Title: Specification Number:

ACCESSORY GEAR 0000-0601-0001

INSPECTION PROCEDURE
Discipline Code: Sheet
M 1 of 15

ACCESSORY GEAR

INSPECTION PROCEDURE

Name Date Name Date

Prepared by: W Clark 10/05/05 Engineering: D A Ross 10/05/05
Checked by: A Smith 10/05/05 Revision: 0 10/05/05
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 2 of 15

Drawing revision status: Determined by the last entry in the “REV” and “DATE” columns:

REV DESCRIPTION SIGNATURE DATE

0 Original Issue W Clark 10/05/05
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 3 of 15

MAINTENANCE AND PLANNING RECOMMENDATIONS

- It is recommended that this work be done during a gas turbine maintenance

inspection.

- A gear tooth contact check should be conducted prior to the disassembly of

the accessory gear/turbine drive coupling. Refer to EM 5210.

- This inspection will require a monorail (6-inch "1" beam), with one-ton trolley,
one-ton and ¾-ton chainblock, and two 2-foot slings.

DISASSEMBLY

1.Ensure the jaw clutch is disengaged.

2. Remove the coupling guards on both the accessory coupling and torque
converter coupling. Store all fasteners in plastic bags and attach bags
to components that were removed.

NOTE: Care must be taken during the removal of the accessory

coupling guard to avoid damage to other components such as the
magnetic speed pickup conduits and the lube oil (thermostatic)
capillary tube assembly. Remove them if necessary.

3. Match-mark the Frame 6 coupling before disconnecting the forward

end accessory coupling flange.

4. Re-assemble all coupling nuts on the mating bolts before proceeding.

(Each nut and bolt is a balanced set that cannot be interchanged).
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 4 of 15

5. In older units, the main cooling water pump was attached to the
forward end of No.2 accessory gear shaft. Do not detach the water
pump from the gear shaft. Remove it as follows:

a. Drain the cooling water off-base skid (or the elevated heat
exchanger).

b. Disconnect the pump pipe flanges (or pipe couplings).

c. Remove the No.2 gear shaft with the assembled water pump as
a unit.

6. Remove the upper oil deflector half on both ends of the No.1
accessory gear shaft.

7. Disconnect all pipe flanges for the liquid fuel system, and remove
vertical bolting on the main atomizing air compressor to the accessory
gear upper case. Move the compressor aft to remove the quill shaft.
Place bolts in plastic bags and label.

NOTE: Match-mark the quill shaft and the mating female spline of
both the main atomizing air compressor and the No.3B gear shaft at
12 o’clock position prior to disassembly.

8. Disconnect the liquid fuel pump/electric clutch taper-lock coupling (if

applicable). Match-mark coupling flanges prior to disassembly. Place
bolts in plastic bags and label.

9. Disconnect the air/oil vent tube connection on the left hand side
inspection plate, forward looking aft. Protect the tube opening from
airborne contaminants.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 5 of 15

INSPECTION PROCEDURE

1. Use a dial indicator to take the as-found axial thrusts of both No.1
and No.2 Accessory Gear Shafts.

2. Remove the left side inspection plate on top of the gear case.
Measure and record as-found axial thrusts of the No.3A and 3B gear
shafts with the same indicator set-up.

3. Remove the right inspection plate. Perform a lift check on the No. 1,
2, 3A and 3B gear shafts and record the as-found radial lift with a dial
indicator.

4. Jack out the four (4) dowels, and remove the accessory gear case
bolting. Do not take the dowels out of the top cover.

5. Mount the monorail (6-inch standard "I" beam) and the one-ton trolley
to the accessory compartment frame directly above the accessory
gearbox, if available.

6. Separate the upper gear case with four (4) one inch -8 thread jack
bolts. Install guide pins at four corners of the gearbox.

