Appendix D Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) ENGINE GENERAL - INSPECTION/CHECK-01A Angular Recommended Location Maximum Probe Access Clockwise Part(s) Viewable Diameter Port From Rear For Inspection Inch/(mm) AP-4 127° Rear of Sth C-Blade .270/6.8 Front of 9th C-Blade AP-5 214° Rear of 10th C-Blade .270/6.8 Front of 11th C-Blade AP-6 • 98° Rear of 12th C-Blade .270/6.8 Front of 13th C-Blade AP-7 80° Rear of 14th C-Blade .270/7.8 Front of 15th C-Blade AP-8 277° Fuel Nozzle . 444/11.3 Combustion Chamber 1st T-Vane AP-8 45° Fuel Nozzle . 444/11.3 128° Combustion Chamber 172° (2) Ist T-Vane .444/11.3 225° 338° (3) AP-9 93° Front of 1st T-Vane .270/6.8 Front of 1st T-Blade AP-10 139° Rear of 2nd T-Blade .270/6.8 Front of 3rd T-Blade AP-11 215° (4) Rear of 1st Turbine Blade 444/11.3 Front of 2nd Turbine Blade Thru 6th T-Blade Exhaust 6th T-Vane Case Struts NOTE: (1) Flexible probe required at this access port (optional all other ports).
(2) Right angle eye piece required at this access port.
(3) Right angle eye piece desirable at this access port.
(4) Optional borescope port location.
Borescope Access Port (AP) Data Table 801 (Continued) Page 803 EFF: ALL Page 3
Appendix D Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) ENGINE GENERAL - INSPECTION/CHECK-01A
- 80° 128° 172° (AP-8) (AP -7)
DIFFUSER CASE
- 14TH STAGE STATOR AP -8
LOCATIONS
TRANSITION DUCT (LPT INLET) Cisso COMBUSTION CASE - - 8TH STAGE STATOR (AP -10) 93° 12TH STAGE STATOR > 127° L-A4366 (AP-9) (AP -4) 980 (AP -6) Borescope Access Ports (Right Side) Figure 801 (Sheet 1) (Task 72-00-00-990-009) Page 804 EFF: ALL Page 4
Appendix D ENGINE GENERAL - INSPECTION/CHECK-01A 215° 233° (AP -2) (AP-11 OPTIONAL) 5TH STAGE STATOR 2ND STAGE VANE AP -8 DIFFUSER CASE LOCATIONS 338° 277°.
4TH STAGE STATOR 225° (AP -8)
(2.5 BLEED VALVE OPENING) - • 10TH STAGE STATOR 6TH STAGE STATOR 2450+ (AP-1) 231° 214° (AP-5) L- A0634 0688 (AP - 3) Borescope Access Ports (Right Side) Figure 801 (Sheet 1) (Task 72-00-00-990-009) Page 805 EFF: ALL Page 5
Appendix D Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) ENGINE GENERAL - INSPECTION/CHECK-01A THRU FAN APZAP3 APá AP5 AP6 AP7 AP8 APT AP9 A AP10 AP11 (OPTIONAL) AP2-7, 9,10 LOW MAGNIFICATION RIGID BORESCOPE, (.270 INCH/6.8 mm BARREL DIA MAX.)
AP8. 11 .HIGH MAGNIFICATION RIGID BORESCOFE, (.444 INCH/11.3 mm BARREL DIA. MAX.)
AP-1... .FLEXIBLE BORESCOPE, (OPTIONAL FOR (.270 INCH/6.8 mm CABLE DIA. MAX.)
AP2-71 THRU FAN..... FLEXIBLE BORESCOPE ISTG. 1 VANE, (.270 INCH/ 6.8 mm CABLE DIA. MAX.)
