Altitude Globalcbt.altitudeglobal.aero/Files/B757 PW Borescope.pdf · 2020. 3. 3. · FOR REFERENCE ONLY Introduction Borescope . inspection is an important practice on any aircraft

FOR REFERENCE ONLY

B757 PW2000 Borescope Recurrent Training 2020

FOR REFERENCE ONLY

Introduction Borescope inspection is an important practice on any aircraft. Inspection requirements vary by engine type, and in-service activity. Additionally, an inspection may also be called when performance has started to lag.

Whenever you perform your inspection, a special focus needs to fall on the engine and techniques required. A modern jet engine is made to withstand extreme circumstances along with efficient and prolonged use, but they are still subject to damage and wear. Routine inspection and maintenance can help prevent most instances of engine failure and prolong the life of the engine in service. During engine borescope inspection the operator can spot issues that indicate future, or imminent failure.

During a complete inspection using a borescope, most issues can be found before they become an issue. This module has been prepared as part of your continuation training.

Remember to always refer to the correct and current issue of the AMM prior and during an inspection. For training purposes please study the information from the aircraft maintenance manual attached.

http://spiborescopes.com/industries/aviation-aerospace-borescopes/

TASK 72-00-00-296-328-P00

13. LPC Rotor and Stator (1st - 2nd Stages) Inspection

A. References

Reference Title

78-31-00 P/B 201 Config 3 THRUST REVERSER SYSTEM - MAINTENANCE PRACTICES

B. Tools/Equipment

NOTE: When more than one tool part number is listed under the same "Reference" number, thetools shown are alternates to each other within the same airplane series. Tool part numbersthat are replaced or non-procurable are preceded by "Opt:", which stands for Optional.

Reference Description

COM-10438 Borescope Kit - PW2000 Engines

757-200Part #: 2200043 Supplier: 32212Opt Part #: OCK-PW2000-A Supplier: 32212

C. Location Zones

Zone Area

412 Nose Cowl - No. 1 Powerplant

422 Nose Cowl

D. Examine the LPC Rotor and Stator (1st - 2nd Stages)

SUBTASK 72-00-00-480-006-P00

WARNING

DO NOT USE THE POWER CABLE TO SUPPLY POWER TO THECHAMBERSCOPE IF YOU FIND DAMAGE TO THE EXTERNAL RUBBERCOVERING. CAREFULLY EXAMINE THE POWER CABLE OF THECHAMBERSCOPE BEFORE YOU USE IT. WHEN THERE ARE SUCHCONDITIONS, THE OPERATOR CAN GET A DANGEROUS ELECTRICALSHOCK.

(1) Get the applicable pw2000 borescope kit, COM-10438 equipment:

(a) The borescopes are available with rigid and flexible probes and have different workinglengths and fields of vision. You can use closed circuit television with some units.

(b) The equipment that follows from Olympus Corp. (IFD 4 Nevada Drive, Lake Success, NY11042) obeys with the requirements of specification CTE 7181. You can get theequivalent equipment from American Cystoscope Makers Inc. (Industrial Division, 300Stillwater Ave., Stamford, CT 06902) or Richard Wolf Medical Instruments Corp (7046Lydon Ave., Rosemont, IL 60018).

1) Rigid Borescope - Olympus Model C100-037-090-50, 10 mm diameter, 37 cmworking length, lateral view, 50-degree field of view

2) Eyepiece right angle adapter - Olympus Model KMR-90/4

3) Flexible Borescope - Olympus Model IF8D3-15, 8 mm diameter, 125 cm workinglength, direct view, 40-degree field of view

4) Distal right angle adapter - Olympus Model IF8D3-A40S, 40-degree field of view

5) Light Source - Olympus Model ILK-4, 150 Watt Halogen

6) Light Cable - Olympus Model 2950B High Intensity Light Cable, 6 mm diameter, 72inch length

757AIRCRAFT MAINTENANCE MANUAL

PW2000 SERIES ENGINES

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ECCN 9E991 BOEING PROPRIETARY - Copyright © Unpublished Work - See title page for details

EFFECTIVITYDHI 201-206

FOR REFERENCE ONLY

7) Flexible Borescope - Olympus Model IF6D3-20, 6 mm diameter, 180 cm workinglength, direct view, 65-degree field of view, Articulating Tip

(c) The television system that follows is supplied by Westinghouse Electronic Tube Division,P.O. Box 284, Elmira, New York 14902

1) Mobile Video Inspection Unit - Model No. M616W, closed circuit television camerasystem.

NOTE: This video inspection unit is used with Richard Wolf Corp. BorescopeModels FIB 750, and FIB 760.

SUBTASK 72-00-00-486-329-P00

(2) Install the pw2000 borescope kit, COM-10438 rearward through the fan.

SUBTASK 72-00-00-296-330-P00

(3) Examine the 2nd-stage blades and vanes.

SUBTASK 72-00-00-296-331-P00

CAUTION

DO NOT PERMIT THE LPC TO TURN AGAINST THE BORESCOPE. DAMAGETO THE BORESCOPE AND THE LPC AIRFOILS CAN RESULT.

IT IS IMPORTANT TO FIND THE CAUSE OF THE FOREIGN OBJECTDAMAGE (FOD) TO MAKE SURE THE COMPRESSOR IS IN SATISFACTORYCONDITION. IF YOU ARE NOT SURE THE COMPRESSOR ISSATISFACTORY, REPLACE THE COMPONENT BEFORE THE SUBSEQUENTOPERATION.

(4) Examine the front compressor blades and vanes for dents, nicks, cracks or other signs ofunwanted material.

SUBTASK 72-00-00-046-332-P00

WARNING

DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENTOPERATION OF THE THRUST REVERSER. ACCIDENTAL OPERATION OFTHE THRUST REVERSER CAN CAUSE INJURY TO YOU OR DAMAGE TOEQUIPMENT.

(5) Do this procedure: Thrust Reverser Deactivation for Ground Maintenance(PAGEBLOCK 78-31-00/201 Config 3).

SUBTASK 72-00-00-226-333-P00

(6) 1st-Stage Vanes - Nicks and Dents Limits

(a) Replace or repair the 1st-stage vanes with the nicks or dents.

(b) 1st-Stage Vane Repair Limits (Figure 611)

NOTE: The limits are for the areas after you make the damage smooth and not before.After you repair the vanes, examine them for cracks by the dye penetrant orfluorescent penetrant inspection. The quantity of the damage is not important.Reject all vanes which have cracks.

1) After you repair the damage on the vane, you must make all surfaces of the vanesmooth.

NOTE: You must keep the removal to a minimum on all repairs of the vane.

2) The radial length of the area made smooth is two or three times the depth of thenick.



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3) You are permitted no more than two leading edge and two trailing edge repairs tothe maximum depth limits for each vane edge.

4) All quantities of repairs are permitted up to one-half of the maximum depth limit. Inaddition, you must have three-fourths of the length of the edge which is not repairedbetween the repairs.

5) The damage on the leading and trailing edges are not directly opposite. In addition,they are isolated diagonally by a minimum distance which is the same as the meanchordal length of the vane.

NOTE: The mean chordal length is the average length of the straight line from theleading edge to the trailing edge.

6) You must remove the 1st-stage vanes with the material which is compressed, withsmall radii, and edges which are lifted or rough.

7) You can blend a maximum of ten percent of the total surface area.

(c) You can operate the engine for a maximum of fifty hours before repair or replacement ofdamaged vanes, if the damage is not more than the limits that follow (Figure 612).

1) The depth of the nicks in the leading edge are less than approximately 3/32 inch(2.381 mm).

2) The depth of the nicks in the trailing edge are less than approximately 3/32 inch(2.381 mm).

3) The damage on the leading and trailing edges are not directly opposite. In addition,they are isolated diagonally by a minimum distance which is the same as the meanchordal length of the vane.

4) The depth of the dents in Area A is less than 1/64 inch (0.397 mm).

a) You must replace the vane if there is damage to the material in Area A.

b) No flyback is permitted.

(d) LPC 2nd-Stage Blades - Nicks and Dents Limits (Figure 613)

1) Install the borescope between the 1st-stage fan blades, and rearward between the1st-stage compressor vanes.

2) Examine the 2nd-stage blades with the borescope.

CAUTION

DO NOT PERMIT THE LPC TO TURN AGAINST THE BORESCOPE.DAMAGE TO THE BORESCOPE AND THE LPC AIRFOILS CANRESULT.

3) Examine the 2nd-stage blades for nicks, dents, cracks, and damage caused byunwanted material.

CAUTION

IT IS IMPORTANT TO FIND THE CAUSE OF THE FOREIGN OBJECTDAMAGE (FOD) TO MAKE SURE THE COMPRESSOR IS INSATISFACTORY CONDITION. IF YOU ARE NOT SURE THECOMPRESSOR IS SATISFACTORY, REPLACE THE COMPONENTBEFORE THE SUBSEQUENT OPERATION.

4) You must replace the damaged blades which do not agree with the limits.



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5) If a replacement for the damaged blades is not available or repair is not applicable,use the Continue-In-Operation Limits.

NOTE: The limits are for the areas after you make the damage smooth and notbefore. After you repair the vanes, examine the vanes for cracks by thelocal fluorescent penetrant inspection to make sure all signs of the cracksare removed. The quantity of the damage is not important. Reject all vaneswhich have cracks.

6) You can operate the engine for a maximum of 125 hours with the damaged blades ifthe limits that follow are applicable (Figure 613):

a) The depth of the damage in Area A is approximately 1/32 inch (0.794 mm). Inaddition, it is at least one inch apart on one of the two edges (leading ortrailing).

b) The damage on the leading and trailing edges are not directly opposite. Inaddition, they are isolated diagonally by a minimum distance which is thesame as the mean chordal length of the vane.

NOTE: The mean chordal length is the average length of the straight line fromthe leading edge to the trailing edge.

c) The damage in Area B is a circular bottomed indication less than 1/32 inch(0.794 mm) and the material has not been torn.

d) Damage in Area C is not permitted.

(e) 2nd-Stage Stator Vanes Inspection (Figure 614)

1) Install the flexible borescope between the 1st-stage fan blades.

2) Move the borescope rearward between the 1st-stage compressor blades and the2nd-stage blades.

3) Examine the 2nd-stage vanes for nicks, dents, cracks, and damage caused byunwanted material.

NOTE: It is important to find the cause of the FOD to make sure the compressor isin satisfactory condition. Damage to the compressor is an importantproblem.

4) 2nd-Stage Stator Vanes - Operation Limits

a) The depth of the damage in the shape of nicks and dents on the leading andtrailing edges are less than 0.050 inch (1.27 mm). In addition, they are at least0.500 inch (12.70 mm) apart.

b) The damage on the leading and trailing edges are not directly opposite. Inaddition, they are isolated diagonally by a minimum distance which is thesame as the mean chordal length of the vane.

c) The depth of the dents in Area A is less than 0.020 inch (0.508 mm) and atleast one inch (25.400 mm) apart.

d) You must replace the 2nd-stage stator vanes if there is damage to the materialin Area A.

E. Return the airplane to its initial condition

SUBTASK 72-00-00-446-334-P00

(1) Do the activation procedure for the thrust reversers (PAGEBLOCK 78-31-00/201 Config 3).

END OF TASK



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A

SEE A

L-90251

SEE B

COMPRESSOR

STATOR

1ST-STAGE

117423 S00061275942_V1

1st-Stage Compressor Stator InspectionFigure 611/72-00-00-990-825-P00 (Sheet 1 of 2)



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(EXAMPLE)

D-D

B

MAX ALLOWABLE BLENDING LIMITS

C

B

A

LIMITVANE AREA

D D

(LEADING EDGE)

(TRAILING EDGE)

BOTH SIDESC

A

B

C

A

L-90114

0683

0.100 INCH (2.540 mm)

0.010 INCH (0.254 mm)

0.100 INCH (2.540 mm)

117431 S00061275943_V1

1st-Stage Compressor Stator InspectionFigure 611/72-00-00-990-825-P00 (Sheet 2 of 2)



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AREA A

LEADING EDGE

TRAILING EDGE

CONVEX

AND

CONCAVE

SURFACE

117532 S00061275944_V1

1st-Stage Compressor Stator Borescope InspectionFigure 612/72-00-00-990-826-P00



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L-90252

LPC 2ND-STAGE

BLADE

FAN CASE

SEE B

SEE A

A

117535 S00061275945_V1

LPC 2nd-Stage Blades InspectionFigure 613/72-00-00-990-827-P00 (Sheet 1 of 2)



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L-91095

CONCAVE

AND

CONVEX

SURFACE

APPROXIMATE

CENTERLINE

AREA

AREA

B

DEPTH DIMENSION

0.500 INCH (12.700 MILLIMETERS)0.500 INCH (12.700 MILLIMETERS)

B

CONTROLLED BY

B

AREA C

AAREA

117538 S00061275946_V1

LPC 2nd-Stage Blades InspectionFigure 613/72-00-00-990-827-P00 (Sheet 2 of 2)



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COMPRESSOR

A

VANE

2ND-STAGE

BSEE

L-90252

ASEE

117540 S00061275947_V1

2nd-Stage Compressor Vane InspectionFigure 614/72-00-00-990-828-P00 (Sheet 1 of 2)



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DEPTH DIMINSION

CONTROLLED BY

L-91096

CONVEX

AND

CONCAVE

SURFACE

AREA

LEADING EDGE TRAILING EDGE

A

B

117549 S00061275948_V1

2nd-Stage Compressor Vane InspectionFigure 614/72-00-00-990-828-P00 (Sheet 2 of 2)



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TASK 72-00-00-211-801-P00

14. 2.5 Engine Bleed System and Linkage Inspection

A. References

Reference Title

75-32-01-004-001-P00 Remove the Intercompressor (2.5) Bleed Actuator (P/B 401)

B. Inspect the 2.5 Engine Bleed System and Linkage

SUBTASK 72-00-00-211-001-P00

(1) Inspect the 2.5 bleed valve actuator housing and seals for external leakage.

(a) If you find any leakage, replace the actuator (Remove the Intercompressor (2.5) BleedActuator, TASK 75-32-01-004-001-P00).

SUBTASK 72-00-00-211-002-P00

(2) Inspect for the 2.5 bleed seal protruding into the bypass air stream through the duct ports.

(a) Engines with portions of the 2.5 bleed seal protruding into the bypass air stream maycontinue in service until the next depot visit provided the following maintenance isconducted:

1) Cut and remove the portion of the 2.5 bleed seal protruding through the duct.

2) Any amount of seal may be removed and missing, up to the complete seal.

SUBTASK 72-00-00-211-003-P00

(3) Inspect the 2.5 bleed valve through the fan case discharge ports to see if the valve isdisconnected.

(a) If the 2.5 bleed valve is disconnected, the engine may be flown on a non-revenue flightback to a maintenance base for repair under the following conditions:

1) The bleed valve must be fully open.

a) If the bleed valve is not fully open, then you move the valve to the fully openposition manually.

b) The bleed valve is fully open when the aluminum bleed valve door is forwardof the forward lip of the bleed valve duct (the duct is completely open).

2) This is limited to one engine per aircraft.

3) You must monitor EGT limits closely.

4) It is recommended but not required, that the engine is run derated.

END OF TASK



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L-97501

BLEED VALVE

(CLOSED)

BLEED VALVE

(OPEN)

DUCT

DOOR

FORWARD

DUCT

DOOR

REARWARD

1973161 S0000379415_V1

2.5 Bleed Valve InspectionFigure 615/72-00-00-990-915-P00



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TASK 72-00-00-296-335-P00

15. 6th- thru 17th-Stage Compressor Inspection

A. References

Reference Title

70-11-16 P/B 201 DEGREASE ENGINE PARTS BY SOLVENT WIPE (SPOP 208)

71-00-00 P/B 201 POWER PLANT - MAINTENANCE PRACTICES (OPERATINGPROCEDURE)

71-00-00 P/B 501 POWER PLANT - ADJUSTMENT/TEST

71-11-04 P/B 201 FAN COWL PANEL - MAINTENANCE PRACTICES(OPEN/CLOSE)

71-11-06 P/B 201 CORE COWL PANELS (OPEN/CLOSE) - MAINTENANCEPRACTICES

72-35-02 P/B 801 HPC FRONT CASE - REPAIRS

72-35-03 P/B 801 Config 1 STAGES 6 THRU 17 COMPRESSOR BLADES - REPAIRLIMITS


B. Tools/Equipment





COM-12108 Puller - Gearbox Crank Drive Cover

757-200Part #: B1359B Supplier: 55719Opt Part #: PWA80044 Supplier: 77445

SPL-2582 Control Kit - Engine Turning

757-200Part #: PWA76271 Supplier: 77445

SPL-10546 Wrench - Borescope Plug, Engine - PW2000 Engines


SPL-10567 Rotator - Pneumatic, Foot / Hand Operated - PW2000 Engine

757-200Part #: PWA76271 Supplier: 77445Part #: PWA80817-1 Supplier: 77445Part #: PWA80817-2 Supplier: 77445Part #: PWA83241 Supplier: 77445

C. Consumable Materials

Reference Description Specification

D00137 [P03-001] Oil - Lubricant, Aircraft Turbine Engine(Synthetic Base)

PWA521 Type II,MIL-PRF-23699

D50124 [P06-054] Paste - Anti-seize, Molykote P-37 PWA 36246



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(Continued)


G02392 [P05-262] Lockwire - MS20995C32, Corrosion ResistantSteel - 0.032 Inch (0.8121 mm) Diameter

NASM20995

D. Location Zones

Zone Area

413 Fan Cowl Panel - Left - No. 1 Powerplant

415 Thrust Reverser - Left - No. 1 Powerplant

417 Core Cowl - Left

423 Fan Cowl Panel - Left

425 Thrust Reverser - Left


E. Prepare to Do the Inspection of the 6th- thru 17th-stage Compressor

SUBTASK 72-00-00-480-005-P00

WARNING















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SUBTASK 72-00-00-016-336-P00

(2) Open the fan cowl panels (PAGEBLOCK 71-11-04/201).

SUBTASK 72-00-00-046-337-P00

WARNING

DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENTTHE OPERATION OF THE THRUST REVERSER. ACCIDENTAL OPERATIONOF THE THRUST REVERSER CAN CAUSE INJURY TO PERSONS ORDAMAGE TO EQUIPMENT.


SUBTASK 72-00-00-016-338-P00

(4) Open the core cowl panels (PAGEBLOCK 71-11-06/201).

SUBTASK 72-00-00-016-339-P00

WARNING

OBEY THE INSTRUCTIONS IN THE PROCEDURE TO OPEN THE THRUSTREVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TOPERSONNEL, AND DAMAGE TO EQUIPMENT CAN OCCUR.

(5) Open the thrust reversers (PAGEBLOCK 78-31-00/201 Config 3).

SUBTASK 72-00-00-036-340-P00

(6) Remove the manual crank pad cover from the gearbox (Figure 603).

(a) Remove the nuts and washers from the crank pad cover.

(b) Engage the hook of the puller, COM-12108 in the crank pad cover.

(c) Operate the slide hammer of the puller to remove the crank pad cover.

NOTE: Keep the crank pad cover, the nuts, and the washers for the installation. It will benecessary to get a new packing when you install the crank pad cover.

SUBTASK 72-00-00-496-341-P00

(7) Install the pneumatic drive unit (Figure 604), the PWA 83241 drive unit with the control kit,SPL-2582 (Figure 605), or a 9/16-inch socket wrench on the manual drive pad.

F. 6th- thru 17th-Stage Compressor Inspection

SUBTASK 72-00-00-296-342-P00

(1) Examine the HPC 6th-Stage Blades for damage caused by the flow of unwanted materialthrough the compressor (Figure 616).

NOTE: The leading edge of the 6th-stage blade is examined through the AP-1 port. Thetrailing edge of the 6th-stage blade is done at the same time as the leading edge of the7th-stage blades through the AP-2 port (refer to the paragraphs below).

(a) Remove the plug from the borescope port at the location AP-1.

(b) Install the borescope through the borescope port.

NOTE: The maximum depth you can install the borescope is six inches (152.4 mm).



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SUBTASK 72-00-00-296-680-P00

CAUTION

DURING THE BORESCOPE INSPECTION, THE LIMITS OF THE FOREIGNOBJECT DAMAGE (FOD) THAT FOLLOW ARE USED TO MAKE A DECISIONIF THE ENGINE CAN STAY IN OPERATION OR IF REPAIR IS NECESSARY.

IT IS IMPORTANT TO FIND THE CAUSE OF THE FOD TO MAKE SURE THECOMPRESSOR IS IN SATISFACTORY CONDITION. DAMAGE TO THECOMPRESSOR IS AN IMPORTANT PROBLEM. IF THE COMPRESSOR ISTHOUGHT TO BE UNSATISFACTORY, REPLACE THE COMPRESSORBEFORE YOU CONTINUE OPERATION.

(2) Examine the 6th-stage blades for nicks, dents, cracks, or damage caused by unwantedmaterial.

NOTE: Use pneumatic foot operated rotator, SPL-10567 at the N2 rotation pad on the maingearbox to turn the N2 rotor (PAGEBLOCK 71-00-00/201).

(a) Refer to the Table 601A and Figure 617 to find the damage limits.

NOTE: Use this table in conjunction with applicable inspection figure.

(b) If necessary, do the blend repair (PAGEBLOCK 72-35-03/801 Config 1).

6th- thru 17th-Stage Compressor Inspection

HPC 6TH-STAGE BLADES - FOREIGN OBJECT DAMAGE LIMITS

LOCATION-

CONDITIONACCEPTABLE

REINSPECT IN LESS THAN 50

CYCLES. EXTEND THE TIME

TO 125 CYCLES, IF THERE IS

NO CHANGE AFTER TWO

CHECKS. DISCONTINUE REIN-

SPECTION IF THERE IS NO

CHANGE AFTER FIVE CHECKS

(475 CYCLES)

FLYBACK

PERMITTED FOR

ENGINE REMOVAL

OR

REPLACEMENT (4

CYCLES

MAXIMUM)

REMOVE

ENGINE

1.

AREAA: (TIPCORNERS):

(a) Missing material 1 Leading edge 1.0inch (25.4 mm)horizontal x 1.25 inch(31.75 mm) vertical

---- 1 Any amount morethan acceptablelimits

----

2 Trailing edge 1.0inch (25.4 mm) x 1.0inch (25.4 mm)

---- 2 Any amount morethan acceptablelimits

----

3 One missing corner ---- 3 Two missingcorners

----

If pieces larger than 0.250 inch (161 mm)are found missing, inspect the rear stages ofthe HPC for damage.

(b) Nicks, dents,tears, or cracks

Any amount withinArea A

---- Any amountextending beyondArea A

----



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6th- thru 17th-Stage Compressor Inspection (Continued)


LOCATION-

CONDITIONACCEPTABLE




NO CHANGE AFTER TWO




(475 CYCLES)

FLYBACK

PERMITTED FOR

ENGINE REMOVAL

OR

REPLACEMENT (4

CYCLES

MAXIMUM)

REMOVE

ENGINE

(c) Curled leadingedge blade tip

See (Figure 618), andtext for limits

---- ---- ----

2

AREA B: (AIRFOIL)

(a) Dents with raisedmaterial on oppo-site side

Not acceptable ---- Any amount ----

(b) Cracks Not acceptable ---- ---- Any amount

3

AREA C:(OUTBOARDLEADING ANDTRAILING EDGES)

(a) Round bottomnicks & dents

Less than 0.062 inch(1.58 mm)

More than 0.062 inch (1.58 mm) ---- ----

(b) V-notch nicks Less than 0.020 inch(0.508 mm)

More than 0.020 inch (0.508 mm)and less than 0.062 inch (1.58mm)

More than 0.062inch (1.58 mm)

----

(c) Tears, missingmaterial

Not acceptable ---- Any amount ----

(d) Cracks Not acceptable ---- ---- Any amount

(e) Bends on leadingedge (Fig. 608,Sheet3)

1 0.125 inch (3.175mm) maximum de-viation from originalcontour

----- 1 Any amount morethan acceptablelimits

----

2 One bend per blade ---- 2 Two or more bendsper blade

----

3 Bends not permittedon adjacent blades

---- 3 Bends on adjacentblades

----

4 Six bent blades perstage

---- 4 More than six bentblades per stage

----

4

AREA D: (FILLET)

(a) Round bottomdents in fillet radius

0.003 inch (0.076mm)

----- Less than 0.015 inch(0.381 mm)

More than 0.015inch (0.381mm)



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LOCATION-

CONDITIONACCEPTABLE




NO CHANGE AFTER TWO




(475 CYCLES)

FLYBACK

PERMITTED FOR

ENGINE REMOVAL

OR

REPLACEMENT (4

CYCLES

MAXIMUM)

REMOVE

ENGINE

(a) Round bottomdents outside filletradius

0.006 inch (0.152mm)

----- Less than 0.015 inch(0.381 mm)

More than 0.015inch (0.381mm)


(c) Bends Not acceptable ---- Any amount ----

5

AREA E: (INBOARDLEADING ANDTRAILING EDGES)

(a) Nicks, dents Less than 0.015 inch(0.381 mm)

More than 0.015 inch (0.381 mm)and less than 0.031 inch (0.787mm)


----

(b) Tears, bends Not acceptable ---- Any amount ----

(c) Cracks Not acceptable ---- ---- Any amount

SUBTASK 72-00-00-296-681-P00

CAUTION



(3) Examine the 6th-stage blade for a blade tip with a curled leading edge (Figure 618).

NOTE: The curled leading edge/blade tip is specified as a triangular piece of blade materialbent about a line. In addition, the line connects the points on the leading edge andblade tip. The average of the convex surface contour is more than 20 degrees but lessthan or the same as 90 degrees out of the plane (to the convex blade side), with theaverage of the concave blade contour.

(a) Curled leading edges on the 6th-stage blade tips are permitted for the limits shown belowand on Figure 618.

1) A maximum of six bent 6th-stage blades.

2) The curled 6th-stage blades are isolated by a minimum of 3 noncurled 6th-stageblades.



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3) The borescope inspection limits for the damage on the 6th-stage blade surface in allother areas other than Area E, Figure 618, are applicable.

4) The damaged, noncurled 6th-stage blades adjacent to the curled 6th-stage bladesare permitted if the adjacent blades are in the limits that follow:

a) The same as or less than 20 degrees out of the plane angle C.

b) The same as or less than the 1.000 inch (25.400 mm) triangular piece of theleading edge, dimension A.

c) The same as or less than the 0.500 inch (12.700 mm) triangular piece of theblade tip length.

d) The leading edge of the 6th-stage blade on the triangular piece is continuousbut not smooth.

(b) After the inspection is completed, install the plug in the borescope port. Do not applyantigallant compound to plug threads.

NOTE: You can replace the damaged threaded inserts on the borescope ports of theHPC front case (PAGEBLOCK 72-35-02/801).

DHI 201-206 PRE SB PW2000-72-0069 AND PRE SB PW2000-72-0123

1) Tighten the plug to 225-250 pound-inches (25.442-28.246 newton-meters).

DHI 201-206 POST SB PW2000-72-0069 OR POST SB PW2000-72-0123


DHI 201-206

SUBTASK 72-00-00-296-663-P00

(4) HPC 6th-Stage Blades (Trailing Edge) and 7th-Stage Blades (Leading Edge) Inspection Limits(Figure 620, Figure 621)



NOTE: The maximum depth you can install the borescope is 4.8 inches (121.9millimeters).

SUBTASK 72-00-00-296-685-P00

CAUTION



(5) Examine the trailing edge of the 6th-stage blades, and use for the limits of the 6th-stageblades.

(a) Refer to the Table 601A and Figure 617 to find the damage limits.




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FOR REFERENCE ONLY

SUBTASK 72-00-00-296-686-P00

CAUTION



(6) Examine the leading edge of the 7th-stage blade for nicks, dents, cracks, and damage causedby unwanted material.

(a) Refer to the Table 601B and Figure 621 to find the damage limits.



HPC 7TH- THRU 10TH-STAGE BLADES - FOREIGN OBJECT DAMAGE LIMITS

LOCATION-

CONDITIONACCEPTABLE

REINSPECT IN LESS THAN

50 CYCLES. EXTEND THE

TIME TO 125 CYCLES, IF

THERE IS NO CHANGE

AFTER TWO CHECKS.

DISCONTINUE REIN-


CHANGE AFTER FIVE

CHECKS (475 CYCLES)

FLYBACK PERMITTED

FOR ENGINE REMOVAL

OR REPLACEMENT (4

CYCLES MAXIMUM)

REMOVE ENGINE

1

AREAA:(CORNERS):

(a) Missingmaterial

0.250 inch (6.350mm) x 0.250 inch(6.350 mm)

---- Any amount more thanacceptable limits

----



---- Any amount extendingbeyond Area A

----

(c) Bends(Figure608,Sheet 3)

1 0.062 inch (1.58mm) maximumdeviation fromoriginal contour

1 More than 0.062 inch(1.58 mm) maximumdeviation

----

2 One bend perblade

---- 2 Two or more bends perblade

----

3 Bends notpermitted onadjacent blades


----

4 Six bent bladesper stage


----

AREA B:(AIRFOIL)



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LOCATION-

CONDITIONACCEPTABLE




THERE IS NO CHANGE

AFTER TWO CHECKS.

