Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly [PW11]

TASK 72-15-00-200-801-A
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AFTER SHUTDOWN. THE ENGINE CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

WARNING: BE CAREFUL TO EXAMINE THE POWER CABLE OF THE LIGHT SOURCE BEFORE YOU USE IT. DO NOT USE THE CABLE IF THE INSULATION HAS CUTS OR WORN OR BROKEN AREAS. INSULATION WITH THIS TYPE OF DAMAGE IS DANGEROUS BECAUSE OF POSSIBLE ELECTRICAL SHOCK TO THE OPERATOR.

WARNING: DO THE BORESCOPE INSPECTION IN AN AREA WHICH HAS PROTECTION FROM THE WEATHER. IF A BORESCOPE INSPECTION IS DONE IN WET CONDITIONS, USE SUFFICIENT PROTECTION TO PREVENT POSSIBLE ELECTRICAL SHOCK TO THE OPERATOR OR DAMAGE TO THE EQUIPMENT. AN ELECTRICAL SHOCK CAN KILL A PERSON OR CAUSE A BAD INJURY.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

CAUTION: MAKE SURE THAT THE INTERNAL ENGINE METAL TEMPERATURE IS NOT LOWER THAN THE OUTSIDE AIR TEMPERATURE. IF NECESSARY, LET THE INTERNAL METAL TEMPERATURE INCREASE TO THE OUTSIDE AIR TEMPERATURE BEFORE YOU REMOVE THE ENGINE COVERS. THIS WILL PREVENT CONDENSATION AND OXIDATION ON ENGINE PARTS.

ZONE: 400

1. Reason for the Job
Use this inspection procedure to do a borescope inspection of the Fan Drive Gearbox (FDG) system.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	COVER - PROTECTION
CTE8003	1	SYSTEM BOROSCOPE (VIDEO)
PWA115424	3	WEDGE, HAND

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS

C. Referenced Information

REFERENCE	DESIGNATION
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 72-15-00-960-801-A	Replacement of the Fan Shaft Cover
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (FDGS Arrangement)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Gear Arrangement)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Scuffing and Scoring Marks Not Permitted Condition)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Spalling and Scuffing Not Permitted Conditions)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Wear Not Permitted Conditions)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Burnish Marks Not Permitted)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Score and Burnishing Permitted)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Gear Face Edge Break Area)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Fan Drive Shaft)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Scuffing Not Permitted)
Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Incorrect Borescope Image for Reference)

3. Job Set-up
Subtask 72-15-00-869-050-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Do the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833).

4. Procedure

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

Subtask 72-15-00-290-050-A ** ON A/C NOT FOR ALL

A. Borescope Inspection of the Fan Drive Gearbox Assembly
(1) Removal of the protection cover.

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

(2) Make sure that you remove all the necessary COVER - PROTECTION to prevent damage to the engine.
(3) Remove the fan shaft cover (Ref. AMM TASK 72-15-00-960-801).

CAUTION: ONLY TURN THE ENGINE IN THE CORRECT DIRECTION OF OPERATION. IF YOU DO NOT OBEY THIS INSTRUCTION, YOU WILL CAUSE DAMAGE TO THE ENGINE.

(4) Do the Fan Drive Gear System (FDGS) borescope inspection as follows:

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Fan Drive Shaft) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (FDGS Arrangement) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Gear Arrangement) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Scuffing and Scoring Marks Not Permitted Condition) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Spalling and Scuffing Not Permitted Conditions) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Wear Not Permitted Conditions) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Burnish Marks Not Permitted) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Score and Burnishing Permitted) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Gear Face Edge Break Area) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Scuffing Not Permitted) ** ON A/C NOT FOR ALL

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Incorrect Borescope Image for Reference) ** ON A/C NOT FOR ALL

NOTE: The 4 mm (0.16 in.) diameter tip from the CTE8003 SYSTEM BOROSCOPE (VIDEO) is used for this procedure.

(a) A near focus borescope tip must be used for the evaluation of geartooth condition. A blurred image of the gearteeth indicates an incorrect tip.

Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Incorrect Borescope Image for Reference) ** ON A/C NOT FOR ALL

(b) The FDG assembly must be turned counterclockwise (aft looking forward) while you do this inspection.
(c) Turn the fan rotor until the sun and star gear roots come into view.

CAUTION: MAKE SURE THAT THE ENGINE DOES NOT TURN WHILE THE FLEXIBLE BORESCOPE IS IN THE ENGINE. IF THE ENGINE TURNS, DAMAGE TO THE BORESCOPE AND ENGINE CAN OCCUR.

(d) Stop the fan rotor when you can see the sun and star gear roots.

