Pinion NS-3913-G1 (Syn-Tech Ltd) C147 None

Assembly phase (Main gearbox P/N 3G6320A00133), step 1
7 6
1
Flanged bearing
R.B.C. assembled installed on the R.B.C.
3 4 5
Flanged bearing + Flanged bearing

Rotor Brake Case + Shim tool installation phase
2
Bearing cage
Input Pinion
(IIstage of reduction) Locking ring Gear Flanged bearing
9 11
10
Installation phase of the

Lip Seal in the Seal case
12
14
13
Bearing cage Shim (22) Gear (21)

(28A) installation installation installation

15
17
16 18
Locking ring (20) Locking ring, Locking Washer Rotor Brake Case Assy
installation wrench and Retaining heating phase -
installation Ring installation

19 20 21
Rotor Brake Case Seal and Seal Retaining Ring

Assy installation Case installation installation

22 24 25
Flange (5)
installation Nipple (13)
installation
23
Locking Washer (2)
and Retaining Ring (1)
installation
26
Locking ring (3)

installation
Tail Rotor Drive Quill Assy

8.2.1.7 - Left and Right Hyd. Pump Drive Quill, assembly procedures
CR&OP Data Module:

Retaining ring
Seal cover quill (main gearbox) - Assemble procedures
C147 application
Support equipment:
Lip seal
Packing Induction oven Local supply
Retaining ring Installation tool, bearing 3G6320A00431A023A

Locking washer Arbor press Local supply
Locking ring
Installation tool, pinion 3G6320A00431A023B
Removal/installation tool, 3G6320A00431A023C

Flanged
C115 application locking ring
bearing+
Washers
Installation tool, lip seal 3G6320A00431A023D
and Nuts
Holder tool, pump case 3G6320A00431A023E
Plug
O-ring O-ring Supplies:

Pump Nomenclature Id. No. Specification references
Fitting
case

Solvent (Loctite quick clean 7031) C023 None
Pinion
Left/right pump drive quill NS-3913-G1 (Syn-Tech Ltd) C147 None

(Hyd. pump No.1 and N0.2
drive quill) Parker super O-lube C115 None

Action No. 1 Installation of the Flanged bearing (11) on the Pump Case (14)
Flanged
bearing
Heated area
Pump
case
Installation tool, bearing

Action No. 2 Installation of Pinion (15) in the Pump Case Assy (14)
External side
Left/right pump Retaining ring

drive quill (Hyd.
Locking washer
pump No.1 and
N0.2 drive quill) Locking ring
Heated area Removal/installation tool, locking ring

Flanged
bearing+
Washers
and Nuts
Pump Inner side

case
Pinion
Installation tool, pinion

Action No. 3 Pump Drive Quill, final assembly
Retaining ring
Seal cover
Lip seal
Packing
Plug
O-ring O-ring
Fitting Pump
case
Installation tool, lip seal Holder tool, pump case

8.2.1.8 - Front Hyd. Pump Drive Quill, assembly procedures
CR&OP Data Module:

39-A-63-20-05-04A-710A-C Front pump drive quill
Pinion
(main gearbox) - Assemble procedures
Pump
case Support equipment:
Plug Induction oven Local supply

Front Hyd.
pump drive Installation tool, bearing 3G6320A00431A023A
quill O-ring O-ring
Installation tool, pinion 3G6320A00531A023A
Heated area Fitting Arbor press Local supply
C115 application Installation tool, lip seal 3G6320A00431A023D

Holder tool, pump case 3G6320A00431A023E
C147 application Front Hyd. pump
Flanged
drive quill Removal/installation tool, 3G6320A00531A023B
bearing
locking ring
Washers + Nuts
Locking ring Supplies:
Locking washer
Retaining ring Nomenclature Id. No. Specification references
Packing
Lip seal
Seal cover
Solvent (Loctite quick clean 7031) C023 None
Retaining ring
Note
NS-3913-G1 (Syn-Tech Ltd) C147 None
The assembly procedure
relevant to the Front Pump
are similar to the LH/RH Hyd.
Pump previously described. Safety wire C014 MS20995C32

8.2.1.9 - ECS-Compressor Drive Quill, assembly procedures
Action No.1 : Flanged Bearing (4) installation
CR&OP Data Module:
39-A-63-20-05-05A-710A-C ECS compressor
Heated area drive quill (main gearbox) - Assemble
procedures Support equipment:
Locking
ring
Pinion Nomenclature Identification No.
ECS-compressor
drive quill Induction oven Local supply
Case Installation tool, bearing 3G6320A00731A023A

Flanged
Installation tool, pinion 3G6320A00731A023B
bearing
ring washer Washers Removal/installation tool, 3G6320A00731A023C
locking ring
Supplies:
Specification
Nomenclature Id. No.
references
2 3 Cloth, soft lint-free C011 None

Case
Oil C007 MIL-PRF-23699
7031)
Adhesive (Loctite 222) C029 MIL-S-46163, Type II
Flanged grade M
bearing

8.2.1.9 - ECS-Compressor Drive Quill, assembly procedures
Action No.2 : Pinion (2) installation and final assembly
Heated area
8 7
Locking
ring
Pinion
Case
Flanged
bearing
5
ring washer Washers
Locking Retaining Removal/installation tool,

washer ring
locking ring
4
Locking
ring
Pinion
Case
Assy
Installation tool, pinion

8.2.1.10 - Fan Drive Quill, assembly procedures
CR&OP Data Module:
Fan drive quill

Fan drive quill gearbox) - Assemble procedures
Supplies: Support equipment:
Specification Nomenclature Identification No.
references
Induction oven Local supply
Installation tool, pinion 3G6320A00931A023A
Heated area Arbor press Local supply
clean 7031) Removal/installation tool, 3G6320A00931A023B
Pinion locking ring
Adhesive (Loctite 222) C029 MIL-S-46163,
Type II grade M
Flanged
bearing
Locking 1 2 3
ring
Locking
Retaining washer
ring
Locking
Pinion ring

8.2.1.11 - Collector Gear Assy, installation procedures
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
Collector Gear
Assy Main gearbox - Assemble
procedures.
Bolts
Bolts
Bolts Bolts
Bearing
Bolts
Support equipment:
Heated area Nomenclature Identification No.
Lifting tool, collector gear 3G6320A00331A181A

Main Case
Supplies:
Specification
references
Washers
+ Solvent, cleaning C010 P-D-680 type II
Nuts

8.2.1.11 - Collector Gear Assy, installation procedures
Installation phases
1
4
Bolts
Heated area
Main Case Collector bearing, locked
Collector Gear
Collector Gear Assy, installed
Assy

8.2.1.12 - Diaphragm Assy and two Oil Jets No. 4 installation procedures
CR&OP Data Module:
Diaphragm 39-A-63-20-05-00A-710A-C
Main gearbox - Assemble
Screws
procedures.
Supplies:
Specification
references

Oil Jet No. 4 (2) Oil C006 MIL-PRF-7808L
Grease (Parker super C115 None
O-rings O-lube).
Main Case Filter
Screw
O-ring +
1 2
Washer
Note
Install the Oil Jets

No. 4 before to
install the 14
locking Screws of
the Diaphragm.

8.2.1.13 - Tail Rotor Drive Quill Assy, installation procedures
Note CR&OP Data Module:

Apply the Compound (C162) on the
three-equally spaced teeth of the
39-A-63-20-05-00A-710A-C
pinion of the tail-rotor drive quill Main gearbox - Assemble
procedures.
Washers + Nuts
Support equipment:
Heated area
Installation tool, tail rotor 3G6320A00331A026M

drive quill
Rotor Brake Housing Heat gun Local supply
Tail Rotor Drive Quill Assy
2 Supplies:
O-ring
Specification
references
1 Compound (Dykem C162 None
Steel Blue)

8.2.1.14 - RH / LH Input Pinion Assy (II stage of reduction),
installation procedures.
Apply the CR&OP Data Module:

Compound C162
on the three-
equally spaced 39-A-63-20-05-00A-710A-C
teeth of the Heated area
pinion of the
right / left input procedures.
pinion
Support equipment:
Apply the Oil
C006 on the
Sleeve Nomenclature Identification No.
Installation tool, input pinion 3G6320A00331A023H

Apply the
grease C115 on
O-rings RH / LH Input Heat gun Local supply
Pinion Assy
Washers +
Nuts (II Stage of Supplies:
reduction)
Specification
references
Compound (Dykem C162 None

Steel Blue)

super O-lube).

8.2.1.14 - RH / LH Input Pinion Assy (II stage of reduction),
installation procedures. Installation phases.
1 4 5
Input Pinion Assy
Main Case
Assy rotate of
90. Main Case Assy.
Inner view
Main Case
Assy, LH side.
2 External view
Grease C115
application on Installation tool, input pinion 3G6320A00331A023H
O-rings

8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation
procedures.
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
procedures.
Screws Support equipment:
RH / LH Input Nomenclature Identification No.

Apply the Oil Hydraulic
C006 on the Pump drive Installation tool, pump drive 3G6320A00331A023L
Sleeve quill
quill Assy
Apply the
l grease C115 on Supplies:
e the O-ring
Specification
references

Heated area

super O-lube).

8.2.1.15 Left and Right Hyd. Pump Drive Quill Assy, installation
procedures. Installation phases
Heated area,
Main Case Assy LH side
Main Case Assy,

RH side Installation tool, pump drive 3G6320A00331A023L
quill

8.2.1.16- Front Hyd. Pump Drive Quill Assy, installation procedures
A
CR&OP Data Module:
39-A-63-20-05-00A-710A-C
procedures.
Support equipment:
Installation tool, pump drive 3G6320A00331A023L

quill
Front Heat gun Local supply
Hydraulic
Pump drive Supplies:
quill Assy
Heated area Specification
references
Apply the Solvent, cleaning C010 P-D-680 type II
grease C115 on
the O-ring Cloth, soft lint-free C011 None

Apply the Oil
Screws C006 on the Grease (Parker C115 None
Sleeve super O-lube).

8.2.1.17 - ECS-Compressor Drive Quill Assy and Seal Cover,
installation procedures.
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
procedures. Refer to Para. 31.
Apply the grease C115 on the O-rings Support equipment:

Nipple
Installation tool, lip seal 3G6320A00731A023D
Apply the Holder tool, ECS- 3G6320A00731A023E

grease C115 on compressor drive quill
the O-rings
Installation tool, ECS 3G6320A00331A023M
ECS-Compressor compressor drive quill
Drive quill Assy Heated area
Supplies:
Specification
Apply the grease Nomenclature Id. No.
references
C147 on the Lip Seal
(inner side)
Screws Seal Cover
Apply the grease C115 on the O-ring Cloth, soft lint-free C011 None
Apply the Oil Retaining Ring Oil C006 MIL-PRF-7808L

C006 on the
Sleeve Grease (Parker C115 None
super O-lube).
Grease (NS-3913- C147 None
G1)

Hyd. Pumps drive quills and ECS-Compressor drive quill.
RH Hyd. Pump
LH Hyd. Pump
Drive quill Assy
Drive quill Assy
Front Hyd.
Pump Drive
quill Assy
ECS-Compressor
Drive quill Assy

8.2.1.18 - Fan Drive Quill Assy, installation procedures.
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
Nuts
+ Support equipment:
Washers
Installation tool, fan drive 3G6320A00331A023N

quill
Fan drive Heat gun Local supply
Quill
Heated area
Supplies:
Specification
references
Main Case Assy, Solvent, cleaning C010 P-D-680 type II

rear side

8.2.1.19 - Main Case, Backlash check

RH Input Pinion II
between:

Fan Drive Quill



Drive Quill
LH Input Pinion II

8.2.1.19.1 - Main Case, Backlash tool (Collector gear) installation
CR&OP Data Module: Nomenclature Identification No.
39-A-63-20-05-00A-713A-C Backlash tool, 3G6320A00331A676L

collector gear
pattern check, Para. 1 Dial gauge Local supply
Support Equipments: Legend:

Item No. Nomenclature
1 Dial Gauge Support (3)
2 Tool Top section
3 Knobs (4)
4 Bolt
5 Nylon Split Ring
6 Bolts (4)
7 Registers (2)
8 Retainers
9 Bolts (2)
10 Wrench (Torque application

point)
11 Expander
12 Tool Bottom Section
13 Torque application point
14 Collector Gear

8.2.1.19.2 - MGB (Collector gear) Top Tool Section installation
1 7
Register
Expander,
installation
Wrench
2
Retainer
Tool Top
Section,
installation
Nylon Split
Ring Bolts
5
4
Collector
Gear
Knobs

8.2.1.19.3 MGB, (Collector gear) Tool Bottom Section installation

8.2.1.19.4 MGB, Backlash tool (Collector gear), torque wrench
application and Collector Gear levelness check
Top Section
Register
(2 positions)
Dial gauges
(3 positions)
Bottom Section
Note: Note:
Lock the Collector Gear with the Use the two Registers to adjust the
Expander as required. levelness of the Collector Gear as
required.
Note:
Push the tool bottom section up

as required.