DISCONTINUE REIN-


CHANGE AFTER FIVE

CHECKS (475 CYCLES)

FLYBACK PERMITTED

FOR ENGINE REMOVAL

OR REPLACEMENT (4

CYCLES MAXIMUM)

REMOVE ENGINE

(a) Dents withraised materialon oppo- siteside

Not acceptable Any amount outboard ofcenterline

Any amount inboard ofcenterline

----


3

AREA C:(OUTBOARDLEADING ANDTRAILINGEDGES ANDTIP)

(a) Nicks, dents Less than 0.062inch (1.58 mm)

More than 0.062 inch (1.58mm) and less than 0.125 inch(3.175 mm)

More than 0.125 inch(3.175 mm)

----

(b) Tears,missing material

Not acceptable Less than 0.093 inch (2.362mm)


----


(d) Bends See Bend Limitsfor Area A

4

AREA D:(FILLET)

(a) Roundbottom dents infillet radius

0.003 inch (0.076mm)

---- Less than 0.015 inch(0.381 mm)


(a) Roundbottom dentsoutside filletradius

0.006 inch (0.152mm)







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FOR REFERENCE ONLY



LOCATION-

CONDITIONACCEPTABLE




THERE IS NO CHANGE

AFTER TWO CHECKS.

DISCONTINUE REIN-


CHANGE AFTER FIVE

CHECKS (475 CYCLES)

FLYBACK PERMITTED

FOR ENGINE REMOVAL

OR REPLACEMENT (4

CYCLES MAXIMUM)

REMOVE ENGINE

5

AREA E:(INBOARDLEADING ANDTRAILINGEDGES)


---- More than 0.015 inch(0.381 mm)

----

(b) Tears Not acceptable Less than 0.015 inch (0.381mm)

More than 0.015 inch(0.381 mm) and less than0.031 inch (0.787 mm)




(b) After the inspection is completed, install the plug in the borescope port. Do not applyantigallant compound to threads of plug.



(c) Tighten the plug to 225-250 pound-inches (25.442-28.246 newton-meters).


(d) Tighten the plug to 200-230 pound-inches (22.597-25.987 newton-meters).

DHI 201-206

SUBTASK 72-00-00-296-659-P00

(7) HPC 7th-Stage Blades (Trailing Edge) and 8th-Stage Blades (Leading Edge) Inspection Limits(Figure 622)






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FOR REFERENCE ONLY

SUBTASK 72-00-00-296-687-P00

CAUTION



(8) Examine the 7th-stage blades trailing edge.

(a) Refer to Table 601B and Figure 621 to find the damage limits.

SUBTASK 72-00-00-296-667-P00

(9) Examine the leading edge of the 8th-stage blades for nicks, dents, cracks, and damagecaused by unwanted material.



(c) After the inspection is completed, install the plug in the borescope port. Do not applyantigallant compound to threads of plug.





(e) Tighten the plug to 200-230 pound-inches (22.597-25.987 newton-meters).

DHI 201-206

SUBTASK 72-00-00-296-668-P00

(10) HPC 8th-Stage Blades (Trailing Edge) and 9th-Stage Blades Inspection Limits (Figure 624)




SUBTASK 72-00-00-296-688-P00

CAUTION



(11) Examine the 8th stage blades (trailing edge) and 9th-stage blades for nicks, dents, cracks, anddamage caused by unwanted material.



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FOR REFERENCE ONLY

(a) Refer to the Table 601B and Figure 623 and 615 to find the damage limits.


(c) After the inspection is completed, install the plug in the borescope port. Do not applyantigallant compound to threads of plug.





(e) Tighten the plug to 200-230 pound-inches (22.597-25.987 newton-meters).

DHI 201-206

SUBTASK 72-00-00-296-660-P00

(12) HPC 10th- and 11th-Stage Blades Inspection Limits (Figure 626)

(a) Remove the plug and the washer from the borescope port at the location AP-5.



SUBTASK 72-00-00-296-689-P00

CAUTION



(13) Examine the 10th-stage blades for nicks, dents, cracks, and damage caused by unwantedmaterials.


SUBTASK 72-00-00-296-671-P00

(14) Examine the 11th-15th stage blades for nicks, dents, cracks, and damage caused by unwantedmaterial.

(a) Refer to the table below and Figure 630 to find the damage limits.




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LOCATION-

CONDITION

ACCEPTABLE REINSPECT IN LESS THAN



THERE IS NO CHANGE

AFTER TWO CHECKS.

DISCONTINUE REIN-


CHANGE AFTER FIVE

CHECKS (475 CYCLES)

FLYBACK PERMITTED

FOR ENGINE

REMOVAL OR

REPLACEMENT (4

CYCLES MAXIMUM)

REMOVE ENGINE

1

AREAA:(CORNERS):

(a) Missing material 0.250 inch (6.350mm) x 0.250 inch(6.350 mm)

---- Any amount more thanacceptable limits

----


Any amountwithin Area A

---- Any amount extendingbeyond Area A

----

(c) Bends (Figure608,Sheet 3)

1 0.062 inch (1.58mm) maximumdeviation fromoriginal contour

1 More than 0.062 inch(1.58 mm) maximumdeviation

----

2 One bend perblade

---- 2 Two or more bendsper blade

----



----

4 Six bent bladesper stage


----

2

AREA B: (AIRFOIL)

(a) Dents with raisedmaterial on oppo- siteside

Not acceptable Any amount outboard ofcenterline

Any amount inboard ofcenterline

----


3

AREA C:OUTBOARDLEADING ANDTRAILING EDGES(11TH STAGE ONLY)


---- More than 0.031 inch(0.787 mm) and lessthan 0.062 inch (1.58mm)


(b) Tears Not acceptable ---- Less than 0.062 inch(1.58 mm)




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FOR REFERENCE ONLY

(Continued)


LOCATION-

CONDITION




THERE IS NO CHANGE

AFTER TWO CHECKS.

DISCONTINUE REIN-


CHANGE AFTER FIVE

CHECKS (475 CYCLES)

FLYBACK PERMITTED

FOR ENGINE

REMOVAL OR

REPLACEMENT (4

CYCLES MAXIMUM)

REMOVE ENGINE



3

AREA C: (LEADINGEDGE, TRAILINGEDGE, AND TIP)12TH THROUGH15TH STAGES


More than 0.062 inch (1.58mm) and less than 0.125 inch(3.175 mm)


----

(b) Tears Not acceptable Less than 0.093 inch (2.362mm)


----



4

AREA D: (FILLET)11TH STAGE ONLY

(a) Damage otherthan cracks or bends

Round bottom, upto 0.005 inch(0.127mm) deepwith no materialpushed aboveadjacent surfaces





4

AREA D: (FILLET)12TH THROUGH15TH STAGES



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FOR REFERENCE ONLY

(Continued)


LOCATION-

CONDITION




THERE IS NO CHANGE

AFTER TWO CHECKS.

DISCONTINUE REIN-


CHANGE AFTER FIVE

CHECKS (475 CYCLES)

FLYBACK PERMITTED

FOR ENGINE

REMOVAL OR

REPLACEMENT (4

CYCLES MAXIMUM)

REMOVE ENGINE

(a) Damage in filletradius, other thancracks or bends

Round bottom, upto 0.005 inch(0.127mm) deepwith no materialpushed aboveadjacent surfaces



(b) Nicks, dents not infillet radius

Less than 0.015inch (0.381 mm)

---- More than 0.015 inch(0.381 mm)

----

(c) Tears not in filletradius

Not acceptable Less than 0.015 inch (0.381mm)

More than 0.015 inch(0.381 mm) and lessthan 0.031 inch (0.787mm)



(e) Bends Not acceptable ---- Any amount ----

(b) After the inspection is completed, clean the threaded areas of the borescope plug and theID of the AP-5 port as follows:

1) Use a wire bristle brush to remove the antigalling compound and the unwanteddeposits per PAGEBLOCK 70-11-16/201.

2) Make sure the deposits are removed from the threaded areas of the borescope plugand the ID of the AP-5 port.

3) Make the threads clean with a lint-free cloth.

(c) Lubricate the threads of the plug with anti-seize paste, D50124 [P06-054].

(d) Install the washer and plug in the borescope port.


2) Install MS20995C32 lockwire, G02392 [P05-262] on the plug.

SUBTASK 72-00-00-296-710-P00

(15) HPC 10th-Stage Vanes Inspection Limits (Figure 626).

(a) Remove the outer plug and the washer from the borescope port at the location AP-5.


(c) Examine the 10th-stage Vanes for cracks, stator lean, or blade to vane contact(Figure 627). Refer to Table 601D to find the borescope inspection limits.

(d) Examine the 10th-stage Vanes for Foreign Object Damage (Figure 627). Refer to Table601E to find the Foreign Object Damage limits.



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FOR REFERENCE ONLY

(e) After the inspection is completed, clean the threaded areas of the borescope plug and theID of the AP-5 port as follows:


2) Make sure the deposits are removed from the threaded areas of the borescope plugand the ID of the AP-5 port.


(f) Lubricate the threads of the plug with anti-seize paste, D50124 [P06-054].

(g) Install the washer and plug in the borescope port.

(h) Torque the plug to 40-50 pound-inches (4.519-5.649 newton-meters).

(i) Install MS20995C32 lockwire, G02392 [P05-262] on the plug.

SUBTASK 72-00-00-296-734-P00

(16) HPC 11th-Stage Vanes Inspection Limits (Figure 627).

(a) Remove the outer plug and washer from the borescope port at the location AP-6.

NOTE: It is recommended you use a standard 3/8 inch square drive, deep socketwrench to loosen the outer plug. Then, use the PWA 80038 wrench to remove it.

(b) Install the engine borescope plug wrench, SPL-10546 into the borescope port to engagethe inner plug.

(c) Engage the engine borescope plug wrench, SPL-10546 over the 6-point head of the innerplug.

1) Tighten the set screw which attaches the rod to the body of the tool.

2) Remove the inner plug with the standard open end wrench on the flats of the tool.

(d) Lubricate the flexible braided section and the articulated end of the borescope with asilicone spray or vaseline-type lubricant. Lubricant will make it easier to insert andremove the borescope.

NOTE: Do not get lubricant on the optical end of the borescope.

(e) Install the borescope through the borescope port.

(f) Articulate the borescope forward to view the trailing edge of the HPC 12th stage blade.

(g) Continue to insert the borescope into the area between the leading edge of the HPC 12thstage blade and the trailing edge of the HPC 11th stage vanes. Push the borescopearound the complete circumference of the stator before you start the inspection.

NOTE: Insert the borescope approximately 12 inches (300.0mm). Withdraw theborescope to make sure that the scope is not hung on the HPC blade. If you feelminimal resistance, continue to insert the borescope. Do this test several timesuntil the borescope is around the complete circumference of the stator. If there istoo much resistance, withdraw the borescope fully and rotate the rotor slightly fora better position.

(h) Articulate the end of the borescope to view the trailing edge of the HPC 11th stage stator.

(i) Pull the borescope out very slowly to examine the 11th-stage Vanes for cracks, statorlean, or blade to vane contact, or Foreign Object Damage (Figure 627). Refer to Table601D to find the borescope inspection limits. Refer to Table 601E to find the ForeignObject Damage limits.

(j) After the inspection is completed, do the steps that follow to install the inner and outerplug assemblies.



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FOR REFERENCE ONLY

1) Clean the threaded area of the inner and outer plug as follows:

a) Use a wire bristle brush to remove the antigalling compound and the unwanteddeposits per PAGEBLOCK 70-11-16/201.

b) Make sure the deposits are removed from the threaded area of the plugs.

c) Make the threads clean with a lint-free cloth.

2) Apply anti-seize paste, D50124 [P06-054] on the threads of the inner plug.

3) Install the inner plug into the borescope port at the location AP-6.

a) Tighten the inner plug to 120-130 pound-inches (13.558-14.688newton-meters).

4) Remove the engine borescope plug wrench, SPL-10546 from the inner plug.

5) Apply anti-seize paste, D50124 [P06-054] on the threads of the outer plug.

6) Install the washer and the outer plug.

7) Tighten the outer plug to 200-225 pound-inches (22.597-25.422 newton-meters).

8) Install MS20995C32 lockwire, G02392 [P05-262] to the outer plug.

HPC 10TH- AND 11TH-STAGE VANES INSPECTION LIMITS

PERMITTED RANGE OF DAMAGE

PROBLEM

AREACONDITION ACCEPTABLE

REINSPECT AT NEXT

BORESCOPE

INTERVAL NOT TO

EXCEED 250

CYCLES

FLYBACK

PERMITTED

FOR ENGINE

REMOVAL OR

REPLACEMENT

REMOVE

ENGINE

Vanes Stator lean orBlade to VaneContact

Not Acceptable _ _ _ _ _ _ Any amount

Cracks in a singlevane

Not Acceptable Less than 0.125 inch(3.175 mm) throughboth sides of vane

More than 0.125inch (3.175 mm)through bothsides of vane

Completelythrough thechord

Cracks in two ormore vanes not inthe same cluster

Not Acceptable Less than 0.075 inch(1.905 mm)

More than 0.075inch (1.905 mm)but not morethan 0.125 inch(3.175 mm)

More than0.125 inch(3.175 mm)

Cracks in two ormore vanes in thesame cluster

Not Acceptable _ _ _ Less than 0.075inch (1.905 mm)through bothsides of vanes

More than0.075 inch(1.905 mm)through bothsides of vanes



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FOR REFERENCE ONLY

HPC 10TH- AND 11TH-STAGE VANES - FOREIGN OBJECT DAMAGE LIMITS

LOCATION-

CONDITIONACCEPTABLE

REINSPECT AT NEXT

INTERVAL NOT TO

EXCEED 125 CYCLES.

EXTEND TO 250

CYCLES IF NO

CHANGE IN

CONDITION AFTER

TWO INSPECTIONS

FLYBACK PERMITTED

FOR ENGINE

REMOVAL OR

REPLACEMENT

REMOVE ENGINE

1

ALL AREAS (ExceptArea B):

(a) Displaced materialthat has not caused anick or a tear

Any amount _ _ _ _ _ _ _ _ _

2

AREAS AAND D:

(a) Nicks, tears Less than 0.062inch (1.575 mm)deep




3

AREA B:

(a) Displaced materialthat has not caused anick or a tear

Not permitted Any amount _ _ _ _ _ _

(b) Tear in one vane Less than 0.125inch (3.175 mm)deep if not inleading or trailingedge fillet area

Less than 0.125 inch(3.175 mm) deep inleading or trailing edgefillet area (one perairplane)

More than 0.125 inch(3.175 mm) deep

_ _ _

(c) Tears in two ormore vanes in differentclusters

Less than 0.125inch (3.175 mm)deep if not inleading or trailingedge fillet area

Less than 0.050 inch(1.270 mm) deep if inleading or trailing edgefillet area

More than 0.050 inch(1.270 mm) and less than0.125 inch (3.175 mm)deep

More than 0.125inch (3.175 mm)deep

(d) Tears in two ormore vanes in thesame cluster

_ _ _ _ _ _ Less than 0.050 inch(1.270 mm) deep

More than 0.050inch (1.270 mm)deep

SUBTASK 72-00-00-296-347-P00


(a) Remove the outer plug and washer from the borescope port at the location AP-6.

NOTE: It is recommended you use a standard 3/8 inch square drive, deep socketwrench to loosen the outer plug. Then, use the engine borescope plug wrench,SPL-10546 to remove it.




72-00-00

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FOR REFERENCE ONLY

(c) Engage the engine borescope plug wrench, SPL-10546 over the 6-point head of the innerplug.

1) Tighten the set screw which attaches the rod to the body of the tool.

2) Remove the inner plug with the standard open end wrench on the flats of the tool.

(d) Install the borescope through the borescope port.


SUBTASK 72-00-00-296-682-P00

CAUTION



(18) Examine the 12th- and 13th-stage blades for nicks, dents, cracks, and damage caused byunwanted material (Figure 632, 621).

(a) Refer to the Table 601C and Figure 632 and 621 for the damage limits.

(b) After the inspection is completed, do the steps that follow to install the inner and outerplug assemblies.

1) Clean the threaded area of the inner and outer plugs as follows:












SUBTASK 72-00-00-296-348-P00

(19) HPC 14th- and 15th-Stage Blades Inspection Limits (Figure 634, 623, 624)

(a) Remove the plug and the washer from the borescope port at the location AP-7.





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FOR REFERENCE ONLY

SUBTASK 72-00-00-296-683-P00

CAUTION



(20) Examine the 14th- and 15th-stage blades for nicks, dents, cracks, and damage caused byunwanted material.

(a) Refer to the Table 601C and Figure 635 and 624 for the damage limits.

(b) After the inspection is completed, clean the threaded areas of the borescope plug and theID of the AP-7 port as follows:


2) Make sure the deposits are removed from the threaded areas of the borescope plugand the ID of the port.


(c) Lubricate the threads of the plug with anti-seize paste, D50124 [P06-054].

(d) Install the washer and plug in the borescope port.



SUBTASK 72-00-00-296-599-P00

(21) HPC 15th- and 16th-Stage Vanes Inspection Limits (Figure 637)


NOTE: It is recommended that a standard 3/8 inch square drive, 12 point deep socketwrench be used to loosen the borescope plug. Then, use the engine borescopeplug wrench, SPL-10546 to remove it.


1) Put the rod detail of the engine borescope plug wrench, SPL-10546 into the innerplug with the threads in the hole.

2) Engage the engine borescope plug wrench, SPL-10546 over the 6-point head of theinner plug.

a) Tighten the set screw which attaches the rod to the body of the tool.

b) Remove the inner plug with a standard, open end wrench on the wrenchingflats of the tool.

(c) Install the borescope through the borescope port.




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FOR REFERENCE ONLY

SUBTASK 72-00-00-296-674-P00

(22) Examine the 15th- and 16th-stage vanes for damage caused by unwanted material(Figure 637).

(a) Refer to the Table to find the damage limits.















HPC 15TH- AND 16TH-STAGE VANE DAMAGE LIMITS

PROBLEM

AREACONDITION


PERMITTED

WITHOUT LIMITS

TO OPERATION

EXAMINE AGAIN IN

LESS THAN 125 -

CYCLES. EXTEND

THE TIME TO 250 -

CYCLES IF THERE IS

NO CHANGE AFTER

TWO CHECKS.

FLYBACK

PERMITTED

FOR ENGINE

REMOVAL OR

REPLACEMENT

REMOVE

ENGINE

Area A-Leading andTrailing Edges

Material movedwithout a nick ortear.

All quantities --- --- ---

Nicks or tears. Less than 0.062 inch(1.575 mm) deep.

More than 0.062 inch(1.575 mm) and lessthan 0.125 inch (3.175mm) deep.

More than 0.125inch (3.175 mm)and less than0.250 inch(6.350 mm)deep.

More than 0.250inch (6.350 mm)deep.



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HPC 15TH- AND 16TH-STAGE VANE DAMAGE LIMITS

PROBLEM

AREACONDITION


PERMITTED

WITHOUT LIMITS

TO OPERATION

EXAMINE AGAIN IN

LESS THAN 125 -

CYCLES. EXTEND

THE TIME TO 250 -

CYCLES IF THERE IS

NO CHANGE AFTER

TWO CHECKS.

FLYBACK

PERMITTED

FOR ENGINE

REMOVAL OR

REPLACEMENT

REMOVE

ENGINE

Area B- OuterBrazed Area

Material movedwithout a nick ortear.


One vane with atear.

Less than 0.125 inch(3.175 mm) deep, notin leading or trailingedge fillet.

Less than 0.125 inch(3.175 mm) deep, inleading or trailing edgefillet (one permitted oneach airplane).


---

Two or more vaneswith tears, vanes indifferent groups.

Less than 0.050 inch(1.270 mm) deep, notin leading or trailingedge fillet.

Less than 0.050 inch(1.270 mm) deep, inleading or trailing edgefillet.

More than 0.050inch (1.270 mm)and less than0.125 inch(3.175 mm)deep.


Two or more vaneswith tears, vanes inthe same group.

--- --- Less than 0.050inch (1.270 mm)deep.


Area C- Airfoil Material movedwithout a nick ortear.



SUBTASK 72-00-00-296-349-P00



NOTE: It is recommended that a standard 3/8 inch square drive, 12 point deep socketwrench be used to loosen the borescope plug. Then, use the engine borescopeplug wrench, SPL-10546 to remove it.


1) Put the rod detail of the engine borescope plug wrench, SPL-10546 into the innerplug with the threads in the hole.

2) Engage the engine borescope plug wrench, SPL-10546 over the 6-point head of theinner plug.

a) Tighten the set screw which attaches the rod to the body of the tool.

b) Remove the inner plug with a standard, open end wrench on the wrenchingflats of the tool.



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FOR REFERENCE ONLY

(c) Install the borescope through the borescope port.


SUBTASK 72-00-00-296-684-P00

CAUTION



(24) Examine the 16th- and 17th-stage blades for damage caused by unwanted material.

(a) Refer to the Table 602 and Figure 639 and 627 to find the damage limits.


Table 602/72-00-00-993-802-P00 6th- thru 17th-Stage Compressor Inspection

HPC 16TH- AND 17TH-STAGE BLADES - FOREIGN OBJECT DAMAGE LIMITS

LOCATION- CONDITION ACCEPTABLE

REINSPECT IN LESS

THAN 125 CYCLES.

EXTEND THE TIME TO

250 CYCLES, IF THERE

IS NO CHANGE AFTER

TWO CHECKS.

DISCONTINUE REIN-

SPECTION IF THERE IS

NO CHANGE AFTER

THREE CHECKS (500

CYCLES)

FLYBACK

PERMITTED FOR

ENGINE

REMOVAL OR

REPLACEMENT

(4 CYCLES

MAXIMUM)

REMOVE ENGINE

1

AREAA: (CORNERS):

(a) Missing material 0.250 inch (6.350mm) x 0.250 inch(6.350 mm)

---- Any amount morethan acceptablelimits

----

(b) Nicks, dents, tears, orcracks


---- Any amountextending beyondArea A

----



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Table 602/72-00-00-993-802-P00 6th- thru 17th-Stage Compressor Inspection (Continued)



REINSPECT IN LESS

THAN 125 CYCLES.

EXTEND THE TIME TO


IS NO CHANGE AFTER

TWO CHECKS.

DISCONTINUE REIN-


NO CHANGE AFTER

THREE CHECKS (500

CYCLES)

FLYBACK

PERMITTED FOR

ENGINE

REMOVAL OR

REPLACEMENT

(4 CYCLES

MAXIMUM)

REMOVE ENGINE

(c) Bends (Figure608,Sheet 3)

1 Less than 0.062inch (1.58 mm)maximum deviationfrom originalcontour

1 More than 0.062 inch(1.58 mm) and less than0.125 inch (3.175 mm)maximum deviation

1 More than 0.125inch (3.175 mm)maximum deviation

----

2 One bend perblade

---- 2 Two or morebends per blade

----


---- 3 Bends onadjacent blades

----

4 Six bent blades perstage

---- 4 More than sixbent blades perstage

----

2

AREA B: (AIRFOIL)

(a) Dents with raisedmaterial on opposite side

Any amount ---- ---- ----


3

AREA C:

(LEADING EDGE,TRAILING EDGE, ANDTIP)

(a) Nicks, dents, tears Less than 0.062 inch(1.58 mm)



----


(c) Bends See Bend Limits forArea A

4

AREA D:

(FILLET)



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FOR REFERENCE ONLY

Table 602/72-00-00-993-802-P00 6th- thru 17th-Stage Compressor Inspection (Continued)



REINSPECT IN LESS

THAN 125 CYCLES.

EXTEND THE TIME TO


IS NO CHANGE AFTER

TWO CHECKS.

DISCONTINUE REIN-


NO CHANGE AFTER

THREE CHECKS (500

CYCLES)

FLYBACK

PERMITTED FOR

ENGINE

REMOVAL OR

REPLACEMENT

(4 CYCLES

MAXIMUM)

REMOVE ENGINE

(a) Damage in filletradius, other than cracksor bends

Round bottom, up to0.005 inch(0.127mm) deep withno material pushedabove adjacentsurfaces


More than 0.015inch (0.381 mm)and less than 0.062inch (1.58 mm)


(b) Nicks, dents, tears notin fillet radius




----


(c) Bends, not in filletradius

Less than 0.040 inch(1.02 mm) maximumdeviation fromoriginal contour

More than 0.040 inch(1.02 mm) and less than0.062 inch (1.58 mm)maximum deviation

More than 0.062inch (1.58 mm)maximum deviation

----

(d) Bends in fillet radius Not acceptable ---- Any amount ----
















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G. Put the airplane back to its initial condition.

SUBTASK 72-00-00-096-350-P00

(1) Remove the pneumatic drive unit (Figure 604), the PWA 83241 drive unit with the control kit,SPL-2582 (Figure 605), or the socket wrench from the manual drive pad on the gearbox.

SUBTASK 72-00-00-436-351-P00

(2) Install the manual crank pad cover on the gearbox (Figure 603).

(a) Install a new packing, lubricated with oil, D00137 [P03-001], in the groove of the crankpad cover.

(b) Install the crank pad cover on the gearbox pad.

(c) Attach the crank pad cover with the washers and nuts.

(d) Tighten the nuts to 75-85 pound-inches (8.474-9.604 newton-meters).

SUBTASK 72-00-00-416-352-P00

WARNING

OBEY THE INSTRUCTIONS IN THE PROCEDURE TO CLOSE THE THRUSTREVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TOPERSONNEL, AND DAMAGE TO EQUIPMENT CAN OCCUR.

(3) Close the thrust reversers (PAGEBLOCK 78-31-00/201 Config 3).

SUBTASK 72-00-00-416-353-P00

(4) Close the core cowl panels (PAGEBLOCK 71-11-06/201).

SUBTASK 72-00-00-446-354-P00

(5) Do the activation procedure for the thrust reverser (PAGEBLOCK 78-31-00/201 Config 3).

SUBTASK 72-00-00-416-355-P00

(6) Close the fan cowl panels (PAGEBLOCK 71-11-04/201).

SUBTASK 72-00-00-796-755-P00

(7) Do the leak test of the Manual Crank Pad Cover that is shown in the Power Plant TestReference Table (PAGEBLOCK 71-00-00/501).

