Visual Examination of the Engine Air Systems [PW11]

TASK 75-00-00-210-802-A
Visual Examination of the Engine Air Systems

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

ZONE: 400

1. Reason for the Job
Use this procedure to visually examine the air system external parts for damage (nicks, dents, corrosion, pitting and scratches), correct installation and correct clearance.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 1M(3 FT)
No specific	1	CLOTH-CROCUS
No specific	1	FLASHLIGHT
No specific	1	MAGNIFYING GLASS POWER 03X
No specific	1	MAGNIFYING GLASS POWER 10X
No specific	1	MIRROR - INSPECTION

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 451AL, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 461AL, 462AR

C. Referenced Information

REFERENCE	DESIGNATION
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-802-A	Closing of the Fan Cowl Doors
TASK 78-30-00-040-805-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-805-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-36-00-010-802-A	Opening of the Thrust Reverser Cowl-Doors
TASK 78-36-00-410-802-A	Closing of the Thrust Reverser Cowl-Doors
Active Clearance Control (ACC) Air System (Right Side)
Active Clearance Control (ACC) Air System (Left Side)
Low Pressure Turbine (LPT) Active Clearance Control (ACC)
Turbine Cooling Air (TCA) Main Tubes and Jumper Tubes
Turbine Cooling Air (TCA) Main Tubes and Jumper Tubes
Compressor Bleed Control
Compressor Stator Vane Actuator-System (Left Side)
Compressor Stator Vane Actuator-System (Right Side)
Engine Bearing Cooling-System (Left Side)
Engine Bearing Cooling-System (Right Side)
Electronic Cooling System (ECS) Ducts
Air/Oil Heat Exchanger Ducts

3. Job Set-up
Subtask 75-00-00-941-051-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).

Subtask 75-00-00-010-052-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR.
(2) Put the ACCESS PLATFORM 1M(3 FT) in position.

Subtask 75-00-00-040-051-A ** ON A/C NOT FOR ALL

C. Deactivation of the Thrust Reverser for Ground Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Do the deactivation of the thrust reverser system for ground maintenance (Ref. AMM TASK 78-30-00-040-805).

Subtask 75-00-00-010-053-A ** ON A/C NOT FOR ALL

D. Get Access
(1) Open the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR.

4. Procedure

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

Subtask 75-00-00-210-051-A ** ON A/C NOT FOR ALL

A. Visual Examination of the Air System
(1) If necessary, use the MIRROR - INSPECTION, MAGNIFYING GLASS POWER 03X - MAGNIFYING GLASS POWER 10X and the FLASHLIGHT to examine the engine air system.
(2) Do a visual inspection of the (non-specified) air system tubes as follows:
Table 1 - Air System Tubes (General)

EXAMINE	DAMAGE	DISPOSITION
For cracks	Any amount	Not permitted. Replace the tube.
For corrosion and stains	Amounts that can be removed by light polishing with CLOTH-CROCUS	Permitted
For loose tube nuts	Any amount	Not permitted. Tighten as necessary.
For loose and/or broken lockwire	Any amount	Not permitted. Replace the lockwire as necessary.
For nicks, scratches, chafing and pitting	All quantities less than 0.003 in. (0.08 mm) depth	Permitted
For dents without sharp edges	Outer diameter is decreased by less than 20 percent at each location	Permitted
For dents with sharp edges	Any amount	Not permitted. Replace the tube.
For dents	Any amount 0.250 in. (6.35 mm) or less from the ferrule	Not permitted. Replace the tube.

(a) Do a visual inspection of the air system tubes as follows:

CAUTION: YOU MUST ADJUST ALL TUBES WITH NO LESS THAN 0.090 INCH (2.286 MM) CLEARANCE TO ADJACENT TUBES OR PARTS. TUBES WITH LESS CLEARANCE CAN RUB DURING ENGINE OPERATION. THIS CAN CAUSE A LEAK AND A POSSIBLE IN-FLIGHT SHUTDOWN.

