Pw4000-100_opencowl Inspection Guide

PW4000 100-inch AIRBUS OPEN COWL VISUAL INSPECTION For the prevention of Delays & Cancellations and IFSD’s

September 2000

FOR REFERENCE ONLY

PW4000-100 AIRBUS 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 shall not be considered in any way as replacing or superceding the information contained in the PW4000 Turbofan Engine Manual or Airbus A330 Maintenance Manual.

Prepared by: Pratt & Whitney Customer Service Line Maintenance & Troubleshooting Pratt & Whitney Customer Training

© COPYRIGHT 2000 UNITED TECHNOLOGIES CORPORATION

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 course.

PW4000-100 AIRBUS OPEN COWL VISUAL INSPECTION CHECK LIST LEFT SIDE 1. a. b. c. d. e.

Inlet Area (CHECK): Inlet cowl for damage (including missing sealant) and evidence of birdstrike. Fan blades for damage. P2/T2 probe for damage or debris. Fan rub strip for heavy wear. Outer barrel for damage (including chipping paint on leading edge).

2. a. b. c. d. e. f.

Fan Cowl / Thrust Reverser Actuation Area – Left (CHECK): Forward/aft fan cowl door for leading edge delamination/chipping paint. For open lock levers. For evidence of Skydrol leaks. All connectors for coupling nut and backshell tightness. Area harness clamps for chafing and general condition. Area harnesses for chafing or cuts.

3. a. b. c. d. e.

Thrust Reverser Area – Left (CHECK): For thrust reverser firecoat/fireblanket damage. For evidence of thrust reverser interference.. For transcowl screen delamination. For damage to transcowl or blocker doors. For upper and lower transcowl fairing cracks.

4. a. b. c. d. e.

EEC / Engine Relay Unit (ERU) / Lower Birfurcation Conduit Area (CHECK): EEC pressure sense line fittings for tightness. ERU mounts for looseness or fractures. All connectors and EEC Programming Plug for coupling nut and backshell tightness. Area harness clamps for chafing and general condition. Area harnesses for chafing or cuts.

5. Fan Bypass Exit Area – Left (CHECK): a. Area for damage (fan blades, fan exit guide vanes and struts). 6. a. b. c. d.

(2.5) Bleed Actuator Area (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 harnesses for chafing or cuts.

7. (2.9) Bleed Solenoid / TVBC Air/Anti-Ice Valve Solenoid / (2.9) Stability Bleed Valve Area (CHECK): a. Temperature probe connections for looseness, cracking or broken lugs on the 2.9 stability bleed valve. b. Area for evidence of fuel/oil leakage. c. Area connectors for coupling nut and backshell tightness. d. Area tubes and harness clamps for chafing and general condition. e. Area harnesses for chafing or cuts.

8. a. b. c. d.

Fuel/Oil Cooler & Bypass Valve Area (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 harnesses for chafing or cuts.

9. a. b. c. d. e. f.

Front Hydraulic Pump / PMA / Main Oil Filter Cover Area (CHECK): Main gearbox chip detector for proper installation and leakage. Oil 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 harnesses for chafing or cuts.

10. Oil Tank / HP Valve Area (CHECK): a. Oil quantity transmitter connector and other connectors for coupling nut and backshell tightness. b. Oil tank cap and O-ring for damage. c. Oil level (per AMM section 12-13-79). d. Master chip detector for proper installation and leakage. e. T3 temperature probe for looseness, cracking or broken lugs. f. Area for evidence of oil leakage. g. Area tubes and harness clamps for chafing and general condition. h. Area harnesses for chafing or cuts. 11. a. b. c. d. e.

IDG / Oil Pump Area (CHECK): Pump chip detectors for proper installation and 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 harnesses for chafing or cuts.

12. a. b. c. d. e.