END OF TASK



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FOR REFERENCE ONLY

AFLANGE E

L-90252

L-90255

INLET

VANE

GUIDE

PLUG (AT AP-1)

BLADE

6TH-STAGE

ASEE

VANE

INLET GUIDE

117546 S00061275957_V1

HPC 6th-Stage Blade InspectionFigure 616/72-00-00-990-829-P00



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FOR REFERENCE ONLY

(50.8 mm)

2.00 INCHES

(25.4 mm)

1.00 INCH

(25.4 mm)

1.00 INCH

1.25 INCHES

(31.75 mm)

(12.70 mm)

0.50 INCH

AREA D

4.90 INCHES

(124.46 mm)

AREA A

AREA B

AREA E

AREA C

1.75 INCHES

(44.50 mm)

1.00 INCH

(25.4 mm)

AREA E

2.00 INCHES

(50.80 mm)

AREA C

ROOT

L97614 (0000)

A

ASEE

117542 S00061275958_V1

HPC 6th-Stage Blade Inspection LimitsFigure 617/72-00-00-990-830-P00



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FOR REFERENCE ONLY

L-92883

A

A

A

A

LEADING

EDGE

SEE

BLADE TIP

1

90 ˚ MAXIMUM

2

3

4

5

6

C

E

E

B

D

A 1

2

3

4

5

5

1.000 INCH (25.400 mm) MAXIMUM

0.500 INCH (12.700 mm) MAXIMUM

THE LEADING EDGE IS SMOOTH AND CONTINUOUS

NO DENTS, GOUGES, CRACKS OR SCRATCHES ARE PERMITTED

LENGTH OF THE BEND

A-A

ON THE BEND RADII FOR THE LENGTH OF THE BEND DIMENSION F

F 6

178233 S00061275959_V1

HPC 6th-Stage Blade - Inspection LimitsFigure 618/72-00-00-990-831-P00



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FOR REFERENCE ONLY

A-A

(MADE LARGER)

DEVIATION

MAXIMUM

BLADE CONTOUR

ORIGINAL

HPC BLADE

AA

L-97621262842 S00061275960_V1

HPC Blades - Leading Edge Bend LimitsFigure 619/72-00-00-990-832-P00



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ASEE

7TH-STAGE

6TH-STAGE

A

PLUG (AP-2)

BLADE

BLADE

L-90256

L-90254

117485 S00061275961_V1

HPC 6th- and 7th-Stage Blade InspectionFigure 620/72-00-00-990-833-P00



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AREA A

(BOTH CORNERS)

(6.350 mm)

(12.700 mm)

AREA B

(38.10 mm)

1.500 INCH

AREA C

0.250 INCH

AREA C

AREA E

0.500 INCH

AREA D

FILLET AREA

LEADING EDGE

(101.60 mm)

4.00 INCH

AREA E

AREA C

TABLE

INSPECTION

SEE

BLADE AREA LIMIT

A

B

C

D

E

TRAILING EDGE

L-90844 (0494)117544 S00061275962_V1




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ASEE

7TH-STAGE

PLUG (AP-3)

A

BLADE

8TH-STAGE

BLADE

L-90257

L-90254

117486 S00061275963_V1




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FOR REFERENCE ONLY

AREA D

FILLET AREA

3.400 INCHES

0.500 INCH

(86.360 mm)

AREA C

AREA E

AREA E

AREA C

0.250 INCH

AREA C

1.350 INCH

(34.290 mm)

LEADING EDGE

(12.700 mm)

(6.350 mm)

(BOTH CORNERS)

TRAILING EDGE

AREA B

AREA A

L-90845 (0494)

E

D

C

B

A

LIMITBLADE AREA

SEE

INSPECTION

TABLE

117547 S00061275964_V1




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FOR REFERENCE ONLY

SEE A

L-90258

L-90254

8TH-STAGE BLADE

PLUG (AP-4)

A

9TH-STAGE

BLADE

8TH-STAGE

BLADE

117487 S00061275965_V1




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FOR REFERENCE ONLY

2.850 INCHES

AREA D

FILLET AREA

0.500 INCH

AREA E

AREA C

(72.390 mm)

AREA C

AREA E

AREA C

0.250 INCH

1.175 INCH

(29.845 mm)

(BOTH CORNERS)

(6.350 mm)

(12.700 mm)

AREA B

LEADING EDGE

AREA A

L-90846 (0494)

TABLE

INSPECTION

SEE

BLADE AREA LIMIT

A

B

C

D

E

TRAILING EDGE

117548 S00061275966_V1




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FOR REFERENCE ONLY

PLUG (AP-5)

BLADE

10TH-STAGE

A

SEE A

117629 S00061275967_V1




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FOR REFERENCE ONLY

REF (11TH-STAGE)(45.72 mm)

1.800 INCH


2.100 INCH

DREF (11TH-STAGE)(48.26 mm)

1.900 INCH


2.200 INCH

L-95936

0793

EDGE

LEADING

A

C

B

REF(3.175 mm)

0.125 INCH

TYPICAL VANE

H85912 S00061275968_V1

HPC 10th and 11th-Stage VaneFigure 627/72-00-00-990-840-P00



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FOR REFERENCE ONLY

11TH-STAGE

BLADE

11TH-STAGE

INSPECTION

LOCATION

STATOR

INNER PLUG

OUTER PLUG

(AP-6)

(AP-6)

A

ASEE

L-98493

L47060 S00061275969_V1




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FOR REFERENCE ONLY

2.450 INCHES

0.250 INCH

AREA C

1.025 INCH

(26.035 mm)

AREA E

AREA C

0.500 INCH

(62.230 mm)

AREA E

AREA C

AREA D

FILLET AREA

LEADING EDGE TRAILING EDGE

AREA B

(12.700 mm)

(6.350 mm)

(BOTH CORNERS)

AREA A

L-90847 (0494)

E

D

C

B

A

LIMITBLADE AREA

SEE

INSPECTION

TABLE

117630 S00061275970_V1




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FOR REFERENCE ONLY

(BOTH CORNERS)

(6.350 mm)

BLADE AREA LIMIT

TABLE

INSPECTION

SEE

A

B

C

D

L-97615 (0000)

AREA C

AREA A

0.250 INCH(25.400 mm)

1.00 INCH

(52.070 mm)

AREA C

AREA B

AREA C

(12.700 mm)

AREA D

FILLET AREA

0.500 INCH

2.050 INCH

117631 S00061275971_V1




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FOR REFERENCE ONLY

OUTER PLUG

A

BLADE

INNER PLUG

(AP-6)

HPC 12TH-STAGE

12TH-STAGE BLADE 13TH-STAGE BLADE

L-90260

L-90254

SEE B

SEE A

117635 S00061275972_V1

HPC 12th- and 13th-Stage Blade InspectionFigure 631/72-00-00-990-844-P00 (Sheet 1 of 2)



72-00-00

Page 698.9D633N189 May 20/2017



FOR REFERENCE ONLY

12TH-STAGE BLADE

13TH-STAGE BLADE

INNER PLUG

ACCESS PORT (AP-6)

C

B

PWA 80038 WRENCH

SET SCREW

L-90261

CSEE

118068 S00061275973_V1

HPC 12th- and 13th-Stage Blade InspectionFigure 631/72-00-00-990-844-P00 (Sheet 2 of 2)



72-00-00

Page 698.10D633N189 May 20/2017



FOR REFERENCE ONLY

(BOTH CORNERS)

(6.350 mm)

BLADE AREA LIMIT

TABLE

INSPECTION

SEE

A

B

C

D

L-97616 (0000)

(24.765 mm)

0.975 INCH0.250 INCH

AREA C

AREA A

AREA C

AREA C

(46.990 mm)

1.850 INCH

AREA D

(12.700 mm)

0.500 INCH

AREA B

FILLET AREA

117639 S00061275974_V1




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FOR REFERENCE ONLY

AREA B

0.500 INCH

(12.700 mm)

AREA D

1.600 INCH

(40.640 mm)

AREA C

AREA C

AREA A

AREA C

0.950 INCH

(24.130 mm) 0.250 INCH

L-97617 (0000)

D

C

B

A

SEE

INSPECTION

TABLE

LIMITBLADE AREA

(6.350 mm)

(BOTH CORNERS)

FILLET AREA

117640 S00061275975_V1




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FOR REFERENCE ONLY

0383

L-90262

A

FLANGE K

15TH- STAGE BLADE14TH-STAGE BLADE

(AP-7)

PLUG

HPC 14TH-STAGE

BLADE

ASEE

L-90254

117645 S00061275976_V1




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FOR REFERENCE ONLY

1.475 INCH

0.500 INCH

FILLET AREA

AREA D

(37.465 mm)

(12.700 mm)

AREA C

AREA C

AREA B

AREA A

AREA C

0.900 INCH

(22.860 mm) 0.250 INCH

L-97618 (0000)

D

C

B

A

SEE

INSPECTION

TABLE

LIMITBLADE AREA

(6.350 mm)

(BOTH CORNERS)

117638 S00061275977_V1




72-00-00

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FOR REFERENCE ONLY

AREA D

FILLET AREA

AREA B

0.500 INCH

(12.700 mm)

1.350 INCH

(34.290 mm)

AREA C

AREA C

AREA A

AREA C

0.900 INCH

(22.860 mm) 0.250 INCH

L-97619 (0000)

D

C

B

A

SEE

INSPECTION

TABLE

LIMITBLADE AREA

(6.350 mm)

(BOTH CORNERS)

117636 S00061275978_V1




72-00-00

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FOR REFERENCE ONLY

15TH-STAGE VANE

L-90263

A-A

FLANGE K

OUTER PLUG

INNER PLUG

16TH-STAGE BLADE 17TH-STAGE BLADE

16TH-STAGE VANE

A

HPC 16TH-STAGE

BLADE POSITION

SEE

A A

117582 S00061275979_V1

HPC 15th- and 16th-Stage Vane and HPC 16th- and 17th-Stage Blade InspectionFigure 637/72-00-00-990-850-P00 (Sheet 1 of 2)



72-00-00

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FOR REFERENCE ONLY

SEE

BLADE

16TH-STAGE

HPC HPC

17TH-STAGE

INNER

PLUG

ACCESS PORT

(AP-8)

PLUG

WRENCH

BLADE

SET

SCREW

PWA 80038

WRENCH

B

B

A

117361 S00061275980_V1

HPC 15th- and 16th-Stage Vane and HPC 16th- and 17th-Stage Blade InspectionFigure 637/72-00-00-990-850-P00 (Sheet 2 of 2)



72-00-00

Page 698.17D633N189 May 20/2017



FOR REFERENCE ONLY

AREF (16TH-STAGE)(30.480 mm)

1.200 INCH

(33.020 mm)

1.300 INCHREF (15TH-STAGE)

L-95936

0793

EDGE

LEADING

A

C

B

REF(3.175 mm)

0.125 INCH

(30.480 mm)

(29.210 mm)

1.150 INCH

1.200 INCH

REF (16TH-STAGE)

REF (15TH-STAGE)

TYPICAL VANE

C76242 S00061275981_V1

HPC 15th and 16th-Stage VaneFigure 638/72-00-00-990-851-P00



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FOR REFERENCE ONLY

PW V

L-90853 (0494)

1.200 INCHES

(BOTH CORNERS)

(6.350 mm)

BLADE AREA LIMIT

TABLE

INSPECTION

SEE

A

B

C

D

0.250 INCH

AREA C

(22.860 mm)

0.900 INCH

AREA A(30.480 mm)

AREA C

AREA B

AREA C

(9.525 mm)

0.375 INCH

AREA D

FILLET AREA

117362 S00061275982_V1




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FOR REFERENCE ONLY

1.175 INCH

(BOTH CORNERS)

(6.350 mm)

BLADE AREA LIMIT

TABLE

INSPECTION

SEE

A

B

C

D

L-97620 (0000)

(29.845 mm)

(27.940 mm)

1.100 INCH

AREA C

0.250 INCH

AREA C

AREA B

AREA A

AREA C

(9.525 mm)

0.375 INCH

AREA D

FILLET AREA

117364 S00061275983_V1




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FOR REFERENCE ONLY

TASK 72-00-00-296-372-P00

16. Combustion Chamber Inspection

(Figure 641)

NOTE: This procedure is a scheduled maintenance task.

A. General

(1) The general data that follows is used during the borescope inspection of the combustionchamber:

(a) To make sure the names agree in the reports or the inspection standards, use thecomponent names found in Figure 641 (Sheets 4-6).

(b) The inspection data used to make sure the combustion chamber is satisfactory includesthe limits of deterioration and damage.

(c) The limits and conditions are for the inner and outer combustion liners unless specifieddifferently.

NOTE: Be careful at all weld joints in the inner and outer liner segments on the inner andouter liner surfaces.

(2) This procedure uses the specified words that follow.

(a) "Material Burning" is an area where one of the results that follows is caused by a localhigh temperature zone: the material color is incorrect, distortion of the material, or thematerial is not fully there. This problem usually occurs directly downstream of a fuelnozzle.

(b) A "burn streak" is an axial sequence of liners which has "material burning". As a burnstreak is made, the liner material bends, cracks or burns away and makes one or more"open holes". Each crack of the axial liner can continue to extend and, although axiallynot straight, connect together to be a continuous crack in the burn streak. "Burn streaks"can start by a local decrease of cooling airflow because of blockage in the cooling hole orfrom the damage to the louver lip.

(c) An "open hole" is specified as an area where "material burning" extended to the point thatthe hole completely goes through the material. An open hole is also an area where thematerial lifts because the cracks go through each other.

B. References

Reference Title



74-21-02 P/B 401 IGNITER PLUG - REMOVAL/INSTALLATION


C. Tools/Equipment




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FOR REFERENCE ONLY




STD-131 Brush - Stainless Steel Wire

D. Consumable Materials


B50131 [P11-027] Solvent - Stoddard MIL-PRF-680B, Type I,Type II, or Type III



NASM20995

E. Location Zones

Zone Area

211 Control Cabin, Left

212 Control Cabin, Right


418 Core Cowl - Right


428 Core Cowl - Right

F. Prepare to Do the Combustion Chamber Inspection

SUBTASK 72-00-00-480-004-P00

WARNING












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FOR REFERENCE ONLY






SUBTASK 72-00-00-016-373-P00


SUBTASK 72-00-00-046-374-P00

WARNING



SUBTASK 72-00-00-016-375-P00


SUBTASK 72-00-00-016-376-P00

WARNING


(5) Open the thrust reverser (PAGEBLOCK 78-31-00/201 Config 3).

SUBTASK 72-00-00-866-377-P00

(6) For the left engine, open these circuit breakers and install safety tags:

Overhead Circuit Breaker Panel, P11

Row Col Number Name

D 19 C01510 ENGINES START CONT L

L 35 C04427 SEC ENG START CONT L

SUBTASK 72-00-00-866-378-P00

(7) For the right engine, open these circuit breakers and install safety tags:


Row Col Number Name


D 20 C01511 ENGINES START CONT R


SUBTASK 72-00-00-036-379-P00

(8) At the locations AP-9, get access for the borescope inspection as follows:

(a) Remove the four plugs and the gaskets at the 2, 3, 7, and 10 o'clock locations.



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FOR REFERENCE ONLY

(b) Remove the igniter plugs (PAGEBLOCK 74-21-02/401).

SUBTASK 72-00-00-486-380-P00

(9) Install the borescope through the access ports.

SUBTASK 72-00-00-296-381-P00

(10) Examine the combustion chamber for damage, condition of the coating, damaged louvres,damaged fuel injector heatshield, and the condition of the fuel injectors (Figure 641).

(a) The acceptable damage for burn-through and cracks of the inner and outer liner(Figure 641).

NOTE: The maximum depth you can install the borescope is 7.8 inches (198.1 mm). Youmust repair or replace the liner damage which is more than the areas and lengthlimits given below.

SUBTASK 72-00-00-226-382-P00

(11) See the Combustion Chamber Damage Limits table that follows for the specified limits. Thedamage limits are only made from how long the combustion chamber liner stays in operationand if the component is satisfactory. The combustion chamber liners are permitted to continueto the maximum levels of the inspection time limits which are decreased. This can cause moredamage to the components which are necessary to repair. This data contains the deteriorationand damage limits as follows:

(a) The combustion chamber is permitted to continue in operation without limits.

(b) The combustion chamber is permitted to continue in operation with an inspection each250 cycles.

1) Combustion chambers that have reached a level of distress that exceeds thecontinued service without restriction limits may be continued in service byemploying the 250 cycle reinspection interval, until the distress level reaches one ormore of the conditions listed under this category.

(c) The combustion chamber is permitted to continue in operation with an inspection each120 cycles.

1) Combustion chambers that have reached a level of distress that exceeds thecontinued service limits but must be reinspected every 250 cycles, may becontinued in service by employing the 120 cycle reinspection interval, until thedistress level reaches one or more of the conditions listed under this category.

(d) The combustion chamber is permitted for continued operation with inspection each 60cycles.

1) Combustion chambers that have reached a level of distress that exceeds thecontinued service limits but must be reinspected every 120 cycles, may becontinued in service by employing the 60 cycle reinspection interval, until thedistress level reaches one or more of the conditions listed under this category.

(e) Replace the combustion chamber.

1) Remove the combustion chambers from operation that show signs of problems thatare more than the limits of the inspection cycle.

2) You can operate the engine with damaged combustion chambers for a maximum offorty more hours to get to a maintenance base. You must make a decision if you cancontinue to operate the engine for five more cycles.

SUBTASK 72-00-00-436-383-P00

(12) After the inspection is completed, install the plugs at the AP-9 location and the igniter plugs asfollows:



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(a) Clean the threaded areas of the borescope plugs and the ID of the AP-9 ports as follows:

1) Use a stainless steel wire brush, STD-131 with solvent, B50131 [P11-027] toremove the antigalling compound and the unwanted deposits.

2) Make sure the deposits are removed from the threaded areas of the borescopeplugs and the ID of the AP-9 ports.


(b) Lubricate the threads of the plugs with anti-seize paste, D50124 [P06-054].

(c) Install the four new gaskets and the plugs at the 2, 3, 7, and 10 o'clock locations.

1) Tighten the plugs to 110-120 pound-inches (12.428-13.558 newton-meters).


(d) Install the igniter plugs (PAGEBLOCK 74-21-02/401).

G. Put the airplane back to its initial condition

SUBTASK 72-00-00-416-384-P00

WARNING



SUBTASK 72-00-00-416-385-P00


SUBTASK 72-00-00-446-386-P00


SUBTASK 72-00-00-416-387-P00


SUBTASK 72-00-00-866-388-P00

(5) For the left engine, remove the safety tags and close these circuit breakers:


Row Col Number Name



SUBTASK 72-00-00-866-389-P00

(6) For the right engine, remove the safety tag and close this circuit breaker:


Row Col Number Name




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COMBUSTION CHAMBER DAMAGE LIMITS

PROBLEM AREA CONDITION CONTINUE - IN - OPERATION LIMITS (MAXIMUM

PERMITTED DAMAGE)

Louver, Outer andInner Chamber,Figure 650

Burn Holes Permitted WithoutLimits of Operation

1. A maximum of four holes burned through the liner wall ispermitted if the largest dimension is not more than 0.500inch (12.700 mm).

2. A maximum of two holes burned through the liner wall ispermitted if the largest dimension is not more than 0.750inch (19.050 mm).

3. It is possible for the holes to be axially aligned, but youmust have a minimum of six inches (152.400 mm) of goodmaterial around each hole (the approximate distance ofthree fuel injectors).

NOTE: Cracks around a hole that start from a burn hole can be part of the burn hole if the largest dimension from aboveis maintained. Cracks around a hole that are longer than these limits must be examined alone as circumferentialcracks.

Permitted with anInspection Each250 - Cycles

1. A maximum of six holes burned through the liner wall ispermitted if the largest dimension is not more than 0.500inch (12.700 mm).

2. A maximum of three holes burned through the liner wallis permitted if the largest dimension is not more than 0.750inch (19.050 mm).

3. It is possible for the holes to be axially aligned, but youmust have a minimum of six inches (152.400 mm) of goodmaterial around each hole (the approximate distance ofthree fuel injectors).

NOTE: Cracks around a hole that start from a burn hole can be part of the burn hole if the largest dimension from aboveis maintained. Cracks around a hole that are longer than these limits must be examined alone as circumferentialcracks.

Burns, Decreasein Coating

No Limit on eachlouver

Bends, Kinks andDistortion on theLouvers,

Figure 652

No Limit on eachlouver

Axial Cracks(Individual andContinuous). See

Figure 652 andFigure 657.

Permitted WithoutLimits to Operation

One louver:

1. No limit in the number up to 0.75 inch (19.050 mm) inlength regardless of spacing.

One louver:

2. Unlimited number of cracks that span the full louverseparated by a minimum of 4 inch (101.60 mm)circumferentially.

Two louvers:

A crack that spans two adjacent louvers is acceptable.Multiple two-louver cracks are permitted in the innerassembly and outer assembly with a minimum separationbetween cracks of 90 degrees.



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COMBUSTION CHAMBER DAMAGE LIMITS (Continued)


PERMITTED DAMAGE)

Three louvers:

Cracks less than 0.060 inch (1.524 mm) wide and louverwall radial deformation or surface mismatch at the crack isless than 0.600 inch (1.524 mm).

NOTE: Perform a borescope procedure of the Hot Side only. No Cold Side inspection required.

NOTE: The intersection or imminent intersection of multi-louver cracks and circumferential cracks is not permitted.

NOTE: The thickness of the louver wall as seen through the large diameter holes is approximately 0.060 inch (1.524mm).

Axial Cracks(Individual andContinuous)

See Figure 652and Figure 657.

Permitted with anInspection Each250 - Cycle

One louver:

1. Two full louver-length cracks separated by a space of 2inches (50.800 mm) in circumference that has no cracks.

One louver:

2. Pairs of full louver cracks in adjacent louvers must beseparated by a space of 4 inches (101.60 mm) incircumference.

Two louvers:

At one location in the inner liner, and one location in theouter liner, a two-louver crack is permitted with a minimumseparation of 50 degrees. Additional multi-louver cracksmust be separated by 90 degrees.

Three louvers:

Cracks less than 0.100 inch (2.540 mm) wide and louverwall radial deformation or surface mismatch at the crack isless than 0.100 inch (2.540 mm).

Permitted with anInspection Each120- Cycles

Two louvers:

Pairs of full-louver cracks in adjacent louvers, separated sothat, at most, only one crack lines up with a crack in theadjacent louver. The other cracks must be separated by aspace of 4 inches (101.60 mm) in circumference.

Three louvers:

Cracks less than 0.150 inch (3.810 mm) wide and louverwall radial deformation (or surface mismatch at the crack) isless than 0.150 inch (3.540 mm).

Four louvers:

Cracks less than 0.060 inch (1.524 mm) wide and louverwall radial deformation (or surface mismatch at the crack) isless than 0.060 inch (1.524 mm).

Permitted with anInspection Each60- Cycles

Three louvers:

At two locations in the combustor, separated by 50 degreesif in the same liner, cracks less than 0.200 inch (5.080 mm)wide and louver wall radial deformation (or surfacemismatch) at the crack is less than 0.200 inch (5.080 mm).If the fourth louver develops a crack, the engine must beremoved within 40 hours.



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PERMITTED DAMAGE)

Four louvers:

At two locations in the combustor, separated by 50 degreesif in the same liner, cracks less than 0.120 inch (3.048 mm)wide and louver wall radial deformation (or surfacemismatch at the crack) is less than 0.120 inch (3.048 mm).When the distortion in the crack width is more than 0.120inch (3.048 mm), the engine must be removed within 40hours.

NOTE: Cracks typically form a "J" shape as they turn and terminate in holes. See Figure 656.

NOTE: Perform a borescope procedure of the Hot Side only. No cold side inspection required.


”J” Cracks Permitted WithoutLimits to Operation

Unlimited number of individual cracks that terminate in acombustion or dilution hole regardless of length, providedcrack is less than 0.060 inch (1.524 mm) wide. Cracks thatcontinue forward of the combustion or dilution holes need tobe evaluated by the Axial Crack Limits.

Permitted with anInspection Each250 - Cycles

One louver:

Individual cracks that terminate in a combustion or dilutionhole, regardless of length, that are greater than 0.060 inch(1.524 mm) wide, provided louver wall radial deformation(or surface mismatch at crack) is less than 0.060 inch(1.524 mm). See Figure 656.

”L” Cracks Permitted with anInspection Each 60- Cycles

One louver:

“L”-shaped cracks less than 0.500 inch (12.700 mm) longaxially intersecting a circumferential crack that is less than0.500 inch (12.700 mm) that are the result of a local hotspot.

See Figure 656.

NOTE: Perform a borescope procedure of the Hot Side only. No cold side inspection required.


CircumferentialCracks

Permitted With AnInspection Each 60- Cycles

1. Cracks are permitted if the crack is contained betweentwo combustion holes.

2. Two cracks on each louver are permitted if the minimumseparation is 90 degrees.

3. Three cracks in the inner assembly and three cracks inthe outer assembly are permitted.

4. The cracks which are not contained are not permitted.

5. Axial and circumferential cracks which go across, or intime will go across, each other are not permitted.



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PERMITTED DAMAGE)

Axial CracksWhich areConnected ByBurn Holes,Figure 653

Axial cracks whichconnect burn holesare permitted. But,the sum of the axialcrack and the holeis less than thelength of the twolouvers.

Bulkhead Surface CracksWhich Start AtThe Inner or OuterBulkhead Louverand Lips, Or OnThe Free Surfaceof The Bulk- head(The Cracks CanExtend In AllDirections),Figure 654

Permitted WithoutLimits Foroperation

1. Single isolated cracks.

A. The crack limit is less than 1 inch (25.400 mm) in length.

B. The cracks are isolated on all sides by 6 inches (152.400mm) of good material

NOTE: The approximate distance between centerlines of two adjacent fuel injectors is 3 inches (76.200 mm).

2. Multiple cracks.

A. Multiple cracks less than 6 inches (152.400 mm) apartare permitted if the sum of the length is less than 2 inches(50.800 mm).

B. A crack more than .75 inch (19.050 mm) in length is notpermitted.

3. Intersecting cracks.

A. Intersecting cracks are permitted if the sum of the cracklength is less than 1 inch (25.400 mm).

B. A crack more than .50 inch (12.700 mm) in length is notpermitted.

4. Crack under the heatshield.

A. Only one crack is permitted to extend below a bulkheadheatshield.



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PERMITTED DAMAGE)

Permitted With AnInspection Each250 - Cycles


A. Each crack 2 inches or less (50.800 mm) in length ispermitted if the minimum separation is 3 inches (76.200mm) of good material.

2. Multiple cracks.

A. Multiple cracks less than 3 inches (76.200 mm) apart arepermitted if the sum of the lengths is less than 3 inches(76.200 mm).

B. A crack more than 1.5 inch (38.100 mm) in length is notpermitted.


A. Intersecting cracks are permitted if the sum of the cracklength is less than 3 inches (76.200 mm).

B. A crack more than 1.5 inch (38.100 mm) in length is notpermitted.

4. Cracks under heatshield.

A. Four cracks are permitted to extend below a bulkheadheatshield.

B. Crack separation must be a minimum of .50 inch (12.700mm) or greater.



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PERMITTED DAMAGE)

Permitted With AnInspection Each120 Cycles


A. A crack more than 2 inches (50.800 mm) in length is notpermitted.

B. Cracks must be separated circumferentially by 2 inches(50.800 mm) of good material.

2. Multiple cracks.

A. Multiple cracks less than 2 inches (50.800 mm) apart arepermitted if the sum of the length is less than 3.5 inches(88.900 mm).

B. A crack more than 2 inches (50.800 mm) in length is notpermitted.


A. Intersecting cracks are permitted if the sum of the cracklength is less than 3.5 inches (80.900 mm).

B. A crack more than 2 inches (50.88 mm) is not permitted.

4. Crack under heatshield.

A. The maximum number of cracks that extend below abulkhead heatshield is five.

B. The crack separation must be 0.500 inch (12.700 mm) orgreater.

Holes And Cracks0.062 inch (0.157mm) or Larger

Permitted With AnInspection Each250 Cycles

1. The total area of the hole between two fuel nozzles isless than 0.100 square inch (64.5 sq mm).

2. The total area of the hole in a 60-degree increment (thedistance between five fuel nozzles that are side by side) isless than 0.100 square inch (64.5 sq mm).

3. The total area of the holes in the bulkhead is less than.400 square inch (258 sq mm).

Holes And Cracks0.062 inch (0.157mm) or Larger


1. The total area of the hole between two fuel nozzles isless than 0.200 square inch (129 sq. mm).

2. The total area of the hole in a 60 degree increment (thedistance between 5 fuel nozzles that are side by side) isless than 0.200 square inch (129 sq. mm).

3. The total area of the holes in the bulkhead is less than0.800 square inch (516 sq. mm).

NOTE: Total area of the hole = (width of the hole) x (length of the hole) + 0.7854 x (Diameter) of a circular hole notcounted.



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PERMITTED DAMAGE)

Large areas ofmaterialmovement ordistortion (0.800square inch orlarger), in whichpieces couldseparate from thebulkhead surface

Not permitted.

Cracks in theHood/ Mount LugArea

Not permitted.

BulkheadHeatshield (FuelInjector Guide)

Heatsheild LipDeterioration,Figure 655

Permitted WithoutLimits of Operation

1. Small quantities of deterioration are permitted. Inaddition, you cannot see holes under the lip of theheatshield when you look at the heatshield from the rear.

2. No deterioration is permitted at the heatshield ID bore.


1. Deterioration of the heatshield lip is permitted to fully seethe holes in the bulkhead. The problem which results iskept to a limit by the deterioration limits of the bulkhead andthe heatshield.

Cracks on theFace of theHeatshield

Permitted WithoutLimits of Operation

1. No limit to the number of cracks which start at the outeredge and are less than 1/4 inch (6.350 mm) in length.

2. The cracks less than 3/4 inch (19.050 mm) in length (theapproximate distance from the edge to the 0.070 inch[1.778 mm] diameter holes) have a minimum separation of45 degrees.

3. The cracks which extend across the face and into theheatshield ID bore, must have a minimum separation of 60degrees (equivalent to five 0.070 inch [1.778 mm] diameterholes which are side by side).


1. The cracks in the heatshield less than 3/4 inch (19.050mm) in length have a minimum separation of 30 degrees (aminimum of three 0.070 inch [1.778 mm] diameter holes).

2. The cracks, which extend across the face and into theheatshield ID bore, have a minimum separation of 45degrees.


1. All surface cracks on the heatshield which can possiblyconnect with less than 1/4 inch (6.350 mm) of intersection.In addition, the surface cracks more than 3/4 inch (19.050mm) in length (which continues into the ID bore) with aminimum separation of 30 degrees.

NOTE: You must remove the fuel nozzle for the inspection of the ID bore.

Decrease incoating

No limit.



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PERMITTED DAMAGE)

Fuel Injector EndCap/ TipHeatshield,Figure 655

Radial Cracks Any quantity ispermitted.

Permitted for regular inspection interval

CircumferentialCracks

Any quantity ispermitted along theouter diameter.

