Pratt Whitney PW2000 Component Locator B757

ADVANCED AIRCRAFT TRAINING

B757 ETIP’s PW2037 PW2000 OPEN COWL VISUAL INSPECTION LINE MAINTENANCE TRAINING The information and instructions in this booklet are prepared for general information purposes only. The data contained herein shall not be considered in any way as replacing or superceding the information contained in the PW2000 Turbofan Engine Manual or Boeing 757 Maintenance Manual.

INTENTIONALLY LEFT BLANK

PW2000 OPEN COWL VISUAL INSPECTION CHECK LIST Left Side 1. Inlet Area A. Check inlet cowl for damage. B. Check fan blades for damage. C. Check P2/T2 sensor for damage. D. Check rub strip for heavy wear. 2. EEC A. Check connectors & data plug for coupling nut & backshell tightness. B. Check pressure fittings. C. Check mounts. 3. Fan Case Harness (EEC to left side fan case components & bifurcation panel.) A. Check harness wires for chafing & cuts. B. Check clamps. 4. Fuel/Oil Heat Exchanger A. Check all fuel & oil fittings for leakage. B. Check connectors on the bypass valve for coupling nut & backshell tightness. C. Check the fuel temperature probe connections for looseness, cracking, & broken lugs. D. Check area for evidence of fuel/oil leakage. E. Check area harness wires for chafing & cuts. 5. Oil Tank A. Check oil level indicator connector for coupling nut & backshell tightness. B. Check oil cap & O-ring for damage. C. Check oil level (per AMM 12-13-01). D. Check the master chip detector for proper installation & leakage. E. Check area for evidence of fuel/oil leakage. F. Check tubes & harness clamps in this area for chafing & general condition. G. Check are harness wires for chafing & cuts. 6. Oil Pump Area A. Check pump housing for oil leakage (wetness). If leakage is present replace the oil pump. Note: Oil leakage through the pump housing is caused by cavitation within the pump. Pre Sunstrand SB 79-14 pump housing can exhibit oil leaks through the housing near the front of the pump. B. Check oil filter for leakage. C. Check area chip detectors (main gearbox, angle gearbox, No.5 bearing, & No. 1,2,3 bearing) for proper installation & leakage. D. Check area for evidence of fuel/oil leakage. E. Check tubes & harness clamps in this area for chafing & general condition. F. Check connectors in the area for coupling nut & backshell tightness. G. Check are harness wires for chafing & cuts.

7. Left Fan Bypass Exit Area A. Check area for damage (fan blades, fan exit guide vanes, & struts). 8. Left Side Bifurcation Panel Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 9. 2.5 Bleed Actuator Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 10. Air/Oil Heat Exchanger Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 11. HPC/HPT LPT Actuator Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 12. Left Modulated TCA Valve Area A. Inspect valve arm for proper installation to control cable. B. Check the T3.5 temperature probe connectors for looseness, cracking & broken lugs. C. Check connectors in area for coupling nut & backshell tightness. D. Check area for evidence of fuel/oil leakage. E. Check tubes & harness clamps in this area for chafing & general condition. F. Check area harness wires for chafing & cuts. 13. Left Side Fuel Distribution Valve Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts.

PW2000 OPEN COWL VISUAL INSPECTION CHECK LIST 14. Left Side HPT/LPT Case Area A. Check cooling manifolds for cracking. B. Check the TCA temperature probe connections for looseness, cracking & broken lugs. C. Check connectors in area for coupling nut & backshell tightness. D. Check area for evidence of fuel/oil leakage. E. Check tubes & harness clamps in this area for chafing & general condition. F. Check area harness wires for chafing & cuts. 15. Left Side Exhaust Case Area A. Check the EGT probe(s) & junction box connectors for looseness, cracking & broken wires. B. Check the No. 5 pressure line for evidence of fuel/oil leakage. C. Check area harness wires for chafing & cuts. D. Check tubes & harness clamps in this area for chafing & general condition. 16. Exhaust Area A. Check turbine blades for damage. B. Check area for evidence of oil leakage.

Right Side 17. Right Side Exhaust Case Area A. Check the EGT probe(s) connectors for looseness, cracking& broken wires. B. Check the No. 5 bearing scavenge line for evidence of oil leakage. C. Check area harness wires for chafing & cuts. D. Check tubes & harness clamps in this area for chafing & general condition. 18. Right Side HPT/LPT Case Area A. Check cooling manifolds for cracking. B. Check connectors in area for coupling nut & backshell tightness. C. Check area for evidence of fuel/oil leakage. D. Check tubes & harness clamps in this area for chafing & general condition. E. Check area harness wires for chafing & cuts. 19. Right Side Fuel Distribution Valve Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 20. TCA Actuator Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts.