HPT / LPT Case Area – Left (CHECK): Cooling manifolds for cracking. Area for evidence of oil leakage. Area connectors for coupling nut and backshell tightness. Area tubes and harness clamps for chafing and general condition. Area harnesses for chafing or cuts.

13. a. b. c. d. e.

Exhaust Case Area – Left (CHECK): EGT probe connections for looseness, cracking and broken lugs. No.4 bearing scavenge tube for evidence of clamp migration, chafing or oil leakage. P4.95 system B-nuts for tightness. Area tubes and harness clamps for chafing and general condition. Area harnesses for chafing or cuts.

14. Exhaust Area (CHECK): a. Turbine blades for damage. b. Area for evidence of oil leakage.

PW4000-100 AIRBUS OPEN COWL VISUAL INSPECTION CHECK LIST RIGHT SIDE 15. a. b. c. d.

Exhaust Case Area – Right (CHECK): EGT probe connections for looseness, cracking or broken lugs. P4.95 system B-nuts for tightness. Area tubes and harness clamps for chafing and general condition. Area harnesses for chafing or cuts.

16. a. b. c. d. e.

HPT / LPT Case Area – Right (CHECK): Cooling manifolds for cracking. Cooling valve linkage and arms for security. Area for evidence of oil leakage. Area tubes and harness clamps for chafing and general condition. Area harnesses for chafing or cuts.

17. a. b. c. d.

Starter / Rear Hydraulic Pump / Igniter Box Area (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 harnesses for chafing or cuts.

18. a. b. c. d. e. f. g.

TCC Actuator / SVA Bellcrank Area (CHECK): 2.9 start bleed temperature probe connections for looseness, cracking or broken lugs. VSV system bolts, attaching adjustor rods to unison rings and bellcrank, for signs of wear. SVA bellcrank for excessive axial or radial movement. 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 harnesses for chafing or cuts.

19. a. b. c. d.

TVBC Air/Nacelle Cooling Valve / Starter Air Valve Solenoid Area (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 harnesses for chafing or cuts.

20. a. b. c. d.

IDG Air/Oil Heat Exchanger Area (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 harnesses for chafing or cuts.

21. a. b. c. d.

N1 Sensor Area (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 harnesses for chafing or cuts.

22. a. b. c. d. e.

VSV Actuator / FMU / Fuel Pump / Upper Bifurcation Conduit Area (CHECK): Fuel filter cover for leakage. Area for evidence of fuel leakage. Area connectors for coupling nut and backshell tightness. Area tubes and harness clamps for chafing and general condition. Area harnesses for chafing or cuts.

23. Fan Bypass Exit Area - Right (CHECK): a. Area for damage (fan blades, fan exit guide vanes and struts). 24. a. b. c. d. e.

Thrust Reverser Area – Right (CHECK): For thrust reverser firecoat/fireblanket damage. For evidence of thrust reverser interference. For transcowl screen delamination. For damage to transcowl or blocker doors. For upper and lower transcowl fairing cracks.

25. a. b. c. d. e. f.

Fan Cowl / Thrust Reverser Actuation Area – Right (CHECK): Forward/aft fan cowl door for leading edge delamination/chipping paint. For open lock levers. For evidence of Skydrol leaks. All connectors for coupling nut and backshell tightness. Area harness clamps for chafing and general condition. Area harnesses for chafing or cuts.

1. Inlet Area (CHECK): a. Inlet cowl for damage (including missing sealant) and evidence of birdstrike. b. Fan blades for damage. c. P2/T2 probe for damage or debris. d. Fan rub strip for heavy wear. e. Outer barrel for damage (including chipping paint on leading edge).

AMM 71-61-00, 71-61-41

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ENGINE LEFT SIDE

Feedback Actuator

Locking Actuator

2. Fan Cowl / Thrust Reverser Actuation Area - Left (CHECK): a. Forward/aft fan cowl door for leading edge delamination/chipping paint. b. For open lock levers. c. For evidence of Skydrol® leaks. d. All connectors for coupling nut and backshell tightness. e. Area harness clamps for chafing and general condition. f. Area harnesses for chafing or cuts.