1 Do a visual inspection of the air system tubes to make sure that there is a 0.090 in. (2.29 mm) minimum clearance with the adjacent tubes or parts. If the clearance is less than 0.090 in. (2.29 mm), do the steps that follow:
2 Loosen all the clamp bolts and/or brackets at all the support points along the tube length.
3 Loosen all the tube fittings.
4 Adjust the tube and clamps to get the 0.090 in. (2.29 mm) minimum clearance with the adjacent tubes or parts.
5 Tighten all the clamp bolts and/or brackets.
6 Tighten all the tube fittings.
7 Examine the tubes that were adjusted for air leaks.
(b) Examine the tubes to make sure they are attached correctly from end to end and at all support locations along the tube length as follows:
1 Replace all worn and/or broken clamps and brackets.
2 Tighten all loose clamps, bolts and brackets.
3 Tighten all loose tube fittings.
(3) Use this inspection procedure to examine the Active Clearance Control (ACC) system for correct attachment and for damage.

Active Clearance Control (ACC) Air System (Right Side) ** ON A/C NOT FOR ALL

Active Clearance Control (ACC) Air System (Left Side) ** ON A/C NOT FOR ALL

Low Pressure Turbine (LPT) Active Clearance Control (ACC) ** ON A/C NOT FOR ALL

(a) Visually inspect the ACC system parts for correct attachment where possible.
1 Tighten all loose bolts.
2 Replace all missing or broken bolts.
3 Tighten the bolts and clamps as necessary if the manifolds or tubes are loose.
4 Correct the installation of the brackets that are installed incorrectly.
(b) Visually inspect the ACC system parts for damage where possible.
1 If you see damage, see Table 2 thru Table 8 for the continue-in-service damage limits.
Table 2 - LPT/HPT Air Collector

EXAMINE	DAMAGE	DISPOSITION
For cracks or nicks with sharp edges	Cracks or nicks with sharp edges any amount, all lengths	Not permitted. Replace the LPT/HPT air collector.
For dents or nicks without sharp edges or corners	Round bottom dents or nicks without sharp edges or corners, any amount, all lengths	Permitted

Table 3 - HPT Air Manifolds and Tubes

EXAMINE	DAMAGE	DISPOSITION
For cracks or nicks with sharp edges	Cracks or nicks with sharp edges any amount, all lengths	Not permitted. Replace the LPT/HPT manifold or tube.
For dents or nicks without sharp edges or corners	Round bottom dents or nicks without sharp edges or corners, any amount, all lengths	Permitted
For chafing	Chafing at all locations not more than 0.004 in. (0.10 mm) depth	Permitted
	Chafing more than 0.004 in. (0.10 mm) depth	Not permitted. Replace the manifold or tube.
For corrosion	Corrosion at all locations not more than 0.004 in. (0.10 mm) depth	Permitted
	Corrosion more than 0.004 in. (0.10 mm) depth	Not permitted. Replace the manifold or tube.
For cracks in supports and clamps	Cracks, any amount, all locations	Not permitted. Replace the clamps and supports as necessary.
For damage to clamp cushion	Any amount of damage	Permitted unless the manifolds or tubes become loose or chafing occurs

Table 4 - ACC Air Valve

EXAMINE	DAMAGE	DISPOSITION
For cracks	Cracks, any amount, all locations	Not permitted. Replace the air valve.