8.2.1.19.5 - Backlash check between the Collector Gear and the Input
pinions
CR&OP Data Module:

Input Pinion
Support Equipments:
Backlash tool, input pinions 3G6320A00331A676B

Note:
- Lock the tool expander and the backlash
tool to the main case as required.
Input Pinion
Backlash Tool - Pull the input pinion externally as required.
installation - Install the Dial Gauge on its support.
positions, 120 apart, as required.
- Perform this action on both Input pinions.
LH Input Pinion II Stage, RH Input Pinion II Stage,

Backlash Backlash
Tool installation Tool installation

8.2.1.19.6 - Backlash check between the Collector Gear and Tail-Rotor Drive Quill
Tail Rotor Drive Quill,

Backlash Tool
CR&OP Data Module:
installation
39-A-63-20-05-00A-713A-C
Support Equipments:
Backlash tool, tail rotor 3G6320A00331A676C

drive quill
Output Pinion Tail Rotor

Drive Quill
Note:
- Lock the tool expander and the backlash
tool to the main case as required.
- Push pinion internally as required.
- Install the Dial Gauge on its support.

8.2.1.19.7 - Backlash check between the Collector Gear and the ECS-Compressor
Drive Quill
CR&OP Data Module:

ECS Compressor 39-A-63-20-05-00A-713A-C
Drive Quill
Support Equipments:
Backlash tool, ECS- 3G6320A00331A676E

compressor drive quill
ECS Compressor
Drive Quill, Dial gauge Local supply
Backlash Tool
installation
Note:
-Lock the tool expander and the backlash tool to
the main case as required.
- Push the pinion internally.

8.2.1.19.8 - Backlash check between the Collector Gear and the Front
Hyd. Pump drive quill
CR&OP Data Module:
Front Hyd. Pump 39-A-63-20-05-00A-713A-C

Drive Quill
Support Equipments:
Backlash tool, front 3G6320A00331A676H

Front Hyd. Pump,
pump drive quill
Backlash Tool
installation Dial gauge Local supply
Note:
- Lock the tool expander and lock the backlash
tool to the main case with the four tool knobs.
- Push the pinion internally.

8.2.1.19.9 - Backlash check between the Left/Right Input Pinion II Stage
and Left/Right Pump (Hyd. Pump No. 1 & No. 2) Drive Quill
CR&OP Data Module:

Support Equipments:
Left/Right Pump
(Hyd. Pump No. 1
and No. 2)
Drive Quill,
Backlash tool, left and right pump drive quill 3G6320A00331A676D
Backlash Tool Dial gauge Local supply
Note:
- Lock the tool expander ad the backlash
Left/Right Pump tool to the main as required.
(Hyd. Pump No. 1 - Pull the pinion externally.
and No. 2) - Install the Dial Gauge on its support.
Drive Quill
- Measure and record the backlash in
three positions, 120 apart, as required.
- Perform this action on both Hyd. Pumps.
Left Pump (Hyd. Right Pump (Hyd.

Pump No. 1) Pump No. 2)
Drive Quill Drive Quill

8.2.1.19.10 - Backlash check between the Tail-Rotor Drive Quill and Fan Drive
Quill
CR&OP Data Module:

Support Equipments:
Backlash tool, fan drive quill 3G6320A00331A676F
Fan Drive Quill, Note:

Backlash Tool - Lock the tool expander and the backlash
tool to the main case as require.
Fan Drive Quill
- Pull the pinion externally.
- Measure and record the backlash in
three positions, 120 apart, as required.

8.2.1.20 - Fan Seal Cover, installation procedures
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
Nuts Support equipment:

+
Washers
Fan Seal Cover
Installation tool, lip seal 3G6320A00331A023P
O-ring
Lip seal
Supplies:
Specification
references
Grease (NS-3913-G1) C147 None

O-lube).

8.2.1.21 - Left / Right Lubrication Pump, assembly procedures
CR&OP Data Module:

39-A-63-20-05-06A-710A-C
Assemble procedures
39-A-63-20-05-24A-710A-C
Gear Locking Retaining ring Right lubrication pump (main gearbox) -
Ring
Assemble procedures
Key Support equipment:
Lubrication Pump
Lock washer
Reaction tool 3G6305G00931
Wrench, oil pump ring nut 3G6305G01051
Shaft Supplies:
Specification
references

clean 7031)
Adhesive (Loctite 222) C029 MIL-S-46163, Type II
grade M

8.2.1.21.1 - LH & RH Lubrication Pumps, assembly phases
A Support equipment

Lubrication
pumps, Reaction tool 3G6305G00931
disassembled
Wrench, Locking ring 3G6305G01051
Key Shaft
B
G
Lock washer
Retaining ring
Locking
Gear Ring
C D E F

8.2.1.22 - Left / Right lubrication Pump, installation procedures
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
Supplies:
Specification
references

O-lube).
Washers + Nut
B
Lub. Pump
O-rings
Rear View RH Lubrication Pump
Rear View LH Lubrication Pump

Rear View
RH Lubrication Pump, installation

8.2.1.23 - Bottom Cover, assembly procedures
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
Support equipment:
Installation tool, slip ring 3G6320A00331A023Q
Special pliers 3G6320A00331A023R
Supplies:
O-ring Specification
references
O-rings
super O-lube).
Bottom Cover
Washers
O-ring + Nut
(x 13)
Slip ring
Retaining ring

8.2.1.24 - Bottom Cover, installation procedures
Main Case
CR&OP Data Module:
39-A-63-20-05-00A-710A-C
Support equipment Supplies:

Lifting tool, main case 3G6320A00131A181B Nomenclature Id. No.

assembly
Grease (Parker C115
super O-lube).
Trolley, main case 3G6320A00131A188C
maintenance
O-ring
O-ring B
Bottom Cover
A
Washers
+ Nut
(x 13)
Bottom Cover

procedures.
CR&OP Data Module:
39-A-63-20-05-00A-710A-C
Main gearbox - Assemble procedures .
Supplies:
Specification
O-ring Nomenclature Id. No.
references
Washers (C115)
+ Grease (Parker super C115 None
Nut O-lube).
O-ring
(C115)
AC Generator
Drive Cover
Plug
(C014)

8.2.2 - Upper Module, assembly procedures
General note
During the assembly of the Upper Module do the operations that follow:
Use new fasteners

Clean (where applicable) the components with Solvent (C010).
Lubricate (where requirerd) the components with Oil (C008) or oil (C007)
Apply Grease (C115) on the packings as required.
Check the conditions of each components for damage, before its installation on the module.
Record and identify the P/N and the S/N of all Components / Main Assemblies used during the
assembly of the Module.
Refer to the specific IPD as necessary.
Observe the Cautions, Warnings, Notes and the Procedures reported on the Data Modules as required.
Supplies

Grease C115 Parker super O-lube. (AMDI) 39-A-00-50-00-08A-078B-D
Oil C008 DOD-L-85734 (AMDI) 39-A-00-50-00-07A-078A-D
Oil C007 MIL-PRF-23699 (AMDI) 39-A-00-50-00-06A-078A-D

8.2.2.1 - Planetary Gears Assy, assembly procedures.
CR&OP Data Module:

39-A-63-20-05-14A-710A-C
Planetary gear assembly (mast planetary
Planetary assembly) - Assemble procedures
Gears Assy
Top-inner Procedure
bearing race
Roller cage
Put the components of the planetary gear assembly (1), on an
Rollers applicable work table.
Assemble the planetary gear assembly (1). Obey the

instructions that follow:
Gear
(outer bearing - Install the bottom-inner bearing race (8), the roller cage (7)
race) and the rollers (6) in their correct position on the gear (5).
Make sure that you install the same parts you removed during
the disassembly. Also make sure to put them on the side you
Rollers identified at the disassembly.
bearing race - Install the top-inner bearing race (2), the roller cage (3) and
the rollers (4) in their correct position on the gear (5). Make
sure that you install the same parts you removed during the
disassembly. Also make sure to put them on the side you
identified at the disassembly.

8.2.2.1 - Planetary Gears, assembly phase.
Inner Bearing
race D
Roller cage
Gear
(outer bearing
B race)
C
Bottom-inner
Bottom-inner Top-inner bearing race
bearing race bearing race
Roller cage
Roller cage Roller cage
Rollers
Rollers Rollers

8.2.2.2 - Mast-planetary Assy, assembly procedures.
Action No. 1: Install the Mast on the Work Trolley.
Retaining CR&OP Data Module: Support equipment:

Items that ring
must be 39-A-63-20-05-13A-710A-C
Lock Nomenclature Identification No.
assembled Mast-planetary assembly
washer Lifting tool 3G6320A00131A181A
(upper module) - Assemble
Ring Nut
procedures. Lifting device Local supply

Ball
bearing
Oil
collector
Note:
Turn the Mast
Mast (7) of 180.
Screws
Lock
Retaining
washers
springs
Bushings
Ring nuts
Flange
Planetary
Gear
assemblies
Pins
Spacers
Plate
Bushings
Pins
Lock washers
Screws

Action No. 2: Install Bushings (10) and Pins (12) on the Flange (11)
CR&OP Data Module: Support equipment:

39-A-63-20-05-13A-710A-C
Mast-planetary assembly (upper Refrigerator Local supply
module) - Assemble procedures. Heat gun Local supply
Bushing 3G6320A07131A023A
Supplies: installation tool
Specification Spacer (Pin) 3G6320A07131A023C
references installation tool
Solvent (Loctite C023 None
quick clean 7031)
Mast Adhesive (Loctite C029 MIL-S-46163,

222) Type II grade M
B
Screws
Lock
washers Note:
Put the Bushings (10) in the
Bushings refrigerator as required
Heated area Flange
Pins
Pins (x5) Note:

Heat the pins (12) as required
AA

Action No. 3: Planetary Gears (19), Pins (17) and Bushing (14) installation.

