PW4000 94-inch BOEING OPEN COWL VISUAL INSPECTION For the prevention of Delays & Cancellations and IFSD’s
FOR REFERENCE ONLY
September September 2002
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PW4000-94 BOEING OPEN COWL INSPECTION FOR THE PREVENTION OF DELAYS & CANCELLATIONS and IFSD’s The information and instructions in this booklet are prepared for general information purposes only. The data contained herein herein shall not be considered in any way as replacing replacing or superceding the information contained in the PW4000 Turbofan Engine Manual or Boeing 747-400, 767 Maintenance Manuals. Manuals.
Prepared by: Pratt & Whitney Whitney Customer Service Servic e Line Maintenance Maintenance & Troubleshooting T roubleshooting Pratt & Whitney Whitney Custome C ustomer r Training T raining
© COPYRIGHT COPYRIGHT 2000 UNITED TECHNOLOGIES CORPORATION
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PW4000-94 BOEING OPEN COWL INSPECTION FOR THE PREVENTION OF DELAYS & CANCELLATIONS and IFSD’s The information and instructions in this booklet are prepared for general information purposes only. The data contained herein herein shall not be considered in any way as replacing replacing or superceding the information contained in the PW4000 Turbofan Engine Manual or Boeing 747-400, 767 Maintenance Manuals. Manuals.
Prepared by: Pratt & Whitney Whitney Customer Service Servic e Line Maintenance Maintenance & Troubleshooting T roubleshooting Pratt & Whitney Whitney Custome C ustomer r Training T raining
© COPYRIGHT COPYRIGHT 2000 UNITED TECHNOLOGIES CORPORATION
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PW4000 OPEN COWL INSPECTION GUIDE
SUBJECT MATTER: This reference guide covers the external visual inspection of the PW4000 series engine, including external components.
INTENDED FOR: This reference guide is intended for maintenance personnel who are responsible for visual inspections of the PW4000 engine. It is intended to be used in conjunction with classroom instruction and as a stand alone learning resource during the PW4000 System Familiarization course or the PW4000 Line and Base Maintenance training training course.
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PW4000-94 BOEING OPEN COWL VISUAL INSPECTION CHECK LIST LEFT SIDE a. b. c. d. e. f.
1. Inlet Area (CHECK): Inlet cowl for damage. Fan blades for damage. P2/T2 sensor for damage and debris. Rub strip for heavy wear. Compressor inlet cone for damage. Spinner for damage.
2. Fan Exit Area - Left (CHECK): a. For damage (fan blades, fan exit guide vanes, and struts).
a. b. c. d.
3. (2.5) Bleed Actuator Area (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d.
4. HPC SFC Valve Solenoid/ TVBCA Valve Solenoid Area (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d.
5. HPC Case Area - Upper Left Front (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
6. (2.9) Bleed Valve Area - Left (CHECK): a. Temperature probe connections for looseness, cracking, and broken lugs. b. Area connectors for coupling nut and backshell tightness. c. Area for evidence of fuel/oil leakage. d. Area tubes and harness clamps for chafing and general condition. e. Area harness wires for chafing and cuts.
a. b. c. d.
7. Fuel/Oil Heat Exchanger (CHECK): All fuel and oil fittings for leakage. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d. e.
8. Oil Filter Area (CHECK): Oil filter cover for damage. Area for evidence of fuel/oil leakage. Area connectors for coupling nut and backshell tightness. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
9. Gearbox Area - Looking Aft (CHECK): a. Main gearbox chip detector for proper installation and leakage. b. Oil temperature probe connections for looseness, cracking, and broken lugs. c. Area for evidence of fuel/oil leakage. d. Area connectors for coupling nut and backshell tightness. e. Area tubes and harness clamps for chafing and general condition. f. Area harness wires for chafing and cuts.
a. b. c. d.