Permitted for regular inspection interval

Missing Material Any quantity ispermitted.

Permitted for regular inspection interval.

END OF TASK



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0383

L-90265LEFT SIDE OF THE ENGINE

PLUGS

(AP-9)

GASKET

COMBUSTION

CHAMBER

A-A

AA

AA

(2 LOCATIONS)

117581 S00061275987_V1

Combustion Chamber InspectionFigure 641/72-00-00-990-855-P00



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COMBUSTION

CHAMBER PLUG

IGNITER

PLUGS

AA

BB

C C

C C

0183

L-90268RIGHT SIDE OF ENGINE

A-A

COMBUSTION

CHAMBER

ASSEMBLY

GASKET

IGNITER PLUG

SEE A

B-B

C-C

GASKET

COMBUSTION

CHAMBER

ASSEMBLY

PLUG (AP-9)

SEE A

COMBUSTION

CHAMBER

ASSEMBLY

SEE A

PLUG (AP-9)

262847 S00061275988_V1




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A

0685

BORESCOPE

FOCUS AREA

BOSS

IGNITER

FWD

AP-9

CHAMBER

COMBUSTION

BORESCOPE

AP-10 VANE

1ST-STAGE

HPT

L-91336

117367 S00061275989_V1




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FOR REFERENCE ONLY

0685

L-91337

HOLES

IMPINGEMENT

B

HEATSHIELD

BULKHEAD

GAP

AIR

HOLES

COOLING

BULKHEAD

COMBUSTION CHAMBER NOMENCLATURE

(EXAMPLE)

FUEL INJECTOR

INNER LINER

FWD

B

C

LINER

OUTER

BOSS ASSEMBLY

SPARK IGNITER

SLEEVE

GUIDE

BULKHEAD

SEE

HOOD

SEE

NUMBERS

IDENTIFICATION

LOUVER

(OVERHANG)

LOUVER LIP

LOUVER

GUIDE

7654

3

2

1

7

6

5

4

3

21

AIR

GAP

C

BULKHEAD

HOLES

COOLING

BULKHEAD

117377 S00061275990_V1




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FOR REFERENCE ONLY

0685

L-91338

LOUVER GAP

ED

HOLE

COOLING

LOUVER

HOLE

COOLING

LOUVER

FWD

DSEE

OUTER

HOLES

COMBUSTION

LUG

MOUNT

HOLES

DILUTIONSUPPORT

SEAL

INNER

PLATE

SUPPORT

SEAL

HOLES

DILUTIONLIP

LOUVER

OUTER

LIP

LOUVER

INNER

SEAL

INNER

LINER

INNERHOLES

COMBUSTIONSUPPORT

GUIDE

INJECTOR

COMBUSTION CHAMBER NOMENCLATURE

ESEELINER

117383 S00061275991_V1




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FOR REFERENCE ONLY

76

2

543

1

0685

L-91409COMBUSTION CHAMBER LINER DEFINITIONS

IDENTIFICATION

FUEL INJECTOR GUIDE

(24 LOCATIONS)

(50.80 mm)

(95.25 mm)

BOSSES

(LOUVER NO. 2 AND 3)

COMBUSTION HOLES

IGNITER

FWD

ATTACHMENT FLANGE

COMBUSTION LINER

INNER

(76.20 mm)

3 INCHES

HOLES

DILUTION

NUMBERS

LOUVERS

3.75 INCHES

APPROX.

2 INCHES

(INNER LINER REMOVED) 117385 S00061275992_V1




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76

543

2

1

0 ˚

30 ˚

60 ˚

90 ˚

120 ˚

150 ˚

180 ˚

210 ˚

240 ˚

270 ˚

280 ˚

300 ˚

330 ˚

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

FWD

FWD

0507

L-91339PLANVIEW-INBOARD SURFACE

FUEL

INJECTORS

LOUVER

IDENTIFICATION

NUMBERS

IGNITER

LOCATIONS

MOUNT LUG

LOCATIONS

FROM REAR

CLOCKWISE

360 ˚

12 O'CLOCK

6 O'CLOCK

12 O'CLOCK

OUTER COMBUSTION CHAMBER LINER

CIRCUMFERENTIAL

AXIAL

RADIAL

HOLE SIZES FOR REFERENCE

A

B

C

D

E

F

20

24

4

48

48

1

0.59 (15)

0.54 (14)

0.59 (15)

0.44 (11)

0.30 (7.7)

0.40 (10)

HOLE A

HOLE B

HOLE D

HOLE E

HOLE F

HOLE C

HOLE QUANTITYDIAMETER

INCH (mm)

117397 S00061275993_V1




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FOR REFERENCE ONLY

FWD

FWD

L-91340

0507

7

6

5

4

321

FROM REAR

CLOCKWISE

IGNITOR

LOCATIONS

(IN OUTER

LINER)

6 O'CLOCK

FUEL

INJECTORS

LOCATIONS

(REF)

LOUVER

IDENTIFICATION

NUMBERS

12 O'CLOCK

12 O'CLOCK

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

0 ˚

30 ˚

60 ˚

90 ˚

120 ˚

150 ˚

180 ˚

210 ˚

240 ˚

270 ˚

300 ˚

330 ˚

360 ˚

INNER COMBUSTION CHAMBER LINER

PLANVIEW-OUTBOARD SURFACE

INNER

LINER

CIRCUMFERENTIAL

AXIAL

RADIAL

HOLE SIZES FOR REFERENCE

A

B

C

D

E

20

24

4

48

48

0.59 (15)

0.59 (15)

0.59 (15)

0.54 (14)

0.25 (6.3)

HOLE QUANTITYDIAMETER

INCH (mm)

HOLE A

HOLE B

HOLE D

HOLE E

HOLE C

117399 S00061275994_V1




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FOR REFERENCE ONLY

FWD

LOUVER 2

LOUVER 1

VIEW OF INBOARD (HOT SIDE) SURFACE OF

COMBUSTION CHAMBER LINER

NOTE: CONTINUOUS AXIAL CRACKS CAN BE

DETERMINED FROM THE HOT SIDE BY

CRACK WIDTH AND/OR MATERIAL

MISMATCH.

KNUCKLE

LOUVER 1

LOUVER 2

NOTE: COLD SIDE INSPECTION

IS OPTIONAL.

2

1

1

2

L-99392 (0507)

VIEW OF OUTBOARD (COLD SIDE) SURFACE OF

COMBUSTION CHAMBER LINER1. CRACK THAT GOES COMPLETELY THROUGH THE

KNUCKLE IS A CONTINUOUS AXIAL CRACK.

2. CRACK THAT DOES NOT GO COMPLETELY

THROUGH THE KNUCKLE IS NOT A CONTINUOUS

AXIAL CRACK.

LINER AXIAL CRACK CLASSIFICATION

CRACK INTERSECTION

117352 S00061275995_V1




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FOR REFERENCE ONLY

FWD

0685

L-91401

COATING DEPLETION

AND LOCAL BURNING BURN HOLES

MISSING MATERIAL

NOT ALLOWED

CIRCUMFERENTIAL

SEPARATION LESS

(152.400 mm)

THAN 6.00 INCHES

LINER BURN HOLE LIMITS

117356 S00061275996_V1




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FOR REFERENCE ONLY

FWD

L-91402

5. AXIAL CRACKS LESS THAN ONE FULL LOUVER IN LENGTH AND

2. AXIAL CRACKS, LESS THAN TWO LOUVERS IN LENGTH WITH 4.000 INCHES

1. AXIAL CRACKS MORE THAN TWO LOUVERS LONG.

3. CIRCUMFERENTIAL CRACKS.

4. INDIVIDUAL AXIAL CRACKS UP TO 0.750 INCH (19.050 MILLIMETERS) LONG.

COMBUSTION

CHAMBER

LINER

5

1

23

LINEAR AXIAL CRACK LIMITS

4

6

6. INDIVIDUAL AXIAL CRACKS THAT TERMINATE IN COMBUSTION OR

DILUTION HOLES ARE ACCEPTABLE REGARDLESS OF LENGTH, PROVIDED

CRACKS ARE LESS THAN 0.060 INCH (1.524 MILLIMETERS) WIDE.

INDIVIDUAL AXIAL CRACKS THAT CONTINUE FORWARD OF COMBUSTION

OR DILUTION HOLES ARE TO BE CONSIDERED LESS THAN TWO LOUVER

INDIVIDUAL CRACKS. SEE INDEX 2.

(101.600 MILLIMETERS) MINIMUM SEPARATION.

WITH LESS THAN 4.000 INCHES (101.600 MILLIMETERS) SEPRATION.

0685

117359 S00061275997_V1




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FOR REFERENCE ONLY

0685

L-91403

LINER WALL-RADIAL DEFORMATION

AND SURFACE MISMATCH

FWD

LINER

CHAMBER

COMBUSTION

RADIAL DEFORMATION

LOCAL BUCKLING

117366 S00061275998_V1




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FOR REFERENCE ONLY

FWD

0685

L-91404

L-91405

LENGTH

CRACK

1

2

3

HOLEHOLE

2. AXIAL CRACK LENGTH TO BE LESS THAN TWO LOUVERS.

1. CIRCUMFERENTIAL CRACKS.

3. MAXIMUM PERMITTED HOLE SIZE.

LINER WALL

LINER WALL-BURN HOLE AND CRACK INTERSECTION

BURNSTREAK

NOT PERMITTED

MISSING MATERIAL

CRACK

AXIAL

COMBUSTION

CIRCUMFERENTIAL

CRACKS

117380 S00061275999_V1




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FOR REFERENCE ONLY

F G

FWD

0685

L-91406

PORTS (REFERENCE)

FUEL INJECTOR

MOUNT LUGSECTION

HOOD

FRONT VIEW LOOKING REARWARD

(EXAMPLE 6 LOCATIONS)

(REFERENCE)

HEATSHIELDS

FUEL INJECTOR GUIDE

BULKHEAD SURFACE

REAR VIEW LOOKING FORWARD

FROM BULKHEAD LIP

CRACK ORIGINATING

CIRCUMFERENTIAL CRACK

(ON FREE BULKHEAD SURFACE)

G

LIP

BULKHEAD

INNER

FSEE

SEE

LIP

BULKHEAD

OUTER

BULKHEAD/MOUNT LUG AREA DISTRESS

117389 S00061276000_V1




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FOR REFERENCE ONLY

0685

L-91407H

BULKHEAD HEATSHIELD DISTRESS

LIP EROSION

BORE EROSION

NOT PERMITTED

FACE CRACKS

(EXAMPLE)

BULKHEAD

IMPINGEMENT HOLES

(UNDER HEATSHIELDS)

HEATSHIELD HOLES

EXCEPT FOR INJECTOR

LOCATIONS 9, 10 AND 11

FUEL INJECTOR

GUIDE HEATSHIELD

CRACK TO HEATSHIELD

HOLE PERMITTED

COATING DEPLETION

PERMITTED

INNER LINER

OUTER LINER

FUEL INJECTOR

GUIDE HEATSHIELD

SEE H

BULKHEAD

IMPINGEMENT HOLES

(UNDER HEATSHIELDS)

I

FUEL INJECTOR END CAP

SEE I END CAP MATERIAL

THAT IS NOT THERE

(GONE)

CIRCUMFERENTIAL

CRACKS

RADIAL

CRACKS

A LIMIT TO THE NUMBER OF

FULL FACE CRACKS INTO THE

ID BORE IS PERMITTED

FWD

117395 S00061276001_V1




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FOR REFERENCE ONLY

FWD

L-P0271 (0112)

PW V

BULKHEAD

"L" CRACK

"J" CRACK

2158006 S0000473609_V1




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FOR REFERENCE ONLY

L-P0272 (0112)

PW V

LOUVER WALL

RADIAL DEFORMATION

LOUVER WALL

RADIAL DEFORMATION

GAP/SURFACE

MISMATCH

L-P0273 (0112)

PW V

2158007 S0000473611_V1




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FOR REFERENCE ONLY

TASK 72-00-00-296-390-P00

17. HPT 1st-Stage Vanes Inspection

(Figure 658)


A. References

Reference Title



74-21-02 P/B 401 IGNITER PLUG - REMOVAL/INSTALLATION


B. Tools/Equipment





SPL-10549 Guide - Borescope - PW2000 Engines








NASM20995

D. Location Zones

Zone Area

211 Control Cabin, Left

212 Control Cabin, Right





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FOR REFERENCE ONLY

E. Prepare to examine the HPT 1st-Stage Vanes

SUBTASK 72-00-00-480-003-P00

WARNING















SUBTASK 72-00-00-016-391-P00


SUBTASK 72-00-00-046-392-P00

WARNING



SUBTASK 72-00-00-016-393-P00




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FOR REFERENCE ONLY

SUBTASK 72-00-00-016-394-P00

WARNING



SUBTASK 72-00-00-866-395-P00

(6) For the left engine, open these circuit breakers and install safety tags:


Row Col Number Name



SUBTASK 72-00-00-866-396-P00

(7) For the right engine, open this circuit breaker and install safety tag:


Row Col Number Name


F. Do the HPT 1st-Stage Vanes Inspection

(Figure 658)

SUBTASK 72-00-00-036-397-P00

(1) At the locations AP-9, get access for the borescope inspection as follows:

NOTE: You can use the borescope port AP-10 also, if necessary.

(a) Remove the four plugs and the gaskets at the 2, 3, 7, and 10 o'clock locations.

(b) Remove the igniter plugs (PAGEBLOCK 74-21-02/401).

SUBTASK 72-00-00-486-398-P00

(2) Install the pw2000 borescope kit, COM-10438 through the borescope ports.

NOTE: The maximum depth you can install the borescope is 7.8 inches (198.1 mm).

SUBTASK 72-00-00-296-399-P00

(3) Examine the turbine vanes for nicks, dents, cracks, burns, deterioration, sulfidation, anddamage caused by unwanted material.

NOTE: The damage limits that follow were based on the newest service experience at thetime of publication. If you operate at a level that is more than these limits, you cancause damage to the downstream gaspath parts. A Pratt & Whitney representative canpossibly have new service experience that permits you to extend these limits.

(a) Surface damage and condition of the coating.

1) Do an inspection each 500 cycles for the following conditions:

a) The circular bottom dents are no more than 0.015 inch (0.381 mm) in depth.

b) In addition, the slots in the trailing edge are not closed.

c) All cracks, checking, and crazing in the coating.

d) Damage which decreases the quantity of the coating. In addition, the basemetal is free of burns, deterioration and cracks.

e) Discoloration or deposits on the airfoil or platform.



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a) The circular bottom dents are between 0.015 inch (0.381 mm) and 0.030 inch(0.762 mm) in depth. In addition, the coating is not damaged and the slots inthe trailing edge are not closed.

3) A limit of four cycles to get to a maintenance base.

a) The circular bottom dents are more than 0.030 inch (0.762 mm) in depth.

b) The circular bottom dents are between 0.015 inch (0.381 mm) and 0.030 inch(0.762 mm) in depth. In addition, the slots in the trailing edge are closed.

(b) Cracks in the vane leading edge.

NOTE: A leading edge crack is defined as any crack on the leading edge of the vane thatbegins and ends between the aft most row of concave side leading edge coolingholes and the third row of the convex side cooling holes.

All cracks or sections of cracks burned to a width of more than 0.050 inch (1.270mm) are considered to be burns.


a) Axial or radial cracks up to 0.050 inch (1.270 mm) wide in the vane leadingedge.

b) Axial and radial cracks may cross if they do not form a closed loop and nolifting up of material has occurred.

c) Each vane leading edge has a maximum of five cracks, if the cracks do notclose to make a loop (Figure 658).

d) Any amount of leading edge coating loss and burning is permitted provided noburn-through is present.

e) Leading edge cracks may connect with vane body (airfoil).

NOTE: Refer to limits for vane body cracks.


a) Any number of leading edge cracks.

b) Multiple burn-through holes are permitted at the leading edge provided noindividual hole is greater than 1.500 inch (38.100 mm) radial and does extendpast the forward most row of concave side airfoil or the second row of convexside cooling holes.

c) Holes must be separated by 0.250 inch (6.350 mm).

d) Exposed baffle is acceptable provided it remains intact.

e) Leading edge cracks may connect with leading edge burn-through or vanebody cracks but refer to limits for vane body cracks.

f) Axial and radial cracks can cross as long as they do not form a closed loopand no lifting of material has occurred.

NOTE: Material lift-up is specified as surface that is not aligned, and is liftedmore than 0.100 inch (2.540 mm) at the crack.

All cracks or sections of cracks burned to a width of more than 0.050inch (1.270 mm) are burns. Use the applicable burn limits.




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a) Holes greater than 1.500 inch (38.100 mm) radial or that extend past theforward most row of concave side airfoil or the second row of convex sidecooling holes.

b) Holes with less than 0.250 inch (6.350 mm) separation.

c) Damage to baffle, material lift, or closed loop cracks.

(c) The cracks in the concave side of the airfoil (Figure 658).


a) A maximum of five axial cracks on each HPT 1st-stage vane in the concaveside extending from the aft most row of the concave side airfoil cooling holes,up to, but not beyond the aft most of concave side leading edge cooling holes.

b) Axial and radial cracks can cross as long as they do not form a closed loopand no lifting of material has occurred (Figure 658).

NOTE: Material lift-up is specified as surface that is not aligned, and is liftedmore than 0.100 inch (2.540 mm) at the crack.


a) One axial crack extending from the aft most row of concave side airfoil coolingholes, and connecting with a leading edge crack is allowed if the crack doesnot extend past the third row of convex side cooling holes.

b) The cracks go across a radial body crack or a cooling hole, but do not close tomake a loop and no lift-up occurs (Figure 658).

NOTE: Material lift-up is specified as surface that is not aligned, and liftedmore than 0.100 inch (2.540 mm) at the crack.

3) Do an inspection each 120 cycles for the following conditions (Figure 658):

a) One axial crack extending from the concave side trailing edge and connectingwith a leading edge crack is allowed if the crack does not extend past theforward most row of concave side leading edge cooling holes.


a) One axial crack extending from the concave side trailing edge, through theleading edge, and terminating at or before the aft most row of the convex sidecooling holes.


a) More than one crack that connects with a leading edge crack.

b) Concave side axial crack that connects with a leading edge crack and whichextends beyond the aft most row of convex side cooling holes.

c) Lifting up of material has occurred.

NOTE: Material lift-up is specified as surface that is not aligned, and liftedmore than 0.100 inch (2.540 mm) at the crack.

d) Closed loop cracks or axial cracks with missing material greater than 0.100inch x 0.100 inch (2.540 mm x 2.540 mm) but less than 0.250 inch x 0.250inch (6.350 mm x 6.350 mm).

e) If missing material is greater than 0.250 inch x 0.250 inch (6.350 mm x 6.350mm), inspect downstream parts before allowing flyback.

(d) Radial cracks in the concave cooling holes.




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a) Up to five radial cracks per vane on concave surface (Index 1, Figure 658).

b) Radial cracks in cooling holes may extend between the ID and OD vaneplatform for the full length of the vane and into the platforms.

c) Cracks may not extend 0.100 inch (2.540 mm) beyond the platform fillet radiusand into the platform.

d) Cracks may cross axial cracks provided they do not form a closed loop and nolifting up of material has occurred.

NOTE: Liftup is specified as a surface that is not aligned and lifted more than0.100 inch (2.540 mm) at the crack.


a) Any number of airfoil radial cracks or up to five radial cracks that extendthrough the platform fillet radius into the platform, more than 0.100 inch (2.540mm) but less than 0.200 inch (5.080 mm) (Index 1, Figure 658).

b) Radial cracks with material missing or a closed loop crack less than 0.100 inchx 0.100 inch (2.540 mm x 2.540 mm).

c) No liftup at the crack is permitted.



a) Radial cracks that extend through the platform fillet radius into the platform,greater than 0.200 inch (5.080 mm) (Index 1, Figure 658).

b) Closed loop crack greater than 0.100 inch x 0.100 inch (2.540 mm x 2.540mm) or radial cracks with material missing greater than 0.100 inch x 0.100inch (2.540 mm x 2.540 mm), but less than 0.250 inch x 0.250 inch (6.350 mmx 6.350 mm).

c) If missing material is greater than 0.250 inch x 0.250 inch (6.350 mm x 6.350mm), inspect downstream parts before allowing flyback.

d) Lifting up of material has occurred.


(e) The concave ID and OD platform cracks are parallel to the fillet radius.


a) The total length of the cracks, which are parallel to the fillet radius, on theconcave side of the ID and OD platform is no more than 0.500 inch (12.700mm). In addition, the cracks do not extend around the leading edge.

b) The cracks can connect radial cracks if they do not make a loop. Themaximum total crack length (airfoil and platform) is less than 1.000 inch(25.400 mm).

c) No axial cracks allowed in fillet radius.


a) The total length of the crack on the ID and OD concave side platform isparallel to the fillet radius and is not more than 0.750 inch (19.050 mm). Inaddition, the crack does not extend around the leading edge.



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b) The cracks can connect radial cracks if they do not make a loop. Themaximum total crack length (airfoil and platform) is less than 1.250 inches(31.750 mm).


a) Cracks in any one side (concave or convex) of any single platform, withcumulative length greater than 0.750 inch (19.050 mm) or any crack whichextends around leading edge.

b) Intersecting cracks that form a closed loop, have lifting up of material, orwhere the combined airfoil and platform crack length is greater than 1.250 inch(31.750 mm).

c) Axial cracks in the fillet radius.

CAUTION

THE CONDITIONS OF THE VANE CRACK THAT FOLLOW CONTAINLIMITS THAT SHOW THE CURRENT SERVICE EXPERIENCE.OPERATION WITH MORE THAN THESE LIMITS COULD CAUSESECONDARY DAMAGE TO THE GASPATH HARDWARE DOWNSTREAM.

(f) Vane body (airfoil) convex side of the axial and radial cracks (Figure 658).

1) Install a borescope guide, SPL-10549 and a 6 mm flexible borescope to view theconvex side of the vanes. Use the following procedure:

NOTE: Use two inspectors, one with a rigid borescope and one with a flexibleborescope. The rigid borescope user guides the flexible borescope user tothe vanes.

a) Insert the borescope guide, SPL-10549 into an AP-9 port. Rotate to pointrearward (Figure 658).

b) Insert the flexible borescope through the borescope guide, SPL-10549.

c) Feed the scope rearward between two vanes. Inspect these adjacent vaneson the way through.

d) Continue feeding the scope between the trailing edge of the 1st stage vanesand the leading edge of the 1st stage blades.

NOTE: Approximately 80 - 90 percent of the scope will be inside the engine.

e) Guide the scope between the vanes until the double row of cooling holes onthe convex side of the vane can be viewed.

f) Twist the scope, as required, to scan the vane from platform to platform.

g) Adjust the position of the scope, as required, so that each successive scanviews an area of the vane closer to the trailing edge than the previous scan.

h) Continue this procedure until the scope is withdrawn to the starting vanes.

NOTE: The inspection procedure should be accomplished at four equallyspaced AP-9 ports if a 1.5 meter scope is used or at three equallyspaced ports if a 2 meter scope is used. This will ensure an overlap.

i) AP-10 and the burner pressure to the EEC sense line may be removed toobtain additional inspection ports.

2) Do an inspection each 500 cycles for the following conditions.

a) Cracks on the convex side of the airfoil body cannot be more than 0.250 inch(6.350 mm) in length.



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b) Cracks may cross as long as they do not form a closed loop and no lifting upof material has occurred.


c) Cracks may extend into but not through fillet radius.


a) The cracks on the convex side of the airfoil body are between 0.250 inch(6.350 mm) and 0.400 inch (10.160 mm) in length.



c) Cracks may extend into but not through fillet radius.


a) Cracks may cross as long as they do not form a closed loop and no lifting upof material has occurred.


b) The cracks on the convex side of the airfoil body are between 0.400 inch(10.160 mm) and 0.750 inch (19.050 mm) in length.

c) Cracks may extend through fillet radius but platform crack limits apply.


a) The cracks on the convex side of the airfoil body are between 0.750 inch(10.160 mm) and 2.125 inches (53.975 mm) in length.



a) All cracks which have liftup or make a loop with other cracks.

NOTE: Liftup is when one side of a crack is more than 0.020 inch (0.508 mm)above the other side of the crack.

b) The cracks on the convex side of the airfoil body are more than 2.125 inches(53.975 mm) in length.

c) The deterioration of the crack is more than 0.025 inch (0.635 mm) in width onthe airfoil body.

NOTE: If this occurs, immediately tell a Pratt and Whitney representative.

(g) Burns on the platform.


a) The burns on the ID and OD platform at the convex side of the airfoil are nomore than 0.050 inch (1.270 mm) from the edge of the platform, inward towardthe cooling air holes for the full length of the cooling hole pattern.

b) For all other areas of the platform, burns in the base metal or erosion less than0.500 sq-in (322.580 sq-mm).

c) No burn-through permitted.



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a) The burns on the ID and OD platform at the convex side of the airfoil are nomore than 0.500 inch (12.700 mm) axially by 2/3 of the trailing edge platformcircumferentially.

b) Burns in the base metal, or erosion, which is more than 0.500 square inch(322.580 sq mm) total.

c) Burn holes which are less than 0.250 inch (6.350 mm) on the longestdimension.


a) Burns on the ID and OD platform at the convex side of the airfoil that aregreater than 0.500 inch (12.700 mm) axially by 2/3 of the trailing edge platformcircumferentially.

b) Burns in the base metal, or erosion, which is more than 0.750 square inches(19.050 sq mm) total.

c) Burn holes which are more than 0.250 inch (6.350 mm) on the longestdimension.

(h) The cracks on the ID and OD platform.


a) Any number of cracks provided no individual crack is greater than 0.500 inch(12.700 mm) in length and cracks do not extend through the fillet more than0.100 inch (2.540 mm) on the concave side.

b) Cracks on the convex side may extend into but not through the fillet radius.

c) The cracks do not go across each other and they do not make a loop.


a) No individual crack is greater than 0.500 inch (12.700 mm) in length.

b) All cracks less than 0.200 inch (5.080 mm) in length are permitted in the ID orOD platform surface.

c) The cracks do not go across each other and they do not make a loop.


a) A maximum of five cracks with a length greater than 0.500 inch (12.700 mm)but less than 1.000 inch (25.400 mm), and which do not continue more than0.500 inch (12.700 mm) through either fillet radius into the airfoil.

b) Platform and airfoil cracks may cross provided the combined crack length isless than 1.500 inches (38.100 mm) and no closed loops are formed. Thecracks can go across each other if they do not make a loop.


a) More than five cracks with a length greater than 0.500 inch (12.700 mm) butless than 1.000 inch (25.400 mm) in length.

b) Any individual crack with a length greater than 1.000 inch (25.400 mm).

c) Cracks which progress more than 0.500 inch (12.700 mm) through the filletradius into the airfoil.

d) Platform and airfoil cracks that cross each other and have a combined cracklength greater than 1.500 inch (38.100 mm) or which form closed loops.

(i) The ceramic coating on the ID and OD platform (Figure 658).



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a) All cracks, checking, and crazing (small square crack pattern) on the ceramicsurface.

(j) ID and OD platform protruding featherseals


a) Three featherseals may protrude above the first stage platform into theairstream at any location.

b) No limit on the length of the exposed featherseal.


a) More than three featherseals protruding above the 1st stage platform into theairstream.

(k) ID Platform Airseal

NOTE: This area is located in the gap between the last combustion chamber louver andthe ID platform.

1) Do an inspection each 500 cycles for the following conditions.

a) Any amount of cracking and base metal burning allowed. Burn-through withthe largest dimension of missing material less than or equal to 1.00 inch(25.400 mm).


a) Burn-through with the largest dimension of missing material greater than 1.00inch (25.400 mm) but less than or equal to 2.00 inches (50.800 mm).


a) Burn-through with the largest dimension of missing material greater than 2.00inches (50.800 mm).

SUBTASK 72-00-00-436-400-P00

(4) After the inspection is completed, close the borescope ports as follows:

(a) Clean the threaded areas of the borescope plugs and the ID of the ports as follows:


2) Make sure the deposits are removed from the threaded areas of the borescopeplugs and the ID of the ports.



(c) Install the four new gaskets and the plugs at the 2, 3, 7, and 10 o'clock positions.



(d) Install the igniter plugs (PAGEBLOCK 74-21-02/401).



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SUBTASK 72-00-00-416-401-P00

WARNING



SUBTASK 72-00-00-416-402-P00


SUBTASK 72-00-00-446-403-P00


SUBTASK 72-00-00-416-404-P00


SUBTASK 72-00-00-866-405-P00

(5) For the left engine, remove the safety tags and close these circuit breakers:


Row Col Number Name



SUBTASK 72-00-00-866-406-P00

(6) For the right engine, remove the safety tag and close this circuit breaker:


Row Col Number Name


END OF TASK



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0000

L-96889

LEADING EDGE CRACKS

ID PLATFORM

AIR HOLES ON THE

AND CONVEX COOLING

BETWEEN THE CONCAVE

CRACK THAT EXTENDS

COOLING AIR HOLES.