39-A-63-20-05-13A-710A-C
Mast-planetary assembly (upper Heat gun Local supply
module) - Assemble procedures. Planetary 3G6320A07231A023B
installation tool
Jack RCH-12H
Guide tool 3G6320A07231A023C
Bushing 3G6320A07131A023A
installation tool
Refrigerator Local supply
Heated area
Ring nuts
Flange
Planetary
Gears Assy Pins
Spacers
Plate
Bushings
Pins Note:
Lock washers
Put the Bushings (14) in the
Screws refrigerator as required
Heated area

Action No. 3: Planetary Gears (19) installation phase
A E
D
C

Action No. 3: Pins (17), Bushing (14) and Plate (13) installation phase.
F
L

Action No. 4: Apply the final torque on Ring Nut (20) and on Screw (16)
39-A-63-20-05-13A-710A-C
Mast-planetary assembly (upper Installation tool, 3G6320A07231A023D
ring nut
module) - Assemble procedures.
Supplies:
Specification
references
quick clean 7031)
Adhesive (Loctite C029 MIL-S-46163,
Ring nuts
Screws

Action No. 5: Ball Bearing (4) installation
Retaining CR&OP Data Module: Support equipment:

Put the top and
bottom races of
ring
the ball bearing
Lock
39-A-63-20-05-13A-710A-C Nomenclature Identification No.
(4) in the Oven
washer Mast-planetary assembly (upper
module) - Assemble procedures.
Ring Nut Lifting device Local supply
Ball Oven Local supply

bearing Tightening tool, 3G6320A07231A023E
ring nut
Oil
collector Reaction Tool 3G6320A07231A023G
Supplies:
Mast Specification
references
Retaining quick clean 7031)
springs Adhesive (Loctite C029 MIL-S-46163,

Action No. 5: Ball Bearing (4) installation phase
B D

Action No. 5: Ball Bearing (4) installation phase
I
F

8.2.2.3 - Upper Fittings, Brackets installation
Note:
Put the upper fitting (2) in the Refrigerator CR&OP Data Module:
39-A-63-20-05-03A-710A-C
Upper
Fittings
Bolts + Assemble procedures.
Washers
Brackets
Support equipment:
TOP
CASE
Screws
Aligning pin, fitting (2) 3G6320A00231A023I
Refrigerator Local supply
Supplies:

Sleeve (Polyurethane C049 MIL-T-7444.
transparent tube)
Grease (Aeroshell 22) C009 MIL-PRF-81322F
Sealing compound (Naftoseal C030 AMS-S-8802B

MC-236 Class B)

8.2.2.3 - Upper Fittings, Brackets installation
Installation phase
A F
Aligning pin, fitting (2)

C
E
B D

8.2.2.4 Mast-Planetary Assy, installation procedures.
Action No. 1: Install the Top Case on an appropriate Work trolley.
CR&OP Data Module:

1
Support equipment:

2
Lifting tool, mast 3G6320A00231A181B
Work trolley (dummy 3G6320A00231A188A

roller bearing and
guide are parts of the
Work Trolley)
Lifting tool, mast- 3G6320A00231A181C
planetary assembly
Note: Aligning pin, bearing 3G6320A00231A023D
turn the TOP CASE 180
Supplies:
Specification
references
3

Action No. 2: Install the Mast-Planetary assembly in the Top Case.
CR&OP Data Module:
39-A-63-20-05-03A-710A-C Upper module (main
TOP CASE gearbox) - Assemble procedures.
Support equipment:
Lifting tool, mast- 3G6320A00231A181C

planetary assembly
Mast-planetary
Assy. Lifting device Local supply
Aligning pin, bearing 3G6320A00231A023D
Ball
bearing Supplies:
Oil Nomenclature Id. No.
Specification
collector references
Nuts + Oil C006 MIL-PRF-7808L
Washers
Note:
During the installation of

the Mast-Planetary Assy in
the Top case, align the
holes of the Ball Bearing
and the holes of the Oil
Collector with the two
Aligning Pins installed on
the Top Case. Heated area

Action No. 2: installation phase

8.2.2.5 Planetary Crown (Fixed Ring Gear), installation procedures
CR&OP Data Module:

gearbox) - Assemble procedures.
Support equipment:
Lifting tool, ring gear 3G6320A00231A181A

TOP CASE
Clamp 3G6320A00231A023M
Supplies:
Specification
references

Packing
Grease C115 Parker super O-

lube.
Ring gear
For Training purpose only 103 of 152 C011

8.2.2.5 Planetary Crown (Fixed Ring Gear), installation procedures
installation phase

8.2.2.6 - Roller Bearing and Cover seal, Installation procedures
CR&OP Data Module:

gearbox) - Assemble procedures.
A
Support equipment:
Screw (M8) Local supply

TOP CASE
Seal installation tool 3G6320A00231A023G
A Bearing installation 3G6320A00231A023C

tool
Nylon Screw Washers +
(C030) Nuts Supplies:
Cover Seal
Specification
Lip seal (C147) references
Packing
Roller Bearing (C115) Solvent, cleaning C010 P-D-680 type II
(C006)
lube.
Packing
(C115) Oil C006 MIL-PRF-7808L
Grease (NS- C147 None

3913-G1)
Heated area Sealing C030 AMS-S-8802B

compound
(Naftoseal MC-
236 Class B)

8.2.2.6 - Roller Bearing and Cover seal, installation procedures
View of the components installed on the TOP Case.

CR&OP Data Module:

Washers +
Nuts 39-A-63-20-05-03A-710A-C
Upper Cooler
Adapter
Supplies:
Specification
Packing Nomenclature Id. No.
references
(C115)
Union Cloth, soft lint-free C011 None
Packing Solvent, cleaning C010 P-D-680 type II
TOP CASE (C115)
lube.

8.2.2.8 - Four Oil jets, installation.
CR&OP Data Module:

39-A-63-20-05-03A-710A-C
Supplies:
Specification
Oil Jets Nomenclature Id. No.
references
lube.
TOP CASE Screw +

Washer
A B
C D
Oil Jet
Filter
Packing
(C115)

8.2.2.9 - Oil Filler Neck, Mast Chip det., Mast Cover and Id. Plate installation
Identification CR&OP Data Module:

Plate (C054)
Mast
Cover (main gearbox) - Assemble procedures.
Packing
(C115)
Support equipment:
Mast-
Planetary
Assy Nomenclature Identification No.
Wrench 3G6320A00231A023L
Support trolley 3G6320A00231A188B
TOP CASE Lifting device Local supply

Oil Filler
plug Clamp 3G6320A00231A023M
Packing
Chip (C115)
Detector
Supplies:
Oil Filler Neck (C014)
(C014)
Chip Det. Packing Nomenclature Id. No. Specification references
Valve (C115)
Grease C115 Parker super O-lube.
Packing Oil
(C115) Scupper Safety wire C014 MS20995C32
Packing Cloth, soft lint-free C011 None

(C115)
Adhesive. C054 199-05-002 class 2,

type II (EA934NA)

- Components installation phases
Mast Cover
E installation
A
Oil Filler Neck
installation
Chip
Detector
installation
Identification
B C Plate installation D

- Installation of the Upper Module on the Support Trolley

8.2.2.10 - Unions, installation procedures
Oil Union
CR&OP Data Module:
A (x4)
39-A-63-20-05-00A-710A-C
Oil Union Main gearbox - Assemble procedures.
B
Supplies:
Specification
references
Main Case Side View

8.2.2.11 - Upper module Assy, installation procedures
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
Nuts
+
Washers
Upper module
Assy
Support equipment:
Lifting tool, mast 3G6320A00231A181C

Packing
Clamp 3G6310A00231A023M
Trolley, upper module 3G6320A00231A188B

support
Supplies:
Main Case Specification

references

lube.

8.2.2.11 - Upper module Assy, installation procedures
Installation phase
A
C

8.2.3.1 Oil Draining Pipe, Oil Level Gauge and Low Oil level Sensor, installation
CR&OP Data Module:
39-A-63-20-05-00A-710A-C
Oil Level Gauge Main gearbox - Assemble procedures.
Nuts Specification
+ Supplies: Nomenclature Id. No.
references
Washers
lube.
Low Oil
Packings (C115) Level
Quick disconnect Sensor
coupling
Packing
(C115)
Packings (C115)
Oil Draining
Pipe
Nuts +
Washers
Drain Cap

8.2.3.2 Oil Filter Head, Oil Temperature sensor, Oil Pressure sensor
and Oil Temperature SW, installation procedures
Packings (C007) Apply Grease (C009)
References:
each sensors
CR&OP: 39-A-63-20-05-29A-720A-C Oil filter element (main gearbox) - Remove procedures
AMP: 39-A-63-41-05-00A-920A-A Oil temperature sensor Replacement
AMP: 39-A-63-41-06-00A-920A-A Oil pressure sensor - Replacement
AMP: 39-A-63-41-07-00A-920A-A Oil temperature switch - Replacement
Oil Pressure sensor
Note :
Oil Temp. sensor
Do not install the Support equipment:
Anti-Spill Valve
and the Oil Filter
Oil Filter Head
Element during Nomenclature Identification No.
this phase
Anti-Spill Lifting tool, mast 3G6320A00231A181C
Oil Temp. Sw Valve
Oil Filter Lifting device Local supply
element
Packing (C007) Clamp 3G6310A00231A023M
Upper Cooler
Adapter Trolley, upper module 3G6320A00231A188B
support
OUT Oil Supplies:

IN Cooler
Id. Specification
Nomenclature
No. references
Ts Ps
Tsw Cloth, soft lint-free C011 None
Oil Filter Head

8.2.3.3 - Rotor Speed Sensor, installation
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
A
Nuts Packings (C115) Supplies:
+
Washers
Specification
references
Speed sensor
lube.

8.2.3.4 - Check valves and Pressure Relief Valve, installation.
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
PRV
Supplies:
Packings (C115)
Specification
Note: references
Apply Grease (C009)
each sensors Grease C115 Parker super O-
lube.
Grease (Aeroshell C009 MIL-PRF-81322F

22)
Packings (C115) Plug (C009)
Check Valve
Retaining Ring)
Packings (C115)

8.2.3.5 Borescope Port (A), Two Chip Detectors (B), Washers (C),
Plugs (D) and Flange Plug (E), installation
CR&OP Data Module:
D
39-A-63-20-05-00A-710A-C
D Borescope port
O-ring (C115)
Supplies:
Screws + Specification
washers Nomenclature Id. No.
references
E
D
Plugs
O-ring (C115)
E Flange
Chip Detector Plug
O-ring (C115) O-ring (C115)
Chip Detector Valve Nuts +

Washer + (C009) Washers
screw O-ring
(C115)

8.2.3.6 - Fifteen (from No. 1 to No. 13) Oil Jets, installation.
CR&OP Data Module:

39-A-63-20-05-00A-710A-C
Supplies:
Specification
references

Top View
Oil Jets Oil Jets

Filter Filter
O-ring O-ring (C115)

(C115)
Screw
Screw
+
+
Washer
Washer
Rear View
O-rings O-rings
(C115)
(C115)

Ref. documentations
Engine 2 Inlet
(Drive Shaft) 39-A-63-20-05-01A-710A-C Left input shaft module
(main gearbox) - Assemble procedures (Effectivity
Right input Code: B01)
shaft module
Or
39-A-63-20-05-01B-710A-C Left input shaft module

Engine 1 Inlet Code: B02)
(Drive Shaft)
Or
39-A-63-20-05-01C-710A-C Left input shaft module

Code: B03)
Left input And

shaft module
module (main gearbox) - Assemble procedures
Effectivity Codes:
Note
CR&OP Data Module: 39-A-63-20-05-00A-000A-C Main The assembly procedures given for the left-input
gearbox General shaft module are applicable to the right-input
shaft module.
- B01 : Input shaft module P/N 3K6320A00133 (installed on MGB Refer to: [B01], [B02], [B03] as necessary.
P/N 3G6320A00132 and 3G6320A00133)
- B02 : Input shaft module P/N 3K6320A00135 (installed on MGB During this activity, replace all old fasteners
P/N 3G6320A00134 and 3G6320A00135) (bolts, screws, washers, nuts, packings .....) with
- B03 : Input shaft module P/N 3K6320A00136 (installed on MGB new items.
P/N 3G6320A00134, 3G6320A00135, 3G6320A00132 and Record the P/N and S/N of the components used
3G6320A00133) during the assembly phase and also record the
P/N and S/N of the main assy.
8.2.4.1 - Shims, installation
CR&OP Data Module:
LH Input Shim 39-A-63-20-05-01A-710A-C Left input shaft module

Shaft Screws (main gearbox) - Assemble procedures.
Module
Supplies:
Specification
references
Shim
Procedure
Screws
- Make sure that the Serial Numbers of the shim (4) and the left input module
are the same.
- Calculate the thickness of the shim (4) as required (refer to the D.M.).
- Install the shim (4) in the left input module.
- Attach the shim (4) to the left input module with the two screws (5).
- Make sure that the Serial Numbers of the shim (2) and of the left input
module are the same.
- Calculate the thickness of the shim (2) as required (refer to the D.M.).
- Install the shim (2) in the left input module
- Attach the shim (2) to the left input module with the two screws (3).
Note 1: Perform the same actions on RH input shaft module.

8.2.4.2 - Bearings, installation
CR&OP Data Module:

Screws
Nuts + 39-A-63-20-05-01A-710A-C Left input shaft module
Washers
Flanged
Roller Support equipment:
Bearing
Nuts + Nomenclature Identification No.