STG. 1.6 BLADE) -OR-
LOW MAGNIFICATION RIGID BORESCOPE (.270 INCH/ 6.8mm BARREL DIA. MAX.) L-A0640 0490 Borescope Access Ports (Right Side) Figure 801 (Sheet 2) (Task 72-00-00-990-009) Page 806 EFF: ALL Page 6
L6/FI/8 AU 43-204 Appendix D ENGINE GENERAL - INSPECTION/CHECK-01A
ISCAVENGE
PUMP DRIVE)
BEARING
HOUSING
ASSEMBLY FRONT -MANUAL CRANK PAD COVER L-A0646 MAIN GEARBOX 0888
FRONT VIEW Manual Crank Pad Locations Figure 803 (Task 72-00-00-990-009) Page 807 EFF: ALL Page 7
AC 43-204 Appendix D 8/14/97 Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) ENGINE GENERAL - INSPECTION/CHECK-01A
- BORESCOPE PROBE
COWL CLEARANCE
PROBE OVERALL LENGTH
PRIMARY GAS PATH
- PROBE WORKING LENGTH
INSPECTION DEPTH L-A0650 Borescope Probe Working Specifications Figure 804 (Task 72-00-00-990-009) Page 808 EFF: ALL Page 8
Appendix D ENGINE GENERAL - INSPECTION/CHECK-01A WARNING: BORESCOPE INSPECTIONS MUST BE PERFORMED IN A PROTECTED AREA. IF INSPECTIONS ARE PERFORMED
IN WET WEATHER, APPROPRIATE PROTECTION MUST
BE USED TO PREVENT DAMAGE TO EQUIPMENT OR POSSIBLE ELECTRICAL SHOCK TO THE OPERATOR.
CAUTION: TESTING AND STRUCTURAL ANALYSIS. CONTINUED BORESCOPE INSPECTION LIMITS ARE DERIVED FROM
SERVICE OF PARTS AT OR NEAR MAXIMUM LIMITS MAY
NOT BE ECONOMICALLY SOUND BECAUSE OF PERFORMANCE LOSS OR REDUCED PART LIFE.
The provisions for borescope inspection of the engine represent a significant aid to effective maintenance. Borescope access is incorporated at 15 locations (16 for engines utilizing AP-11) along the engine gaspath, allowing for detailed examination of critical internal engine areas.
NOTE: Borescope ports used in the following procedures are identified by their AP" (access port) designation as shown in Figures 801 and 802 The regular inspection interval referred to in this procedure is obtained from the Maintenance Planning Guide. The reduced inspection interval is set at half that value. These inspection intervals may be adjusted based on operator experience and consultation with the local regulatory agency.
C. Special Borescope Equipment CAUTION: TEMPERATURES IN AREAS TO BE BORESCOPED SHOULD BE PERMITTED TO COOL TO BELOW 150°F
(65.6°C) FOLLOWING ENGINE OPERATION. DAMAGE
RESULT TO BORESCOPE EQUIPMENT IF
EQUIPMENT IS EXPOSED TO GASPATH OR METAL TEMPERATURES IN EXCESS OF 150°F (65.6°C). AS A
GUIDE - IF ADJACENT CASES ARE TOO HOT TO TOUCH COMFORTABLY, INSPECTION SHOULD BE DELAYED.
(1) requirements of CTE 6181 as published by Support Equipment Engineering, Borescope inspection equipment for the PW4000 engine should satisfy the Pratt & Whitney, Commercial Products Division, Middletown, CT 06457.
(2) Specification CTE 6181 identifies the equipment and associated hardware (such as power source, light cables, adapter etc.) required during borescope inspection and sets the quality and functional standards for this equipment.
In summary the following borescope equipment is recommended:
(a) Low magnification rigid borescope,. ..AP2-7, 9
(0.270 inch/(6.8 mm) barrel diameter maximum)
(b) High magnification rigid borescope... ...AP8, 11
(0.444 inch/(11.3 mm) barrel diameter maximum)
(c) Flexible borescope... ...AP-1. (optional for AP2-7)
(0.270 inch/(6.8 mm › cable diameter maximum ) Page 809 EFF: ALL Page 9
AC 43-204 Appendix D 8/14/97 Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443)
(3) Optional borescope equipment and sizes are also provided in CTE 6181 to enhance the borescoping capability and ease the task for the inspector. These items range from clamping equipment to hold the borescope in position to optical video equipment to view and videotape record the borescoping session for later in depth review.
D. Rotation Of High Pressure Rotor During Borescope Inspection See Figure 803.
(1) Full 360 degree borescope inspection of the high pressure rotor can be accomplished using the rotor-cranking provision on the gearbox.
(2) Remove manual crank pad cover (Figure 803) on main gearbox.
CAUTION: DO NOT REMOVE THE GEARBOX (SCAVENGE PUMP DRIVE) BEARING HOUSING ASSEMBLY.
INSTALLATION OF THE BEARING HOUSING ASSEMBLY IS DIFFICULT. INCORRECT INSTALLATION WILL DAMAGE THE BEARING.
(a) Remove two bolts and two washers securing manual crank pad cover.
Using PWA 85768 Puller, remove crank pad cover. Discard packing from stem of cover.