FRONT CONCAVE

REAR ROW OF THE

THAT EXTENDS TO THE

LEADING EDGE CRACK

OD PLATFORM

LEADING EDGE1ST-STAGE VANE

OF THE HPT

LEADING EDGE

CLOSED LOOP

CRACK

117400 S00061276003_V1

HPT 1st-Stage Vane Crack InspectionFigure 658/72-00-00-990-870-P00



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0000

L-96890

AIRFOIL CRACKS - CONCAVE SIDE

APPROXIMATELY

(2.540 mm)

0.100 INCH

(REF)

AXIAL CRACK BETWEEN

THE FRONT AND REAR

COOLING HOLES THAT

CONNECTS WITH A

LEADING EDGE CRACK

AXIAL CRACK THAT EXTENDS

AFT OF THE REAR COOLING

HOLES AND GOES ACROSS A

RADIAL COOLING HOLE CRACK


FORWARD TO THE FRONT

COOLING HOLES


FORWARD FROM THE REAR

COOLING HOLES TO THE

FRONT COOLING HOLES

AXIAL CRACK

THAT TOUCHES

A RADIAL BODY

CRACK

MATERIAL THAT

IS GONE AND AN

AXIAL CRACK

AXIAL CRACK FROM THE

LEADING EDGE TO THE

TRAILING EDGE

117405 S00061276004_V1




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PLATFORM

VANE

RADIAL CRACKS IN THE CONCAVE COOLING HOLES

EXTEND THE FULL LENGTH

RADIAL CRACKS WHICH

IN THE VANE PLATFORM RADIUS

OF THE VANE PLATFORM AND

RADIAL CRACKS

AXIAL CRACK

VANE

1ST-STAGE

HPT

CONCAVE PLATFORM CRACKS THAT ARE PARALLEL TO THE FILLET RADIUS

HPT 1ST-STAGE VANE

A

L-90861

L-90862

PLATFORM CRACK

RADIAL CRACK

HPT 1ST-STAGE VANE

ASEE

INDEX 1

APPROXIMATELY

(2.540 mm)

(REF)

0.100 INCH

117412 S00061276005_V1




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L-90863

0684

INTERSECTING

CRACKS

AIR FOIL

BODY CRACKS

OD PLATFORM

HPT 1ST-STAGE VANE

CONVEX SIDE BODY CRACKS

COMBUSTION CHAMBER

DIFFUSER CASE

BORESCOPE

GUIDE TUBE

TURBINE VANE

GUIDE TUBE

1ST-STAGE

CONVEX FRONT

COOLING HOLES

CONVEX LEADING

EDGE COOLING HOLES

117415 S00061276006_V1




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AIR HOLES

COOLING

PLATFORM

CIRCUMFERENTIAL

AXIAL

OD PLATFORM

ID PLATFORM

0684

L-90864

L-90865

HPT 1ST-STAGE VANE

AIRFOIL/PLATFORM

OD PLATFORM CRACKS

INTERSECTING

CRACKS

CRACKS

CRACKS

PLATFORM

BURN

PLATFORM BURNS

HPT 1ST-STAGE VANE

117422 S00061276007_V1




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L-90866

COATING CRACKS

CHECKING/CRAZING

HPT 1ST-STAGE VANE

PLATFORM CERAMIC COATING

117432 S00061276008_V1

HPT 1st-Stage Vane Crack InspectorFigure 663/72-00-00-990-875-P00



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TASK 72-00-00-296-407-P00

18. HPT 1st-Stage Blades Inspection


A. References

Reference Title





B. Tools/Equipment





















NASM20995



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D. Location Zones

Zone Area



E. Prepare to Examine the HPT 1st-Stage Blades

SUBTASK 72-00-00-480-002-P00

WARNING















SUBTASK 72-00-00-016-408-P00




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SUBTASK 72-00-00-046-409-P00

WARNING



SUBTASK 72-00-00-016-410-P00


SUBTASK 72-00-00-016-411-P00

WARNING



SUBTASK 72-00-00-436-412-P00






SUBTASK 72-00-00-496-413-P00

(7) Install the pneumatic drive unit (Figure 604), the PWA 83241 drive unit with the control kit,SPL-2582 (Figure 605), or a 9/16-inch socket wrench on the manual drive pad.

F. HPT 1st-Stage Blades Inspection

(Figure 664)

SUBTASK 72-00-00-036-414-P00

(1) For engines without a borescope port in the turbine HPT cooling air manifold on the lower leftside, use the borescope plug at the location AP-9 to get access to the HPT 1st-stage blades(Figure 601):

(a) Remove the plug and the gasket from the borescope port at the 7 o'clock position (rearview), location AP-9.

(b) Do these steps to examine the 1st-stage blades.

1) Put the borescope guide, SPL-10549 and the flexible borescope through theborescope port.

a) Hold the flanged end of the borescope guide, SPL-10549 so that the end withthe curve is pointed up.

b) Put the borescope guide, SPL-10549 into the borescope port until the flangetouches the borescope port boss.



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c) With the flange against the borescope boss, turn the borescope guide,SPL-10549 clockwise and to the rear of the engine until it stops.

NOTE: The end of the borescope guide, SPL-10549 is in a position where youcan examine the 1st-stage blades.

d) Attach the borescope guide, SPL-10549 to the borescope boss.

<1> Tighten the nut on the borescope guide, SPL-10549.

e) Put the flexible borescope into the borescope guide, SPL-10549.

<1> Extend, retract or turn the borescope fiber bundle in small incrementsuntil you can see the area.

CAUTION

BEFORE YOU TURN THE ENGINE, MAKE SURE THE TIP OF THEBORESCOPE IS CLEAR OF THE 1ST-STAGE BLADES. IF YOU DONOT DO THIS, YOU CAN CAUSE DAMAGE TO THE BORESCOPE.

2) Turn the engine with pneumatic foot operated rotator, SPL-10567, as necessary,while you examine the blades.

SUBTASK 72-00-00-036-415-P00

(2) For engines with a borescope port in the HPT cooling air manifold on the lower left side,remove this borescope plug for access to the HPT 1st-stage blades (Figure 601):

NOTE: This access port is an alternative to the AP-9 port for an inspection of the HPT1st-stage blades. You can also use this port to do an inspection of the HPT 2nd-stageblades.

(a) Remove the three bolts that attach the borescope plug to the cooling air manifold.

(b) Remove the borescope plug and the gasket from the manifold.

1) Discard the gasket.

(c) Examine the 1st-stage blades with the steps that follow:

1) Install a flexible borescope into the port and through the access port in the2nd-stage vane platform.

2) Move the borescope until you can see the HPT 1st-stage blades.

CAUTION

BEFORE YOU TURN THE ENGINE, MAKE SURE THE TIP OF THEBORESCOPE IS CLEAR OF THE 1ST-STAGE BLADES. IF YOU DONOT DO THIS, YOU CAN CAUSE DAMAGE TO THE BORESCOPE.

3) Turn the engine, as necessary, while you examine the blades.

DHI 201-206 PRE SB PW2000-72-0479

SUBTASK 72-00-00-296-416-P00

(3) Examine the 1st-stage blades for nicks, dents, cracks, damage to the tip, deterioration,sulfidation, and damage caused by unwanted material.

NOTE: For the blades which show signs of cracks, use the dye penetrant inspection to makesure the blade is satisfactory.

(a) Airfoil inspection limits (convex side).

1) All quantities of damage are permitted.

(b) Airfoil inspection limits (concave side).



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DHI 201-206 PRE SB PW2000-72-0479 (Continued)

1) Identify the inspection areas of the airfoil (Figure 665).

(c) For defects on the airfoil in Area B (Figure 666), refer to the inspection limits in the twotables that follow.

NOTE: The first table has the inspection limits for all defects other than cracks. Thesecond table has the crack limits.

(d) Discoloration or deposits on the airfoil or platform (no limits are necessary).

HPT 1st-Stage Blades Inspection

HPT 1st-STAGE BLADE - AREA B INSPECTION LIMITS

LOCATION/

CONDITION

INSPECTION AND REMOVAL LIMITS

PERMITTED

WITH NO

LIMITS

EXAMINE EACH

200 - 250 CYCLES

EXAMINE EACH

100 - 125 CYCLES

REMOVE IN A

MAXIMUM OF

50 CYCLES

REMOVE IN A

MAXIMUM OF

4 CYCLES

Airfoil/ Decrease of theCoating

0.250 inch (161

mm)

>0.250 inch (161

mm)

-- -- --

Airfoil/ Burns orOxidation Corrosion ofthe Base Metal

-- -- Any Quantity -- --

Airfoil/ Erosion or Burnsthat Cause a Leak ofCooling Air

-- -- 0.100 inch (2.540

mm) x 0.100 inch

(2.540 mm)

>0.100 inch

(2.540 mm) x

0.100 inch

(2.540 mm)

--

Airfoil/ Nicks or Dents Any quantity if

there is no torn

metal, no

blockage of the

inner cooling air

passage, and

no cooling air

leak

-- -- Any quantity if

the damage is

not permitted

--

Airfoil/ Cracks Refer to the

Table that

follows

Trailing Edge Area/Decrease of theCoating

Any quantity -- -- -- --

Trailing Edge Area/Burns or OxidationCorrosion of the BaseMetal

-- Any Quantity -- -- --

Trailing Edge Area/Burn Through

-- -- 0.250 inch (6.350

mm) from trailing

edge

0.250 - 0.500

inch (6.350 -

12.700 mm)

from trailing

edge

>0.500 inch

(12.700 mm)

from trailing

edge



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HPT 1st-Stage Blades Inspection (Continued)


LOCATION/

CONDITION


PERMITTED

WITH NO

LIMITS

EXAMINE EACH

200 - 250 CYCLES

EXAMINE EACH

100 - 125 CYCLES

REMOVE IN A

MAXIMUM OF

50 CYCLES

REMOVE IN A

MAXIMUM OF

4 CYCLES

Trailing Edge Area/Cracks Dents

Refer to the

Table that

follows

Cooling Holes/Cracks Refer to the

Table that

follows


HPT 1st-STAGE BLADE - AREA B CRACK LIMITS

CRACK CONDITION


PERMITTED

WITH NO

LIMITS

EXAMINE

EACH 200 -

250 CYCLES

EXAMINE EACH 100

- 125 CYCLES

REMOVE IN A

MAXIMUM OF 50

CYCLES

REMOVE IN A

MAXIMUM OF 4

CYCLES

Cooling Hole Cracks onthe Concave Side

0.050 inch

(1.270 mm)

0.050 - 0.150

inch (1.270 -

3.810 mm)

0.150 - 0.500 inch

(3.810 - 12.700 mm)

0.500 - 0.625

inch (12.700 -

15.875 mm)

>0.625 inch

(15.875 mm)

Trailing Edge Cracks 0.100 inch

(2.540 mm)

0.100 - 0.250

inch (2.540 -

6.350 mm)

0.250 - 0.375 inch

(6.350 - 9.525 mm)

0.375 - 0.500

inch (9.525 -

12.700 mm)

>0.500 inch

(12.700 mm)

Radial Cracks 0.150 inch

(3.810 mm)

0.150 - 0.375

inch (3.810 -

9.525 mm)

0.375 - 0.550 inch

(9.525 - 13.970 mm)

0.550 - 0.625

inch (13.970 -

15.875 mm)

>0.625 inch

(15.875 mm)

Axial Cracks 0.050 inch

(1.270 mm)

0.050 - 0.100

inch (1.270 -

2.540 mm)

0.100 - 0.250 inch

(2.540 - 6.350 mm)

-- >0.250 inch

(6.350 mm)

Cooling Hole ChainLink- ing (Number ofCracks)

3 5 6 7 or a Closed

Loop

>7

NOTE: The chain linking can extend into Area A.

SeparatedHoles/Cracks thatPermit a Cooling AirLeak

-- -- 0.100 inch (2.540 mm)

x 0.100 inch (2.540

mm)

>0.100 inch

(2.540 mm) x

0.100 inch (2.540

mm)

--


(e) Tips which are bent.

1) None are permitted.



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CAUTION

THE PURPOSE OF THE LIMITS THAT FOLLOW IS ONLY TO CONTINUEENGINES IN SERVICE. THESE LIMITS ARE ANALYZED FROM PARTSTRUCTURAL DATA. HOWEVER, IT IS POSSIBLE THAT, WITH PARTSOPERATED AT THE LIMITS GIVEN, ENGINE PERFORMANCE, ENGINESTABILITY, OPERATION LIMITS, OR AVAILABLE PART REPAIRS WILLNOT BE THE SAME.

(f) Cracks on the airfoil in Area A (Figure 665).

1) The condition is permitted without limits of operation.

a) The axial or radial cracks are no more than 0.050 inch (1.270 mm) in length inArea A. In addition, there are no open areas that permit a decrease in coolingair and no cracks which go across each other.

2) Do an inspection after every 200 cycles.

a) The cracks, not related with cooling holes, in Area A are more than 0.050 inch(1.270 mm) in length.

b) The cracks in Area A of the cooling holes on the concave side are more than0.050 inch (1.270 mm) in length. In addition, the cracks are not in the directionof the adjacent cooling holes.

c) The cracks which start on the trailing edge in Area A and are more than 0.050inch (1.270 mm) in length.

3) It is necessary to remove the engine in 50 cycles or less:

a) Trailing edge - the cracks start along the full trailing edge and are between0.375 inch (9.525 mm) and 0.500 inch (12.70 mm) in length.

b) The cracks in Area A are not on the trailing edge, not related with coolingholes, and are 0.150 inch (3.810 mm) or longer.

c) The cracks in Area A which extend more than 0.150 inch (3.810 mm) throughthe cooling holes on the concave side. In addition, the cracks do not point tothe adjacent cooling holes.

d) Connected holes which make a loop in Area A.

4) It is necessary to remove the engine in four cycles or less.

a) Trailing edge - the cracks which start along the full trailing edge and are morethan 0.500 inch (12.700 mm) in length.

(g) A decrease of the coating in Area A (Figure 665).

1) Do an inspection every 200 cycles for burns/oxidation or corrosion.

CAUTION

THE PURPOSE OF THE LIMITS THAT FOLLOW IS ONLY TOCONTINUE ENGINES IN SERVICE. THESE LIMITS AREANALYZED FROM PART STRUCTURAL DATA. HOWEVER, IT ISPOSSIBLE THAT, WITH PARTS OPERATED AT THE LIMITSGIVEN, ENGINE PERFORMANCE, ENGINE STABILITY,OPERATION LIMITS, OR AVAILABLE PART REPAIRS WILL NOTBE THE SAME.

a) All quantities

(h) Nicks and dents in Area A (Figure 665).



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1) The condition is permitted with the limits that follow.

a) In Area A, two are permitted if there is no torn metal. In addition, there is nodecrease in the inner cooling air or no open areas to permit a decrease of thecooling air.

2) It is necessary to remove the engine in 50 cycles or less.

a) All nicks or dents which are more than the limits above.

CAUTION


(i) Defects on the leading edge in Area C (Figure 665).

NOTE: The defects can be nicks, cracks, dents or coating oxidation/erosion. Coatingoxidation is gray/black in color.

1) Do an inspection every 200 to 250 cycles.

a) All defects in Area C.

2) Do an inspection every 50 to 60 cycles.

a) Base metal oxidation or erosion.

NOTE: The oxidation or erosion is gray/green in color.

b) The cracks that go across each other.

c) The cracks which connect more than five cooling holes (Figure 667).


a) A crack that starts at the concave row of cooling holes on the leading edgeand extends axially away from the leading edge (Figure 667).

b) The total length of the cracks from the leading edge to the platform fillet radiusis no more than 0.500 inch (12.700 mm).

c) The nicks and dents are more than 0.050 inch (1.270 mm) in length on theinner 75 percent of the airfoil (does not include the leading edge to theplatform fillet radius).

d) The open areas / cracks which permit a decrease in the cooling air.

e) Cracks which connect more than five cooling holes.

f) Cracks between cooling holes which make a closed loop.

CAUTION


(j) Deterioration, corrosion, burns and oxidation on the airfoil in Area A (Figure 665).

1) Do an inspection every 200 cycles:



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FOR REFERENCE ONLY


a) All quantities in all areas.


a) Deterioration, corrosion, burns or oxidation that decreases the cooling air.

(k) The defects in the tip cap.

NOTE: The defects can be cracks, dents, and pieces of cap material which are brokenoff.

CAUTION

THE PURPOSE OF THE LIMITS THAT FOLLOW IS ONLY TOCONTINUE ENGINES IN SERVICE. THESE LIMITS ARE ANALYZEDFROM PART STRUCTURAL DATA. HOWEVER, IT IS POSSIBLETHAT, WITH PARTS OPERATED AT THE LIMITS GIVEN, ENGINEPERFORMANCE, ENGINE STABILITY, OPERATION LIMITS, ORAVAILABLE PART REPAIRS WILL NOT BE THE SAME.


a) All quantities.

NOTE: If an engine has a high EGT and the tip caps of the 1st-stage bladesare not damaged, examine the 2nd-stage blades with a borescope.The pieces of ceramic material from the 1st-stage duct segments cancause damage to the 2nd-stage blades. If the 2nd-stage blades showsigns of damage, the pieces of ceramic material from the 1st-stageduct segments can cause high EGT.

CAUTION


(l) Blockage of the holes (Figure 665)


a) Two holes in Area A which are not adjacent (includes the leading edge, theconcave side, and all holes in the platform).

b) All holes on the tip along the chord on the concave side.

CAUTION


(m) Burns/Oxidation in the platform (Figure 668).


a) Burns/oxidation which fully go through the platform in Area D.

2) Do an inspection every 200 cycles.



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a) All quantities in Area E without burns/oxidation which fully go through theplatform.


a) Burns/oxidation which fully go through the platform in Area E.

DHI 201-206 POST SB PW2000-72-0479

SUBTASK 72-00-00-296-733-P00

(4) Examine the 1st-stage blades for nicks, dents, cracks, tip damage, deterioration, sulfidation,and damage caused by unwanted material.

(a) Airfoil inspection limits (convex side): distress or damage is permitted in this area. Referto Figure 670 (Sheet 4).

(b) Airfoil inspection limits (concave side): Refer to Figure 670 (Sheet 2) to identify airfoilinspection areas.

(c) Area A defects: Refer to Figure 670 (Sheet 2) and Area A Inspection Limits table.

(d) Area B defects: Refer to Figure 670 (Sheet 2) and Area B Inspection Limits table.

(e) Area C defects: Refer to Figure 670 (Sheet 7) and Area C Inspection Limits table.

(f) Area D defects: Refer to Figure 670 (Sheet 2) and Area D Inspection Limits table.

(g) Area E defects: Refer to Figure 670 (Sheet 2) and Area E Inspection Limits table.

(h) Discoloration or deposits on the airfoil or platform (no limits are necessary).


HPT 1st-STAGE BLADE - AREAA INSPECTION LIMITS

LOCATION/

CONDITION


PERMITTED

WITH NO

LIMITS

EXAMINE

EACH 200 -

250 CYCLES

EXAMINE EACH 100

- 125 CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL

All Damage Types Any quantity

permitted

-- -- -- --



LOCATION/

CONDITION


PERMITTED

WITH NO

LIMITS

EXAMINE

EACH 200 -

250 CYCLES

EXAMINE EACH 100

- 125 CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL

Decrease of theCoating

Any quantity

permitted

-- -- --

Burning/Oxidation orCorrosion ofBase Metal

Permitted if no

cracks or holes.

If there are

cracks, refer to

following crack

sections

-- -- -- --



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FOR REFERENCE ONLY

DHI 201-206 POST SB PW2000-72-0479 (Continued)



LOCATION/

CONDITION


PERMITTED

WITH NO

LIMITS

EXAMINE

EACH 200 -

250 CYCLES

EXAMINE EACH 100

- 125 CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL

Holes -- -- Hole area ≤0.100 inch

(2.540 mm) x ≤0.100

inch (2.540 mm)

Hole area >0.100 -

≤0.250 inch (2.540 -

6.350 mm) x >0.100 -

≤0.250 inch (2.540 -

6.350 mm)

Hole area >0.250

inch (6.350 mm) x

>0.250 inch (6.350

mm)

Nicks or Dents All damage

permitted if no

cracks or holes.

For cracks,

refer to

following

sections. For

holes, see

previous

section.

Radial Cracks Permitted -- -- -- --

Axial cracks andaxial cracksconnected tocooling holes ordamage holes

≤0.05 inch

(1.270 mm)

>0.05 - ≤0.100

inch (1.270 -

2.540 mm)

>0.100 - ≤0.200 inch

(2.540 - 5.080 mm)

>0.200 - ≤0.300 inch

(5.080 - 7.620 mm)

>0.300 inch (7.620

mm)

Cooling holesconnected bycracks ("chain-linked")

All cracks

extended into

adjacent areas

permitted.

Cracks cannot

extend into

Area E.

-- -- -- --

Diagonal Cracks Measure the

axial and radial

dimensions and

use the

applicable axial

or radial limits

(see Sheet 6).



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HPT 1st-STAGE BLADE - AREA C INSPECTION LIMITS

LOCATION/

CONDITION


PERMITTED

WITH NO

LIMITS

EXAMINE

EACH 200 -

250 CYCLES

EXAMINE EACH 100

- 125 CYCLES50 CYCLE REMOVAL

10 CYCLE

REMOVAL

Decrease ofthe Coating

Any quantity

permitted

-- -- --


Permitted if no

cracks or

holes. If there

are cracks/

holes refer to

following crack/

hole sections

-- -- -- --

Holes Hole area

≤0.050 inch

(1.270 mm) x

≤0.050 inch

(1.270 mm)

Hole area

>0.050 inch

(1.270 mm)-

≤0.100 inch

(2.540 mm) x

>0.050 inch

(1.270 mm)-

≤0.100 inch

(2.540 mm)

Hole area >0.100 inch

(2.540 mm)- ≤0.150

inch (3.810 mm) x

>0.100 inch (2.540

mm)- ≤0.150 inch

(3.810 mm)

Hole area >0.150

inch (3.810 mm) x

>0.150 inch (3.810

mm)


permitted if no

cracks or

holes. For

cracks, refer to

following

sections. For

holes, see

previous

section.

-- -- -- --


Axial cracks(Figure 632BSheet 7)

Upper 50% All cracks -- -- -- --

Lower 50% <0.080 inch

(2.032 mm)

≥0.080 -

<0.120 inch

(2.032 - 3.048

mm)

≥0.120 - ≤0.160 inch

(3.048 - 4.064 mm)

>0.160 inch (4.064

mm)



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HPT 1st-STAGE BLADE - AREA C INSPECTION LIMITS

LOCATION/

CONDITION


PERMITTED

WITH NO

LIMITS

EXAMINE

EACH 200 -

250 CYCLES

EXAMINE EACH 100

- 125 CYCLES50 CYCLE REMOVAL

10 CYCLE

REMOVAL

Cracks thatconnectcooling holes indifferent rows(see Sheet 7)

Upper 50% All cracks

Lower 50% -- -- 2 holes connected 3 holes connected 4 holes connected or

in a closed loop


HPT 1st-STAGE BLADE - AREA D INSPECTION LIMITS

LOCATION/

CONDITION


PERMITTED

WITH NO LIMITS

EXAMINE EACH

200 - 250

CYCLES

EXAMINE EACH

100 - 125 CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL


Any quantity

permitted

-- -- -- --


Permitted if no

cracks or holes. If

there are cracks/

holes refer to

following crack/

hole sections

-- -- -- --

Holes -- -- Hole area ≤0.100

inch (2.540 mm) x

≤0.100 inch (2.540

mm)

Hole area >0.100 -

≤0.250 inch (2.540

- 6.350 mm) x

>0.100 - ≤0.250

inch (2.540 - 6.350

mm)

Hole area >0.250

inch (6.350 mm) x

>0.250 inch (6.350

mm)


permitted if no

cracks or holes.

For cracks, refer to

following sections.

For holes, see

previous section.




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HPT 1st-STAGE BLADE - AREA D INSPECTION LIMITS

LOCATION/

CONDITION


PERMITTED

WITH NO LIMITS

EXAMINE EACH

200 - 250

CYCLES

EXAMINE EACH

100 - 125 CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL

Axial cracksBurned- throughareas andburned- throughareas with axialcracks

Into but not

beyond the trailing

edge slots

Includes and

goes beyond

trailing edge slots

≤0.250 inch

(6.350 mm) from

the trailing edge

-- >0.250 inch (6.350

mm) from the

trailing edge up to

and including Row

8 cooling holes

Forward of Row 8

cooling holes

Cooling holesconnected bycracks ("Chain-linked")

Permitted, can

extend into

adjacent areas.

Cracks cannot

extend into Area E

-- -- -- --


HPT 1st-STAGE BLADE - AREA E INSPECTION LIMITS


LOCATION/

CONDITION

PERMITTED

WITH NO

LIMITS

EXAMINE

EACH 200 - 250

CYCLES

EXAMINE EACH 100

- 125 CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL


Any quantity

permitted

-- -- --


Permitted if no

cracks or holes.

If there are

cracks/holes

refer to following

crack/hole

sections

-- -- -- --

Burn- throughof trailing edge

Permitted in

trailing edge

slots

-- -- -- --

Radial Cracks All permitted -- -- -- --

Axial Cracks ≥0.100 inch

(2.540 mm) into

but not beyond

trailing edge slot

-- -- Includes and goes

beyond trailing edge

slot

Holes No holes

permitted

-- -- -- Remove if there are

holes



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FOR REFERENCE ONLY



HPT 1st-STAGE BLADE - PLATFORM INSPECTION LIMITS


LOCATION/

CONDITION

PERMITTED

WITH NO LIMITS

EXAMINE EACH

200 - 250 CYCLES

EXAMINE EACH

100 - 125

CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL


Any quantity

permitted

-- -- --


Any quantity

permitted

-- -- -- --

Holes -- -- -- Hole area <0.250

inch (6.350 mm) x

<0.250 inch (6.350

mm)

Hole area ≥0.250

inch (6.350 mm) x

≥0.250 inch (6.350

mm)

Cracks If crack extends into

fillet radius, not to

include platform to

leading edge fillet

-- -- If crack extends

into airfoil or in

axial direction

Burn- Through ofPlatform Edge

-- -- -- -- More than 0.120

inch (3.048 mm)

from original

contour


KEY TO FIGURE 632B (SHEET 9)

INSPECT / REMOVE LIMITS

LOCATION/

CONDITION


PERMITTED

WITH NO LIMITS

EXAMINE EACH

200 - 250 CYCLES

EXAMINE

EACH 100 - 125

CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL

NOTE: The material that follows explains inspection areas illustrated in Figure 632B (sheet 9).

Trailing edgecracks in Area D

[1] Into trailing

edge permitted

[2] Cracks that

include and go

beyond trailing

edge slots 0.250

inch (6.350 mm)

from the trailing

edge

-- [3] Cracks >0.250

inch (6.350 mm)

from the trailing

edge (up to and

including Row 8

cooling holes)

[4] Forward of

Row 8 cooling

holes



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FOR REFERENCE ONLY



KEY TO FIGURE 632B (SHEET 9)

INSPECT / REMOVE LIMITS

LOCATION/

CONDITION


PERMITTED

WITH NO LIMITS

EXAMINE EACH

200 - 250 CYCLES

EXAMINE

EACH 100 - 125

CYCLES

50 CYCLE

REMOVAL

10 CYCLE

REMOVAL

Burning/Oxidation of basemetal withdamage hole inArea D

[5] Inspection

intervals are set by

hole dimensions.

Refer to Area D

Inspection Limits

table for inspection

intervals.

Trailing edgeburn- through inArea D

[6] Burn- through

in trailing edge slot

wall (missing

material in the slot

area can be the

result of this

damage)

[7] Burned through

areas with cracks

that include and go

past trailing edge

slots 0.250 inch

(6.350 mm) from

the trailing edge

[8] Burned through

areas >0.250 inch

(6.350 mm) from the

trailing edge, with

missing concave

wall surface (core

open)

[9] Burned through

areas forward of

Row 8 cooling

holes

Burning/ oxidationof base metalwithout holes orcracks

[10] Permitted

[11] Permitted

DHI 201-206

SUBTASK 72-00-00-436-419-P00

(5) If you removed the AP-9 borescope plug for this inspection, install the borescope plug at thelocation AP-9:

(a) Clean the threaded areas of the borescope plug and the ID of the port as follows:





(c) Install the new gasket and the plug in the borescope port.


2) Install MS20995C32 lockwire, G02392 [P05-262] to the plug.

SUBTASK 72-00-00-436-420-P00

(6) If you removed the borescope plug in the HPT cooling air manifold for this inspection, installthe borescope plug in the manifold:



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(a) Clean the threaded areas of the three bolts that attach the blanking plug to the borescopeport and the holes where the bolts install as follows:


2) Make sure the deposits are removed from the threaded areas of the bolts andholes.