Washers
Oven Local supply
Flanged Ball Bearing Holder, bearing 3K6320A00131A023Y

(outer race)
Screws Supplies:
Specification
references
LH Input Oil C007 MIL-PRF-23699

Shaft
Module

8.2.4.3 - Diaphragm Assy, assembly procedures
Flanged CR&OP Data Module:

Roller Diaphragm
Bearing 39-A-63-20-05-01A-710A-C Left input shaft module
Screw (main gearbox) - Assemble procedures.
Support equipment:
Oven Local supply
Supplies:
Nuts + Specification
Washers references
A B

8.2.4.4 - Gear (I stage of reduction), assembly procedures
Flanged Ball Bearing CR&OP Data Module:

A (Bottom Inner half-race)
39-A-63-20-05-01A-710A-C Left input shaft module
Support equipment:
B
Oven Local supply
Stand, gear 3K6320A00131A023D
Pusher, gear bearing 3K6320A00131A023N

inner race

Gear
Supplies:
C Specification
Nom. Id. No.
references
Oil C007 MIL-PRF-

23699
Note:
Put the Bottom Inner half-

race and the Top Inner
half-race in the Oven

8.2.4.5 - Gear Assy and Diaphragm Assy, installation procedures
Bolts +
Washers Diaphragm CR&OP Data Module:
Assy

module (main gearbox) - Assemble
Supplies: procedures.
Nom. Id. No.

Specification Oil Dam Support equipment:
references
Packing
Oil C007 MIL-PRF- Nomenclature Identification No.
23699
Stand, gear 3K6320A00131A023D
Gear
Reaction, locknut 3K6320A00131A023H
installation
Heated Wrench 3K6320A00131A023I
area
Pusher, oil dam 3K6320A00131A023Z
Ball Bearing Cage
Lock Ring
Lock Nut
LH Input Flanged Ball
Shaft Bearing (Top
Module Inner half-race) Flanged Ball Bearing ,
Input (installation completed on
Shaft Gear)
Module

- Gear Assy, installation phase on the Input Shaft Module
A C E G
Lock nut and lock ring

Lock ring, installation installed on the Gear
Torque phase of the Lock
nut with Wrench
Pusher, Oil dam
B D
F H
Bending phase of the

Oil dam,
Lock nut, installation Input shaft module and Gear Locking ring
installation phase
installed on the Reaction tool, (two position)
installation

- Diaphragm Assy, installation phase on the Input Shaft Module
Heated
area
Gear
Input Shaft Module, Inner view

C
Bolts installation phase
B
D
Diaphragm,
Bolts, torque phase
installation view

8.2.4.6 - Input Drive Quill group, assembly procedures
CR&OP Data Module:

procedures.
Support equipment:

Key
(2 position)
Oven Local supply
Plug
(C042) Pusher, pinion 3K6320A00131A023C
Input
bearing outer race
Pinion
Heated Bearing Arbor press Local supply
components Sleeve
Bolts +
Washers Heated Stand, pinion 3K6320A00131A023B
component
Pusher, input pinion 3K6320A00131A023A
Duplex Ball
bearing
Bearing
Supplies:
Note:
Put these components in the Oven as required. Nom. Id. No.

Specification
- The bearing sleeve (13) references
LH Input - The two inner half-races (top and bottom) of the ball Oil C007 MIL-PRF-
Shaft bearing (15A) 23699
Module
- The inner race of the ball bearing (15B). Epoxy C042 MIL-P-23377.
Primer

- Duplex ball bearing installation phase
Pusher used to install the

Bottom Outer race (15B)
and the Top Outer race (15A)
(15A) of the duplex ball (15B)
bearing in the Bearing
Sleeve
Pusher used to install the Bottom Inner race (15B) and the Bottom and TOP Inner Half-
Race (15A) on the Input Pinion

- Assembly phase
Bottom Outer
A C Race (15B)
installed in the
Bearing Sleeve.
Marks applied
on the Duplex
Ball Bearing
D
Bottom Inner
Mark applied Mark applied on Race (15B),
on the Bearing the stem of the installation
Sleeve input pinion phase on the
Input Pinion.

- Assembly phase
H
F
View of the Plug, (the outer surface of

the plug is protected with Primer C042)
L
G
View of the Plug

installed inside the
Input Pinion.
View of the Key installed

in the Bearing Sleeve
Plug, installation
phase in the input
Pinion
View of the Ball bearing 15B and of the two
Keys. installed inside the bearing sleeve.

- Assembly phase
Q
M O
Top Outer
Race (15A)
installed in the
Ball Bearing Cage
Bearing Sleeve.
(15A), installation
phase
Pusher used to
install the Top
N Inner half-race
(15A), on the
P Pinion
Bottom Inner Top Inner Half-

Half-Race Race (15A), View of the Input
(15A) installed installed on the drive quill group
on the Pinion. Pinion assembled.

8.2.4.7 - Input Drive Quill group and Gimbal Assy, installation procedures.
Support equipment: Supplies: CR&OP Data Module:

Nomenclature Identification No. Specification
Nom. Id. No.
references 39-A-63-20-05-01A-710A-C Left input
Oven Local supply
shaft module (main gearbox) - Assemble
Heat gun Local supply procedures.
Epoxy C042 MIL-P-23377. Nuts +
Pusher GJ-06-02 Primer Washers
Arbor press Local supply Retaining

Grease C009 MIL-PRF-81322F
Spring
Tool, bushing EA6305G631-041
installation Gimbal
Tool, gimbal carbon 3G6305G13231 Packing (C007) Locknut (C009)

seal installation Carbon seal Flange (C007)
Pusher, flange 3G6305G11731 Ring Bushings (C042)
Reaction, locknut 3K6320A00131A023F

installation
Wrench 3G6305G11331
Items
Stand, backlash 3K6320A00131A676A Heated
Mating Carbon Seal
check Ring
Spacer
Packing
Heated
area Input Drive Items
Quill Group Heated
LH Input
Shaft
Module

- Installation phase
A C E
Carbon seal (31), Carbon seal (31),

Ring (30), installation phase installed in the
installation on on the Gimbal Gimbal
the Pinion
B D F
Gimbal (33),
pre-installation
phase of the Carbon seal (31), installation
phase view of the Arbor Gimbal installed
carbon seal
press + Gimbal carbon seal on the Input drive
(31)
installation tool quill group.

G I M
Flange (40),
installation phase Marks applied on Torque application
in the spline of the Locknut on the locknut
Input Pinion.
L N
Marks applied Wrench Retaining Spring

on the Flange installation (39) installation

Tool, bushing Use of the tool

installation

Q View of the Heated area

of the Input Shaft Model S
+ Gimbal Assy.
View of the Input drive quill

group installed on the Input
drive module.
Installation of the Input Drive

Quill group + Gimbal Assy on the Gimbal Assy, front view.
Input Shaft Module.

8.2.4.8 - Input Shaft Module, Backlash check.

Shaft Module
39-A-63-20-05-01A-713A-C
Note

Use the specific Data Module.
Gear, I Stage Record the backlash found between the Input Pinion and the Gear.
of reduction
Support equipment:
Flange Nomenclature Identification No.
Stand, backlash check 3K6320A00131A676A
Stopper, gear 3K6320A00131A023L
Backlash tool, input drive quill 3K6320A00131A676B

Input
Pinion

8.2.4.8 -Input shaft module (main gearbox) Backlash check.
- Procedures
Left Input Shaft Procedure:
A
A Module (1),
Input side 1 - Put the left input module (1) on the Stand.
2 - Install the Stopper on the Stand.
3 - Lock the gear (2) in the left input module (1) with the Stopper.
4 - Install the Backlash Tool on the input side of the left input module (1).
Stand 5 - Lock the Backlash Tool to the flange (3).
(3K6320A00131A676A ) 6 - Do a check of the backlash between the gear (2) and the input pinion (4) as
follows:
6.1 Install the Dial Gauge on the support of the Stand.
6.2 Set the dial gauge to zero.
Stopper, gear 6.3 Pull and Turn the input pinion (4) through the arc allowed by the tooth
(3K6320A00131A023L) clearance.
Note
Backlash tool, installation Measure three position at 120 to each other. The value is the average of the three
B
measures.
(3K6320A00131A676B)
6.4 Measure, calculate and record the backlash as required.
6.5 Push and Turn the input pinion (4) through the arc allowed by the tooth
clearance. Note
Measure three position at 120 to each other. The value is the average of the
three measures.
6.6 Measure, calculate and record the

C D backlash as required.
Note
Gear, 1 Stage Perform this action on both
of reduction (2) Input Shaft Modules.
Input
Pinion (4)
Flange (3) Dial gauge,

installation Backlash check

8.2.4.9 - Freewheel Group, assembly procedures.
LH Input
Shaft
CR&OP Data Module:
Module
procedures.
Inner Bearing (oven) Oil Vane
Support equipment:
Left Input Shaft
Freewheel
Oven Local supply
Pusher, outer 3G6305G04631

bearing installation
Outer Bearing (oven)
Supplies:
Specification
Nom. Id. No.
references
Oil C007 MIL-PRF-

23699
Oil Vane
Freewheel

8.2.4.9 - Freewheel Group, assembly procedures.
- Assembly phase
Pusher
Input Shaft
Inner Bearing C
Oil
Vane
Freewheel
Outer
Bearing
Arbor Press

8.2.4.10 - Freewheel Group and Oil jet Cover, installation
LH Input
Shaft CR&OP Data Module:
Note:
Module
During the installation phase 39-A-63-20-05-01A-710A-C Left input shaft
of the Oil Jet Cover (57) use module (main gearbox) - Assemble
the Heat Gun to increase the
temperature of the Input procedures.
Shaft Module.
Support equipment:

Packing
Oven Local supply
Spacer
Packing Pusher, clutch inner race 3G6305G04731
installation
Freewheel Heat gun Local supply

Group
Retaining ring
Supplies:
Packings Specification
Nom. Id. No.
references
Oil Jet Oil C007 MIL-PRF-
Cover Nuts +
Washers 23699

- Installation phase of the freewheel group
Phase 2
Phase 1
Final positioning of the Freewheel group
Installation of the Freewheel Group on inside the Gear. During this phase
the Pusher and the positioning of the continue to use the pusher until the
Pusher on the Input Shaft Module freewheel group is fully against the
shoulder in the gear.

- Installation phase of the freewheel group
Positioning of the Pusher inside the Installation phase of the freewheel

Positioning of the Freewheel group on
Freewheel group group inside the Gear
the Input Shaft Module

- Spacer and Oil Jet Cover installation phase
F H
D
Spacer
Retaining ring
installation phase
Oil Jet Cover

preparation
E
G
I
Spacer installed inside Oil Jet Cover installed on

Oil Jet Cover the Input Shaft Module
the Gear

8.2.4.11 - Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation
Plug C014) Thermocouple (C014, hexagon)
LH Input Packing
Shaft Packing (C009) (Input Pinion Bearing Temperature sensor) CR&OP Data Module:
Module (C009)
Washer + module (main gearbox) - Assemble
Screw
procedures.
Packing
(C007)
Supplies:
Fitting
Specification
(C014) Nom. Id. No.
references
Packing Safety wire C014 MS20995C32

(C009)
Grease C009 MIL-PRF-81322F
Pressure Sw (Aeroshell 22)
(C014)
Screw
Washer
Packings
(C007)
Oil Jet
(C014)

8.2.4.11 - Oil Jets, Thermocouple, Oil Pressure SW, Plug and Fitting installation
- External components installation view
C E
A
Oil Jet (64A) Oil Jet (64B) Pressure Sw
B D
F
64C
64B
64A
View of the Oil Jets Bearing Thermocouple

Oil Jet (64C) (64A,B,C) installed on
the Input Shaft module

8.2.4.12 - LH/RH Input Shaft Module, installation.
CR&OP Data Module:

C164)
39-A-63-20-05-00A-710A-C
Cross Shaft Support equipment:

Packing Nomenclature Identification No.
Outer Plug Plug, installation tool Tbd

Packing
Inner cap
Supplies:
Packing
Specification
(C115) Nom. Id. No.
references
Adhesive (Shellac) C163 None
Packing Sealing compound (AMS- C164 AMS-S-8802,
S-8802, Class A-1/2) Class A-1/2.
Cork Plug (C163) Grease C115 Parker super O-
LH Input
Shaft Module lube.
Union
Washers +
nuts Note:
Packings The installation procedure used for LH Input

(C115) Module is also applicable for RH Input
Module. See D.M. as required.