(b) Attach PWA 85572-1 Foot Operated Rotator or PWA 85572-2 Hand Operated Rotator to N2 rotator pad. Make sure socket drive in the angle drive adapter aligns correctly with hex end of oil pump idler gear in gearbox and secure using two 1/4 - 28 cap screws provided. Attach an air supply to the pneumatic motor. Actuate using foot or hand NOTE: Use of motor-drive unit will free operator to use both hands to position and adjust the borescope. It is recommended that rotation be stopped as each rotor blade is positioned properly for inspection. This will allow thorough, detailed appraisal of each blade's condition.
(3) Install manual crank pad cover.
(8) Install packing lubricated with Engine Oil (P03-001), in groove on stem of manual crank pad cover. Install cover and secure with two washers and two bolts lubricated with Antigalling Compound (P06-003).
Torque bolts to 62 - 72 Ib-in. (7.005 - 8.135 N.m).
EFF: ALL Page 8010 Page 10
Appendix E APPENDIX E. DC-9 SERVICE BULLETIN
SAMPLE INSPECTION PROCEDURE Excerpts of Douglas Aircraft Company McDonnell Douglas DC-9 Service Bulletin Alert. Bulletin A53-232, March 28/90.
Retyped with permission of Douglas Aircraft Company McDonnell Douglas Page
AC 43-204 Appendix E 8/14/97
SAMPLE VISUAL INSPECTION PROCEDURE
DOUGLAS AIRCRAFT COMPANY
MCDONNELL DOUGLAS ALERT DC-S P.О. Box 1711 BULLETIN Long Beach, CA 90801
SERVICE BULLETIN FUSELAGE - Main Frame - Inspect/Repair Aft Fuselage Ventral Pressure Bulkhead Tee.
SUMMARY This Alert Service Bulletin is affected by Federal Aviation Administration Airworthiness Directive No. 89-16-12: Amendment 39-6287. effective September 7, This Alert Service Bulletin is applicable only to aircraft equipped with ventral aft pressure bulkhead which have accumulated 35,000 or more landings.
Replacement of all six aft pressure bulkhead tee sections with new improved parts per this Alert Service Bulletin constitutes closing action for the repetitive inspection.
requirements of this Alert Service Bulletin.
This Alert Service Bulletin supersedes but does not cancel the requirements of DC-9 Alert Service Bulletin XXXXX. Only aircraft listed in this Alert Service Bulletin that are contained in the Affectivity of Alert Service Bulletin XX-XXX are affected by this contingency.
This Alert Service Bulletin is issued as a partial record-type change. A service rework drawing or aperture cards are furnished in lieu of illustrations.
1. Planning Information:
A Affectivity:
‹1) Aircraft Affected:
DC-9, Series 10, 20. 30, 40, 50, and C-9, DC-9-81. -82, and -83 (MD-81, -82, and -83) McDonnell Douglas Corporation (MDC) proprietary rights are included in the information disclosed herein, and recipient by accepting this document agrees that the information is proprietary to MDC MDC authorizes recipient to reproduce such information in other documents created for internal use if these documents are protected similarly by a proprietary legend.
Bulletin XX-XXX March 28/90 Page 2
8/14/97 FOE-EE DE
FUS (FSN) FUS (FSN) FUS (NSE) FUS (FSN) NSET STE FUS (FSN) 1160 (49257) 1185 (49265) 1210 (49291) 1235 (49236) 1260 (49415) 1285 (49394) 1161 (49258) (0976) 98 (Z6Z67) IIZ (8) 97 1261 (49402) 1286 (49395) 1162 (49259) (8876 18 (886) (9) 890 1287 (49386) 1163 (49263) (9076) 887 (6867) 8I8 (996 88 (767) 897 1288 (49387) 1164 (49269) (L076P) 681X (967) (1967) 1264 (49422) 1289 (49324) 1165 (49270) (80767) 06T (97767) 0771 1265 (49318) 1290 (49352) 1166 (49271) (60767) 1611 (87767) 1887 1266 (49319) 1291 (49443) 1167 (49272) 1192 (49210) (86867) LI ZEZI (49429) (0Z867) 29Z1 1292 (49501) 1168 (49273) 1193 (49289) (6) 87 (6) 7 (L6) 8971 (8) 7 1169 (49252) 1194 (49280) (98867 77 (0) 690 1294 (49358) 1170 (49202) (06767) 961 (71Z67) 9781 1270 (49391) 1295 (49326) 1171 (49264) 1196 (49366) 1221(49302) 1246 (49309) 1271 (49416) 1296 (49327) 1172 (49188) 1197 (49367) 1222 (49303) 1247 (49310) 1272 (49392) 1297 (49479) 1173 (49189) 1198 (49368) 1223 (49304) 1248 (49311) 1273 (49321) 1298 (49480)