(b) Put a new gasket on the port in the HPT cooling air manifold.

(c) Install the borescope plug in the port on the HPT cooling air manifold.

1) Make sure the borescope plug is correctly aligned in the port.

(d) Lubricate the threads of the three bolts with the anti-seize paste, D50124 [P06-054].

(e) Install the key washer and the three bolts to the borescope port.

1) Tighten the bolts to 65-85 pound-inches (7.345-9.605 newton meters).


SUBTASK 72-00-00-096-421-P00

(1) Remove the pneumatic drive unit (Figure 604), the pneumatic foot operated rotator,SPL-10567 drive unit with the control kit, SPL-2582 (Figure 605), or the socket wrench fromthe manual drive pad on the gearbox.

SUBTASK 72-00-00-436-422-P00


(a) Install a new packing, lubricated with oil, D00137 [P03-001], in the groove of the crankpad cover.




SUBTASK 72-00-00-016-423-P00

WARNING


(3) Close the thrust reverser (PAGEBLOCK 78-31-00/201 Config 3).

SUBTASK 72-00-00-016-424-P00


SUBTASK 72-00-00-046-425-P00


SUBTASK 72-00-00-016-426-P00


SUBTASK 72-00-00-796-756-P00


END OF TASK



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FOR REFERENCE ONLY

HPT 1ST-STAGE

VANES

HPT 1ST-STAGE

BLADES

PWA 81760

BORESCOPE

GUIDE TUBE

FWD

A (0393)

(0383)

L-90265

L-92393

PLUGS (AP-9)

ASEE

CHAMBER

GASKET

COMBUSTION

A-A

AA

305822 S00061276019_V1

Borescope Inspection HPT 1st-Stage BladesFigure 664/72-00-00-990-876-P00



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FOR REFERENCE ONLY

TIP CAP

AREA A

AREA B

AREA C

EDGE OF

LAST ROW OF

COOLING HOLES

(LEADING EDGE)

AIRFOIL LENGTH

50 PERCENT OF

L-96942

117421 S00061276020_V1

HPT 1st-Stage Blade - Airfoil Inspection Areas (Concave Side)Figure 665/72-00-00-990-877-P00



72-00-00

Page 698.86D633N189 May 20/2017


EFFECTIVITYDHI 201-206 PRE SB PW2000-72-0479

FOR REFERENCE ONLY

THE LAST ROW OF COOLING HOLES)

(AREA BETWEEN THE TRAILING EDGE AND

TRAILING EDGE AREA

AIRFOIL

A

SEE A

APPROXIMATELY

0.150 INCH (3.810 mm)

BETWEEN COOLING

HOLES (REF)

TRAILING EDGE

CRACK

COOLING HOLE

CHAIN LINKING

AXIAL CRACK

RADIAL CRACK

HOLES OR CRACKS

THAT PERMIT

A LEAK OF

COOLING AIR

L-96943

50 PERCENT OF THE

AIRFOIL LENGTH

COOLING HOLES

LEADING

EDGE

SEPARATED

COOLING HOLE

CRACK

(CRACK DOES

NOT POINT TO

AN ADJACENT

COOLING HOLE)

188284 S00061276022_V1

HPT 1st-Stage Blades - Area B InspectionFigure 666/72-00-00-990-879-P00



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FOR REFERENCE ONLY

(3.810mm)

HOLES (REF)

COOLING

BETWEEN

0.150 INCH

APPROXIMATELY

A

SEE A

1091

L-92919

THAT EXTEND ACIALLY

0.060 INCH (1.52mm)

LEADING EDGE

HOLES

CONNECTED

SIX

LOOP

CLOSED

(REF)

OF COOLING HOLES

CONCAVE SIDE ROW

LEADING

EDGE

COOLING HOLES

SIDE ROW OF

FROM THE CONCAVE

CRACKS EXCEEDING

A04599 S00061276023_V1

HPT 1st-Stage Blades - Leading Edge Cooling Air Hole Crack Limits That Require Engine Removal in 10Cycles or Less

Figure 667/72-00-00-990-880-P00



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FOR REFERENCE ONLY

AREA D

AREA E

A A

L-92918

1091

A-A

BLADE PLATFORM

117429 S00061276024_V1

HPT 1st-Stage Blade - Platform Inspection AreasFigure 668/72-00-00-990-881-P00



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FOR REFERENCE ONLY

PRE PW SB 72-479

ATB PLATFORM COOLING

TRAILING EDGE

HOLE PATTERN

HOLE PATTERN

ATB COOLING

COOLING SLOTS

TRAILING EDGE

L-97936 (0000)

POST PW SB 72-479

(ADVANCED TECHNOLOGY BLADES)

F47858 S00061276026_V1

1st-Stage Turbine Blade DifferencesFigure 669/72-00-00-990-883-P00



72-00-00

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FOR REFERENCE ONLY

NOMENCLATURE (ADVANCED TECHNOLOGY TYPE)

L-97921 (0000)

ROOT

ROW 8 COOLING HOLES

TRAILING EDGE

PLATFORM

TRAILING EDGE

INSPECTION AREA

(INCLUDES LAST ROW

OF COOLING HOLES

ROW 8)

COOLING AIR SLOTS

TRAILING EDGE

COOLING HOLES

BLADE TIP

LEADING EDGE

AIRFOIL SURFACE

AIRFOIL FILLET RADIUS

(APPROXIMATELY 1/32 INCH

ABOVE PLATFORM)

LEADING EDGE

PLATFORM

F47646 S00061276028_V1

1st-Stage Turbine BladeFigure 670/72-00-00-990-885-P00 (Sheet 1 of 9)



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FOR REFERENCE ONLY

NUMBER 11 AND 12 AND THE TOP COOLING SLOT)

TIP AREA (INCLUDES COOLING HOLE ROWS

CONCAVE SIDE AREAS

NUMBER 8).

AT ONE SIDE) (INCLUDES COOLING HOLES IN ROW

LENGTH FROM PLATFORM TO AREA D WITH AREA B

AIRFOIL TRAILING EDGE (50 PERCENT OF AIRFOILAREA E

AREA D AIRFOIL TRAILING EDGE (WITH AREA A,B, AND E

ROW NUMBER 8)

ON ITS SIDES) (INCLUDES COOLING HOLES IN

AREA C LEADING EDGE. INCLUDES THE FOUR ROWS OF

LEADING EDGE COOLING HOLES (REFER TO SHEET 3)

AREA B

ROWS NUMBER 8 AND 4.

GOES UP TO BUT DOES NOT INCLUDE COOLING HOLE

AREA A

AREA C

INSPECTION AREAS

AIRFOIL LENGTH

50 PERCENT OF

AREA E

TOP COOLING SLOT

AREA B ROW 12

ROW 11

ROW NUMBER 4

COOLING HOLE

ROW NUMBER 8

COOLING HOLES

L-97922 (0000)

AREA D

AREA A

AIRFOIL CONCAVE SIDE WITH AREA A ON ONE SIDE,

F47667 S00061276029_V1




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HOLES) (CALLED "SHOWERHEAD" COOLING HOLES).

LEADING EDGE (INCLUDES FOUR ROWS OF COOLING1

ROW 4

ROW 3

ROW 2

ROW 1

COOLING HOLES

LEADING EDGE

ASEE

LEADING EDGE INSPECTION

A

L-97924 (0000)

AREA C

1

F47715 S00061276030_V1




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CONVEX SIDE INSPECTION AREA

COOLING HOLES

PLATFORM

CONVEX-SIDE

COOLING HOLES

CONVEX-SIDE

VERTICAL

COOLING HOLES

BLADE TIP

THIS AREA

PERMITTED IN

ALL DAMAGE

L-97923 (0000)F47728 S00061276031_V1




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DAMAGE DIMENSION ILLUSTRATION

MAXIMUM

DIMENSION

MAXIMUM

DIMENSION

MAXIMUM

DIMENSION

MAXIMUM

DIMENSION

MAXIMUM

DIMENSION

CRACK EXTENDED FROM COOLING HOLE

HOLE WITH RADIAL CRACK

NICK,DENT,CORROSION, OR

EROSION/CORROSION WITH HOLE

HOLE WITH AXIAL CRACK

NICK,DENT,CORROSION, OR

HOLE,NICK,OR DENT

AXIAL/RADIAL DIRECTIONS

RADIAL

AXIAL

L-97925 (0000)F47756 S00061276032_V1




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DAMAGE DIMENSION ILLUSTRATION

BY CRACKS

RADIAL HOLES CONNECTED

HOLES ("CHAIN LINKS)

RADIALLY CONNECTED

BURN THROUGH ON AIRFOIL

(HOLE OPEN TO BLADE CORE)

NICK OR DENT WITH HOLE

WITH CRACK

OPEN TO BLADE CORE

EDGE BURN THROUGH

AIRFOIL TRAILING

THROUGH

SLOT BURN

TRAILING EDGE

TRAILING EDGE

BURN THROUGH AT

DIMENSION

MAXIMUM AXIAL

RADIAL

AXIAL

AXIAL/RADIAL DIRECTIONS NICK,DENT,CORROSION,OR HOLE

WITH DIAGONAL CRACK

NICK,DENT,BURN THROUGH

DIMENSION

MAXIMUM AXIAL

L-97926 (0000)

3

2

3

2

F47797 S00061276033_V1




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AXIAL CRACK

L-97928 (0000)

ROW 1

ROW 2

ROW 3

ROW 4

RADIAL CRACK

BURNING

CLOSED LOOP

4 ROWS OF COOLING HOLES

CONNECTED BY CRACK

3 ROWS OF COOLING HOLES

CONNECTED BY CRACK

LOWER

50 PERCENT

UPPER

50 PERCENT

AREA C AIRFOIL LEADING

EDGE INSPECTION LIMITS

F47823 S00061276034_V1




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A

BLADE PLATFORM INSPECTION

EDGE CRACK

PLATFORM

EDGE CRACK

PLATFORM

ASEE

L-97929 (0000)

F47831 S00061276035_V1




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INSPECTION AREAS

EXAMPLES OF TRAILING EDGE DAMAGE LIMITS

TRAILING EDGE BURN-THROUGH

MAXIMUM

0.250 INCH

MAXIMUM

DIMENSION

7

5

6

11

10

9

8

TRAILING EDGE CRACKS

EDGE

FROM TRAILING

0.250 INCH

4

3

2

1

50 PERCENT

AREA E

AREA D

TRAILING EDGE

HOLES

COOLING

ROW 8

L-97927 (0000)

AIRFOIL LENGTH

F47843 S00061276036_V1




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TASK 72-00-00-290-802-P00

19. HPT 1st-Stage Duct Segments Inspection

A. References

Reference Title




B. Tools/Equipment









B00090 Solvent - Inhibited Trichloroethane 1,1,1 MIL-T-81533



NASM20995

D. Location Zones

Zone Area



E. Prepare to Examine the HPT 1st-Stage Duct Segments

SUBTASK 72-00-00-840-001-P00

WARNING






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SUBTASK 72-00-00-010-009-P00


SUBTASK 72-00-00-040-001-P00

WARNING

DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENTTHE OPERATION OF THE THRUST REVERSER. THE ACCIDENTALOPERATION OF THE THRUST REVERSER CAN CAUSE INJURIES TOPERSONS OR DAMAGE TO EQUIPMENT.


SUBTASK 72-00-00-010-010-P00


SUBTASK 72-00-00-010-011-P00

WARNING

OBEY THE INSTRUCTIONS IN THE PROCEDURE TO OPEN THE THRUSTREVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TOPERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.


F. HPT 1st-Stage Duct Segments Inspection

SUBTASK 72-00-00-010-012-P00

(1) For engines without a borescope port in the turbine HPT cooling air manifold on the lower leftside, use the borescope plug at the location AP-9 to get access to the HPT 1st-stage duct(Figure 601):



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(a) Remove the plug and the gasket from the borescope port at the 7 o'clock position (rearview), location AP-9.

(b) Do these steps to examine the 1st-stage duct.

1) Put the borescope guide, SPL-10549 and the flexible borescope through theborescope port.

a) Hold the flanged end of the borescope guide, SPL-10549 so that the end withthe curve is pointed up.

b) Put the borescope guide, SPL-10549 into the borescope port until the flangetouches the borescope port boss.

c) With the flange against the borescope boss, turn the borescope guide,SPL-10549 clockwise and to the rear of the engine until it stops.

NOTE: The end of the borescope guide, SPL-10549 is in a position where youcan examine the 1st-stage duct.

d) Attach the borescope guide, SPL-10549 to the borescope boss.

<1> Tighten the nut on the borescope guide, SPL-10549.

e) Put the flexible borescope into the borescope guide, SPL-10549.

<1> Extend, retract or turn the borescope fiber bundle in small incrementsuntil you can see the area.

SUBTASK 72-00-00-010-013-P00

(2) For engines with a borescope port in the HPT cooling air manifold on the lower left side,remove this borescope plug for access to the HPT 1st-stage duct (Figure 601):

NOTE: This access port is an alternative to the AP-9 port for an inspection of the HPT1st-stage duct. You can also use this port to do an inspection of the HPT 2nd-stageblades.

(a) Remove the three bolts that attach the borescope plug to the cooling air manifold.

(b) Remove the borescope plug and the gasket from the manifold.


(c) Examine the 1st-stage duct with the steps that follow:

1) Install a flexible borescope into the port and through the access port in the2nd-stage vane platform.

2) Move the borescope until you can see the HPT 1st-stage duct.

SUBTASK 72-00-00-290-001-P00

(3) Examine the HPT 1st-stage duct segments with a borescope for spalling (ceramic coatingwhich is not there).

(a) All quantities of spalling are permitted.

(b) Ceramic spalling causes the conditions that follow:

1) increased tip clearance of the HPT 1st-stage blade

2) increased EGT

3) increased fuel consumption

4) possible damage to the tip of the HPT 1st-stage blades

5) possible damage to the HPT 2nd-stage blade.



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SUBTASK 72-00-00-290-002-P00

(4) If the HPT 1st-stage duct segments are spalled, do the inspection of the HPT 1st- and2nd-stage blades for damage.

SUBTASK 72-00-00-410-003-P00

(5) If you removed the AP-9 borescope plug for this inspection, install the borescope plug at thelocation AP-9:

(a) Clean the threaded areas of the borescope plug and the ID of the port as follows:

1) Use a wire bristle brush and the solvent, B00090 to remove the antigallingcompound and the unwanted deposits.




(c) Install the new gasket and the plug in the borescope port.


2) Install MS20995C32 lockwire, G02392 [P05-262] to the plug.

SUBTASK 72-00-00-410-004-P00

(6) If you removed the borescope plug in the HPT cooling air manifold for this inspection, installthe borescope plug in the manifold:


1) Use a wire bristle brush and the solvent, B00090 to remove the antigallingcompound and the unwanted deposits.

2) Make sure the deposits are removed from the threaded areas of the bolts andholes.




1) Make sure the borescope plug is correctly aligned in the port.



1) Tighten the bolts to 65-85 pound-inches (7.345-9.605 newton meters).


SUBTASK 72-00-00-410-005-P00

WARNING

OBEY THE INSTRUCTIONS IN THE PROCEDURE TO CLOSE THE THRUSTREVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TOPERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.


SUBTASK 72-00-00-410-006-P00




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SUBTASK 72-00-00-440-001-P00


SUBTASK 72-00-00-410-007-P00


END OF TASK

TASK 72-00-00-290-801-P00

20. HPT 2nd-Stage Vane Inspection

A. General

(1) Use either of two methods to examine the 2nd stage HPT vanes.

(a) Method 1 is done through the borescope port AP-9.

1) This is the preferred method.

(b) Method 2 is done through the borescope port AP-41.

NOTE: The concave side of the vane airfoil is the pressure side. The convex side of the vaneairfoil is the suction side.

B. References

Reference Title

72-61-05 P/B 401 MANUAL CRANK PAD COVER - REMOVAL/INSTALLATION




D. Inspect the 2nd stage HPT vanes (Method 1)(Preferred)

SUBTASK 72-00-00-840-003-P00

(1) Prepare the engine for inspection as follows:

(a) Let the engine become cool to touch (or to less than 150 Deg. F (65.5 deg.C)).

(b) Remove the AP-9 borescope plug.

(c) Remove the HPC crank pad cover (PAGEBLOCK 72-61-05/401). This will give access toa 9/16 inch drive. Turn the rotor with a hand crank or a small motor-driven unit.

NOTE: Use of a motor-driven unit will let the operator use two hands to get theborescope in position and adjust it. It is recommended to stop the rotor rotationwhen a vane is seen through the borescope.

SUBTASK 72-00-00-290-007-P00

(2) Examine 2nd stage HPT vanes by Method 1

NOTE: A borescope with a wide-view range will let the operator see vanes and platforms andnot do procedure steps more than is necessary.

(a) Put the borescope guide tube into the AP-9 port pointed rearward toward the nozzleguide vanes Figure 671 or Figure 672 or Figure 673 or Figure 674 or Figure 675.

(b) Install the flexible borescope into the guide tube.

(c) Continue to move the borescope into the tube along the curvature of the guide tube, untilthe bore-scope goes out the inner end of the tube.

(d) Find the 1st stage HPT guide vanes through the borescope.



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(e) Carefully push the borescope between the vanes until it is possible to see the 1st stageturbine blades through the borescope, but do not push the borescope farther than thetrailing edges of the 1st stage vanes.

NOTE: A small movement of the N2 rotor (bump) can be necessary to get the bestposition for the borescope Figure 671 or Figure 672 or Figure 673 or Figure 674or Figure 675.

(f) Find a path for the borescope to go that is along the concave side of a 1st stage HPTblade Figure 671 or Figure 672 or Figure 673 or Figure 674 or Figure 675.

(g) Carefully continue to move the borescope rearward until there is a view of the 2nd stageHPT vane leading edge and airfoil concave (pressure) side through the borescope.

NOTE: A small movement of the N2 rotor (bump) can be necessary to get the bestposition for the borescope Figure 671 or Figure 672 or Figure 673 or Figure 674or Figure 675.

(h) When there is a good view of the vanes, lock the articulation controls of the borescope inposition.

(i) Use a piece of tape to mark the sheathing of the borescope at the point where it goes inthe guide tube. This mark will be a reference point when the scope is removed.

NOTE: Count the vanes during borescope inspection to make sure that all 40 vanes areexamined.

(j) Examine each 2nd stage vane, with careful inspection of the leading edge and theconcave (pressure) side of the airfoil while the borescope is moved into the guide tube.

CAUTION

MAKE SURE THAT THE SCOPE DOES NOT MOVE BETWEEN THE 2NDSTAGE VANES WHEN THE ROTOR IS TURNED. DAMAGE TO THEBORESCOPE OR THE ENGINE COULD BE THE RESULT.

(k) Turn the rotor slowly in a clockwise direction as viewed from the rear of the engine andstop at each vane for inspection.

(l) If damage is found, stop and photograph the damage and make note of the position.Compare the damage with the limits in Inspect/Remove Limits table.

NOTE: It is not necessary to use much force on the borescope. Keep light force on theborescope as the rotor is turned to pull the borescope in.

If not all 40 vanes are in view because of the length of the borescope, it can benecessary to use more than one AP-9 position to make full inspection of all thevanes.

(m) To remove the borescope after the inspection is completed, pull the borescope carefullyout of the tube while a second operator turns the N2 rotor counterclockwise as seen fromthe rear of the engine.

(n) When the reference mark (tape) on the scope sheathing comes out of the guide tube,stop the rotor.

(o) When the scope tip comes back out of the tube, disengage the articulation locks andcarefully remove the borescope.

(p) If there was not a full view of all vanes, put the borescope in another AP-9 port and do theprocedure again until all vanes are examined.

(q) Refer to Inspect/Remove Limits table and Figure 671 or Figure 672 or Figure 673 orFigure 674 or Figure 675 for 2nd stage vane inspection limits.



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(r) Install the AP-9 borescope plug back in position.

E. Second Stage HPT Vane Borescope Inspection - Through Borescope Port AP-41 (Method2)(Alternate Method)

SUBTASK 72-00-00-290-006-P00

(1) Prepare the engine for inspection as follows:

(a) Let the engine become cool to touch (or less than 150~F (65.6~C).

(b) Bend the keywasher tabs away from the two bolts that hold the AP-41 borescope plug tothe instrumentation boss Figure 671 or Figure 672 or Figure 673 or Figure 674 orFigure 675.

(c) Remove the two bolts and key washers.

(d) Remove the AP-41 borescope plug and the gasket from the port. Discard the gasket.

(2) Examine 2nd stage HPT vanes by Method 2 (alternate method).

NOTE: A borescope with a wide-view range will let the operator see vanes and platforms andnot do procedure steps more than is necessary.

(a) Install the borescope tube into the AP-41 port until the articulating tip is through the portand the 2nd stage HPT vane ID platform is in view in the borescope Figure 671 orFigure 672 or Figure 673 or Figure 674 or Figure 675.

(b) Find a path for the borescope to go along the concave (pressure) side of the 2nd stageHPT vane toward the vane leading edge.

NOTE: At this point, the trailing edge of the 1st stage HPT blades will be in view.

(c) Carefully continue to install the borescope into the area between the 2nd stage HPT vaneleading edge and the 1st stage HPT blade trailing edge Figure 671 or Figure 672 orFigure 673 or Figure 674 or Figure 675.

(d) When the borescope comes into view, articulate the tip of the borescope in the directionof the concave (pressure) side of the 2nd stage HPT vane airfoil.

NOTE: At this point the scope will be in the gap between the 2nd stage HPT vanes andthe 1st stage HPT blades, pointed in a direction where the concave (pressure)side of the vane is in view Figure 671 or Figure 672 or Figure 673 or Figure 674or Figure 675.

(e) Carefully continue to install the scope in the area between the 2nd stage vane leadingedge and the 1st stage blade trailing edge until the point where the borescope came inand the borescope are in view.

(f) When the borescope is in view, articulate the tip until the leading edge and the concave(pressure) side of the 2nd stage vane nearest to where the borescope came in are inview.

(g) Examine the vanes as the borescope is slowly pulled back. Articulate the scope tip whennecessary to get a full view of the vanes, with careful inspection of the leading edge andthe concave (pressure) side of the vane airfoil.

NOTE: Count the vanes during borescope inspection to make sure that all 40 vanes areexamined.

(h) If damage is found, photograph the defect and make a note of the position. Compare thefindings with the limits shown in the Inspect/Remove Limits table.

(i) Continue to examine each 2nd stage vane, with careful inspection of the leading edgeand the concave side of the airfoil as the borescope is carefully pulled back, until theborescope is where it came in and is removed from the engine.



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(j) Refer to Inspect/Remove Limits table and Figure 671 or Figure 672 or Figure 673 orFigure 674 or Figure 675 for 2nd stage vane inspection limits.

(k) Clean the threads of the bolts that attach the borescope plug and the holes where theyare installed, as follows:

1) Use a wire bristle brush and solvent to remove antigalling compound and unwanteddeposits from the threads.

2) Clean the threads with a lint-free cloth.

(l) Put a new gasket in the borescope plug groove.

(m) Install the borescope plug in the port (make sure that the plug is aligned correctly in theport).

(n) Lubricate the bolt threads with anti-seize paste, D50124 [P06-054].

(o) Install the bolts with key washers on the borescope port on the turbine case cover.

1) Tighten the bolts to 65 - 85 lb-in. (7.345 - 9.605 N.m).

(p) Safety the bolts with the key washer tabs.

Inspect/Remove Limits

Location/Condition

Examine again in 500

cycles or less


cycles or less

Remove in 10 cycles or

less

Concave and convex sides ofairfoil and trailing edge axialcracks and burn-through

Missing coating and burningpermitted. Burn-througharea cannot be more than0.063 sq-in (40.64 sq-mm).Axial cracks with burnthrough must not be morethan 25 percent of chord.Axial cracks withoutburn-through cannot bemore than 1.6 inch (40.64mm). No more than threesuch cracks are permitted.Crack width cannot be morethan 0.05 inch (1.3 mm).

Cracks with airfoilburn-through cannot bemore than 1.6 inch (40.64mm). Combined leadingedge and trailing edge axialcracks cannot be more than2 inch (50.8 mm). Total areaof burn-through cannot bemore than 0.9 sq-inch (581sq-mm). Closed loop cracksare not permitted. No morethan three pressure sideaxial cracks without airfoilburn-through that extendfrom the trailing edge to butnot into the leading edgeare permitted. Crack widthcannot be more than 0.05inch (1.3 mm). No twoadjacent vane airfoils canhave axial cracks withburn-through with acombined length more than3 inches (76 mm).

Cracks with burn-throughthat are more than 1.6 inch(40.64 mm). Combinedleading edge and trailingedge cracks that are morethan 2 inch (50.80 mm).Area of burn-through morethan 0.9 sq-inch (581sq-mm). Adjacent vaneairfoils with axial cracks withburn-through with combinedlength more than 3 inch (76mm). More than threepressure-side axial crackswithout airfoil burn-throughthat extend from the trailingedge up to but not into theleading edge or with crackwidth more than 0.05 inch(1.3 mm).



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Inspect/Remove Limits (Continued)

Location/Condition


cycles or less


cycles or less

Remove in 10 cycles or

less

Concave airfoil radial cracks No more than three radialcracks on the pressure sidewith crack lengths less than.5 inch (12.7 mm) andcracks that do not extend to.5 inch (12.7 mm) minimumfrom the filet radius. Axialcracks that connect withradial cracks are permittedClosed loop cracks are notpermitted.

No more than three radialcracks on the pressure sidewith crack lengths less than2.25 inch (57.2 mm) if thecracks do not extend intothe fillet radius. Axial cracksthat connect with radialcracks are permitted.Closed loop cracks are notpermitted.

Radial cracks on thepressure side of the airfoilthat are more than 2.25 inch(57.2 mm) or which extendinto the fillet radius. Closedloop cracks.

Leading edge cracks burningand burn-through

Missing coating is permitted.Crack length less than 0.511inch (13 mm), crack widthless than 0.05 inch (1.3mm), and cracks thatconnect are permitted.Closed loop cracks arepermitted. Closed loopcracks less than 0.12 inchby 0.12 inch (3 mm by 3mm) are permitted no morethan 50 percent of leadingedge burning is permitted(with no exposed baffle).

Crack length less than 1inch (25 mm). Crack widthless than 0.05 inch (1.3mm). Burning more than 50percent of the airfoil ispermitted if the baffle is notexposed and cracks doextend into the fillet radius.

Leading edge burn-throughthat exposes the baffle.Cracks that are more than 1inch (25 mm). Cracks thatextend into the fillet radius.

Inner and outer platformcracks and burning

Inner and outer platformcracks/burning into but notthrough the airfoil filletradius with crack width lessthan 0.05 inch (1.3 mm). Noaxial cracks are permitted inthe airfoil fillet radius. Noclosed loop cracks or Jcracks that connect withperpendicular platformedges are permitted.

Inner and outer platformcracks or burning throughthe airfoil fillet radius. Innerand outer platform crackswith width more than 0.05inch (1.3 mm). Closed loopcracks or J cracks thatconnect with perpendicularplatform edges.

Inner and outer platformburn-through

Burn-through area less than.25 inch (6.4 mm) axial by.25 inch (6.4 mm)circumferential. Noburn-through permitted inthe fillet radius.

Burn through area morethan .25 inch (6.4 mm) axialby .25 inch (6.4 mm)circumferential but less than.5 inch (12.7 mm) by .5 inch(12.7 mm).

Burn-through more than .5inch (12.7 mm) axial by .5inch (12.7 mm)circumferential.Burn-through in the filletradius.

Nicks, dents and scratches All permitted All permitted All Permitted

END OF TASK



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A A

FWD

L-99719 (0207)A-A

7 O'CLOCK

POSITION

AP-9

BOROSCOPE PORT

BORESCOPE

PLUG GASKET

PWA 81760 BORESCOPE

GUIDE TUBE

HPT 1ST

STAGE VANES

HPT 1ST

STAGE BLADES

1971062 S0000378084_V1

Borescope Access Through AP-9 PortFigure 671/72-00-00-990-919-P00



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FWD

L-99720 (0207) PW V

NOZZLE GUIDE VANE

FLEXIBLE BORESCOPE

GUIDE TUBE 1ST TURBINE BLADE

2ND TURBINE VANEPRESSURE SIDE

1971493 S0000378078_V1

Position of Borescope from AP-9 PortFigure 672/72-00-00-990-920-P00



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1

2

3

4

5

6

7

1

2

3

4

5

6

7 L-99721 (0207) PW V

CRACK WITH BURN-THROUGH MORE THAN 1.6 INCH (40.64 mm)

IS NOT PERMITTED.

LEADING EDGE CRACK MORE THAN 1 INCH (25.4 mm)

IS NOT PERMITTED.