8.2.4.12 - LH/RH Input Shaft Module, installation procedures.
B C Plug + Cap
A
Plug, Installation Tool
Packing E
Cross Shaft
RH Input Shaft Module
(inner side) + Cross Shaft
RH Input Shaft Module RH Input Shaft Module

F Union, (inner side) , installation phase
(inner side) , installation phase
installation
G H
Main Case
Cross Shaft

8.2.5 - Anti-Torque Beam, Installation procedures
Support equipment: CR&OP Data Module:

39-A-63-20-05-00A-710A-C
Lifting tool, main gearbox 3G6320A00131A181A
Upper Module C
MGB
Trolley, main gearbox support 3G6320A00131A188B
Main Case
Main Case RH
RH
Anti-Torque Beam
LH
Washers + LH
Nut (x 23) B

Chapter 8 - Assembly Procedures
THE END

TECHNICIAN TRAINING

9 MGB Functional Check
INDEX

9.1.1 Introduction
9.1.2 Description of operations of flushing
9.2 Functional Check (Test A)

9.2.1 Procedure
(Conts)
9.1.1 INTRODUCTION
Before to carrying out a Functional Check , the internal areas of the MGB should be flushed to remove any dirt or debris.
This procedure is reported in the following CR&OP data module: 39-A-63-20-05-00A-255A-C (Main gearbox
Purge). Support equipments:
Electric motor GJ-34-04

Flushing bench 156-1
Trolley, main gearbox HE-04-00
transport
Refer to the data module for further information
Supplies / Spares
Specification
Nomenclature Identification No
references
(Turbo Oil 2380)
Plug CJ-34-10 and
CJ-34-09
9.1.2 DESCRIPTION OF OPERATIONS OF FLUSHING Refer to the data module for further information
The operation is performed by flow of oil under pressure sent into circulation by the pump discharge flow bench, adjusted to obtain a pressure value equal
to 5.5 +/- 0.5 Bar (80 +/- 7 PSI).
The fluid in circulation at a temperature of about 80 C, thought the Oil Jets of the Transmission, is used for rinsing dynamic components such as gear
teeth, bearings and their slopes.
The fluid is simultaneously conveyed to the tank of the bench through the recovery pump.
Limited to flushing expected before the Functional Check, the rotation of the dynamic parts of the MGB (gears - bearings) performed by the Electrical
Motor installed on No.1 Hyd. Pump Drive Quill helps to improve the effectiveness of the operation. The Flushing cycle should be performed for 30 minutes.

9.2 - Functional Check (Test A)
9.2.1 PROCEDURE
In the IETP/CR&OP the operator can find 2 different procedures, one can be used when a Test Bench is
available and one when the Test Bench is not available, in particular:
If the Test Bench is available refer to CR&OP data module: 39-A-63-20-05-00A-344A-C (Main gearbox -
Functional check) vice versa, if the Test Bench is not available, you can do the functional check with the
main gearbox installed on the helicopter applying the procedure reported on the CR&OP data module: 39-A-
63-20-05-00A-344B-C (Main gearbox - Functional check).
In this section will be described the actions reported on CR&OP data module 39-A-63-20-05-00A-344A-C
following a specific guideline. Hereinafter are reported the equipments and the supplies required to perform
this action.
Support equipments: Supplies:
Nomenclature Identification No. Specification

references
Test bench, gearbox 139G6300E001 Oil C007 MIL-PRF-23699
(Turbo Oil 2380)
or or
Test bench LTR100-2000-02

or equivalent
Transport trolley 139G6320A00331A188E

a) The MGB must be installed on the Test Bench carrying out the necessary mechanical and electrical
connections required.
b) Fill the transmission with approximately 20 dm3 (5.3 US gal) of Oil (C007) as required.
Refer to CR&OP 39-A-63-20-05-00A-212A-C.
Test Bench, front view
Test Bench, side view

(Conts)
Note: During the Functional Check, make sure that the Temperature and Pressure indications are not more
than the values that follow:
- Input Pinion Bearing Temperature : 130C
- Oil Temperature : 110C
- Oil Temperature variation (input/output of the MGB) : < 15C
- Oil Pressure : 5 thru 5.5 Bar.
c) Start the Test Bench and gradually get the 100% of the nominal speed (21000 RPM).
d) During this phase make sure that :
- The test bench operates correctly
- The oil pressure is 5 thru 5.5 bar
- The oil low pressure indicator is off
e) If the oil pressure is not in the specified range, stop the test bench
and adjust the PRV (Pressure Relief Valve) before to continue.
Note
The pressure setting must be the same for the two pressure relief valves.
Procedure
Adjust the two pressure relief valves as follow:
Get access to the pressure relief valve
Loosen the lock nut fully.
Adjust the pressure relief valve as follow:
Turn the adjustment screw clockwise to increase the pressure setting Adjustment
Turn the adjustment screw (3) counter clockwise to decrease the pressure setting. Screw
Note
One complete turn of the adjustment screw (3) changes the pressure setting by approximately Lock nut Pressure
0.5 bar. Relief Valve
Tighten the lock nut (2).

f) After the adjustments Start the Test Bench and do the green run cycle. Obey the instructions given in
the Table reported hereinafter:

g) At the end of the Functional Check (green run cycle) perform the following actions:
- Compile a specific Test Report

- Remove the MGB from the Test Bench
- Install the MGB on the Transport Trolley
- Disassemble the MGB and perform the visual examination of the components.

THE END

TECHNICIAN TRAINING
Chapter 10 Disassembly
procedures after Functional check
10 Disassembly procedures after Functional Check
INDEX
10.1 Introduction
10.2 MGB - Disassembly procedures, initial phase
10.4 MGB - Disassembly procedures, final phase
10.5 Left / Right Input Shaft Module - Disassembly procedures, initial phase
10.7 Left / Right Input Shaft Module - Disassembly procedures, final phase
10.8 Upper module, disassembly procedures
10.9 Mast-Planetary Assy, disassembly procedures
10.10 Front Hyd. Pump drive quill, disassembly procedures
10.11 LH/RH Hyd. Pump drive quills, disassembly procedures

10.1 Introduction
In order to inspect and check the internal components of the MGB after the Functional Check performed on
specific Test Bench, the MGB must be disassembled once again; this action is required before to perform
the Leak Check (Test B) and before it can be declared serviceable.
During this phase the MGB will be disassembled but to a lesser degree.
In particular, will be performed the following actions:
- If not already performed just after the Functional Check, drain the Oil from the Main Case.
Refer to CR&OP data module: 39-A-63-20-05-00A-222A-C (Main gearbox Drain Oil)
- Start with the disassembly phase of the MGB.

Refer to CR&OP data module: 39-A-63-20-05-00A-539A-C (Main gearbox Disassemble procedures
after functional check).
- Perform the Backlash check on the Main Case and on each Input Shaft Module as required.
Refer to the following CR&OP data modules:
39-A-63-20-05-00A-713A-C (Main gearbox - Backlash/gear pattern check),

39-A-63-20-05-01A-713A-C (Left input shaft module Backlash/gear pattern check) and to
39-A-63-20-05-02A-713A-C (Right input shaft module backlash/gear pattern check).
- After completion of the MGB disassembly, each parts removed (Main Case, Upper Module, Input Shaft
modules and Mast-Planetary Assy) or disassembled must be re-inspected (Visual Examinations) i.a.w. the
specific CR&OP data modules.

10.2 MGB Disassembly procedures, initial phase
During this phase refer to CR&OP data module: 39-A-63-20-05-00A-539A-C (Main gearbox
Disassemble procedures after functional check).
In particular, referring to this D.M. disassemble the MGB as necessary to perform the backlash check on the
Main Case. Perform the following actions:
1. Remove the Draining Pipe as required.
2. Remove the Anti-Torque Beam as required.

3. Remove the Bottom Cover as required.
Mast-
Planetary
assembly
4. Install the MGB on the Maintenance Trolley Upper

Module
RH Input
LH Input Shaft
Shaft Module
Module
Main Case
Assembly
Maintenance
Trolley
Side View

5. Remove the Left and Right Input Shaft Module.
6. Remove the Plugs from the open Drive Quills (Hydraulic Pumps drive quills, ECS drive quill and FAN
drive quill) and the Seal Cover from the Fan Drive Quill and from the ECS Compressor Drive Quill.
LH/RH Hydraulic Pump, ECS Compressor, Drive Quill plug Front Hydraulic Pump, FAN, Drive Quill plug + Seal
Drive Quill plug + Seal Cover Drive Quill plug Cover

7. Remove the Oil Filter Head from the Upper Module.
8. Remove Rotor Speed Sensor (NR).

9. Remove the two Check Valves.
10. Remove the two Pressure Relief Valves.

11. Remove the two (LH/RH) Chip Detectors
12. Remove the Left and Right Lubrication Pump.

13. Remove the Fifteen Oil Jets from the Main Case.
Top View
Rear View

14. Remove the left/right-input shaft module
Main Case
O-ring
Plug
Cross Shaft
LH Input Shaft Module
Union
Washers
Washers
Cross Shaft Nuts
Washers
O-rings
Bracket
Washers
Nuts NutsWashers
Washers
Bracket
+ Nuts
Bracket Set screw (Nylon)

15. Remove the Upper Module, the Unions and the Planetary Crown (Ring gear).
Oil Union
A (x4) Upper Module
Assy
Oil Union
B
Planetary
Crown
Main Case (Fixed Ring
Gear)


RH Input Pinion II
between:

Fan Drive Quill



Drive Quill
LH Input Pinion II
Note
Measure and Record the backlash

10.4 MGB Disassembly procedures, final phase
During this phase refer to CR&OP data module: 39-A-63-20-05-00A-539A-C (Main gearbox
Disassemble procedures after functional check).
In particular, referring to this D.M. perform the final disassemble of the MGB as follows.
1. Remove the Fan, LH & RH Hyd. Pump, Front Hyd. Pump and ECS-Compressor Drive Quills.
Engine 2 Inlet
(Drive Shaft)
Details

V - Fan Drive Quill
Engine 1 Inlet
(Drive Shaft)

2. Remove the Right & Left Input Pinion Assy (II stage of reduction).
Input Pinion II
Stage

(RH Side)
Assembly removed

3. Remove the Tail-rotor drive-quill Assy.
Tail Rotor Drive

Quill Assembly
4. Remove the Diaphragm.

5. Remove the Collector Gear. See Para. 39.
6. Remove the Collector Bearing. See Para. 39.6

10.5 - Left / Right Input Shaft Mod. Disassembly proc., initial phase
Ref. documentations
Engine 2 Inlet
Right input
procedures after functional check
(Effectivity Code: B01)
Engine 1 Inlet
(Drive Shaft) Or
Left input
shaft module
And
Effectivity Codes: procedures after functional check
Note
- B01 : Input shaft module P/N 3K6320A00133 (installed on [MGB
A01] P/N 3G6320A00132 and 3G6320A00133) The disassemble procedures given for the left-
- B02 : Input shaft module P/N 3K6320A00135 (installed on [MGB input shaft module are applicable to the right-
A02] P/N 3G6320A00134 and 3G6320A00135) input shaft module.