CAUTION: DO NOT USE FAN BLADE WEDGE TOOLS IN WINDS MORE THAN FIVE MILES PER HOUR. IF YOU DO NOT OBEY THIS INSTRUCTION, DAMAGE TO THE ENGINE CAN OCCUR.

(e) Install the three PWA115424 WEDGE, HAND as necessary to stop the fan blade windmill during this inspection and make sure that the red streamer comes out of the fan cowl and you can see it.

CAUTION: BE CAREFUL WHEN YOU MOVE THE BORESCOPE PROBE THROUGH THE MESHING GEARS. IF YOU CANNOT MOVE THE BORESCOPE IN OR OUT, ENGINE DISASSEMBLY CAN BE NECESSARY TO REMOVE THE BORESCOPE. DO NOT USE TOO MUCH FORCE WHEN YOU PUSH OR PULL THE BORESCOPE. IF YOU DO, YOU CAN CAUSE DAMAGE TO THE BORESCOPE.

CAUTION: BE CAREFUL NOT TO CRUSH THE BORESCOPE PROBE. A SMALL AMOUNT OF FAN ROTOR MOVEMENT CAN MOVE THE GEARS ENOUGH TO CRUSH THE BORESCOPE PROBE. IF YOU DO NOT OBEY THIS INSTRUCTION, DAMAGE TO THE BORESCOPE CAN OCCUR.

(f) Examine the sun and star gearteeth and roots for the conditions and limits in Table 1, Table 2 and Table 3.
(g) An inspection of each star gear must be done at one location by Table 2.

Table 1 - FDGS Sun and Star Gears (All Surfaces)

EXAMINE	SERVICEABLE LIMITS	DISPOSITION
Cracks	Not permitted	Contact P&W
Sharp edges and raised material	Not permitted	Contact P&W
Corrosion pitting	Not permitted	Contact P&W
Spalling	Not permitted	Contact P&W
Scuffing	Not permitted	Contact P&W

Table 2 - FDGS Sun and Star Gears (Gearteeth Surfaces and Chamfers)

EXAMINE	SERVICEABLE LIMITS	DISPOSITION
Score and grind marks	Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Scuffing and Scoring Marks Not Permitted Condition) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Spalling and Scuffing Not Permitted Conditions) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Wear Not Permitted Conditions) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Burnish Marks Not Permitted) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Score and Burnishing Permitted) ** ON A/C NOT FOR ALL	Contact P&W
Wear and loss of material	Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Scuffing and Scoring Marks Not Permitted Condition) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Spalling and Scuffing Not Permitted Conditions) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Wear Not Permitted Conditions) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Burnish Marks Not Permitted) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Score and Burnishing Permitted) ** ON A/C NOT FOR ALL	Contact P&W
Burnishing	Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Scuffing and Scoring Marks Not Permitted Condition) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Spalling and Scuffing Not Permitted Conditions) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Wear Not Permitted Conditions) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Burnish Marks Not Permitted) ON A/C NOT FOR ALL Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly (Score and Burnishing Permitted) ** ON A/C NOT FOR ALL	Contact P&W

Table 3 - FDGS Sun and Star Gears (Forward Axial Face)

EXAMINE	SERVICEABLE LIMITS	DISPOSITION
Superficial corrosion	Less than 0.020 in. (0.508 mm) diameter separated by 0.125 in. (3.175 mm) minimum, located 0.070 in. (1.778 mm) minimum from gear face edge break and no more than three areas in 1.000 in. (25.400 mm) of each other. Pits not permitted. Borescope Inspection of the Fan Drive Gearbox (FDG) Assembly - (Gear Face Edge Break Area) ** ON A/C NOT FOR ALL	Contact P&W

(5) Install the fan shaft cover (Ref. AMM TASK 72-15-00-960-801).
(6) Remove the three PWA115424 WEDGE, HAND from the fan blades.
(7) Do the Special Procedure 72-15 if any of the damage is not within serviceable limits.

NOTE: Due to the critical nature of this procedure, Special Procedure 72-15, is subject to source demonstration requirements. IAE LLC may be contacted via the Pratt & Whitney Global Operations Center to determine the current list of qualified vendors or to request a new facility demonstration program.

(8) Examine the assembly for foreign objects, damage and correct assembly.
(9) Installation of the protection cover.

CAUTION: INSTALL PROTECTION COVERS ON ALL THE OPENINGS IMMEDIATELY TO PREVENT DAMAGE TO THE ENGINE.

(10) Make sure that you install all the necessary COVER - PROTECTION to prevent damage to the engine.

5. Close-up
Subtask 72-15-00-860-050-A ** ON A/C NOT FOR ALL

A. Put the aircraft back to its initial configuration.
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 12:57:04 UTC