7. Install one eye bolt in the bolt hole of each inspection plate on the top
case. Use short nylon slings (two foot long) and a 1-ton chainblock
(whenever possible), or ¾ ton come-a-long to rig the upper half gear
case. A nominal headroom clearance of 32 inches is required to
remove the top gear case.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 6 of 15

CAUTION: While rigging, be aware of all upper half gear shaft

bearings (No. 1, 2, 3A and 3B Shafts) still in the top gear case. Do not
allow the top case to rock. Failure to stabilize the gear case will result
in damages to the babbitt on the bearing thrust face.

8. Block all holes in the oil feed channels with rags, and tape rags over
the lower casing horizontal joint.

9. Attach a safety string or steel wire to a plastic bag of rags and place
it over the gearbox drain oil hole. Tie the safety line to a visible spot.

10. Rotate the No.1 Shaft and measure gap of the overspeed bolt
assembly with a set of feeler gage and record measurements. (0.065
+/- 0.005 inches).

11. Block the No.2 gear shaft from rotating with a wooden wedge. Check
the as-found gear backlash on the No.1, 3A and 3B gear shafts with a
dial indicator. Record all readings. Remove the wooden wedge on the
No.2 gear shaft.

12. Remove the No.1 gear shaft. Protect the emergency governor (the
overspeed bolt assembly) from airborne contaminants.

13. Block the No.2 gear shaft again. Record the as-found backlash on the
No.4 gear shaft.

14. Remove the No.2 gear shaft.

15. Remove upper No. 3A and 3B bearing cap and the No. 3A and 3B gear
shafts.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 7 of 15

16. Disconnect the main hydraulic pump oil pipe flanges. Check for and
note any pipe strains.

17. Unbolt and remove the main hydraulic pump. The pump must be pulled
straight out from the pump adapter. Use wooden blocks to support
the hydraulic pump while pulling.

18. Remove the "Nyflex" coupling on the No.4 accessory gear shaft
coupling hub.

19. Match-mark, label, and remove the main lub oil pump end cover and
shims.

20. Use 3/8 inch all-thread, remove the top outboard main lube oil pump
bearing first then the bottom outboard bearing. Identify bearing
locations.

NOTE: The correct bearing orientation is to place the angled oil

groove on the bearing facing toward the pump gear (impeller).

21. Remove the top main lube oil pump gear. The quillshaft should come
out with this assembly. Note the female spline on the outboard end of
the pump gear.

22. Remove the bottom main lube oil pump gear. Be aware of its heavy
weight.

CAUTION: The outboard journal of the bottom pump gear is

approximately 3/16 inches longer that the inboard journal. The quill
shaft will break if this pump gear is installed in reverse.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 8 of 15

NOTE: The orientation of the inboard upper bearing and the lower
inboard pump bearing is that the bearing oil groove always angles to
the pump discharge pocket on the right hand side aft looking forward.

23. Record as-found No.4 gear shaft axial end play (thrust).

24. Perform a lift check on the No.4 gear shaft with a dial indicator and
record the as-found clearance.

25. Support the forward end of the No.4 shaft with a nylon sling. Match-
mark the pump adapter flange and spacer shim prior to removal.
Remove the small O-ring on the pump adapter. Retain the O-ring as a
sample for the replacement part.

26. Carefully move the No.4 shaft forward to disengage shaft from the
aft bearing and remove.

27. Tap and remove the No.4 shaft aft bearing (press fit in the casing
bore).

28. Measure the No.4 gear shaft bearing fit diameters and bearing inner
diameters.

29. Measure the No.4 gear shaft journal diameters and record.

30. Measure the No. 1, 2, 3A and 3B shaft journal diameters and record.

a. Inspect all gear shafts for any signs of distress such as

abnormal or uneven gear contact pattern, pitting on the gear
tooth due to electrostatic current discharge, and scoring on
bearing journal and thrust face.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 9 of 15

b. Examine all bearings for excessive wear, scored or wiped

babbitt.

c. Inspect the No.1 accessory gear shaft oil seals for rub. Replace
them as deemed necessary. Look for oil leaks on the gearbox
which may be indicative of a worn seal.

d. Inspect the quillshaft spline(s) for any abnormal wear and tear.
Replace if necessary.

e. Inspect the main hydraulic pump "Nyflex" coupling for wear and
tooth loss. Check for a loose coupling hub on the No.4 gear
shaft, and on the main hydraulic pump.

f. Disassemble the main cooling water pump from the No.2

accessory gear shaft (if applicable), for inspection. Replace the
mechanical seal as required.