10.5 - Left / Right Input Shaft Mod. Disassembly proc., initial phase
Description
During this phase refer to CR&OP data module: 39-A-63-20-05-01A-539A-C, 39-A-63-20-05-01B-539A-C

or to 39-A-63-20-05-02A-539A-C as required.
In particular, taking into account the D.M. 39-A-63-20-05-01A-539A-C (as example), perform the actions
reported hereinafter:
Remove the three Oil Jets, the Oil Jet Cover, the Thermocouple, the Freewheel Group and disassemble
the Freewheel Group as required.
Note
Thermocouple
LH Input Shaft
Module
Thermocouple
Freewheel
Group
Oil Jet
Cover
Oil Jet
Oil Jet RH Input Shaft
Cover
Module

10.6 - Input Shaft Modules, Backlash check

Shaft Module
39-A-63-20-05-01A-713A-C
Note

Gear, I Stage Use the specific Data Module.
Record the backlash found between the Input Pinion and the Gear.
of reduction
Flange
Input
Pinion

10.7 Left / Right Input Shaft Mod. - Disassembly proc., final phase
- Description
During this phase refer to CR&OP data module: 39-A-63-20-05-01A-539A-C, 39-A-63-20-05-01B-539A-C or

to 39-A-63-20-05-02A-539A-C as required.
In particular, taking into account the D.M. 39-A-63-20-05-01A-539A-C (as example), remove the Input drive-
quill group as required.
Input Drive-Quill
Group
Note
Use the Heat Gun and

(as required) of the LH Input
Pinion.

10.8 - Upper module, disassembly procedures
During this phase refer to CR&OP data module: 39-A-63-20-05-03A-539A-C - Upper module (main
gearbox) - Disassemble procedures after functional check , as required.
In particular, taking into account this D.M. perform the actions reported hereinafter.
1. Remove the four Oil Jets
A B
C D
2 Oil Jets No. 1
2 Oil Jets No. 2

2. Remove the Chip Detector and the Chip Detector Valve .
Chip Detector
O-ring
Chip Det. Valve
O-ring

3. Remove the Roller Bearing, the Seal cover and the Mast-Planetary Assy as required.
Top Case
Mast-
Planetary
Assembly
Seal Cover
Roller
Bearing Note:
Planetary crown
(Fixed ring gear)
already removed

10.9 - Mast-Planetary Assy, disassembly procedures
During this phase refer to CR&OP data module: 39-A-63-20-05-13A-539A-C - Mast-planetary assembly
(upper module) - Disassemble procedures after functional check.
In particular, remove one of the five Planetary Gear Assy from the Flange and then disassemble the
Planetary gear Assy i.a.w. the following D.M.: 39-A-63-20-05-14A-530A-C Planetary gear assembly (mast
planetary assembly) - Disassemble procedures.
Top-inner
bearing race
Roller cage
Rollers
Flange Gear
(outer bearing
Planetary race)
Gear Assy.
Rollers
bearing race

10.10 - Front Hyd. Pump drive quill, disassembly procedures
During this phase refer to CR&OP data module: 39-A-63-20-05-04A-539A-C Front pump drive quill
(main gearbox) - Disassemble procedures after functional check
In particular, remove the Retaining Ring, the Seal Cover and the Packing from the drive quill.
Front Hyd. pump

drive quill
Inner side
Packing
Seal cover External side
Retaining ring

10.11 - LH/RH Hyd. Pump drive quills, disassembly procedure
During this phase refer to CR&OP data module: 39-A-63-20-05-27A-539A-C Left/right pump drive quill
(main gearbox) - Disassemble procedures after functional check.
In particular, remove the Retaining Ring, the Seal Cover and the Packing from the drive quills.
Left/right pump drive quill (Hyd.

Retaining ring pump No.1 and No.2 drive quill)
Seal cover Inner side
Packing
External side

Chapter 10 Disassembly procedure after Functional check
THE END

TECHNICIAN TRAINING
Chapter 11: Inspection criteria after

Functional check
11 Inspection Criteria after Functional check
INDEX
11.1 General guideline for visual examination of components after functional check
11.2.2 Input pinion (II stage of reduction) Wear Pattern Check

11.1 General guideline for visual examination of components after
functional check
This section lists the general criteria for the inspection of the main components of the main transmission.
Note
For more data on the visual examination of the components of the main gearbox and
for the definition of the defects refer to the following CR&OP data modules:
39-A-63-20-05-00A-919A-C Main gearbox - General guidelines for visual

examination of components after functional check
39-A-63-20-05-00A-913A-C Main gearbox - General guidelines for visual

examination of components
All information reported in this Chapter must be considered for Training purpose only
1. GEARS
Check the gear teeth for corrosion, overload indication, pitting and scoring. Light indication of contact
are allowed on the top and on the bottom. Light particle passage indication is allowed.
Verify the dimension and the pattern position.
2. BEARINGS
Check the ball and roller bearing for corrosion, scratches, pitting, spalling and check for free to rotate.
Check the internal and external diameters for fretting and/or rotation; light indication of rotation between
external race and housing is allowed for no flanged bearings. Light scratches on the rollers and on the
races are allowed.

11.1 General guideline for visual examination of components after
functional check
(continued)
3. SPLINE
Check the spline teeth for corrosion, fretting, overload indication and indentation. Light fretting is allowed.
4. FREEWHEELS
Check the SPRAG of the freewheel for corrosion, cracks, wear and pitting.
Check the cage outer diameter for heavy contact pattern and the SPRAG pocket for deformation.
Check the races for wear, overheating and heavy contact pattern.
5. CASE
Check for damage due to movement and displacement before, during and after the green-run.
Check the bearing housing on case and liner; light fretting is allowed.
Check the connecting surfaces; light fretting is allowed.
Check the studs for elongation, deformation, corrosion.
6. SEALS
Check the static and rotating seal for damage, deformation, scratches, breakage and rubber
degradation
Inspect the races of the rotating seal for wear.
Inspect the input rotating seal.
In case of leakage during the green-run change the seal.

As reported on CR&OP data module: 39-A-63-20-05-00A-319A-C Main gearbox - Visual examinations

after functional check, perform the following inspections:
1. Examine the Splines of the two Cross-Shafts (1) for fretting.
2. Examine the two roller bearings (2) for corrosion, scratches, pitting and spalling. The roller bearings
stay in the main case.

3. Examine the interface planes of the diaphragm (3) for (continued)

fretting.
4. Examine the bearing (4) for corrosion, scratches, pitting
and spalling. The bearing (4) stays in the diaphragm (3).
5. Examine the teeth (spiral bevel gear and spur gear) of the
collector gear (5) for corrosion, indentation, scoring and
pitting. Examine the teeth for acceptable wear pattern.
Refer to CR&OP data module: 39-A-63-20-05-00A-
379A-C. See Para. 11.2.1. of this Training Manual.
6. Examine the bearing race on the collector gear (5) for
corrosion, scratches, pitting and spalling.
7. Examine the interface planes of the collector bearing
(6) for fretting. Make sure that the collector bearing is free
to turn. The collector bearing (6) stays on the collector
gear (5).
8. Examine the main case (7) for:
General condition. This is very important on the external

surfaces.
Fretting on the interface planes. This is very important
for the interface planes with the ring gear, the diaphragm
and the anti-torque beam.
Fretting on the line housings.
9. Examine the studs of the main case (7) for damage,

scratches and distortion.

(continued)
10. Examine the teeth of the two pinions (8) for

corrosion, indentation, scoring and pitting.
Examine the teeth for acceptable wear pattern.
Refer to CR&OP data module: 39-A-63-20-05-
00A-379A-C. See Para. 11.2.2. of this Training
Manual.
11. Examine the bearing races on the pinions (8) for
12. Examine the splines of the pinions (8) for fretting.
13. Examine the interface surfaces of the bearing
sleeve (9) for fretting.
14. Make sure that the bearing (10) is free to turn.
15. Examine the teeth of the gear (11) for corrosion,
indentation, scoring and pitting. Examine the teeth
for acceptable wear pattern. Refer to CR&OP data
module: 39-A-63-20-05-00A-379A-C.
See Para. 11.2.3. of this Training Manual.

During this inspection it is required to examine the wear pattern located on the:
Convex side of the Gleason Crown (W.P. with Second stage pinion); see detail A1.
Concave side of the Gleason crown (W.P. with Tail Rotor drive pinion); see detail A2.
Sun Gear (W.P. with Planetary gear); see detail A3.
Concave side of the Gleason Crown (W.P. with Front Pump drive quill gear); see detail A4.
Concave side of the Gleason Crown (W.P. with ECS Compressor drive quill gear); see detail A5.
Concave side of the Gleason Crown (W.P. with Lubrication Pump gear); see detail A6.
These information are reported in the following CR&OP data module: 39-A-63-20-05-00A-379A-C Main
gearbox - Gears - Wear pattern check.

11.2.2 Input pinion (II stage of red.) Wear Pattern Check
During this inspection it is required to examine the wear pattern located on the:
Concave side of the Gear (Eng. No. 1); see detail B1.
Concave side of the Gear (Eng. No. 2); see detail B2.

During this inspection it is required to examine the wear pattern located on the Convex side of the Gear (3);
see detail C.

As reported on the following CR&OP data modules:

39-A-63-20-05-01A-319A-C Left input shaft module (main gearbox) - Visual examinations after
functional check, or
39-A-63-20-05-01B-319A-C Left input shaft module (main gearbox) - Visual examinations after
39-A-63-20-05-02A-319A-C Right input shaft module (main gearbox) - Visual examinations after
functional check, perform the actions reported hereinafter:
1. Examine the oil jet cover (6) for conditions.
2. Examine the input shaft (3). Use the
Magnifying Glass and obey the instructions
that follow:
2.1 Examine for corrosion, wear and seizure.
2.2 Examine for signs of not circumferential
operation.
2.3 Examine for sprag engagement scratches
with a depth more than 0.010 mm (0.0004
in).
3. Examine the ball and roller bearings (2),
(5), (7), (12) and (13) and the duplex
bearing (10) for damage.
4. Examine the outer diameters and the related
seats of the ball bearings (2) and (5) for
condition.
5. Examine the freewheel (4).
Refer to CR&OP data module: 39-A-63-20-
05-01A-311B-C. See Para. 11.3.1 of this
Training Manual.
(continued)
6. Examine outer surfaces of the Gimbal
(14) for damage and dents.
7. Examine the attach holes and the mating
surface of the flange (15) for fretting,
dents and damage.

(continued)
8. Examine the input pinion (11) and the crown
gear (8). Obey the instructions that follow:
8.1 Examine the bearing seats for fretting and 11
conditions.
8.2 Examine the teeth for damage and condition.
8.3 Examine the teeth for acceptable wear pattern.
9. Examine the freewheel sprags engaging area of
the gear (8) for corrosion, wear, seizure and
sprag engagement deep scratches.
Note
Only small contamination with material from
freewheel springs is permitted.
10. Examine the interface surfaces of the sleeve (9)

for fretting and seizure. 8
11. Examine the left input module (1). Obey the
instructions that follow:
11.1 Examine the case for general condition.
11.2 Examine the outer surface for handling damage.
11.3 Examine the interface planes for fretting.
11.4 Examine the sleeve seats for fretting and
seizure.
11.5 Examine the studs for stretching, distortion and
damage.
12. Reject the parts that are damaged.

During the inspection of the Freewheel it is required to follow the procedure reported on CR&OP data
module: 39-A-63-20-05-01A-311B-C Left input shaft module (main gearbox) - Freewheel - Detailed
visual examination.
In particular, perform a detailed
visual examination with the aid of
the Magnifying Glass, of a Mirror
and of a strong light.
Examine the freewheel for corrosion
and distress caused by the heat.
Reject it if you find one of these
defects.
Continue the inspection following
the instructions reported this
CR&OP Data Module.

As reported on the following CR&OP data module: 39-A-63-20-05-03A-319A-C Upper module (main
gearbox) - Visual examinations after functional check, perform the actions reported hereinafter:
1. Examine the lip seal (3) for wear.

2. Examine the roller bearing (4) for corrosion,
scratches, pitting and spalling.
3. Examine the seal housing (2) for condition.
4. Examine the bearing seat on the mast (5) for
fretting and conditions.
5. Do a check on the ring gear (6) as follows:
5.1 Examine the pin seats for fretting and conditions.
5.2 Examine the teeth for corrosion, dents, scoring and
pitting.
1
Manual.
6. Examine the upper module (1) as follows:
6.1 Examine the case for general condition.
6.2 Examine the outer surface for handling damage.
6.3 Examine the interface planes for fretting.
6.4 Examine the seat of the bearing (4) on the upper
module for fretting.
6.5 Examine the studs for stretching, distortion and
damage.