Table 5 - ACC Inlet Air Duct

EXAMINE	DAMAGE	DISPOSITION
For cracks	Cracks, any amount, all locations	Not permitted. Replace the inlet air duct.
For dents or nicks without sharp edges or corners	Round bottom dents or nicks without sharp edges or corners	Permitted

Table 6 - LPT ACC Rubber Jumper Tubes

EXAMINE	DAMAGE	DISPOSITION
For cracks in rubber jumper tubes (six locations)	Cracks, any amount	Not permitted. Replace the jumper tubes as necessary.
For deformation of rubber jumper tubes (six locations)	Deformation, any amount	Not permitted. Replace the jumper tubes as necessary.
For nicks, dents, and scratches in rubber jumper tubes (six locations)	Damage that does not go through the silicon rubber surface and the internal glass fabric is not seen.	Permitted
	Damage that goes through the silicon rubber surface and the internal glass fabric is seen.	Not permitted. Replace the jumper tubes as necessary.

Table 7 - LPT ACC Air Tubes (Visible Surfaces)

EXAMINE	DAMAGE	DISPOSITION
For cracks	Cracks, any amount	Not permitted. Replace the tube as necessary.
For nicks and scratches	Nicks and scratches not more than 0.005 in. (0.13 mm) depth	Permitted
	Nicks and scratches more than 0.005 in. (0.13 mm) depth	Not permitted. Replace the tube as necessary.
For dents	Dents not more than 0.016 in. (0.41 mm) depth	Permitted
	Dents more than 0.016 in. (0.41 mm) depth	Not permitted. Replace the tube as necessary.

Table 8 - LPT ACC Panels

EXAMINE	DAMAGE	DISPOSITION
For cracks	Cracks, any amount	Not permitted. Replace the panel as necessary.
Area C for nicks and scratches	Nicks and scratches not more than 0.003 in. (0.08 mm) depth	Permitted
	Nicks and scratches more than 0.003 in. (0.08 mm) depth	Not permitted. Replace the panel as necessary.
Parts of panel you can see other than Area C for nicks and scratches	Nicks and scratches not more than 0.004 in. (0.10 mm) depth	Permitted
	Nicks and scratches more than 0.004 in. (0.10 mm) depth	Not permitted. Replace the panel as necessary.
Area A for dents or deformation	Dents or deformation not more than 0.040 in. (1.02 mm) depth	Permitted
	Dents or deformation more than 0.040 in. (1.02 mm) depth	Not permitted. Replace the panel as necessary.
Area B for dents	A maximum of five dents not more than 0.040 in. (1.02 mm) depth on each Area B on each part	Permitted
	More than five dents on each Area B on each part	Not permitted. Replace the panel as necessary.
	Dents more than 0.040 in. (1.02 mm) depth	Not permitted. Replace the panel as necessary.
Area C for dents	Dents not more than 0.020 in. (0.51 mm) depth	Permitted
	Dents more than 0.020 in. (0.51 mm) depth	Not permitted. Replace the panel as necessary.
Area D for dents or deformation	Dents or deformation not more than 0.020 in. (0.51 mm) depth	Permitted
	Dents or deformation more than 0.020 in. (0.51 mm) depth	Not permitted. Replace the panel as necessary.

(4) Use this inspection procedure to examine the Turbine Cooling Air (TCA) system for correct installation and for damage.

Turbine Cooling Air (TCA) Main Tubes and Jumper Tubes ** ON A/C NOT FOR ALL

(a) Visually inspect the TCA system parts for correct attachment where possible.
1 Tighten all loose bolts.
2 Replace all missing or broken bolts.
3 Tighten the bolts and clamps as necessary if the manifolds or tubes are loose.
4 Correct the installation of the brackets that are installed incorrectly.
(b) Visually inspect the TCA system parts for damage where possible.
1 If you see damage, see Table 9 for the continue-in-service damage limits.
Table 9 - TCA Main Tubes and Jumper Tubes