21. SVA Actuator Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 22. Bell Crank Area A. Check attaching nuts in the area for proper locking installation. B. Check attach bolt for signs of wear. NOTE: If wear is present perform the inspection called for in SB PW2000 A72-536. C. Check bell crank for excessive axial & radial movement. D. Check connectors in area for coupling nut & backshell tightness. E. Check tubes & harness clamps in this area for chafing & general condition. 23. Right Side Bifurcation Panel Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/ oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 24. 14th Stage Converter Valve Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/ oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 25. Right Fan Bypass Exit Area A. Check area for damage (fan blades, fan exit guide vanes, & struts). 26. Fuel Control Unit (FCU)/ Fuel Pump Area A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/ oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts. 27. Deoiler Housing A. Check the deoiler housing for leakage with special attention to the welded flanges. 28. PMA A. Check connectors in area for coupling nut & backshell tightness. B. Check area for evidence of fuel/ oil leakage. C. Check tubes & harness clamps in this area for chafing & general condition. D. Check area harness wires for chafing & cuts.

1. Inlet Area A.

Check inlet cowl for damage. Pay particular attention to acoustical lining and cracked or loose previous repairs.

B.

Check fan blades for damage.

C.

In-Flight Shut Down(IFSD) Focus Item Check P2/T2 sensor for damage. Check for condition and security. Visually inspect probe looking for blockage due to bird ingestion.

D.

Check rub strip for heavy wear.

E.

Check compressor inlet cone for damage

Rub Strip

P2/T2 Probe

Fan Blades

Compressor Inlet Cone

Inlet Cowl

2. EEC A.

Check connectors & data plug for coupling nut & backshell tightness.

B.

Check pressure fittings.

C.

Check mounts.

Connectors (8 ea.) EEC

Data Plug

Mounts (4 ea.) Pressure Fittings

3. Fan Case Harness (EEC to left side fan case components & bifurcation panel.) A.

Check harness wires for chafing & cuts.

B.

Check clamps.

NOTE: Harness may be color coded for identification. Blue Primary Channel Wiring Green - Secondary Channel Wiring Yellow - Temp Sensor Wiring

Harness Wires

4. Fuel/Oil Heat Exchanger A.

Check all fuel & oil fittings for leakage.

B.

Check connectors on the bypass valve for coupling nut & backshell tightness.

C.

Check the fuel temperature probe connections for looseness, cracking, & broken lugs.

D.

Check area for evidence of fuel/oil leakage.

E.

Check area harness wires for chafing & cuts.

Fuel/Oil Heat Exchanger

Fuel Temperature Probe

Bypass Valve Connectors

5. Oil Tank A.

Check oil level indicator connector for coupling nut & backshell tightness.

B. C.

Check oil cap & O-ring for damage. Check oil level

Warning: Wait a minimum of 5 minutes after engine shut-down before servicing.

D.

Check the master chip detector for proper installation & leakage.

E.


F.

Check tubes & harness clamps in this area for chafing & general condition.

G.

Check are harness wires for chafing & cuts.

Oil Quantity Indicator Connector Oil Cap

Master Chip Detector

6. Oil Pump Area A.

Check pump housing for oil leakage (wetness).

If leakage is present replace the oil pump. Note: Oil leakage through the pump housing is caused by cavitation within the pump. Pump can exhibit oil leaks through the housing near the front of the pump. B.

(IFSD Item)Check oil filter for leakage. Inspect main oil filter bowl and housing. The filter bowl if installed correctly will be flush with the filter housing (No Gap).

Continued on next page...

Lubrication and Scavenge Oil Pump

Oil Trimmer Adjustment Screw

#5 Bearing Chip Detector

#1,2,3 Bearing Chip Detector

Main Gearbox Chip Detector

Main Oil Filter Bowl

6. Oil Pump Area (Continued) C.

Check area chip detectors (main gearbox, angle gearbox, No.5 bearing, & No. 1,2,3 bearing) for proper installation & leakage.

D.


E.


F.

Check connectors in the area for coupling nut & backshell tightness.

G.

Check are harness wires for chafing & cuts.

#1,2,3 Bearing Chip Detector

Main Gearbox Chip Detector

7. Left Fan Bypass Exit Area A. Check following for damage - Fan blades - Fan exit guide vanes - Fan case struts - Sound panels

Sound Panels Strut

Fan Exit Guide Vanes

8. Left Side Bifurcation Panel Area A.

Check connectors in area for coupling nut & backshell tightness.

B.


C.


D.

Check engine vents and drains. Refer to AMM for allowable leak limits. Use Fluid Traps to Identify source of Fuel leaks

E.