During this inspection it is required to examine the wear pattern along the surface of the tooth (4) as shown
on detail D.

As reported on the following CR&OP data module: 39-A-63-20-05-13A-319A-C Mast-planetary

assembly (upper module) - Visual examinations after functional check, perform the actions reported
hereinafter.
1. Examine the mast (5) as follows:
1.1 Examine the seat of the rotating seal for wear and
corrosion.
1.2 Examine the spline teeth for fretting, dents and
damage caused by the work trolley.
1.3 Examine seat of the roller bearing (1) for corrosion,
1.4 Examine the mating surface between the planetary
gear support and the shims (2) for fretting.
2. Examine the mating surface between the plate (3)
and the shims (2) for fretting.
3. Examine the opposite end surfaces of the shims
(2) for fretting.
4. Do a check on the planetary gear (4) as follows:
pitting.
4.2 Examine the outer race and the rollers for corrosion,
4.3 Examine the inner race only if a defect is found on
the outer race or on the rollers. Do a check for
4.4 Examine the teeth for acceptable wear pattern. Refer
to CR&OP data module: 39-A-63-20-05-00A-379A-
C. See Para. 11.5.1. of this Training Manual.
During this inspection it is required to examine the wear pattern along the surface of the tooth located on the
sun-gear drive side of the Planetary gear (5, see detail E1) and on the ring-gear drive side of the planetary
gear (5, see detail E2).

As reported on the following CR&OP data modules: 39-A-63-20-05-27A-319A-C Left/right pump drive quill
(main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter.
1. Examine the cover (1) for conditions.

2. Examine the lip seal (2) for wear and overheating.
3. Examine the sleeve (3) and the related bearing as
follows:
3.1 Examine the mating surfaces with the components
for fretting.
3.2 Examine the bearing races for wear, breaks and
deformation.
3.3 Turn the bearing to do a check for the correct and
freely operation.
4. Do a check on the drive gear (4) as follows:
4.1 Examine the spline teeth for fretting.
4.2 Examine the race of the seal for wear.
pitting.
Manual.

During this inspection it is required to examine the wear pattern located on the Concave side of the Gear (6);
see detail F.

As reported on the following CR&OP data module: 39-A-63-20-05-04A-319A-C Front pump drive quill
(main gearbox) - Visual examinations after functional check, perform the actions reported hereinafter.
follows:
for fretting.
deformation.
freely operation.
pitting.
Manual. 39-A-63-20-05-00A-379A-C.

see detail G.

As reported on the following CR&OP data module: 39-A-63-20-05-05A-319A-C ECS compressor drive
quill (main gearbox) - Visual examinations after functional check, perform the actions reported
hereinafter.
follows:
for fretting.
deformation.
freely operation.
pitting.
Manual

see detail H.

As reported on the following CR&OP data modules:

39-A-63-20-05-06A-319A-C Left lubrication pump (main gearbox) - Visual examinations after
39-A-63-20-05-24A-319A-C Right lubrication pump (main gearbox) - Visual examinations after
functional check, perform the actions reported hereinafter.
1. Examine the lubrication pump (2) as follows:

1.1 Examine the mating surfaces with the main
gearbox case for fretting.
1.2 Examine the shaft of the left lubrication pump (2)
for wear.
1.3 Turn the lubrication pump (2) to do a check for the
correct and freely operation.
2.1 Examine the key seat and the housing of the pump
shaft for wear.
pitting.
Manual

see detail J.

As reported on the following CR&OP data module: 39-A-63-20-05-07A-319A-C Fan drive quill (main
gearbox) - Visual examinations after functional check, perform the actions reported hereinafter.

2. Examine the lip seal (3) for wear.
follows:
for fretting.
deformation.
freely operation.
pitting.
Manual

During this inspection it is required to examine the wear pattern located on the Concave side of the Gear
(10); see detail K.

Examine the Tail Rotor Drive Quill for general condition, check the roller bearing per corrosion and
damages then inspect the wear pattern located on the Convex side of the fan drive gear (see detail L1) and
on the Convex side of the Tail-rotor drive pinion (see detail L2).

Chapter 11: Inspection criteria after Functional check
THE END

TECHNICIAN TRAINING
Chapter 12 Assembly
procedures after Functional check
12 Assembly procedures after Functional Check
INDEX
12.1 Introduction

12.1 Introduction
When the examination of the components are completed the MGB must be re-assembled and then
tested with a Leak Check (Test B). In this section will be described the assembly procedure of the
MGB.
During this phase, observe the procedures reported on the following CR&OP data modules:
39-A-63-20-05-00A-714A-C (Main gearbox - General guidelines for assemble procedures),

39-A-63-20-05-00A-719A-C (Main gearbox - Assemble procedures after functional check).
In particular, during the re-assembly phase performed i.a.w the specific data modules, it is required to
re-check the Backlash on the Main Case and on each Input shaft module. For these actions refer to the
following CR&OP Data Modules:
39-A-63-20-05-00A-713A-C (Main gearbox - Backlash/gear pattern check),

39-A-63-20-05-01A-713A-C (Left input shaft module Backlash/gear pattern check) and to
39-A-63-20-05-02A-713A-C (Right input shaft module backlash/gear pattern check).
After completion of the assembly, the MGB must be tested on the specific Test Bench performing a Leak
Check (Test B).

During this initial phase refer to CR&OP data module: 39-A-63-20-05-00A-719A-C Main gearbox -
Assemble procedures after functional check.
In particular, following the steps (from 1 to 5) reported hereinafter, prepare the Main Case of the MGB to the
Backlash Check .
1. Install the Collector Bearing and the Collector Gear in the Main Case as required.
2. Install the Diaphragm as required. Refer to Para. 8.

3. Install the Tail-rotor drive quill.
Tail Rotor Drive

Quill Assembly

4. Install the Right & Left Input Pinion Assy (II stage of reduction).
Input Pinion
(II Stage of reduction)

(RH Side)
Assembly

5. Install the Fan drive quill (without its Packing and Lip Seal Cover), the Right Hydraulic Pump drive quill,
the Left Hydraulic Pump drive quill, the Front Hydraulic Pump drive quill and the ECS drive quill as
required.
The RH, LH and Front Pump Drive Quills, must be assemble before their installation on the Main Case.
These specific procedures are reported in following CR&OP data modules:
- 39-A-63-20-05-27A-719A-C Left/right pump drive quill (main gearbox) - Assemble procedures

after functional check.
- 39-A-63-20-05-04A-719A-C Front pump drive quill (main gearbox) - Assemble procedures after
functional check. Engine 2 Inlet

V - Fan Drive Quill
Engine 1 Inlet
(Drive Shaft)


RH Input Pinion II
between:

Fan Drive Quill



Drive Quill
LH Input Pinion II
Note
Measure and Record the backlash

During this phase refer to CR&OP data module: 39-A-63-20-05-00A-719A-C (Main gearbox Assemble
procedures after functional check).
In particular, following this D.M. continue with the assembly of the MGB performing the actions reported
hereinafter .
1. Install the Packing and the Lip Seal Cover of the Fan drive quill as required.
FAN, Drive Quill + Seal Cover
2. Install the Left and Right Lubrication Pump and the Bottom Cover as required.

During this phase refer to CR&OP data module: 39-A-63-20-05-13A-719A-C - Mast-planetary assembly
(upper module) - Assemble procedures after functional check.
In particular, assemble the Planetary Gear Assy previously removed i.a.w. D.M.: 39-A-63-20-05-14A-710A-
C (Planetary gear assembly (mast planetary assembly) - Assemble procedures) and then install it on
the Flange and perform the final assembly of the Mast-Planetary Assy.
Top-inner
bearing race
Roller cage
Rollers
Flange Gear
(outer bearing
Planetary race)
Gear Assy.
Rollers
bearing race

During this phase refer to CR&OP data module: 39-A-63-20-05-03A-719A-C Upper module (main
gearbox) - Assemble procedures after functional check, as required.
In particular , taking into account this D.M. Perform the actions (see steps 1, 2 and 3) reported hereinafter:
1. Install the Mast-Planetary Assy, the Planetary Crown (Fixed ring gear), the Packing, the Roller Bearing
and Seal Cover on the Top Case.
Top
Case
Mast-
Planetary
Assembly
Seal
Cover
Roller
Planetary crown
Bearing
(Fixed ring gear)
and Packing

2. Install the four Oil Jets.
A B
C D
2 Oil Jets No. 1
2 Oil Jets No. 2

3. Install the Chip Detector and the Chip Detector Valve as required.
Chip
Detector
O-ring
Chip Det. Valve
O-ring

Taking into account the procedures reported in the CR&OP data module 39-A-63-20-05-00A-719A-C (Main
gearbox - Assemble procedures after functional check), install the Unions and the Upper Module Assy
on the Main Case as required.
Oil Union
A (x4) Upper Module
Assy
Oil Union
B
Main Case

Taking into account the procedures reported in the CR&OP data module 39-A-63-20-05-00A-719A-C
(Main gearbox - Assemble procedures after functional check), install the following external
components (see steps from 1 to 7):
1. Install the Plugs on the open Drive Quills (Hydraulic Pumps drive quills, ECS drive quill and FAN
drive quill) and the Lip Seal Cover on the Fan Drive Quill as required.
LH/RH Hydraulic Pump, ECS Compressor, Drive Quill plug Front Hydraulic Pump, FAN, Drive Quill plug
Drive Quill plug Drive Quill plug

2. Install the Oil Filter Head (during this phase without the Filter Element and the Anti-spill valve) as
required. Refer to AMP data module: 39-A-63-20-05-21A-720A-A Oil filter head (main gearbox)
Install procedures.
3. Install the Drain Pipe i.a.w. CR&OP data module :39-A-63-20-05-00A-719A-C Main gearbox -

4. Install the Rotor Speed Sensor (NR). Refer to CR&OP Data module: 39-A-63-20-05-00A-719A-C
Main gearbox - Assemble procedures after functional check.
5. Install the 3 Servo-Actuator Brackets (Front, Left and Right) on the Main Case i.a.w. CR&OP Data module:
39-A-63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check.

12.7 Upper Module, Installation procedure
6. Install the 2 Check Valves i.a.w. CR&OP data module :39-A-63-20-05-00A-719A-C Main gearbox -
7. Install the 2 Pressure Relief Valves (PRV) and the 2 Chip Detectors i.a.w. CR&OP data module :39-A-
63-20-05-00A-719A-C Main gearbox - Assemble procedures after functional check.
PRV
Chip Detectors

8. Install the Oil jets on the Main Case i.a.w. CR&OP data module : 39-A-63-20-05-00A-719A-C Main
gearbox - Assemble procedures after functional check.
Top View
Rear View

Engine 2 Inlet
Right input
Engine 1 Inlet
(Drive Shaft) Or
Left input
shaft module And
Effectivity Codes: procedures after functional check
- B01 : Input shaft module P/N 3K6320A00133 (installed on [MGB Note

A01] P/N 3G6320A00132 and 3G6320A00133)
- B02 : Input shaft module P/N 3K6320A00135 (installed on [MGB The assemble procedures given for the left-input
A02] P/N 3G6320A00134 and 3G6320A00135) shaft module are applicable to the right-input
shaft module.

During this phase refer to CR&OP data module: 39-A-63-20-05-01A-719A-C, 39-A-63-20-05-01B-719A-C

or to 39-A-63-20-05-02A-719A-C as required.
In particular, taking into account the D.M. 39-A-63-20-05-01A-719A-C (as example), install the Input Drive-
Quill Group as required.
Input Drive-Quill
Group
Note
Use the Heat Gun and

(as required) of the LH Input
Pinion. Perform the same
action on the RH Input
Module.
Continued

12.11 - Input Shaft Modules, Backlash check

Shaft Module
39-A-63-20-05-01A-713A-C
Note

Gear, I Stage Use the specific Data Module.
of reduction Record the backlash found between the Input Pinion and the Gear.
Flange
Input
Pinion

Taking into account the CR&OP Data Module 39-A-63-20-05-01A-719A-C (as example), assemble the
Freewheel Group, install the Freewheel Group, the Oil Jet Cove, the three Oil Jets and the Thermocouple
on the Input Shaft Module and then install the Brackets on the Oil Jet Cover as required.
Note
Thermocouple
LH Input Shaft
Module
Thermocouple
Freewheel
Group
Oil Jet
Cover
Brackets
Oil Jet
Oil Jet RH Input Shaft
Cover
Module

Taking into account the CR&OP data module : 39-A-63-20-05-00A-719A-C Main gearbox - Assemble
procedures after functional check, install the Left and Right Input Shaft Module on the Main Case as
required.