(0) LI (6986) 66I 1224 (49355) 1249 (49312) 1274 (49218) 1299 (49283) (98767) 9LII 1225 (49380) 1250 (49356) 1275 (896) 1300 (49502) 1176 (49287) 1201 (49373) 1226 (49305) 1251 . (49357) 1276 (49364) 1301 (49328) 1177 (49231) 1202 (49211) 1227 (49306) 1252 (49372) 1277 (49365) 1302 (49329) 1178 (49232) (49233) 1228 (49307) 1253 (49215) 1278 (49417) 1303 (49436) 1179 (49204) 1229 (49308) 1254 (49420) 1279 (49393) 1304 (49440) 1180 (49190) 1230 (49279) 1255 (49313) 08ZT 1305 (49396) 1231 (49381) 1256 (49314) 1281 (49323) 1306 (49331) 1182 (49164) 1207 (49371) 1232 (49382) 1257 (49315) 1282 (49282) 1307 (49332) 1183 (49278) 1208 (49374) 1233 (49212) 1258 (49316) ESZI (8767) 1184 (49205) 1209 (49284) 1234 (49235) 1259 (49317) 1284 (49424) 1309 (49482)
(a) Operator and Aircraft Number:
This modification will be incorporated prior to delivery on all applicable DC-9, Series MD-80; MD-88 aircraft, manufacturer's fuselage number 1310 and subsequent.
(2) Spares Affected:
None:
B. Reason:
Eight operators have reported cracks in the ventral aft pressure bulkhead attach tee sections on eight aircraft. The affected aircraft had accumulated between 45,492 and 60,969 landings when the cracks were found. The predominant areas of cracks are at the upper pylon attach angle between longerons 13 and 14 (6 cases) and lower pylon attach angle between longerons 16 and 17 (2 cases). Longerons 2, 7, 11, and 18 each had one crack. The cracks exhibited similar bebavior, cracking circumferentially approximately 1.9 inches outboard of the inboard edge of the upstanding leg of the bulkhead attach tee sections. Cracks were found up to 8.8 inches in length. Analysis of failed parts revealed that the cracks initiated at multiple sites on the forward surface of the upstanding leg of the tee as the result of fatigue due primarily to bending loads. If cracks are not detected and repaired. they could progress to the point March 28/90 Bulletin XX-XXX Page 3
AC 43-204 Appendix E 8/14/97
SAMPLE VISUAL INSPECTION PROCEDURE accomplishment of repairs based on condition will allow continued flight operation. that rapid decompression could occur. Inspection of high cycle aircraft and
c. Description:
This Service Bulletin accomplishes the following on the fuselage aft pressure bulkhead.
Inspection from Aft Side of Bulkhead Performs visual inspections for cracked aft pressure bulkhead web-to-fuselage tee sections around entire periphery of the fuselage from aft side of bulkhead and accomplishes the following:
Condition 1 (No Crack) Repetitively visually inspects for cracks from aft side of bulkbead at intervals specified in Compliance paragraph.
Condition 2 (Crack) Replaces cracked tee section with new or improved part and repetitively visually and for cracks from aft side of bulkhead at intervals specified in Compliance paragraph.
D. Compliance:
It is recommended that initial inspection/repair of aft pressure bulkhead tee be accomplished as follows on aircraft having logged over 35,000 landings.
Accumulated Landings Initial Inspection 35,000 to 49,999 Within 1500 landings from issue date of this Service Bulletin.
50,000 to 59,999 Within 100 landings from issue date of this Service Bulletin.
60.000 and over Within 300 landings from issue date of this Service Bulletin.
When aft pressure bulkhead tee section is replaced with new like part, the repetitive inspection for that section of tee may be discontinued until the aircraft has accumulated an additional 35.000 landings at which time the repetitive inspection for that section of tee are reinstated along with the ongoing repetitive inspections of the remaining original sections of tee.
When aft pressure bulkhead tee section is replaced with new improved part per this Service Bulletin, the repetitive inspection for that section of tee may be discontinued as this constitutes closing action for that section of tee. Perform the recommended repetitive inspections on the remaining original tee sections.
Bulletin XX-XXX March 28/90 Page 4