LEADING EDGE CLOSED LOOP CRACKS MORE THAN

0.12 X 0.12 INCH (3.048 X 3.048 mm)

ARE NOT PERMITTED.

MORE THAN 3 RADIAL CRACKS, OR CRACKS WHICH EXTEND

INTO THE AIRFOIL RADIUS ARE NOT PERMITTED.

MORE THAN 3 RADIAL CRACKS WITHOUT BURN-THROUGH,

OR WHICH EXTEND INTO THE LEADING EDGE ARE NOT PERMITTED.

AREA OF BURN-THROUGH MORE THAN

0.90 X 0.90 INCH (22.86 X 22.86 mm) IS NOT PERMITTED.

COMBINED LEADING AND TRAILING EDGE CRACK MORE THAN

2 INCHES (50.8 mm) IS NOT PERMITTED.1972170 S0000378085_V1

Borescope Inspection LimitsFigure 673/72-00-00-990-921-P00 (Sheet 1 of 3)



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L-99722 (0207) PW V

ADJACENT VANES WITH CRACKS

AND BURN-THROUGH WITH

COMBINED LENGTH MORE THAN

3 INCHES (76.2 mm)

ARE NOT PERMITTED.

1972511 S0000378086_V1




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L-99723 (1107) PW V

BURN-THROUGH AREA MORE THAN

0.5 X 0.5 INCH (12.7 X 12.7 mm)

IS NOT PERMITTED.

AXIAL CRACKS IN FILLET RADIUS

ARE NOT PERMITTED

AXIAL CRACKS IN FILLET RADIUS

ARE NOT PERMITTED

CLOSED LOOP OR J CRACKS

THAT CONNECT PERPENDICULAR

PLATFORM EDGES ARE NOT PERMITTED.

PLATFORM CRACKS/BURN-THROUGHS

THAT DO NOT EXTEND THROUGH THE

FILLET RADIUS AND ARE LESS THAN

0.05 INCH (1.27 mm) WIDE ARE PERMITTED.

CRACKS CAN CONNECT IF THEY ARE NOT

IN THE FORM OF A CLOSED LOOP.

BURN-THROUGH OR CRACKING

THROUGH AIRFOIL FILLET RADIUS

IS NOT PERMITTED.

1972682 S0000378087_V1




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A A

FWD

HPT 2ND STAGE

TURBINE VANEHPT 2ND STAGE

TURBINE BLADE

FLANGE N

AP-41

A-A

L-99724 (0207)

1972001 S0000378088_V1

Borescope Access Through AP-41 PortFigure 674/72-00-00-990-922-P00



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FOR REFERENCE ONLY

FWD

L-99725 (0207) PW V

NOZZLE GUIDE VANE

1ST TURBINE BLADE

2ND TURBINE VANE

PRESSURE SIDE

FLEXIBLE BORESCOPE

AP-41 ACCESS PORT

1972779 S0000378089_V1

Position of Borescope from AP-41 PortFigure 675/72-00-00-990-923-P00



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FOR REFERENCE ONLY

TASK 72-00-00-296-427-P00

21. HPT 2nd-Stage Blades Inspection


A. References

Reference Title

70-11-06 P/B 201 FLUORESCENT PENETRANT INSPECTION (SPOP 70) -MAINTENANCE PRACTICES

70-11-16 P/B 201 DEGREASE ENGINE PARTS BY SOLVENT WIPE (SPOP 208)


71-00-02 P/B 401 POWER PLANT - REMOVAL/INSTALLATION



72-53-92 P/B 401 BLANKING PLUG - REMOVAL/INSTALLATION


B. Tools/Equipment









SPL-10548 Guide Tube - Borescope - PW2000 Engines








NASM20995



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FOR REFERENCE ONLY

D. Location Zones

Zone Area



E. Prepare to Examine the HPT 2nd-Stage Blades

SUBTASK 72-00-00-480-001-P00

WARNING















SUBTASK 72-00-00-016-428-P00




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SUBTASK 72-00-00-046-429-P00

WARNING



SUBTASK 72-00-00-016-430-P00


SUBTASK 72-00-00-016-431-P00

WARNING



SUBTASK 72-00-00-036-432-P00






SUBTASK 72-00-00-496-433-P00

(7) Install the pneumatic drive unit (Figure 604), the pneumatic foot operated rotator, SPL-10567with the control kit, SPL-2582 (Figure 605), or a 9/16-inch socket wrench on the manual drivepad.

F. Do the Inspection of the HPT 2nd-Stage Blades

SUBTASK 72-00-00-486-434-P00

(1) For engines with a borescope port in the HPT cooling air manifold on the lower left side,remove this borescope plug to make an inspection of the HPT 2nd-stage blades (Figure 601):

NOTE: You can also make an inspection of the HPT 1st-stage blades through the borescopeport in the HPT cooling air manifold.

(a) Remove the three bolts that attach the borescope plug to the HPT cooling air manifold.

(b) Remove the borescope plug and the gasket from the HPT cooling air manifold.


(c) Install the 6 mm diameter flexible borescope in the HPT cooling air manifold and throughthe access port in the HPT 2nd-stage vane platform.

(d) Move the borescope to examine the 2nd-stage blades.

SUBTASK 72-00-00-496-435-P00

(2) Make an inspection of the HPT 2nd-stage blades through the borescope port at the locationAP-11:



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DHI 201-206 PRE SB PW2000-72-0372

(a) Do these steps to remove the blanking plug from the borescope port at the location AP-11(Figure 676):

1) Remove the bolts which hold the plug in the borescope port at the location AP-11.

2) Remove the adjusting plate(s) for the blanking plug and the flanged sleeve from theborescope port.

NOTE: Keep the adjusting plate(s) with the blanking plug to make sure they are inthe correct position during installation.

DHI 201-206 POST SB PW2000-72-0372

(b) Do these steps to remove the blanking plug from the borescope port at the location AP-11(Figure 676):

1) Remove the lockwire and the bolts that attach the blanking plug to the borescopeport at the location AP-11.

2) Remove the bolts and the blanking plug from the borescope port.

3) Remove the two screws that attach the retaining plate to the borescope port.

4) Remove the retaining plate, the spacer plate, and the sleeve bushing from theborescope port.

NOTE: Keep the retaining and the spacer plates with the blanking plug to makesure they are in the correct position during the installation.

DHI 201-206

(c) Examine the blanking plug for damage.

1) Repair the bends in the blanking plug as follows:

a) Make the bends in the blanking plug straight as necessary without the use ofheat.

b) Do the Fluorescent Penetrant Inspection on the blanking plug made straight(PAGEBLOCK 70-11-06/201).

(d) Install the borescope guide tube, SPL-10548 in the borescope port.

(e) Install the 6 mm diameter flexible borescope through the borescope guide tube,SPL-10548.

SUBTASK 72-00-00-296-436-P00

(3) Examine the 2nd-stage blades for nicks, dents, cracks, damage to the tip, oxidation, erosion,sulfidation, airfoil growth or bending, and damage caused by passage of foreign material.Evaluate as follows:

See Figure 676, (Sheets 1, 2, and 3) and Table 603 B.



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Table 603/72-00-00-993-803-P00 HPT 2nd-Stage Blades - Inspection For Airfoil Growth, Bending

HPT 2nd-STAGE BLADE - AREAA (NON-CRITICAL) DAMAGE LIMITS

LOCATION/

CONDITION


ACCEPTABLE200 - 250 CYCLES

REINSPECT

100 - 150 CYCLE

REINSPECT

50 CYCLE

REINSPECT

10 CYCLE

REMOVAL OR

AS NOTED

BELOW

Cracks All permitted if

damage will not let

cooling air out

--- --- ≤ .100 inch

(2.540 mm) if

the damage will

let cooling air

out

> .100 inch

(2.540 mm) if

the damage will

let cooling air

out

Oxidation All permitted if

damage will not let

cooling air out

--- --- ≤.100 inch

(2.540 mm) X

≤.100 inch

(2.540 mm) if

the hole will let

cooling air out

>.100 inch

(2.540 mm) X

>.100 inch

(2.540 mm) if

the hole will let

cooling air out

Erosion (see limitsfor oxidation)

Corrosion (see limitsfor oxidation)

Nicks (see (limits foroxidation)

Dents (see limits foroxidation)

Burn-through attrailing edge

All permitted --- --- >.200 inch

(5.080 mm),

≤.250 inch

(6.350 mm)

from trailing

edge

>.250 inch

(6.350 mm)

from trailing

edge

Airfoil growth (asevidenced bynecking or localizedthinning of the airfoilin mid-span region orother such signs ofobvious bladegrowth)

None Permitted (see

Figure 636, sheet 2)

--- --- --- Any indication

10 cycles

removal or 5

cycles re-

moval if cracks

are found in

areas A or C

Airfoil bending (asevidenced bydisplacement relativeto adjacent blades)

None Permitted (see


--- --- --- Any indication

10 cycles

removal or 5

cycles re-

moval if cracks

are found in

areas A or C



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HPT 2nd-Stage Blades Inspection

HPT 2nd-STAGE BLADE - AREAA (CRITICAL) DAMAGE LIMITS

LOCATION/

CONDITION


PERMITTED WITH

NO LIMITS

EXAMINE EACH 200 -

250 CYCLES

EXAMINE EACH

100 - 125

CYCLES

EXAMINE

EACH 50

CYCLES

10 CYCLE

REMOVAL

Cracks --- --- --- --- All lengths

Oxidation All permitted (if not

into base metal)

Damage into base

metal

>.350 inch (8.890

mm) X >.350 inch

(8.890 mm) into

base metal

≤.100 inch

(2.540 mm) X

≤.100 inch

(2.540 mm) if

the hole will let

cooling air out

>.100 inch (2.540

mm) X >.100 inch

(2.540 mm) if the

hole will let cooling

air out

Erosion (seelimits foroxidation)

Corrosion(see limitsfor oxidation)

Nicks (seelimits foroxidation)

Dents (seelimits foroxidation)

Burn-throughat trailingedge

All permitted --- --- >.200 inch

(5.080 mm),

≤.250 inch

(6.350 mm)

from trailing

edge

>.250 inch (6.350

mm) from trailing

edge

Airfoil growth(asevidencedby neckingor localizedthinning ofthe airfoil inmid-spanregion orother suchsigns ofobviousbladegrowth)

None Permitted (see


--- --- --- Any indication 10

cycles removal or 5

cycles removal if

cracks are found in

areas A or C



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FOR REFERENCE ONLY

HPT 2nd-Stage Blades Inspection (Continued)

HPT 2nd-STAGE BLADE - AREAA (CRITICAL) DAMAGE LIMITS

LOCATION/

CONDITION


PERMITTED WITH

NO LIMITS

EXAMINE EACH 200 -

250 CYCLES

EXAMINE EACH

100 - 125

CYCLES

EXAMINE

EACH 50

CYCLES

10 CYCLE

REMOVAL

Airfoilbending (asevidencedbydisplacementrelative toadjacentblades)

None Permitted (see



cycles removal or 5

cycles removal if

cracks are found in

areas A or C


HPT 2nd-STAGE BLADE - AREA B DAMAGE LIMITS

LOCATION/

CONDITION


PERMITTED WITH

NO LIMITS

EXAMINE EACH

200 - 250

CYCLES

EXAMINE EACH

100 - 125

CYCLES

EXAMINE EACH

50 CYCLES

10 CYCLE

REMOVAL

CracksAll permitted (if

damage will not let

cooling air out)

--- ---

.100 inch (2.540

mm) if damage

will let cooling air

out

> .100 inch (2.540

mm) if damage will let

cooling air out

Oxidation

All permitted (if

damage will not let

cooling air out)

--- ---

.100 inch (2.540

mm) X .100 inch

(2.540 mm) if the

hole will let

cooling air out

>.100 inch (2.540

mm) X >.100 inch

(2.540 mm) if the


air out


Corrosion (seelimits for

Nicks (see(limits foroxidation)

Dents (see limitsfor oxidation)

Tip dents --- --- --- --- All dents

NOTE: Cracks and holes above the tip bonding line will not let cooling air out.



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HPT 2nd-STAGE BLADE - AREA C (NON-CRITICAL) DAMAGE LIMITS

LOCATION/

CONDITION


PERMITTED WITH

NO LIMITS

EXAMINE EACH

200 - 250

CYCLES

EXAMINE EACH

100 - 125 CYCLES

EXAMINE EACH

50 CYCLES

10 CYCLE

REMOVAL

Cracks ≤.050 inch (1.270

mm)

--- --- >.050 inch (1.270

mm) ≤.100 inch

(2.540 mm)

>.100 inch (2.540

mm) or cooling air

passage open

Oxidation All permitted (if

damage will not let

cooling air out)

--- --- ≤.100 inch (2.540

mm) X ≤.100 inch

(2.540 mm) if the

hole will let

cooling air out

>.100 inch (2.540

mm) X >.100 inch

(2.540 mm) if the


air out


Corrosion (seelimits oxidation)

Nicks (see(limits foroxidation)

Dents (seelimits foroxidation)

Airfoil growth(as evidencedby necking orlocalizedthinning of theairfoil inmid-span regionor other suchsigns of obviousblade growth)

None Permitted

(see Figure 636,

sheet 2)


cycles removal or 5

cycles removal if

cracks are found in

areas A or C


HPT 2nd-STAGE BLADE - AREA C (CRITICAL) DAMAGE LIMITS

LOCATION/

CONDITION


PERMITTED WITH

NO LIMITS

EXAMINE

EACH 200 - 250

CYCLES

EXAMINE EACH

100 - 125

CYCLES

EXAMINE

EACH 50

CYCLES

10 CYCLE

REMOVAL

Cracks --- --- --- --- None permitted



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FOR REFERENCE ONLY

HPT 2nd-Stage Blades Inspection (Continued)

HPT 2nd-STAGE BLADE - AREA C (CRITICAL) DAMAGE LIMITS

LOCATION/

CONDITION


PERMITTED WITH

NO LIMITS

EXAMINE

EACH 200 - 250

CYCLES

EXAMINE EACH

100 - 125

CYCLES

EXAMINE

EACH 50

CYCLES

10 CYCLE

REMOVAL

Oxidation All damage not into

base metal

All damage into

base metal

>.100 inch (2.540

mm) X >.100 inch

(2.540 mm)

>.350 inch

(8.890 mm) X

>.350 inch

(8.890 mm)

into base

metal

All damage

which lets out

cooling air

Erosion (see limits foroxidation)

Corrosion (see limitsfor oxidation)

Nicks --- --- --- All damage

into base

metal

All damage

which lets out

cooling air

Dents (see limits foroxidation)

Airfoil growth (asevidenced by neckingor localized thinning ofthe airfoil in mid-spanregion or other suchsigns of obvious bladegrowth)

None Permitted (see



cycles removal

or 5 cycles

removal if cracks

are found in

areas A or C


HPT 2nd STAGE BLADE - AREA D (See Figure 676, Sheet 3)

Axial cracks

extending from

Area F

<= .050 inch (1.270

mm)

--- --- > .050 in. (1.270 mm) <=

.300 in. (7.620 mm) or

> .050 in. (1.270 mm) <=

.200 in. (5.080 mm)

if extending from

missing material in Area

F

> .300 inch (7.620 mm)

or > .200 inch (5.080

mm)

if extending from missing

material in Area F


HPT 2nd STAGE BLADE - AREA F

(Figure 676, Sheet 3)

Cracks All Permitted --- --- --- ---

Missing All Permitted --- --- --- ---



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FOR REFERENCE ONLY

SUBTASK 72-00-00-086-437-P00

(4) For engines with a borescope port in the HPT cooling air manifold on the lower left side, installthe borescope plug in the port:



2) Make sure the deposits are removed from the threaded areas of the bolts and theholes.




1) Make sure the borescope plug is aligned correctly in the port.



1) Tighten the bolts to 65-85 pound-inches (7.345-9.605 newton-meters).

SUBTASK 72-00-00-486-438-P00

(5) Make sure the 6 mm diameter flexible borescope is installed through the borescope port at thelocation AP-11 (Figure 680).

SUBTASK 72-00-00-296-439-P00

(6) Examine the rim of the rear retaining plate of the HPT 2nd-stage blade for cracks (Figure 679).

NOTE: You cannot do the borescope inspection of the retaining plate on engines which havethe HPT 2nd-stage blades with extended platforms and segmented LPT innertransition ducts. There is not sufficient clearance between the HPT 2nd-stage bladesand the LPT inner transition ducts.

(a) No cracks are permitted.

SUBTASK 72-00-00-866-440-P00

(7) Turn the N2 rotor, as necessary, to examine all of the retaining plates of the 2nd-stage blades.

DHI 201-206 POST SB PW2000-72-0203

SUBTASK 72-00-00-216-442-P00

(8) Do an Inspection of the Outer Inter Turbine (Transition) Duct Segments.

NOTE: You must only do the initial inspection on the outer inter turbine duct segments withmore than 3,000 hours of operation. Make a decision on how frequently you must doan inspection from the level of corrosion as given in Table 602.

(a) Use the borescope to examine the turbine duct segments for the conditions that follow:

1) Holes which were caused from corrosion.

2) Turbine duct segments disengaged because of the corrosion on the retaining lugs.

(b) If corrosion of the turbine duct segments is found, do the steps that follow:

1) Count the number of the turbine duct segments with corrosion in the gas path.

2) Make a record of the length of the circumference of the largest incident of corrosion.

3) See Table 602 to find the maximum time until the subsequent borescope inspection.

(c) If a hole is found, do the steps that follow in no more than two cycles:



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FOR REFERENCE ONLY


1) Remove the engine (PAGEBLOCK 71-00-02/401).

2) Replace the turbine duct segments with the holes.

3) Install the engine (PAGEBLOCK 71-00-02/401).

(d) If a turbine duct segment is disengaged because of corrosion on the retaining lugs, dothe steps that follow:

1) Remove the engine (PAGEBLOCK 71-00-02/401).

2) Replace the turbine duct segments with the corrosion.

3) Install the engine (PAGEBLOCK 71-00-02/401).

Limits of Operation for Turbine Duct Segments with Corrosion

MAXIMUM TIME FOR THE

SUBSEQUENT

BORESCOPE INSPECTION

CONDITIONS

NUMBER OF TURBINE DUCT

SEGMENTS WITH GAS PATH

CORROSION

LARGEST CIRCUMFERENCE OF THE

CORROSION ON THE TURBINE DUCT SEGMENTS*[1]

1300 hours or 600 cycles 0 - 4 AND Less than 0.500 inch (12.7 mm)

700 hours or 350 cycles 5 - 6 OR Between 0.500 inch (12.7 mm) and 0.750 inch (19.05mm)

120 hours or 60 cycles 7 or more OR More than 0.750 inch (19.05 mm)

Removal in two cycles orless

All size holes caused by corrosion

*[1] - The length of the circumference of one turbine duct segment is approximately six inches (152.4 mm) The usual gaspath corrosion continues to get larger while the corrosion in the axial direction gets to a maximum length ofapproximately 0.250 inch (6.35 mm). With this as an aid, corrosion with a length of circumference of 0.250 inch (6.35mm) would be about two times as long as the width (axial direction).

DHI 201-206 PRE SB PW2000-72-0372

SUBTASK 72-00-00-436-444-P00

(9) Do these steps to install the blanking plug in the borescope port at the location AP-11 after theinspection is completed:

NOTE: If the plug is replaced, the quantity of necessary adjusting plates is unknown, or aninspection of the plug is necessary, do the depth check of the plug(PAGEBLOCK 72-53-92/401).

(a) Clean the threaded areas of the bolts that attach the blanking plug to the borescope portand the holes where the bolts install as follows:




(b) Install the flanged sleeve bushing to the borescope boss.

(c) Put the adjusting plate(s) (as necessary) over the blanking plug.

(d) Install the plug to the borescope boss.

(e) Apply anti-seize paste, D50124 [P06-054]to the threads of the bolts.



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FOR REFERENCE ONLY


(f) Attach the blanking plug to the borescope boss with the bolts.


DHI 201-206 POST SB PW2000-72-0372

SUBTASK 72-00-00-436-445-P00



(a) Clean the threaded areas of the two bolts that attach the blanking plug to the borescopeport and the holes where the bolts install as follows:




(b) Install the sleeve bushing into the borescope port.

(c) Install the spacer plate on the sleeve bushing.

(d) Install the retaining plate over the spacer plate and align the screw holes.

(e) Install the two screws, lubricated with the engine oil, to attach the retaining plate to theborescope port.

1) Tighten the screws to 24-32 pound-inches (2.712-3.616 newton-meters).

(f) Install the blanking plug in the borescope port.

1) Apply the anti-seize paste, D50124 [P06-054]to the threads of the two bolts thatattach the blanking plug to the borescope port.

2) Install the two bolts to attach the blanking plug to the borescope port.

3) Tighten the two bolts to 36-40 pound-inches (4.067-4.519 newton-meters).

4) Connect the two bolts together with the MS20995C32 lockwire, G02392 [P05-262].

DHI 201-206


SUBTASK 72-00-00-096-446-P00


SUBTASK 72-00-00-436-447-P00


(a) Install a new packing, lubricated with engine oil, in the groove of the crank pad cover.






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FOR REFERENCE ONLY

SUBTASK 72-00-00-416-448-P00

WARNING



SUBTASK 72-00-00-416-450-P00


SUBTASK 72-00-00-446-451-P00


SUBTASK 72-00-00-416-452-P00


SUBTASK 72-00-00-796-757-P00


LPT 3rd-Stage Vane Inspection For Corrosion

END OF TASK



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FOR REFERENCE ONLY

1086

L-90267

1086

L-90267

BOLTS

BLANKING

PLUG

BLANKING PLUG

B 1

1 ENGINES PRE-PW SB 72-372

BLANKING PLUG

BSEE

SLEEVE

BUSHING

AP-11 PORT

AP-11 PORT

AA

A

SEE A

1

LPT

3RD-STAGE

TURBINE

BLADE

B

BADJUSTING

PLATE

SEE

HPT 2ND-STAGE

TURBINE BLADE

D

FLANGE N

B-B 1

BLANKING PLUG

1.644-1.663 INCHES

(41.76-42.24 mm)

(10.008-10.109 mm)

0.394-0.398 INCH

0.325-0.345 INCH

(8.26-8.76 mm)

A-A

L-96377

117534 S00061276048_V1

HPT 2nd-Stage Blade InspectionFigure 676/72-00-00-990-894-P00 (Sheet 1 of 4)



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FOR REFERENCE ONLY

2

2

22

CSEE

C

B

B

BOLTS

BLANKING

PLUG

BLANKING PLUG

ENGINES POST-PW SB 72-372

TURBINE BLADE

LPT 3RD-STAGE

A-A

HPT 2ND-STAGE

TURBINE BLADE

RETAINING PLATEBLANKING PLUG

SPACER PLATE

AP-11 PORT

SLEEVE BUSHING

BLANKING PLUG

0.409-0.413 INCH

(10.389-10.490 mm) 0.394-0.398 INCH

(10.008-10.109 mm)

0.433-0.437 INCH

(10.999-11.099 mm)1.886-1.894 INCHES

(47.904-48.108 mm)

L-96375

L-96375

B-B

871575 S00061276049_V1




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FOR REFERENCE ONLY

CC

L098346 (1197)

C-C

HPT 2ND-STAGE

TURBINE VANE

HPT 2ND-STAGE

TURBINE BLADE

FLANGE N

HPT COOLING

AIR MANIFOLD

ELBOW (REF)

AP-41

ENGINE POST-PW-SB 72-360 OR 72-382

J77511 S00061276050_V1




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FOR REFERENCE ONLY

DD

L-98347 (1197)

HPT 2ND-STAGE

TURBINE BLADEHPT 2ND-STAGE

TURBINE VANE

FLANGE N

D-D

AP-41

ENGINES WITH MODULATED TCA SYSTEM

J77509 S00061276051_V1




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FOR REFERENCE ONLY

AA

(0296)

L-90871

LEADING EDGE

AREA C

A-A

0.400 INCH

(10.160 mm)

CRITICAL AREA

AREA A

AREA C

CRITICAL AREA

ONE-HALF

AIRFOIL LENGTH

AIRFOIL LENGTH

THREE-FOURTHS

0.187 INCH (4.762 mm)

INCLUDES TIP CAP

TRAILING

EDGE

TIP CAP

AREA B

AREA A

AREA C

EDGE

LEADING

CRACK LIMITS

LEGEND:______

117539 S00061276052_V1

HPT 2nd-Stage Blade Inspection AreasFigure 677/72-00-00-990-898-P00



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FOR REFERENCE ONLY

COOLING SLOTS

TRAILING EDGE

ASEE

A

B B

(0000)

L-98058

LEADING EDGE

AREA C

0.400 INCH

(10.160 mm)

B-B

(4.762 mm)

0.187 INCH

CRITICAL AREA

AREA A

AREA C

CRITICAL AREA

ONE-HALF

AIRFOIL LENGTH

AIRFOIL LENGTH

THREE-FOURTHSTRAILING

EDGE

TIP CAP

AREA B

AREA A

AREA C

EDGE

LEADING

CRACK LIMITS

(PN1B6222)AREA D AREA F

LAST TRAILING

EDGE WINDOW

LEGEND:______

117541 S00061276053_V1

HPT 2nd-Stage Blade Inspection AreasFigure 678/72-00-00-990-899-P00 (Sheet 1 of 2)



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FOR REFERENCE ONLY

L-99503 (0205)

PW V

BORESCOPE VIEW AS SEEN THROUGH

AP-11 PORT SHOWING 2ND-STAGE

BLADE DISPLACEMENT

BLADE TIP BENT AFT

(TYPICAL)

NECKING OF BLADE

AT MIDSPAN

CORRECT BLADE

TRAILING EDGE

POSITIONBLADE WITH DISPLACED

TRAILING EDGE

BLADE RUB AREA

(REFERENCE)

ACCEPTABLE BLADE UNACCEPTABLE BLADE

D74855 S00061276054_V1

HPT 2nd-Stage Blade Inspection AreasFigure 678/72-00-00-990-899-P00 (Sheet 2 of 2)



72-00-00

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FOR REFERENCE ONLY

1186

L-94036

L-94036

BLADE TRAILING

EDGE PLATFORM

PLATE

RETAINING

PLATFORM GAP

EDGE SLOT

INNER INTER

REAR

DUCT EDGE

BLADE TRAILING

BLADE

ACCEPTABLE CONDITION UNACCEPTABLE CONDITION

CRACKS

FLANGE N

INTER DUCT

A

BLADE

3RD-STAGE

LPT

AP-11

BORESCOPE

HPT BLADE

2ND-STAGE

INNER

PLATE RIM

REAR RETAINING

ASEE

229306 S00061276055_V1

HPT 2nd-Stage Blade Rear Retaining Plate InspectionFigure 679/72-00-00-990-900-P00



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FOR REFERENCE ONLY

GAS PATH SIDE

OF THE SEGMENT

THE LENGTH OF THE CIRCUMFERENCE

IS APPROXIMATELY 6 INCHES (152.4 mm)

BORESCOPE

TURBINE DUCT

OUTER INTER

AP-11FLANGE N

HPT BLADE

2ND-STAGE

OUTER INTER TURBINE (TRANSITION)

DUCT (16 SEGMENTS)

C

A

B

BASEE

SEE C

1186

L-94036

L-96278

L-96278

759577 S00061276056_V1

Outer Inter Turbine DuctFigure 680/72-00-00-990-901-P00



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FOR REFERENCE ONLY

TASK 72-00-00-290-803-P00

22. LPT 3rd-Stage Blades Inspection


A. References

Reference Title







B. Tools/Equipment









SPL-10548 Guide Tube - Borescope - PW2000 Engines











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FOR REFERENCE ONLY

(Continued)



NASM20995

D. Location Zones

Zone Area



E. Prepare to Examine the HPT 2nd-Stage and LPT 3rd-Stage Blades

SUBTASK 72-00-00-840-002-P00

WARNING















SUBTASK 72-00-00-010-014-P00




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FOR REFERENCE ONLY

SUBTASK 72-00-00-040-002-P00

WARNING

DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENTTHE OPERATION OF THE THRUST REVERSER. THE ACCIDENTALOPERATION OF THE THRUST REVERSER CAN CAUSE INJURIES TOPERSONS OR DAMAGE TO EQUIPMENT.


SUBTASK 72-00-00-010-015-P00


SUBTASK 72-00-00-010-016-P00

WARNING

OBEY THE INSTRUCTIONS IN THE PROCEDURE TO OPEN THE THRUSTREVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TOPERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.


SUBTASK 72-00-00-010-017-P00






SUBTASK 72-00-00-480-011-P00

(7) Install the pneumatic drive unit (Figure 604), the pneumatic foot operated rotator, SPL-10567with the control kit, SPL-2582 (Figure 605), or a 9/16-inch socket wrench on the manual drivepad.