EXAMINE	DAMAGE	DISPOSITION
For cracks	Any amount	Not permitted. Contact P&W.
For nicks, scratches or pitting	0.003 in. (0.08 mm) maximum depth	Permitted
	More than 0.003 in. (0.08 mm) depth	Not permitted. Replace the damaged tube.
For dents	Dents in 0.250 in. (6.35 mm) or less of the ferrules	Not permitted. Replace the damaged tube.
	Dents with sharp creases or corners	Not permitted. Replace the damaged tube.
	Dents without sharp creases or corners and the tubing outer diameter is not decreased by more than 20 percent at each location	Permitted
Chafing	Not more than 0.003 in. (0.08 mm) depth maximum	Permitted
	More than 0.003 in. (0.08 mm) depth	Not permitted. Replace the damaged tube.
Corrosion	Corrosion that can be removed by polishing lightly with a CLOTH-CROCUS	Permitted
	More than permitted limit	Not permitted. Replace the damaged tube.

(5) Use this inspection procedure to examine the compressor bleed control-system for correct installation and for damage.

Compressor Bleed Control ** ON A/C NOT FOR ALL

(a) Visually inspect the compressor bleed control-system-parts for correct attachment where possible.
1 Tighten all loose bolts.
2 Replace all missing or broken bolts.
3 Tighten the bolts and clamps as necessary if the manifolds or tubes are loose.
4 Correct the installation of the brackets that are installed incorrectly.
(b) Visually inspect the compressor bleed control-system-parts for damage where possible.
1 If you see damage, see Table 10 for the continue-in-service damage limits.
Table 10 - LPC (2.5) Bleed-Valve Actuator Linkage

EXAMINE	DAMAGE	DISPOSITION
For cracks	Any amount	Not permitted. Replace the linkage.
For loose or damaged pins or missing pins	Any amount	Not permitted. Replace the linkage.

(6) Use this inspection procedure to examine the compressor Stator Vane Actuator (SVA) system for correct installation and for damage.

Compressor Stator Vane Actuator-System (Left Side) ** ON A/C NOT FOR ALL

Compressor Stator Vane Actuator-System (Right Side) ** ON A/C NOT FOR ALL

(a) Visually inspect the compressor stator vane control-system-parts for correct attachment where possible.
1 Tighten all loose bolts.
2 Replace all missing and broken bolts.
3 Tighten the bolts and clamps as necessary if manifolds or tubes are loose.
4 Correct the installation of the brackets that are installed incorrectly.
(b) Visually inspect the compressor stator vane control-system-parts for damage where possible.
1 If you see damage, see Table 11 for the continue-in-service damage limits.
Table 11 - Compressor Stator Vane Actuator-System

EXAMINE	DAMAGE	DISPOSITION
Actuator for cracks or leakage	Any amount	Not permitted. Replace the actuator.
Actuator electrical connections	Found loose	Not permitted. Tighten as necessary.
Actuator rod end bearing for looseness or wear	Any amount	Not permitted. Replace the rod end bearing.
Connector link rod end bearings for looseness or wear	Any amount	Not permitted. Replace the rod end bearings as necessary.
Bellcrank for cracks	Any amount	Not permitted. Replace the bellcrank.
Connector links for cracks or damage	Any amount	Not permitted. Replace the links as necessary.
Connector links for looseness	Any amount	Not permitted. Tighten as necessary.
Retaining pins for looseness or damage	Any amount	Not permitted. Replace the pins as necessary.
Unison rings for cracks	Any amount	Not permitted. Replace the unison ring as necessary.
Unison rings for damage	Minor damage if ring operation is satisfactory	Permitted
SVA support, front support bracket and rear support bracket for cracks or damage	Any amount	Not permitted. Replace the support as necessary.
SVA support, front support bracket and rear support bracket for looseness	Any amount	Not permitted. Tighten or replace the mounting bolts and/or nuts as necessary.

(7) Use this inspection procedure to examine the engine bearing cooling-system for correct installation and for damage.