10. Gearbox Area - Left (CHECK): Area for evidence of fuel/oil leakage. Area connectors for coupling nut and backshell tightness. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
11. Oil Tank Area (CHECK): a. Oil cap and O-ring for damage. b. Oil level indicator connector for coupling nut and backshell tightness. c. Oil level (per AMM). d. Master chip detector for proper installation and leakage. e. Area for evidence of fuel/oil leakage. f. Area tubes and harness clamps for chafing and general condition. g. Area harness wires for chafing and cuts.
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PW4000-94 BOEING OPEN COWL VISUAL INSPECTION CHECK LIST RIGHT SIDE a. b. c. d. e.
a. b. c. d.
12. HPT/LPT Case Area - Left (CHECK): Cooling manifolds for cracking. Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
15. Turbine Exhaust Case Area - Right (CHECK): a. EGT probe and junction box connections for looseness, cracking, and broken lugs. b. Area tubes and harness clamps for chafing and general condition. c. Area harness wires for chafing and cuts.
13. Turbine Exhaust Case Area - Left (CHECK): EGT probe connections for looseness, cracking, and broken lugs. No.4 bearing pressure and scavenge lines for evidence of oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d. e. f.
16. HPT/LPT Case Area - Right (CHECK): Cooling manifolds for cracking. HPT/LPT valve linkage and arms for security. Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d.
17. Diffuser/Combustor Case Area - Right (CHECK): Tt3 probe for connection looseness, cracking and broken lugs. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
14. Exhaust Area (CHECK): a. Turbine blades for damage. b. Area for evidence of oil leakage.
18. Main Gearbox Oil Pump Area (CHECK): a. Chip detectors for proper installation and leakage. b. If SB 79-36 is not incorporated, LPO1 oil line clamps and wear sleeves for wear. c. No.3 bearing temperature probe for connection looseness, cracking, and broken lugs. d. Area connectors for coupling nut and backshell tightness. e. Area for evidence of fuel/oil leakage. f. Area tubes and harness clamps for chafing and general condition. g. Area harness wires for chafing and cuts.
a. b. c. d.
19. Ignition Exciter Box Area (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
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PW4000-94 BOEING OPEN COWL VISUAL INSPECTION CHECK LIST
a. b. c. d.
20. TCC Actuator Area (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d. e.
21. Bellcrank Area (CHECK): Area attaching nuts for proper locking installation. Attaching bolt for signs of wear. Bellcrank for excessive axial and radial movement. All brackets attached to SVA support bracket for cracks/breaks. Area connectors for coupling nut and backshell tightness.
a. b. c. d.
22. Stator Vane Actuator (SVA) Area (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d.
23. TVBCA Valve Area - Right (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d. e. f.
24. Fuel Metering Unit (FMU)/Fuel Pump Area (CHECK): Fuel temperature probe connections for looseness, cracking, and broken lugs. Fuel filter cover for leakage. Area for evidence of fuel/oil leakage. Area connectors for coupling nut and backshell tightness. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d.
25. IDG Oil Cooling Valve Solenoid/ HPC SFC Valve Solenoid Area (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d.
26. Start/Stability Bleed Valve Solenoid & Stability Bleed Pneumatic Relay Valve Area (CHECK): Area connectors for coupling nut and backshell tightness. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
a. b. c. d.
27. Fuel Oil Cooler Outlet Area (CHECK): T2.9 probe for connection looseness, cracking, and broken lugs. Area for evidence of fuel/oil leakage. Area tubes and harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
28. Fan Exit Area - Right (CHECK): a. Area for damage (fan blades, fan exit guide vanes, and struts).
a. b. c. d.
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29. EEC (CHECK): Pressure fittings and mounts. Connectors and data plug for coupling nut and backshell tightness. Area harness clamps for chafing and general condition. Area harness wires for chafing and cuts.