Note: The breather line from the deoiler is susceptible to cracking at the T connection along the wield lines due to vibration or over torque.

Bifurcation Panel

Breather T Line

9. 2.5 Bleed Actuator Area A.


B.


C.


D.

Check area harness wires for chafing & general condition.

Note: The 2.5 Bleed Actuator can be responsible for certain engine parameter shifts. Wear in the bleed ring and actuator linkages should be suspected.

2.5 LVDT’s

2.5 Bleed Actuator

10. Air/Oil Heat Exchanger Area A.


B.


C.


D.


E.

Check low oil pressure switch, oil pressure transmitter and #4 bearing scavenge oil pressure transmitter for oil leakage.

Note: Oil pressure indicated on EICAS with the engine in a static condition may indicate an excessive oil operating pressure and require transmitter replacement.

Low Oil Pressure Switch

Oil Pressure Transmitter

Air/Oil Heat Exchanger #4 Bearing Scavenge Pressure Transmitter

11. HPC/HPT LPT Actuator Area A.


B.


C.


D.


LPT Case Cooling Air Valve

HPC and HPT Case Cooling Air Valve

12. Left Modulated TCA Valve Area (post 94 package engine) A.

Inspect TCA valve arm for proper installation to control cable.

B.

Check the T3.5 temperature probe connectors for looseness, cracking & broken lugs.

C.


D.


E.


F.


Modulated TCA Valve

T3.5 Temperature Probe

13. Left Side Fuel Distribution Valve Area A.


B.


C.


D.


E.

Check fuel distribution valve.

Turbine Cooling Air (TCA) Probe

Fuel Distribution Valve

14. Left Side HPT/LPT Case Area A.

Check cooling manifolds for cracking.

B.

Check the TCA temperature probe connections for looseness, cracking & broken lugs.

C.


D.


E.


F.


Turbine Cooling Air (TCA) Probe

Cooling Manifold

15. Left Side Exhaust Case Area A.

Check the EGT probe(s) & junction box connectors for looseness, cracking & broken wires.

B.

Check the No. 5 pressure line for evidence of fuel/oil leakage.

C.


D.


Note: Pay particular attention to the brackets and terminals on the junction box due to history of hairline cracks. Note: Inspect EGT probes for damaged or broken studs. If the probe is replaced care should be taken not to over torque the studs.

EGT Probe

EGT Junction Box

#5 Oil Pressure Line

16. Exhaust Area A.

Check turbine blades for damage.

B.

Check area for evidence of oil leakage.

Note: Oil streaking in the tailpipe between the 6 and 9 o’clock position can be caused by an internal failure of the Fuel/Oil Heat Exchanger. This may also be the cause of High Oil Consumption. Note: Oil puddles in the tailpipe can also be caused by insufficient scavenging of the number 5 bearing compartment. This may be due to coking in the number 5 bearing scavenge oil line or damage to the number 5 bearing compartment cover seal. Caution: After a high power engine run, allow the engine to run at idle for a minimum of 5 minutes. This will allow sufficient time for the engine to cool down. Failure to allow sufficient cooling time can contribute to coking in the number 5 bearing and scavenge oil line.

Turbine Blades

17. Right Side Exhaust Case Area A.

Check the EGT probe(s) connectors for looseness, cracking & broken wires.

B.

Check the No. 5 bearing scavenge line for evidence of oil leakage.

C.


D.


EGT Probes

18. Right Side HPT/LPT Case Area A.

Check cooling manifolds for cracking.

B.


C.


D.


E.


Cooling Manifolds

19. Right Side Fuel Distribution Valve Area A.


B.


C.


D.


20. TCA Actuator Area A.


B.


C.


D.


Note: Pre 94 Pak engines will not have a (TCA) Turbine Cooling Air actuator. On Delta’s domestic B757 fleet post 94 Pak engines will have a TCA actuator however the system is currently locked out. TCA faults sometimes show up on these engines but should be considered nuisance faults. Be aware this system may be operational on Delta’s B757ERs.

TCA Actuator

21. SVA Actuator Area A.

In-Flight Shut Down(IFSD) Focus Item Check connectors in area for coupling nut & backshell tightness.

B.


C.


D.


Caution:

Miss-rigging, wear of linkages, cracked or loose actuator support brackets or wiring faults associated with the Variable Stator Vane(VSV) system can lead to In-flight Shut Downs. Care should be taken when working on or around this system.

Bellcrank

SVA Actuator

22. Bell Crank Area A.

In-flight Shut Down(IFSD) Focus Item Check attaching nuts in the area for proper locking installation.

B.