REASSEMBLY

1. Clean all casing flange joints. Clean casing bolt holes with a proper size
tap (5/8 inch – 11 threads).

NOTE: When scraping old sealant from the lower gear casing flange,
ensure that all oil feed holes are protected from contamination.

2. Check oil feed pipe or tube fitting for looseness. Tighten as required.

3. Wipe clean the bottom of the accessory gearbox. Protect the open
gear case with a plastic cover.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 10 of 15

4. Use dry ice (if available) to shrink the No.4 shaft bearings before
pressing in their respective bores. Install the bearings with the single
radial bearing feed hole at 6 o’clock position. Check for any gap
between the bearing thrust face and the mating bore with a feeler
gage. Verify there is no gap, and correct as required.

5. Wipe clean the No.4 accessory gear shaft and bearing journal
surfaces. Ensure that the coupling hub is secured on the forward end
shaft. Apply clean turbine oil on shaft journals and install the gear
shaft. Support the No.4 shaft forward end with a nylon sling.

6. Remove all high spots on the pump adapter space shim with a hand
stone. Apply a thin film of silicone sealant (such as Hylomar, Permatex
Ultra Blue, Permatex Aviation No.2), on both sides of the space shim.
Replace the O-ring with Viton material. Install it with the pump
adapter. Verify that the pump guide sleeve is still in the pump
adapter.

NOTE: While scraping old sealant off the adapter flange and the
spacer shim, ensure that the oil feed hole (spot faced for the O-ring)
is protected from contaminants.

7. Record the as-left radial lift (designed value 0.005 – 0.009 inches),
and the axial thrust on No.4 shaft with a dial indicator.

NOTE: Radial clearance (lift check) of the No. 3A and 3B accessory

gear shaft outboard bearings can not readily be taken with a dial
indicator if the liquid fuel pump electric clutch and the main atomizing
air compressor are still in place. Use plastic gage instead to measure
radial clearance for the No. 1, 2, 3A and 3B shafts.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 11 of 15

8. Apply clean turbine oil on bearings and install the No. 3A and 3B
accessory gear shafts. Record the as-left radial clearances of the
inboard bearings with a dial indicator. (A lift check cannot be
performed on the outboard bearings at this point).

9. Apply clean turbine oil on bearings and install the No.2 accessory gear
shaft. Block the No.2 shaft with a wooden wedge and record the as-
left gear backlash of the replacement gear shaft(s) only. (Other as-
left readings should be same as the as-found readings).

10. Apply clean turbine oil on bearings and install the No.1 accessory gear
shaft.

11. Measure the gap of the overspeed bolt (0.065 +/- 0.005 inches) with a
feeler gage only if the No.1 gear shaft is replaced.

12. Apply silicone sealant on the No.1 gear shaft lower half oil deflector.
Set seal tooth clearances to be 0.003 – 0.005 inches low and even on
the sides.

13. Block the No.2 gear shaft with a wooden wedge. Record the as-left
gear backlash for the No.1 gear shaft only if this shaft is to be
replaced. Otherwise, the as-left gear backlash should be the same as
the as-found reading.

14. Apply clean turbine oil and install new main oil pump gears and bearings
(as applicable), including the quill shaft. Line-up the marking on the
quill shaft spline to its mating ends. Insert the quill assembly (with
the reduced shaft diameter inward) into the gearbox.

NOTE: New (or old) bearings must be set in the same orientation as
the removed parts.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 12 of 15

15. Push both pump gears against the inboard bearings, then the outboard
bearings to the pump gears.

16. Use a depth micrometer to measure the step at three places, between
the outboard bearing and the accessory gearbox machined surface.
Grind shims, if necessary, to obtain a final axial thrust.

17. Install the shims flush with the accessory gearbox machined surface.

18. Apply a thin film of silicone sealant on the sealing surface area (only),
and sealant on bolt threads prior to re-assembly of the main oil pump
end cover.