AMM 71-13-00, 78-30-00, 78-31-00

Transcowl Blocker Doors

Transcowl Fairing

Thrust Reverser Door

3. Thrust Reverser Area - Left (CHECK): a. For transcowl screen delamination. b. For damage to transcowl or blocker doors. c. For upper and lower transcowl fairing cracks. d. For thrust reverser firecoat/fireblanket damage. e. For evidence of thrust reverser interference.

AMM 78-30-00

4. EEC / Engine Relay Unit (ERU) / Lower Bifurcation Conduit Area (CHECK): a. EEC pressure sense line fittings for tightness. b. EEC and ERU mounts for looseness or fractures. c. All connectors and EEC Programming Plug for coupling nut and backshell tightness. d. Area tubes and harness clamps for chafing and general condition. e. Area harnesses for chafing or cuts.

AMM 73-21-00

5. Fan Bypass Exit Area - Left (CHECK): a. Area for damage (fan blades, fan exit guide vanes and struts).

AMM 72-33-12

Actuator

6. (2.5) Bleed Actuator Area (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 harnesses for chafing or cuts.

AMM 75-32-00

2.9 Bleed Valve Solenoid

TVBC Air SOV/Anti-Ice Valve Solenoid

2.9 Stability Bleed Valve Probe

7. (2.9) Bleed Solenoid / TVBC Air/Anti-Ice Valve Solenoid / (2.9) Stability Bleed Valve Area (CHECK): a. Temperature probe connections for looseness, cracking or broken lugs on the 2.9 stability bleed valve. b. Area for evidence of fuel/oil leakage. c. Area connectors for coupling nut and backshell tightness. d. Area tubes and harness clamps for chafing and general condition. e. Area harnesses for chafing and cuts.

AMM 75-32-00

Fuel/Oil Cooler

Bypass Valve

8. Fuel/Oil Cooler & Bypass Valve Area (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 harnesses for chafing or cuts.

AMM 79-00-00

Hydraulic Pump

PMA

Main Oil Filter

Main Chip Detector

9. Front Hydraulic Pump / PMA / Main Oil Filter / Upper Bifurcation Area (CHECK): a. Main gearbox chip detector for proper installation and leakage. b. Oil 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 harnesses for chafing and cuts (including forward hydraulic lines for gouging).

AMM 75-26-16, 79-00-00, 79-22-11

HP Valve

T3 Probe

Master Chip Detector

Oil Quantity Transmitter

10. Oil Tank Area / HP Valve Area (CHECK): a. Oil quantity transmitter connector and other area connectors for coupling nut and backshell tightness. b. Oil tank cap and O-ring for damage. c. Oil level. d. Master chip detector for proper installation and leakage. e. T3 temperature probe connections for looseness, cracking or broken lugs. f.

Area for evidence of oil leakage.

g. Area tubes and harness clamps for chafing and general condition. h. Area harnesses for chafing or cuts.

AMM 12-13-79, 79-00-00, 79-22-00

IDG

Oil Pump

Chip Detectors

11. IDG / Oil Pump Area (CHECK): a. Pump chip detectors for proper installation and leakage. b. Area for evidence of fuel/oil leakage. c. Area connectors for coupling nut and backshell tightness. d. Area tubes and harness clamps for chafing and general condition. e. Area harnesses for chafing or cuts.

AMM 24-21-00, 79-22-11

12. HPT / LPT Case Area - Left (CHECK): a. Cooling manifolds for cracking. b. Area for evidence of oil leakage. c. Area connectors for coupling nut and backshell tightness. d. Area tubes and harness clamps for chafing and general condition. e. Area harnesses for chafing or cuts.