Rub Strip
P2/T2 Probe
Fan Blades
Compressor Inlet Cone
Inlet Cowl
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1. Inlet Area (CHECK): a. Inlet cowl for damage. b. Fan blades for damage. c. P2/T2 sensor for damage. d. Rub strip for heavy wear. e. Compressor inlet cone for damage. f.
Spinner for damage.
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ENGINE LEFT SIDE
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Struts
Fan Exit Guide Vanes
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2. Fan Exit Area - Left (CHECK): a. For damage (fan blades, fan exit guide vanes, and struts).
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2.5 Bleed Actuator
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3. (2.5) Bleed Actuator Area (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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Solenoids
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4. HPC SFC Valve Solenoid/ TVBCA Valve Solenoid Area (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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5. HPC Case Area - Upper Left Front (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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Temperature probe (on side of valve)
2.9 Bleed Valve
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6. (2.9) Bleed Valve Area - Left (CHECK): a. Temperature probe connections for looseness, cracking, and broken lugs. b. Area connectors for coupling nut and backshell tightness. c. Area for evidence of fuel/oil leakage. d. Area tubes and harness clamps for chafing and general condition. e. Area harness wires for chafing and cuts.
•
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Fuel/Oil Cooler
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7. Fuel/Oil Heat Exchanger (CHECK): a. All fuel and oil fittings for leakage. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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Oil Filter Cover
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8. Oil Filter Area (CHECK): a. Oi Oill filte filterr cove coverr for for leak leakag age. e. b. Area Area for eviden evidence ce of fuel/o fuel/oil il leaka leakage. ge. c. Area Area connec connector tors s for coup couplin ling g nut and and backsh backshell ell tightness. d. Area Area tubes tubes and harne harness ss clamp clamps s for chaf chafing ing and and general condition. e. Area Area harnes harness s wires wires for for chafi chafing ng and and cuts. cuts.
•
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Main Gearbox Chip Detector
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9. Gearbox Area - Looking Aft (CHECK): a. Main gearbox chip detector for proper installation and leakage. b. Oil temperature probe connections for looseness, cracking, and broken lugs. c. Area for evidence of fuel/oil leakage. d. Area connectors for coupling nut and backshell tightness. e. Area tubes and harness clamps for chafing and general condition. f.
Area harness wires for chafing and cuts.
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10. Gearbox Area - Left (CHECK): a. Area for evidence of fuel/oil leakage. b. Area connectors for coupling nut and backshell tightness. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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Oil Level Indicator Connector
Oil Tank Cap
Master Chip Detector
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11. Oil Tank Area (CHECK): a. Oil cap and O-ring for damage. b. Oil level indicator connector for coupling nut and backshell tightness. c. Oil level (per AMM). d. Master chip detector for proper installation and leakage. e. Area for evidence of fuel/oil leakage. f.
Area tubes and harness clamps for chafing and general condition.
g. Area harness wires for chafing and cuts. •
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Cooling Manifolds
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12. HPT/LPT Case Area - Left (CHECK): a. Cooling manifolds for cracking. b. Area connectors for coupling nut and backshell tightness. c. Area for evidence of fuel/oil leakage. d. Area tubes and harness clamps for chafing and general condition. e. Area harness wires for chafing and cuts.
•
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EGT Harness and Probes
#4 Bearing Scavenge Line
#4 Bearing Pressure Line
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13. Turbine Exhaust Case Area - Left (CHECK): a. EGT probe connections for looseness, cracking, and broken lugs. b. No.4 bearing pressure and scavenge lines for evidence of oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
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Turbine Exhaust Case Struts
Turbine Blades
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14. Exhaust Area (CHECK): a. Turbine blades for damage. b. Area for evidence of oil leakage.
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ENGINE RIGHT SIDE
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EGT Harness and Probes
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15. Turbine Exhaust Case Area - Right (CHECK): a. EGT probe and junction box connections for looseness, cracking, and broken lugs. b. Area tubes and harness clamps for chafing and general condition. c. Area harness wires for chafing and cuts.