19. Perform this step only if the existing main hydraulic pump is to be
replaced with another assembly:

Measure the step between the end of the existing pump shaft to the
"Nyflex" coupling hub face prior to transferring the hub to the new
hydraulic pump. It is assumed that the existing coupling hub is
suitable for re-use. Place the coupling hub on the new pump and set it
to the same dimension as measured above, then tighten the set screw
in the hub.

Measure the distance between the coupling hub face mounted on the
No.4 accessory gear and the forward face of the pump adapter.

Measure the distance between the coupling hub face mounted on the
new (if replaced), main hydraulic pump shaft to the pump flange
surface in contact with the pump adapter. Set the "Nyflex" coupling
hub on the main hydraulic pump to the above dimension as required.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 13 of 15

20. Ensure that the "Nyflex" coupling hub is secured to the main hydraulic
pump shaft.

21. Apply a thin film of sealant to the main hydraulic pump flange face and
install pump.

22. Transfer the hydraulic pump manifold from the old pump to the new
assembly. Discard the old O-rings and install new gaskets. (O-rings).

23. Install the hydraulic pump oil pipes and/or hoses without any pipe
strain.

NOTE: Hydraulic oil lines must be free of all pipe strains. Mis-aligned
pipe flanges must be eliminated to prevent premature failure of the
main hydraulic pump, the Nyflex coupling, and the No.4 accessory gear
shaft and bearings.

24. Inspect the accessory gear for cleanliness. Remove all debris in the
gear housing.

25. Move the top gear case into position. Check both flange joints for
nicks and high spots. Apply silicone sealant on the lower gear case
joint. (Keep all sealant at least ½ inch away from the oil feed grooves).
Remove all temporary rags or other materials protecting the oil feed
holes.

26. Lower the top gear cover slowly and evenly. Use guide pins as
necessary to guide the cover into position. Install all dowels when the
gearbox flanges are ¼ inch to 3/8 inches apart.

CAUTION: Avoid rocking of the top gear case cover during assembly.
Rocking may damage the bearing babbitt thrust face.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 14 of 15

27. Apply silicone sealant to the threaded bolts prior to installation to

prevent potential oil leaks underneath the bolt head.

28. Record the as-left axial clearance of the No. 1, 2, 3A and 3B gear
shafts with a dial indicator.

29. Record the as-left bearing radial clearances of the above gear shafts
with a dial indicator through the inspection openings on the top gear
case. Perform this step only if these readings were not taken with
plastic gage(s).

30. Apply silicone sealant and install No.1 Gear Shaft oil deflectors. The
lower half oil deflector should be set 0.002 – 0.004 inches low and
even on the sides.

31. Re-install the cooling water pump assembly to the No.2 accessory gear
shaft (if equipped), and end cover(s).

32. Line-up all match marks and install the main atomizing air compressor
quill shaft, if equipped. Replace O-ring(s) as required. Apply sealant
and install the atomizing air compressor.

33. Apply sealant and install the liquid fuel pump/electric clutch housing, if
equipped. Re-assemble the taper lock coupling.

34. Re-assemble the inspection plates on top of the accessory gear case
with new gaskets.

35. Re-connect the air/oil vent tube connection on the top left hand side
inspection plate, forward looking aft.
Title: Specification Number:
ACCESSORY GEAR 0000-0601-0001
INSPECTION PROCEDURE
Discipline Code: Sheet
M 15 of 15

36. Apply fresh grease on the accessory gear coupling, if applicable.

Match mark the coupling halves and install accessory coupling bolts.
Torque bolts to specification in two successive steps.

37. Install the coupling guards.

NOTE: Care should be taken to avoid damage to components such as

the magnetic speed pick-up conduits and the lube oil (thermostatic)
capillary tube assembly during re-assembly of the accessory coupling
guard. Re-install such components if they were removed during the
course of inspection.

38. Remove the monorail (6-inch standard "I" beam) and one-ton trolley
over the accessory gearbox (if installed). Properly store them for
future use.