Check attach bolt for signs of wear.

C.

Check bell crank for excessive axial & radial movement.

D.


E.


Bellcrank

23. Right Side Bifurcation Panel Area A.


B.

Check area for evidence of fuel/ oil leakage.

C.


D.


Bifurcation Panel

24. 14th Stage Converter Valve Area A.


B.


C.


D.


Note: A failure of the 14th stage bleed converter valve may result in the 14th stage bleed valve remaining open during start up. This condition will result in a low N2 speed on start and no throttle response. The condition is easily detectable due to the noise created by the 14th stage bleed when it is open. A stuck 14th stage bleed can be closed on occasion by momentarily putting the engine into reverse thrust.

25. Right Fan Bypass Exit Area A.

Check following for damage - Fan blades - Fan exit guide vanes - Fan case struts - Sound panels

Strut Sound Panels

d

d

Fan Exit Guide Vanes

26. Fuel Control Unit (FCU)/ Fuel Pump Area A.


B.


C.


D.


Fuel Control

27. Deoiler Housing A.

Check the deoiler housing for leakage with special attention to the welded flanges.

Note: There are 2 styles of deoiler housing in service. One is aluminum the other is steel. Pay particular attention to the outer housing of the aluminum deoilers as they are prone to cracking particularly along the welded flanges. The number 4 bearing chip detector will be found mounted to the deoiler housing if the housing is aluminum. It may also be found on the number 4 bearing scavenge valve. If the housing is steel there may be a plug in the deoiler housing and the number 4 bearing chip detector will be located on the number 4 bearing scavenge valve.

Deoiler

28. Permanent Magnet Alternator A.


B.


C.


D.


Note: Care should be taken not to damage the PMA stator housing when removing the crank pad cover plug for boroscope. Replacement of the PMA rotor requires performing a concentricity and run-out check to ensure PMA will not fail due to internal gearbox bearing problems.

N2 Crank Pad Cover

Typical Damage to PMA Stator Housing

Power Plant Adjustment/Test B757 MM 71-00-00 Test No.

Title

1

Engine Driven (Hydraulic) Pump (EDP) Test

2

Engine Motoring (Dry) Leak Test

2A

Engine Motoring (Wet) Leak Test

3

Minimum Idle Test

3A

Idle Leak Test for the Oil and Fuel Systems

4

Integrated Drive Generator (IDG) Test

5

Main Gearbox Replacement Test

6

Fourteenth-Stage Bleed System Test

7

Electronic Engine Control (EEC) Static Test

8

Vibration Survey

9

Performance Test

10

Engine Replacement Test

11

Oil Pressure Test

12

Engine Replacement Test (Pre-tested)

13

Intercompressor 2.5 Bleed Actuator Test

14

Stator Vane Actuator Test

15

Fuel Control Replacement Test

16

Test No. 16 Not Used

17

Thrust Lever Angle (TLA) Resolver Test

18

Low Pressure Rotor Trim Balance

19

PT2 System Leak Check

20

Static Leak Test

Power Plant - Fault Isolation (Visual Checks) B757 FIM/71-07-00 Check No.

Title

1

Oil Leakage in the Turbine Exhaust Area

2

Gearbox Seal Drains

2A

Ejector Inlet Breather Tube

3

External Oil System Components

4

Stator Vane Unison Ring/Actuator Linkage

5

PB Hose, Manifold and Tube Condition

6

No. 4 Bearing Scavenge Manifold and Tube Condition

7

No. 4 Bearing Scavenge Valve Supply Tube Condition

Check No.

Title

Power Plant - Fault Isolation (Engine Checks) B757 FIM/71-08-00

1

Magnetic Chip Detectors and Main Oil Filter

2

Oil System Static Leak Test

3

Ignition System (Arcing/Flashover)

4

Fuel Pump Pressure Check

5

Fuel System Contamination

6

14th-Stage Bleed System

7

Not Used

8

No. 4 Bearing Seal Leak Check

9

No. 4 Bearing Pressure Tube Check

10

Burner Pressure (Pb) Manifold Blockage Check

11

Wire Harness Check

12

Pt4.9 Manifold Check

13

Turbine Cooling Air (TCA) System Check

14

T2 Signal

ADVANCED AIRCRAFT TRAINING

B757 ETIP’s PW2037 PW2000 OPEN COWL VISUAL INSPECTION LINE MAINTENANCE TRAINING The information and instructions in this booklet are prepared for general information purposes only. The data contained herein shall not be considered in any way as replacing or superceding the information contained in the PW2000 Turbofan Engine Manual or Boeing 757 Maintenance Manual.

Pratt Whitney PW2000 Component Locator B757

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