•
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HPT/LPT Valve Linkage and Arms
Cooling Manifolds
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16. HPT/LPT Case Area - Right (CHECK): a. Cooling manifolds for cracking. b. HPT/LPT valve linkage and arms for security. c. Area connectors for coupling nut and backshell tightness. d. Area for evidence of fuel/oil leakage. e. Area tubes and harness clamps for chafing and general condition. f. Area harness wires for chafing and cuts.
•
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Tt3 Probe
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17. Diffuser/Combustor Case Area - Right (CHECK): a. Tt3 probe for connection looseness, cracking, and broken lugs. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
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LPO1
Dot 3 Probe (#3 Bearing Temp Probe)
Chip Detectors
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18. Main Gearbox Oil Pump Area (CHECK): a. Chip detectors for proper installation and leakage. b. If SB 79-36 is not incorporated, LPO1oil line clamps and wear sleeves for wear. c. No.3 bearing temperature probe for connection looseness, cracking, and broken lugs. d. Area connectors for coupling nut and backshell tightness. e. Area for evidence of fuel/oil leakage. f. Area tubes and harness clamps for chafing and general condition. g. Area harness wires for chafing and cuts. •
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Exciter Boxes
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19. Ignition Exciter Box Area (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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TCC Actuator
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20. TCC Actuator Area (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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Bellcrank
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21. Bellcrank Area (CHECK): a. Area attaching nuts for proper locking installation. b. Attaching bolt for signs of wear. c. Bellcrank for excessive axial and radial movement. d. All brackets attached to SVA support bracket for cracks/breaks. e. Area connectors for coupling nut and backshell tightness.
•
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Stator Vane Actuator
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22. Stator Vane Actuator (SVA) Area (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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TVBCA Valve
(Right) HPC Secondary Flow Control Valve
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23. TVBCA Valve Area - Right (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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Fuel Temperature Probe
FMU
Fuel Filter Cover
Fuel Pump
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24. Fuel Metering Unit (FMU)/ Fuel Pump Area (CHECK): a. Fuel temperature probe connections for looseness, cracking, and broken lugs. b. Fuel filter cover for leakage. c. Area for evidence of fuel/oil leakage. d. Area connectors for coupling nut and backshell tightness. e. Area tubes and harness clamps for chafing and general condition. f.
Area harness wires for chafing and cuts.
•
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Solenoid Area
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25. IDG Oil Cooling Valve Solenoid/ HPC SFC Valve Solenoid Area (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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Valve Solenoid and Relay Valve Area
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26. Start/Stability Bleed Valve Solenoid & Stability Bleed Pneumatic Relay Valve Area (CHECK): a. Area connectors for coupling nut and backshell tightness. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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2.9 Bleed Temperature Probe
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27. Fuel Oil Cooler Outlet Area (CHECK): a. T2.9 probe for connection looseness, cracking, and broken lugs. b. Area for evidence of fuel/oil leakage. c. Area tubes and harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
•
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28. Fan Exit Area - Right (CHECK): a. For damage (fan blades, fan exit guide vanes, and struts).
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EEC Data Plug
Mount Pad (4 locations)
Pressure Ports (4)
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29. EEC (CHECK): a. Pressure fittings and mounts. b. Connectors and data plug for coupling nut and backshell tightness. c. Area harness clamps for chafing and general condition. d. Area harness wires for chafing and cuts.