Taking into account the CR&OP data module : 39-A-63-20-05-00A-719A-C Main gearbox - Assemble
procedures after functional check, install the Anti-Torque Beam on the Main Case as required.
Then install the MGB on the specific Transport Trolley and perform the Test B (Leak Check).
Anti-Torque Beam, installation
MGB Transport Trolley

Chapter 12 Assembly procedure after Functional check
THE END

TECHNICIAN TRAINING
Chapter 13 Leak Check

13 MGB Leak Check
INDEX
13.1 Leak Check (Test B)

13.1 - Leak Check (Test B)
PROCEDURE
In the IETP/CR&OP the operator can find 2 different procedures, one can be used when a Test Bench is
available and one when the Test Bench is not available, in particular:
If the Test Bench is available refer to CR&OP data module: 39-A-63-20-05-00A-364A-C Main gearbox -
Leak check vice versa, if the Test Bench is not available, you can do the leak check with the main gearbox
installed on the helicopter applying the procedure reported on the CR&OP data module: 39-A-63-20-05-
00A-364B-C Main gearbox - Leak check
In this section will be described the actions reported on CR&OP data module 39-A-63-20-05-00A-364A-C
following a specific guideline. Hereinafter are reported the equipments and the supplies required to perform
this action. See Steps from A to N reported below. Supplies:
Nomenclature Identification No Specification references
Support equipments:
Oil C007 (Turbo Oil 2380) MIL-PRF-23699
Cloth, soft lint free C011 None
Test bench, gearbox 139G6300E001 Solvent, cleaning C010 P-D-680 type II
or or Aliphatic naphtha C059 TT-N-95
Test bench LTR100-2000-02 Dye penetrant C131 QPL-SAE-AMS-2644-3.
or equivalent Corrosion preventative C132 (Brayco 599) MIL-L-14107.

Corrosion preventive oil C123 (Brayco 589) MIL-PRF-8188D.
Bristle brush Local supply
Oil C366 (Aeroshell DOD-PRF-85734
Transport trolley 139G6320A00331A188E Turbine Oil 555

a) The MGB must be installed on the Test Bench carrying out the necessary mechanical and electrical
connections required.
b) Fill the transmission up to the maximum level with Oil (C007).
Test Bench, front view
Test Bench, side view

(continued)
c) Clean the external surfaces of the MGB with the Cloth (C011) and the Solvent (C010).
d) Dry the cleaned surfaces as necessary.
e) Start the Test Bench and operate the MGB as required for the phase 1. See the table reported
hereinafter.
(continued)

f) At the end of the phase 1, stop the test bench.

g) Clean and Examine all mating edges between the different parts for leaks.
h) Apply the Dye Penetrant (C131) on the area.
i) Start the test bench again (phase 2) and operate the MGB as required. Refer to the table reported on
the previous page.
j) If you do not find leaks, continue with Step I or M.
k) If you find leaks:
Do the necessary operations to remove the leaks

Do the leakage check again
If used, remove the unwanted dye penetrant from the surfaces of the MGB.
To do this, use the Bristle Brush.
l) If you know that the MGB will remain in storage for more than 30 days, perform the instructions
that follow:
I.1) Disconnect the oil cooling lines of the test bench from the MGB and install the oil bypass.
I.2) Drain the oil from the MGB. Refer to CR&PO D.M.: 39-A-63-20-05-00A-222A-C Main gearbox - Drain
oil
I.3) Fill the MGB up to FULL level with the Corrosion Preventive Oil (C123). As an alternative to the
corrosion preventive oil you can use a mixture of Oil (MIL-PRF-23699) or Oil (DOD-PRF-85734) and
Corrosion Preventative (C132) (5 thru 15% by volume - 15% recommended).
I.4) Start the test bench and operate the MGB at 100% rpm for 3 min maximum.
I.5) Drain the oil from the MGB.
l.6) Attach a warning tag to the filler neck to tell personnel that the MGB has an internal protection with the
corrosion preventive oil (or mixture).
m) Remove the MGB from the test bench and install it on the Transport Trolley. (continued)
n) At the end of the Leak Check (Test B) perform the following actions:
- Compile a specific Test Report

- Install the Oil Filter Element and all the Nylon Setscrews on the MGB as required.
- Apply the Paint Finish to the MGB.

Chapter 13 Leak Check
THE END

TECHNICIAN TRAINING
Chapter 14 Finish after Leak
Check
14 MGB Finish after leak check
INDEX

(Conts)

Following the instructions reported on the CR&OP data module: 39-A-63-20-05-29A-720A-C Oil filter
element (main gearbox) - Install procedures, replace all packings, install the Anti-spill Valve into the Oil
Filter Case and then install the Oil Filter Element and the Filter Head as required.
In particular, during this phase make sure that the Filter Element engages the Anti-Spill Valve in the inner
side of the Oil Filter Case and, holding in position the Oil Filter Head with hand lock the Filter Head with the
relative fasteners as required.
Packing
(C115)
Packings
(C007)
Supplies:
Specification
Anti-Spill Oil Filter Head Nomenclature Identification No
references
Valve
Oil Filter Oil C007 (Turbo Oil MIL-PRF-
element 2380) 23699
Cloth, soft lint free C011 None
Solvent, cleaning C010 P-D-680 type
II
Grease C115 (parker super None
O-lube)
Anti-Spill
Valve
Oil Filter
element Oil Filter Head

Looking the CR&OP data module: 39-A-63-20-05-00A-719A-C (Main gearbox - Assemble procedures
after functional check, Para. 38 and Para. 39), install the Nylon setscrews on the MGB as required.
During the installation of the setscrew put a small quantity of Grease (C009) into the hole for the setscrew
and then seal the area around the head of the setscrew with a bead of Sealing Compound (C030). During
this last action be careful not to apply the sealing compound in the screwdriver slot.
Supplies:
Specification
references
Grease C009 (Aeroshell 22) MIL-PRF-81322 F.
Sealing C030 (Naftoseal MC- AMS-S-8802B

compound 236 Class B)
In particular, install the Nylon Setscrews on the components reported hereinafter or verify their presence on
the MGB as required. Refer to the specific data modules.
- LH / RH Input Shaft Module.

- ECS compressor drive quill.
- Front, LH and RH Hyd. Pump drive quills.
- LH and RH Lubrication Pumps.
- Front, LH and RH Servo-actuator, Brackets.
- Tail-Rotor drive quill
- Upper Fittings and Seal Cover (Upper Module).
- Bottom Cover.
- Anti-Torque Beam.
At the end these actions apply the Paint Finish to the MGB.

Chapter 14 Finish after Leak Check
THE END

TECHNICIAN TRAINING
Chapter 15 Painting procedures

15 MGB Painting procedures
Taking into account the Procedure , the Figures and the Supplies reported on the CR&OP data module: 39-A-
63-20-05-00A-257A-C (Main gearbox - Paint and apply markings), perform the following actions:
Supplies:
Nomenclature Identification No Specification references
Solvent, cleaning C010 P-D-680, Type II

Masking tape C064 UU-T-106
Sealing compound C153 MIL-S-8802, Type II, Class B2
Primer C042 MIL-P-23377

Tape, adhesion testing C276 PPP-T-42C, Type II
Paint, polyurethane or C277 BSX34, Type A
Paint, polyurethane C314 BSX34, Type B
Install the MGB on the Paint Stand as necessary,

Clean and dry the external surface of the MGB as necessary
Apply the Masking Tape on the surfaces of the MGB where the paint is not required.
Apply a bead of Sealing Compound on the matching surface and on other parts of the MGB where required.
Apply one layer of Primer to all external surface of the MGB.
When the Primer is dried (minimum 4 hrs at ambient temperature) do an adhesion test. If you find signs of
primer on the tape (length: 100 mm), remove the primer from the MGB and apply it again.
Within maximum 72 hours after of the primer application, apply a top layer of Poly. Paint (colour : light gray
glossy).
Remove the MGB from the Paint Stand and put it into storage.

15 MGB Painting procedures
MGB - Front side MGB - Rear side
MGB Final view

Chapter 15 Painting procedures
THE END

TECHNICIAN TRAINING
Chapter 16 Final Acceptance

16 Final Acceptance
Hereinafter are described the most important actions that should be performed on the MGB during its
final acceptance phase and before of the release to service of the part:
Verify that the overhauled MGB configuration is congruent with the IETP and applicable for the
involved helicopter.
Verify that the Overhaul process has been completed correctly in any parts.
Verify that , if required, the applicable SB (Service Bulletin) or AD (Airworthiness Directive) have
been embodied as required.
Fill the MGB Log Card as required.
Install the MGB Serviceable Tag on the MGB as necessary.

Chapter 16 Final Acceptance
THE END


Aw139 MGB O/h Training Course

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MAIN TRANSMISSION GEARBOX

(MGB) REPAIR & OVERHAUL

DOCUMENT No.: 39-A0126-MG001-00

ISSUE DATE REMARKS

002 2014.04.16 2st Issue

All information reported in this Manual

For Training purpose only 2 of 18

Hereinafter is shown the Table of Contents of this manual.

For Training purpose only 4 of 18

2.1 A/C Publication

For Training purpose only 5 of 18

Chapter 3 - General information

3.1 General description

For Training purpose only 6 of 18

Chapter 5 Pre-Disassembly Procedures

5.1 Safety Information

Chapter 6 Disassembly Procedures

6.25 FAN Drive Quill Disassembly procedures.

7.20 LH/RH Hyd. Pump Drive Quill Detailed Visual Examination

For Training purpose only 10 of 18

7.40 Main gearbox Dye Penetrant Examination

For Training purpose only 11 of 18

Chapter 8 Assembly Procedures

8.1 Pre-Assembly Requirements

8.2.1.19 Main Case, Backlash check

For Training purpose only 13 of 18

8.2.3 Main Case, External components installation procedures

Chapter 9 Functional Check

Chapter 10 Disassembly procedure after functional check

For Training purpose only 15 of 18

Chapter 11 - Inspection Criteria after Functional check

For Training purpose only 17 of 18

RETURN TO LESSON SUMMARY RETURN TO COURSE MENU

2.1 A/C Publication

The AgustaWestland AW139

Maintenance Publication (AMP)

The Technical Publications are

Each chapter is composed of

Each Data Module is identified by a unique Data Module Code (DMC)

39 - A - XX-XX-XX - XYA - XXXA - A

The Model Identification Code for the AW139 is 39.

39 - A - XX-XX-XX - XYA - XXXA - A

39 - A - XX-XX-XX - XYA - XXXA - A

SUBSYSTEM eg: AMP 39-A-29-10-00-00A-231A-A Main hydraulic system - Bleed

COMPONENT eg: IPD 39-A-29-11-01-010-941A-A Number 1 Power Control Module Assy

39 - A - XX-XX-XX - XYA - XXXA - A

The Disassembly Code has two digits

The Disassembly Code in AMP shows the breakdown of a component, as follows:

- 00 - Data module for all of the helicopter, system, subsystem or component

39 - A - XX-XX-XX - XYA - XXXA - A

The Disassembly Code Variant

eg: These items are different,

39 - A - XX-XX-XX - XYA - XXXA - A

The Information Code has three digits and Code Definition

39 - A - XX-XX-XX - XYA - XXXA - A

Examples of location codes:

List of Data Modules and

List of Tasks to be performed

List of Special Tools and Support Equipment

General Warnings and Cautions

Sequence of Steps and Illustrations

Instructions necessary to return

Requirement After Job Completion