AMM 75-24-00

EGT Probes

No. 4 Brg. Scavenge Tube

P4.95 ‘B’ Nut

13. Exhaust Case Area - Left (CHECK): a. EGT probe connections for looseness, cracking or broken lugs. b. No.4 bearing scavenge tube for evidence of clamp migration, chafing or oil leakage. c. P4.95 system B-nuts for tightness. d. Area tubes and harness clamps for chafing and general condition. e. Area harnesses for chafing or cuts.

AMM 77-13-11, 77-21-11, 79-22-00

14. Exhaust Area (CHECK): a. Turbine blades for damage. b. Area for evidence of oil leakage.

AMM 78-11-00

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ENGINE RIGHT SIDE

EGT Probes

P4.95 ‘B’ Nut

15. Exhaust Case Area - Right (CHECK): a. EGT probe connections for looseness, cracking or broken lugs. b. P4.95 system B-nuts for tightness. c. Area tubes and harness clamps for chafing and general condition. d. Area harnesses for chafing or cuts.

AMM 77-13-11, 77-21-11

16. HPT/LPT Case Area - Right (CHECK): a. Cooling manifolds for cracking. b. Cooling valve linkage and arms for security. c. Area for evidence of oil leakage. d. Area tubes and harness clamps for chafing and general condition. e. Area harnesses for chafing or cuts.

AMM 75-24-00

Hydraulic Pump

Starter

Igniter Box

17. Starter / Rear Hydraulic Pump / Igniter Area (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 harnesses for chafing and cuts.

AMM 74-00-00, 80-11-11

TCC Actuator

SVA Bellcrank

18. TCC Actuator / SVA Bellcrank Area (CHECK): a. 2.9 start bleed temperature probe connections for looseness, cracking or broken lugs. b. VSV system bolts, attaching adjustor rods to unsion rings and bellcrank, for signs of wear. c. SVA bellcrank for excessive axial or radial movement. d. Area for evidence of fuel/oil leakage. e. Area connectors for coupling nut and backshell tightness. f.

Area tubes and harness clamps for chafing and general condition.

g. Area harnesses for chafing and cuts.

AMM 75-24-00, 75-31-00

Starter Air Valve Solenoid

TVBC Air/Nacelle Cooling Valve Solenoid

19. TVBC Air/Nacelle Cooling Valve / Starter Air Valve Solenoid Area (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 harnesses for chafing and cuts.

AMM 75-25-00

20. IDG Air/Oil Heat Exchanger Area (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 harnesses for chafing and cuts.

AMM 24-21-00

21. N1 Sensor (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 harnesses for chafing and cuts.

VSV Actuator

Fuel Pump

FMU

22. VSV Acuator / FMU / Fuel Pump / Upper Bifurcation Conduit Area (CHECK): a. Fuel filter cover for leakage. b. Area for evidence of fuel leakage. c. Area connectors for coupling nut and backshell tightness. d. Area tubes and harness clamps for chafing and general condition. e. Area harnesses for chafing and cuts.

AMM 73-00-00, 75-31-00

23. Fan Bypass Area - Right (CHECK): a. Area for damage (fan blades, fan exit guide vanes and struts).

AMM 72-32-12

Transcowl Blocker Doors

Transcowl Fairing

Thrust Reverser Door

24. Thrust Reverser Area - Right (CHECK): a. For transcowl screen delamination. b. For damage to transcowl or blocker doors. c. For upper and lower transcowl fairing cracks. d. For thrust reverser firecoat/fireblanket damage. e. For evidence of thrust reverser interference.

AMM 78-30-00

Feedback Actuator

Directional Control Valve

Locking Actuator

25. Fan Cowl / Thrust Reverser Actuation Area - Right (CHECK): a. Forward/aft fan cowl door for leading edge delamination/chipping paint. b. For open lock levers. c. For evidence of Skydrol® leaks. d. All connectors for coupling nut and backshell tightness. e. Area harness clamps for chafing and general condition. f. Area harnesses for chafing or cuts.

AMM 71-13-00, 78-30-00, 78-31-00

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