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Power Plant Adjustment/Test B747-400 MM 71-00-00 Test Number
Title of Test
1
Pneumatic Leak Test
2
Engine Motoring Test
3
Ground Test - Idle Power
4
Engine Power and Acceleration/Deceleration Test
5
Oil System Static Leak Test
6
Electronic Engine Control (EEC) Idle Test
7
Electronic Engine Control (EEC) Static Test
8
Vibration Survey
9
Performance Test
10
Replacement Engine Test (Pre-tested)
11
Replacement Engine Test (Untested)
12
Engine Vacuum Test
13
Main Oil Pressure Test
14
Pt2 System Leak Test
15
EEC Ground Test of Engine Control System Actuators {For all EECs without the P/N 791100-4-035 (50D437), 791100-4-038 (50D821) 791100-4-044 (50D823), 791100-4-048 (51D011), or 791100-4-049 (51D012)}
20
High Power Engine Surge Test
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Power Plant - Fault Isolation (Visual Checks) B747-400 FIM/71-07-00
Check No.
Title of Check
1
NOT USED
2
Stator Vane Unison Ring/Actuator Linkage Check
3
NOT USED
4
Burner Pressure (Pb) Manifold Leakage Check
5
Nacelle Zone Ventilation Shutoff Valve Pneumatic Line Check
6
Nacelle Zone Ventilation Shutoff Valve Position Check
7
EPR/EEC (PT4.95) Manifold Leakage Check
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Power Plant - Fault Isolation (Engine Checks) B747-400 FIM/71-08-00 Check No.
Title
1
Servo Fuel Contamination Check
2
Magnetic Chip Detectors and Main Oil Filter Contamination Check
3
Fuel System Contamination Check
4
2.9 Bleed Valve System Check
5
Fuel Pump Pressure Check
6
Condition Motor Operation
7
Turbine Case Cooling (TCC) Valve Actuation Check
8
Nacelle Zone Ventilation Shutoff Valve Operational Check
9
Variable Stator Vane System Check
10
2.5 Bleed Valve System Check
11
Burner Pressure (Pb) Manifold Blockage Check
12
Wire Harness Check
13
Oil Leak Check
14
Smoke/Fumes in Cabin
15
T2 Signal
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Power Plant Adjustment/Test B767 MM 71-00-00 Test Number
Title of Test
1
Pneumatic Leak Test
2
Engine Motoring Test
3
Ground Test - Idle Power
4
Engine Power and Acceleration/Deceleration Test
5
Oil System Static Leak Test
6
Electronic Engine Control (EEC) Idle Test
7
Electronic Engine Control (EEC) Static Test
8
Vibration Survey
9
Performance Test
10
Replacement Engine Test (Pre-tested)
11
Replacement Engine Test (Untested)
12
Engine Vacuum Test
13
Main Oil Pressure Test
14
Pt2 System Leak Test
15
EEC Ground Test of Engine Control System Actuators {For all EECs without the P/N 791100-4-035 (50D437), 791100-4-038 (50D821) 791100-4-044 (50D823), 791100-4-048 (51D011), or 791100-4-049 (51D012)}
20
NOT USED
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Power Plant - Fault Isolation (Visual Checks) B767 FIM/71-07-00
Check No.
Title of Check
1
NOT USED
2
Stator Vane Unison Ring/Actuator Linkage Check
3
NOT USED
4
Burner Pressure (Pb) Manifold Leakage Check
5
Nacelle Zone Ventilation Shutoff Valve Pneumatic Line Check
6
NOT USED
7
NOT USED
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Power Plant - Fault Isolation (Engine Checks) B767 FIM/71-08-00 Check No.
Title
1
EICAS Auto Event Message Verification/Erase Procedure
2
Magnetic Chip Detectors and Main Oil Filter Contamination Check
3
Fuel System Contamination Check
4
2.9 Bleed Valve System Check
5
Fuel Pump Pressure Check
7
Turbine Case Cooling (TCC) Valve Actuation Check
8
Nacelle Zone Ventilation Shutoff Valve Operational Check
9
Variable Stator Vane System Check
10
2.5 Bleed Valve System Check
11
Burner Pressure (Pb) Manifold Condition
12
Wire Harness Check
13
Oil Leak Check
14
Smoke/Fumes in Cabin
15
Servo Fuel Contamination Check
16
T2 Signal
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