Engine Bearing Cooling-System (Left Side) ** ON A/C NOT FOR ALL

Engine Bearing Cooling-System (Right Side) ** ON A/C NOT FOR ALL

(a) Visually inspect the engine bearing cooling-system parts for correct attachment where possible.
1 Tighten all loose bolts.
2 Replace all missing or broken bolts.
3 Tighten the bolts and clamps as necessary if the manifolds or tubes are loose.
4 Correct the installation of the brackets that are installed incorrectly.
(b) Visually inspect the engine bearing cooling system parts for damage where possible.
1 If you see damage, see Table 12, Table 13 and Table 14 for the continue-in -service damage limits.
Table 12 - Engine Bearing Cooling-System Tubes and Buffer Air Manifold

EXAMINE	DAMAGE	DISPOSITION
For cracks or nicks with sharp edges	Cracks or nicks with sharp edges any amount, all lengths	Not permitted. Replace the LPT/HPT manifold or tube.
For dents or nicks without sharp edges or corners	Round bottom dents or nicks without sharp edges or corners, any amount, all lengths	Permitted
For chafing	Chafing at all locations not more than 0.004 in. (0.10 mm) depth	Permitted
	Chafing more than 0.004 in. (0.10 mm) depth	Not permitted. Replace the manifold or tube.
For corrosion	Corrosion at all locations not more than 0.004 in. (0.10 mm) depth	Permitted
	Corrosion more than 0.004 in. (0.10 mm) depth	Not permitted. Replace the manifold or tube.
For cracks in supports and clamps	Cracks, any amount, all locations	Not permitted. Replace the clamps and supports as necessary.
For damage to clamp cushion	Any amount of damage	Permitted unless the manifolds or tubes become loose or chafing occurs

Table 13 - LP Buffer Shutoff valve

EXAMINE	DAMAGE	DISPOSITION
For cracks	Cracks, any amount, all locations	Not permitted. Replace the air valve.

Table 14 - Buffer Air Heat Exchanger

EXAMINE	DAMAGE	DISPOSITION
For cracks	Any amount	Not permitted. Replace the buffer air heat exchanger.
For round bottom dents	Not more than 0.050 in. (1.27 mm) depth	Permitted
	More than 0.050 in. (1.27 mm) depth	Not permitted. Replace the buffer air heat exchanger.
Nicks, gouges or scratches	Not more than 0.030 in. (0.76 mm) depth	Permitted
	More than 0.030 in. (0.76 mm) depth	Not permitted. Replace the buffer air heat exchanger.
Pitting and corrosion	Not more than 0.020 in. (0.51 mm) depth	Permitted
	More than 0.020 in. (0.51 mm) depth	Not permitted. Replace the buffer air heat exchanger.

(8) Use this inspection procedure to examine the Air/Oil Cooler (AOC) and Environmental Control System (ECS) ducts for correct attachment and for damage.

Electronic Cooling System (ECS) Ducts ** ON A/C NOT FOR ALL

Air/Oil Heat Exchanger Ducts ** ON A/C NOT FOR ALL

(a) Visually inspect the AOC and ECS ducts for correct attachment where possible.
1 Tighten all loose bolts.
2 Replace all missing or broken bolts.
3 Tighten the bolts and clamps as necessary if the manifolds or tubes are loose.
4 Correct the installation of the brackets that are installed incorrectly.
(b) Visually inspect the AOC and ECS ducts for damage where possible.
1 If you see damage, see Table 15 for the continue-in-service damage limits.
Table 15 - AOC and ECS Ducts

EXAMINE	DAMAGE	DISPOSITION
For cracks	Cracks, any amount, all locations	Not permitted. Replace the inlet air duct.
For dents or nicks without sharp edges or corners	Round bottom dents or nicks without sharp edges or corners, any amount, all lengths	Permitted

(9) Examine the assembly for foreign objects, damage and correct assembly.

5. Close-up
Subtask 75-00-00-410-052-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR.

Subtask 75-00-00-440-051-A ** ON A/C NOT FOR ALL

B. Do the reactivation of the thrust reverser system after ground maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 75-00-00-410-053-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR.
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 13:01:58 UTC