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
Feb 20, 2016
Boeing 757 component locator for the PW2000 Engine
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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 SideLeft Side1. 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. EECA. 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 ExchangerA. 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 TankA. 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 AreaA. Check pump housing for oil leakage (wetness). If leakage is present
replace the oil pump. Note: Oil leakage through the pump housing iscaused by cavitation within the pump. Pre Sunstrand SB 79-14 pumphousing can exhibit oil leaks through the housing near the front of thepump.
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 AreaA. Check area for damage (fan blades, fan exit guide vanes, & struts).
8. Left Side Bifurcation Panel AreaA. 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 AreaA. 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 AreaA. 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 AreaA. 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 AreaA. 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 AreaA. 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.
14. Left Side HPT/LPT Case AreaA. 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 AreaA. 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 AreaA. Check turbine blades for damage.B. Check area for evidence of oil leakage.
Right SideRight Side17. Right Side Exhaust Case Area
A. Check the EGT probe(s) connectors for looseness, cracking& brokenwires.
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 AreaA. 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 AreaA. 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 AreaA. 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 AreaA. 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 AreaA. 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 AreaA. 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 AreaA. 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 AreaA. Check area for damage (fan blades, fan exit guide vanes, & struts).
26. Fuel Control Unit (FCU)/ Fuel Pump AreaA. 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 HousingA. 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.
PW2000 OPEN COWL VISUAL INSPECTION CHECK LIST
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
P2/T2 Probe
Rub Strip
Compressor Inlet Cone
Inlet Cowl
Fan Blades
2. EEC
A. Check connectors & data plug for coupling nut & backshell tightness.
B. Check pressure fittings.
C. Check mounts.
Data Plug
Pressure Fittings
Mounts (4 ea.)
Connectors (8 ea.)
EEC
3. Fan Case Harness
(EEC to left side fan case components & bifurcationpanel.)
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
Bypass Valve Connectors
Fuel Temperature Probe
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 Warning: Wait a minimum of 5 minutes after engine shut-down before servicing.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.
Oil Quantity Indicator Connector
Oil CapMaster 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...
#5 Bearing Chip Detector
Lubrication and Scavenge Oil Pump
#1,2,3 Bearing Chip Detector
Main Oil Filter Bowl
Oil Trimmer Adjustment Screw
Main Gearbox Chip Detector
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. 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.
Main Gearbox Chip Detector
#1,2,3 Bearing Chip Detector
7. Left Fan Bypass Exit Area
A. Check following for damage- Fan blades- Fan exit guide vanes- Fan case struts- Sound panels
Fan Exit Guide Vanes
Strut
Sound Panels
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 engine vents and drains. Refer to AMM for allowable leak limits. Use Fluid Traps to Identify source of Fuel leaks
E. Check area harness wires for chafing & cuts.
Note: The breather line from the deoiler issusceptible to cracking at the T connection along the wield lines due to vibration or over torque.
Breather T Line
Bifurcation Panel
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 & 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 Bleed Actuator
2.5 LVDT’s
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.
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. 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.
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. 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.
Modulated TCA Valve
T3.5 Temperature Probe
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.
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. 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.
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. Check area harness wires for chafing & cuts.
D. Check tubes & harness clamps in this area for chafing & general condition.
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
#5 Oil Pressure Line
EGT Junction Box
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. Check area harness wires for chafing & cuts.
D. Check tubes & harness clamps in this area for chafing & general condition.
EGT Probes
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.
Cooling Manifolds
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.
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. 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.
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.
SVA Actuator
Bellcrank
22. Bell Crank Area
A. In-flight Shut Down(IFSD) Focus ItemCheck 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. Check connectors in area for coupling nut & backshell tightness.
E. Check tubes & harness clamps in this area for chafing & general condition.
Bellcrank
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.
Bifurcation Panel
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.
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
d
d
Fan Exit Guide Vanes
StrutSound Panels
26. Fuel Control Unit (FCU)/ Fuel PumpArea
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.
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. 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.
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/TestB757 MM 71-00-00
Test No. Title1 Engine Driven (Hydraulic) Pump (EDP) Test2 Engine Motoring (Dry) Leak Test2A Engine Motoring (Wet) Leak Test3 Minimum Idle Test3A Idle Leak Test for the Oil and Fuel Systems4 Integrated Drive Generator (IDG) Test5 Main Gearbox Replacement Test6 Fourteenth-Stage Bleed System Test7 Electronic Engine Control (EEC) Static Test8 Vibration Survey9 Performance Test10 Engine Replacement Test11 Oil Pressure Test12 Engine Replacement Test (Pre-tested)13 Intercompressor 2.5 Bleed Actuator Test14 Stator Vane Actuator Test15 Fuel Control Replacement Test16 Test No. 16 Not Used17 Thrust Lever Angle (TLA) Resolver Test18 Low Pressure Rotor Trim Balance19 PT2 System Leak Check20 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 TubeCondition
7 No. 4 Bearing Scavenge Valve Supply TubeCondition
Power Plant - Fault Isolation (Engine Checks)
B757 FIM/71-08-00Check No. Title
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.
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