F. Do the inspection of the LPT 3rd-Stage Blades

SUBTASK 72-00-00-010-018-P00

(1) For engines with a borescope port in the HPT cooling air manifold on the lower left side,remove this borescope plug to make an inspection of the LPT 3rd-stage blades (Figure 601):

NOTE: You can also make an inspection of the HPT 1st-stage blades through the borescopeport in the HPT cooling air manifold.

(a) Remove the three bolts that attach the borescope plug to the HPT cooling air manifold.

(b) Remove the borescope plug and the gasket from the HPT cooling air manifold.


(c) Install the 6 mm diameter flexible borescope in the HPT cooling air manifold and throughthe access port in the LPT 3rd-stage vane platform.

(d) Move the borescope to examine the 3rd-stage blades.

SUBTASK 72-00-00-290-003-P00

(2) Make an inspection of the LPT 3rd-stage blades through the borescope port at the locationAP-11:



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DHI 201-206 PRE SB PW2000-72-0372

(a) Do these steps to remove the blanking plug from the borescope port at the location AP-11(Figure 676):

1) Remove the bolts which hold the plug in the borescope port at the location AP-11.

2) Remove the adjusting plate(s) for the blanking plug and the flanged sleeve from theborescope port.

NOTE: Keep the adjusting plate(s) with the blanking plug to make sure they are inthe correct position during installation.

DHI 201-206 POST SB PW2000-72-0372

(b) Do these steps to remove the blanking plug from the borescope port at the location AP-11(Figure 676):

1) Remove the lockwire and the bolts that attach the blanking plug to the borescopeport at the location AP-11.

2) Remove the bolts and the blanking plug from the borescope port.

3) Remove the two screws that attach the retaining plate to the borescope port.

4) Remove the retaining plate, the spacer plate, and the sleeve bushing from theborescope port.

NOTE: Keep the retaining and the spacer plates with the blanking plug to makesure they are in the correct position during the installation.

DHI 201-206

(c) Examine the blanking plug for damage.

1) Repair the bends in the blanking plug as follows:

a) Make the bends in the blanking plug straight as necessary without the use ofheat.

b) Do the Fluorescent Penetrant Inspection on the blanking plug made straight(PAGEBLOCK 70-11-06/201).

(d) Install the borescope guide tube, SPL-10548 in the borescope port.

(e) Install the 6 mm diameter flexible borescope through the borescope guide tube,SPL-10548.

SUBTASK 72-00-00-290-004-P00

(3) Insert the borescope through the port and make an inspection of the 3rd-stage blades fornicks, cracks, clashing and damage caused by passage of foreign material (Figure 682).Clashing is defined as circumferential scoring of the blade platforms. The three types of bladeclashing are defined as follows:

(a) Minor Clashing:

1) Scattered blade platforms that show circumferential scoring which does not extendall the way across the platform and has a 0.005-inch (0.127 mm) maximum depth.

(b) Moderate Clashing:

1) Scattered blade platforms that show circumferential scoring which extends all theway across the platforms on a maximum of 15 blades with a 0.010-inch (0.250 mm)maximum depth.

(c) Heavy Clashing:



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1) Circumferential scoring which extends completely across the platform of more than15 blades and/or is 0.040-inch (1.00 mm) maximum depth.

INSPECT/REMOVE LIMITS

LOCATION

CONDITION

PERMITTED

WITHOUT

RESTRICTION

100 HOUR OF

OPERATION

REINSPECTION

2 CYCLE LIMIT

FOR FLYBACK

ENGINE

REMOVAL

NECESSARY

300 HOUR OF

OPERATION

REINSPECTION

AREAA;Cracks

None permitted A single fine hair crack

at the leading edge

(possibly coating only)

with a maximum

length of 0.040 inch

(1.02 mm) is permitted

on any number of

blades

A 0.080 - inch (2.0

mm) maximum

length is permitted

with a 10 - blade

maximum limit

Any one crack

more than 0.080 -

inch (2.0 mm)

length

--

Burning,oxidation ofnonabuting sidefaces

Any amount -- -- -- --

Round- bottomdents and nickswith no sharpedges

Any number,

0.010-inch (0.25

mm) maximum

depth and 0.040-

inch (1.00 mm)

maximum

diameter or

length

One permitted for

each blade, 0.020-

inch (0.50 mm)

maximum depth with a

0.080-inch (2.03 mm)

maximum diameter or

length

-- -- --

Nicks withsharp edges

Any number,

0.005-inch (0.13

mm) maximum

depth and 0.040-

inch (1.00 mm)

maximum

diameter or

length

One permitted for

each blade, 0.010 -

inch (0.25 mm)


0.080 - inch (2.03

mm) maximum

diameter or length

-- -- --

Nicks anddents

-- -- Any amount

0.050-inch (1.27

mm) maximum

depth with no size

limit

Any one more

than 0.050 - inch

(1.27 mm) depth

--

AREA B:Round- bottomdents and nickswith no sharpedges

Any number,

0.010-inch (0.25

mm) maximum

depth with no

size limits

One permitted for

each blade, 0.020-

inch (0.50 mm)

maximum depth with

no size limit

-- -- --



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FOR REFERENCE ONLY

INSPECT/REMOVE LIMITS (Continued)

LOCATION

CONDITION

PERMITTED

WITHOUT

RESTRICTION

100 HOUR OF

OPERATION

REINSPECTION

2 CYCLE LIMIT

FOR FLYBACK

ENGINE

REMOVAL

NECESSARY

300 HOUR OF

OPERATION

REINSPECTION

Nicks withsharp edges

Any number,

0.005-inch (0.13

mm) maximum

depth with no

size limits

One permitted for

each blade, 0.010-

inch (0.25 mm)

maximum depth with

no size limit

-- -- --

Nicks anddents

-- -- Any amount

permitted, 0.040 -

inch (1.02 mm)

maximum depth

with no size limit

Any one more

than 0.040-inch

(1.02 mm) depth

--

Clashing (Seedefinition)

Minor clashing

permitted, 0.005-

inch (0.13 mm)

maximum depth

Moderate clashing is

permitted, 0.010-inch

(0.25 mm) maximum

depth

Heavy clashing is

permitted, 0.040 -

inch (1.02 mm)

maximum depth

Any signs of

clashing more

than 0.040 - inch

(1.02 mm) depth

--

For PW2037and PW2040Engines:

AREA C:Cracks inleading edgeand trailingedge

None permitted A single closed crack

at the leading edge

which extends 0.010

inch (2.54 mm)

maximum length into

airfoil is permitted for

one blade only

A maximum length

of 0.125 inch (3.17

mm) is permitted

for one blade

Any one more

than 0.125 inch

(3.17 mm) length

--

NOTE: Refer to subsequent table for more Area C crack data

For PW2337and PW2040Engines:

Cracks None permitted A single closed crack

at the leading edge

which extends 0.010

inch (2.54 mm)

maximum length into

airfoil is permitted for

one blade only

A maximum length

of 0.125 inch (3.17

mm) is permitted

for one blade

Any one more

than 0.125 inch

(3.17 mm) length

--

Deposit growth Any amount -- -- -- --

Flaked or lifteddeposits

Permitted if the

coating does not

flake or lift

-- -- -- --



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LOCATION

CONDITION

PERMITTED

WITHOUT

RESTRICTION

100 HOUR OF

OPERATION

REINSPECTION

2 CYCLE LIMIT

FOR FLYBACK

ENGINE

REMOVAL

NECESSARY

300 HOUR OF

OPERATION

REINSPECTION

Blistering, lossof coating

Up to a total

amount of 0.500

sq. inch (322.0

sq. mm) for each

blade with no

related cracking

is permitted

Up to a total amount

of 1.000 sq. inch (645

sq. mm) for each

blade with no related

cracking is permitted

Any amount is

permitted

-- --

Sulfidation(shows as agreen to paleblue color

None permitted A single area for each

blade of not more than

0.500 sq. inch (322.0

sq. mm) with no

related cracking is

permitted with a five

blade maximum limit.

If appearance of

findings did not

change after three

sequenced

inspections, return to

standard borescope

interval.

Any amount with

only minimal loss

of parent material

is permitted

Any loss of parent

material which can

be measured

A single area for

each blade of not

more than 0.250 sq.

inch (161.3 sq. mm)

with no related

cracking is

permitted with a five

blade maximum

limit. If appearance

of findings did not

change after three

sequenced

inspections, return

to standard

borescope interval.

Round- bottomdents and nickswith no sharpedges inleading edge,airfoil face andtrailing edge

Any number,

0.010-inch (0.25

mm) maximum

depth and a

0.080-inch (2.03

mm) maximum

diameter or

length

One permitted for

each blade 0.020-

inch (0.50 mm)


0.120-inch (3.05 mm)

maximum diameter or

length

-- -- --

Nicks withsharp edges inleading edge,airfoil face andtrailing edge

Any number,

0.005-inch (0.13

mm) maximum

depth and a

0.080-inch (2.03

mm) maximum

diameter or

length

One permitted for

each blade 0.010-inch

(0.25 mm) maximum

depth with a 0.120-

inch (3.05 mm)

maximum diameter or

length

-- -- --



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FOR REFERENCE ONLY


LOCATION

CONDITION

PERMITTED

WITHOUT

RESTRICTION

100 HOUR OF

OPERATION

REINSPECTION

2 CYCLE LIMIT

FOR FLYBACK

ENGINE

REMOVAL

NECESSARY

300 HOUR OF

OPERATION

REINSPECTION

Nicks anddents in leadingedge, airfoilface and trailingedge

-- -- Any amount

permitted with a

0.050 - inch (1.27

mm) maximum

depth with no size

limit. No break-

through in the

hollow section of

the airfoil is

permitted

Leading and

Trailing Edge:

More than 0.050 -

inch (1.27 mm)

depth. Airfoil Face:

Break- through

into hollow section

of blade

--

Trailing edgedistortion

-- A maximum

displacement of 0.040

inch (1.00 mm) with

not more than three

bends for each blade

and a total of 10

percent of the trailing

edge length is

permitted

A maximum

displacement of

0.100 inch (2.54

mm) is permitted

with no more than

one for each blade

and a maximum

limit of 10 blades

More than 0.100

inch (2.54 mm)

maximum

displacement on

any one blade

--

Trailing edgetears

-- A 0.100 inch (2.54

mm) maximum length

with no related

cracking is permitted

with not more than

one for each blade

with a five blade

maximum limit

A maximum length

of 0.100 inch (2.54

mm) is permitted

with related

cracking of 0.125

inch (3.17 mm)

maximum length

with a limit of not

more than one for

each blade and no

more than five

blades maximum

More than 0.100

inch (2.54 mm)

length or related

cracks of more

than 0.125 inch

(3.17 mm) length

--

INSPECT/REMOVE LIMITS

LOCATION

CONDITION

PERMITTED

WITHOUT

RESTRICTION

25 CYCLE LIMIT

FOR

REINSPECTION

5 CYCLE LIMIT

FOR

REINSPECTION

5 CYCLE LIMIT

FOR FLYBACK

ENGINE

REMOVAL

NECESSARY

AREA C:

(a) Cracks in theairfoil face

None permitted One radial crackless than 1.000inch (25.4 mm)

One radial crackgreater than orequal to 1.000inch (25.4 mm)but less than orequal to 1.500inch (38.1 mm)

One radial crackgreater than orequal to 1.500inch (38.1 mm)but less than orequal to 2.000inch (50.8 mm)

Transverse cracks,multiple cracks,radial cracksgreater than 2.000inch (50.8 mm) ordistress indicativeof immediaterelease of material



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FOR REFERENCE ONLY

SUBTASK 72-00-00-290-005-P00

(4) Do a routine inspection of the 3rd stage turbine (at intervals of not more than 500 cycles).Examine 3rd stage turbine blades under the blade shrouds to see if the blade shrouds wentacross each other (this is called "shingling"). If it is apparent that the blade shrouds are in thiscondition (or were in this condition and are now separated), the maintenance actions specifiedin this paragraph will be necessary.

(a) "Shingling" is a condition is which adjacent blade shrouds move under or above eachother. This condition will be apparent during borescope inspection if one or more bladeshrouds are seen to be very much higher or lower than adjacent shrouds, and a blade isseen to be pushed to the rear as shown in Figure 683.

NOTE: If there is a wide clearance between blade shrouds, (caused by loose blades inthe rotor), this condition is not automatically shingling by the definition given.Shingling marks are shiny, polished, or worn areas on the inner side of bladeouter shrouds. These marks show that the blades were shingled at one time butare now separated at the time of borescope inspection.

(b) If shingled blades (or blades whose marks show that they were shingled at one time) arefound in an engine, these procedures will be necessary:

1) Do a borescope inspection on the other engine of the aircraft to look for the samecondition of the 3rd stage turbine blades.

2) If the other engine is found to have shingled 3rd stage blades (or shingling marks onthe blades), replace one of the engines in 50 cycles or less (it is recommended thatthe engine with the highest number of shingled blades be the one to replace).

3) The remaining engine (if it has shingled blades or blades which have shinglingmarks) can stay in service for a maximum of 125 cycles after the shingled blades(or blades with shingling marks) are found.

4) Send a report to Pratt & Whitney/Customer Technical Support and MTU (Motorenand Turbinen Union) with the engine serial number, hours on the low pressureturbine, and number of shingled blades found. The operator will then get a finalservice limit for the engine which has the shingling condition, calculated for theoperator's mission profile and Take-Off rating.

(c) No cracks are permitted on shingled blades, on blades which have shingling marks, or onblades in the rotor which do not have the shingling condition.

(d) If shingling was found in a 3rd stage turbine rotor which has blades with cracks (possiblycaused by sulfidation), or if cracks occur in a rotor which operated with shingled blades, itwill be necessary to remove this engine after one ferry/flyback flight cycle.

DHI 201-206 PRE SB PW2000-72-0372

SUBTASK 72-00-00-410-008-P00







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(c) Put the adjusting plate(s) (as necessary) over the blanking plug.


(e) Apply anti-seize paste, D50124 [P06-054]to the threads of the bolts.



DHI 201-206 POST SB PW2000-72-0372

SUBTASK 72-00-00-410-009-P00



(a) Clean the threaded areas of the two bolts that attach the blanking plug to the borescopeport and the holes where the bolts install as follows:










1) Apply the anti-seize paste, D50124 [P06-054]to the threads of the two bolts thatattach the blanking plug to the borescope port.




DHI 201-206


SUBTASK 72-00-00-080-001-P00




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FOR REFERENCE ONLY

SUBTASK 72-00-00-410-010-P00


(a) Install a new packing, lubricated with engine oil, in the groove of the crank pad cover.




SUBTASK 72-00-00-410-011-P00

WARNING

OBEY THE INSTRUCTIONS IN THE PROCEDURE TO CLOSE THE THRUSTREVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TOPERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.


SUBTASK 72-00-00-410-012-P00


SUBTASK 72-00-00-440-002-P00


SUBTASK 72-00-00-410-013-P00


SUBTASK 72-00-00-790-001-P00


LPT 3rd-Stage Vane Inspection For Corrosion

END OF TASK



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FOR REFERENCE ONLY

L96966 (0295)

INNER SHROUD

OUTER SHROUD AREA

(2.5 MILLIMETERS)

0.100 INCH

(3.0 MILLIMETER)

0.120 INCH

AREA A

AREA C

AREA B

INNER SHROUD AREA

(3.0 MILLIMETER)

0.120 INCH

EDGE

LEADING

AIRFOIL FACE

LEADING EDGE AREA

(3.0 MILLIMETER)

0.120 INCH

TRAILING EDGE AREA

TRAILING EDGE

OUTER SHROUD

117494 S00061276058_V1

LPT 3rd-Stage Blade Inspection LimitsFigure 681/72-00-00-990-916-P00



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FOR REFERENCE ONLY

4

3

2

1

A-A

L-96377

1086

L-93604

THE AFT EDGE OF THE AIRSEAL TOUCHES THE 3RD-STAGE ROTOR FINGER DAMPER

THE LEADING EDGE OF THE 3RD-STAGE BLADE PLATFORM TOUCHES THE

SHOULDER OF THE INNER SIDE OF THE 3RD-STAGE VANE INNER PLATFORM

TOUCHES THE LEADING EDGE OF THE 3RD-STAGE BLADE PLATFORM

AT THE FILLET RADIUS

THE TRAILING EDGE OF THE 3RD-STAGE VANE INNER PLATFORM

THE 3RD-STAGE ROTOR TIEBOLT NUT TOUCHES THE CORNER OF THE AIRSEAL

FLANGE N

ASEE

AP-11 PORT

AA

A

1

2

3

4

LPT 3RD-STAGE

TURBINE BLADE

LPT 3RD-STAGE

TURBINE VANE

AP-11 PORT

214921 S00061276059_V1

LPT 3rd-Stage Vane and Blade InspectionFigure 682/72-00-00-990-917-P00



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FOR REFERENCE ONLY

BLADE TRAILING EDGE

BLADE SHROUD

MOVEMENT DISTANCE

SHINGLED SHROUD SURFACE

BORESCOPE VIEW OF SHINGLED BLADE

BORESCOPE VIEW OF SEPERATED BLADES

(WITH SHINGLING MARKS)

SHINGLED MARKS

L-97944 (0000)G34233 S00061276060_V1

LPT 3rd -Stage Blade Borescope Inspection for ShinglingFigure 683/72-00-00-990-918-P00



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FOR REFERENCE ONLY

TASK 72-00-00-296-453-P00

23. LPT 3rd-Stage Vane Inspection for Corrosion

A. References

Reference Title





B. Tools/Equipment













NASM20995

D. Location Zones

Zone Area



E. Prepare to Examine the LPT 3rd-Stage Vanes.

SUBTASK 72-00-00-480-008-P00

WARNING





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FOR REFERENCE ONLY

(a) The equipment that follows from Olympus Corp. (IFD 4 Nevada Drive, Lake Success, NY11042) obeys with the requirements of specification CTE 7181. You can get theequivalent equipment from American Cystoscope Makers Inc. (Industrial Division, 300Stillwater Ave., Stamford, CT 06902) or Richard Wolf Medical Instruments Corp. (7046Lydon Ave., Rosemont, IL 60018).


SUBTASK 72-00-00-016-454-P00


SUBTASK 72-00-00-046-455-P00

WARNING

DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENTTHE OPERATION OF THE THRUST REVERSERS. THE ACCIDENTALOPERATION OF THE THRUST REVERSERS CAN CAUSE INJURIES TOPERSONS OR DAMAGE TO EQUIPMENT.


SUBTASK 72-00-00-016-456-P00


SUBTASK 72-00-00-016-457-P00

WARNING



F. Do the Inspection of the 3rd-Stage Vanes for Corrosion.

DHI 201-206 PRE SB PW2000-72-0372

SUBTASK 72-00-00-036-458-P00

(1) Do these steps to remove the blanking plug from the borescope port at the location AP-11:

(a) Remove the bolts which hold the plug in the borescope port (Figure 676).

(b) Remove the adjusting plate(s) for the blanking plug and the flanged sleeve bushing fromthe borescope port.

NOTE: Keep the adjusting plate(s) with the blanking plug to make sure they are in thecorrect position during the installation.

DHI 201-206 POST SB PW2000-72-0372

SUBTASK 72-00-00-036-459-P00

(2) Do these steps to remove the blanking plug from the borescope port at the location AP-11(Figure 676):

(a) Remove the lockwire and the bolts that attach the blanking plug to the borescope port.

(b) Remove the bolts and the blanking plug from the borescope port.

(c) Remove the two screws that attach the retaining plate to the borescope port.



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FOR REFERENCE ONLY


(d) Remove the retaining plate, the spacer plate, and the sleeve bushing from the borescopeport.

NOTE: Keep the retaining and the spacer plates with the blanking plug to make surethey are in the correct position during the installation.

DHI 201-206

SUBTASK 72-00-00-296-460-P00

(3) Install the borescope through the borescope port, AP-11, and examine the LPT 3rd-stagevanes for an external indication of corrosion.

(a) During the inspection, make a record of the conditions that follow:

NOTE: There are 38 vane clusters, each with 3 airfoils, on an engine. Thus, there is atotal of 114 LPT 3rd-stage vanes on each engine.

The LPT 3rd-stage vanes have a radial length of approximately 3.0 inches (76.20mm). Thus, 1.0 inch (25.40 mm) is approximately 1/3 the radial length, and 1.50inch (38.10 mm) is approximately 1/2 the radial length of the vanes.

1) The number of vanes with cracks

2) The maximum length of a radial crack

3) The number and length of all cracks that are not radial cracks

4) All the vanes with wall material that is gone or lifted because of cracks.

(b) Use the record from the step above and the table below to find the condition of theengine and limits for subsequent borescope inspections.

GROUP CONDITIONMAXIMUM LIMIT FOR SUBSEQUENT BORESCOPE

INSPECTION

I No indications No inspections are necessary

II 1-36 Airfoils which show radial cracks withmaximum lengths of 1.0 inch (25.400 mm)

700 hours of engine operation or 350 cycles

For radial cracks with lengths more than1.0 inch (25.400 mm), or on more than 36airfoils, continue to Group III.

III 37-57 Airfoils which show radial crackswith maximum lengths of 1.50 inch(38.100 mm)

120 hours of engine operation or 60 cycles

For radial cracks with lengths more than1.50 inch (38.100 mm), or on more than57 airfoils, continue to Group IV.

IV 58 or more airfoils which show radialcracks with maximum lengths of 1.50 inch(38.100 mm)

OR

Any number of airfoils which show radialcracks with lengths more than 1.50 inch(38.100 mm).

Engine removal is necessary in 2 cycles

V One or more airfoils with a crack otherthan a radial crack of any length.




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FOR REFERENCE ONLY

(Continued)

GROUP CONDITIONMAXIMUM LIMIT FOR SUBSEQUENT BORESCOPE

INSPECTION

VI One or more airfoils with material that isgone or lifted because of cracks.


DHI 201-206 PRE SB PW2000-72-0372

SUBTASK 72-00-00-436-461-P00

(4) Do these steps to install the blanking plug in the borescope port at the location AP-11:







(c) Put the adjusting plate(s) over the blanking plug as necessary.


(e) Apply the anti-seize paste, D50124 [P06-054] to the threads of the bolts.



DHI 201-206 POST SB PW2000-72-0372

SUBTASK 72-00-00-436-462-P00

(5) Do these steps to install the blanking plug in the borescope port at the location AP-11:

NOTE: If the blanking plug is replaced, the quantity of necessary spacer plates is unknown, oran inspection of the blanking plug is necessary, do the depth check of the plug(PAGEBLOCK 72-53-92/401).








(e) Install the two screws, lubricated with the oil, D00137 [P03-001], to attach the retainingplate to the borescope port.



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FOR REFERENCE ONLY




1) Apply the anti-seize paste, D50124 [P06-054] to the threads of the two bolts thatattach the blanking plug to the borescope port.

2) Install the two bolts to attach the blanking plug.



DHI 201-206

G. Put the Airplane Back to its Usual Condition.

SUBTASK 72-00-00-416-463-P00

WARNING



SUBTASK 72-00-00-416-464-P00


SUBTASK 72-00-00-446-465-P00

(3) Do the activation procedure for the thrust reversers (PAGEBLOCK 78-31-00/201 Config 3).

SUBTASK 72-00-00-416-466-P00


END OF TASK

DHI 201-206 PRE SB PW2000-72-0278

TASK 72-00-00-296-467-P00

24. LPT Inner Inter Turbine Duct Assembly Inspection

NOTE: This procedure is for This procedure is for PN 8A1360 and A8A1312 turbine ducts only.

NOTE: This procedure is for PN 8A1360 and A8A1312 turbine ducts only. This inspection is notnecessary for engines POST-PW-SB 72-278.

A. References

Reference Title







72-00-00

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FOR REFERENCE ONLY


B. Tools/Equipment











NASM20995

D. Location Zones

Zone Area



E. Prepare to Do the LPT Inner Inter Turbine Duct Assembly Inspection

SUBTASK 72-00-00-480-009-P00

WARNING



(a) The borescopes are available with rigid and flexible probes and have different workinglengths and fields of vision.

(b) The equipment that follows from Olympus Corp. (IFD 4 Nevada Drive, Lake Success, NY11042) obeys with the requirements of specification CTE 7181. You can get theequivalent equipment from American Cystoscope Makers Inc. (Industrial Division, 300Stillwater Ave., Stamford, CT 06902) or Richard Wolf Medical Instruments Corp. (7046Lydon Ave., Rosemont, IL 60018).


SUBTASK 72-00-00-016-468-P00




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SUBTASK 72-00-00-046-469-P00

WARNING



SUBTASK 72-00-00-016-470-P00


SUBTASK 72-00-00-016-471-P00

WARNING



F. Do the LPT Inner Inter Turbine Duct Assembly Inspection

(Figure 684)


SUBTASK 72-00-00-036-472-P00


(a) Remove the bolts that attach the plug to the borescope port at the location AP-11.

(b) Remove the plug, adjusting plate(s) and sleeve bushing from the port.

NOTE: Keep the adjusting plate(s) with the plug to make sure of the correct positionduring the installation.

DHI 201-206 POST SB PW2000-72-0372 AND PRE SB PW2000-72-0278

SUBTASK 72-00-00-036-473-P00


(a) Remove the lockwire and the bolts that attach the blanking plug to the borescope port atthe location AP-11.

(b) Remove the bolts and the blanking plug from the borescope port.

(c) Remove the two screws that attach the retaining plate to the borescope port.

(d) Remove the retaining plate, the spacer plate, and the sleeve bushing from the borescopeport.

DHI 201-206 PRE SB PW2000-72-0278

SUBTASK 72-00-00-216-474-P00

(3) Examine the plug for damage.

(a) If necessary, repair the plug with the bends as follows:

1) Make the bent plug straight, as necessary, without the use of heat.



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2) Do a fluorescent penetrant inspection of the plug (PAGEBLOCK 70-11-06/201).

SUBTASK 72-00-00-486-475-P00

(4) Do the steps that follow to install the flexible borescope.

(a) Put the PWA 81755 Guide Tube into the port boss at the location AP-11.

(b) Turn, as necessary, to put the tip of the borescope near the turbine duct.

(c) Put the 6 mm diameter flexible borescope into the PWA 81755 Guide Tube.

SUBTASK 72-00-00-296-476-P00

(5) Examine the full circumference of the turbine duct for cracks, specially the leading edge.

(a) See the table that follows for the crack limits.

NOTE: The turbine duct is approximately 3.5 inches (88.90 mm) in length the axialdirection. 1.750 inches (44.450 mm) is approximately half the length of the visibleduct.

LPT Inner Inter Turbine Duct Assembly - Crack Limits

Crack Length Inspection Cycles

No Cracks 500

Same as or less than 0.500 inch (12.700 mm) 250

More than 0.500 inch (12.700 mm) but thesame as or less than 1.750 inches (44.450mm)

50

More than 1.750 inches (44.450 mm) Remove the Engine Immediately

SUBTASK 72-00-00-086-477-P00

(6) Remove the borescope and the PWA 81755 Guide Tube.


SUBTASK 72-00-00-436-478-P00






(b) Install the sleeve bushing into the borescope boss.

(c) Put the adjusting plate(s), as necessary, over the plug.

(d) Install the plug into the borescope boss.

(e) Lubricate the threads of the bolts with anti-seize paste, D50124 [P06-054].

(f) Attach the plug with the bolts.




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DHI 201-206 POST SB PW2000-72-0372 AND PRE SB PW2000-72-0278

SUBTASK 72-00-00-436-479-P00












1) Apply the anti-seize paste, D50124 [P06-054] to the threads of the two bolts thatattach the blanking plug to the borescope port.




DHI 201-206 PRE SB PW2000-72-0278


SUBTASK 72-00-00-016-480-P00

WARNING



SUBTASK 72-00-00-016-481-P00


SUBTASK 72-00-00-046-482-P00


SUBTASK 72-00-00-016-483-P00


END OF TASK



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INNER-INTER-TURBINE-DUCT ASSEMBLY

AP-11

GUIDE TUBE

BORESCOPE AND PWA 81755

FLANGE N

L-95855

LPT 3RD-STAGE

VANE

HPT 2ND-STAGE

DUCT SEGMENT

HPT 2ND-STAGE

BLADE

707702 S00061276065_V1

LPT Inner-Inter-Turbine-Duct Assembly InspectionFigure 684/72-00-00-990-906-P00



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DHI 201-206

TASK 72-00-00-726-711-P00

25. Towershaft Bumper Bearing Housing Borescope Inspection

A. General

(1) The data that follows is used during the borescope inspection of the towershaft bumperbearing housing. Procedure A, B, or C can be used optionally depending on the chosen accessport and the available borescope (rigid or flexible).

B. References

Reference Title


73-21-06 P/B 401 EEC N1 SPEED TRANSDUCER - REMOVAL/INSTALLATION


C. Tools/Equipment





D. Consumable Materials



E. Prepare to Do the Towershaft Bumper Bearing Housing Inspection

SUBTASK 72-00-00-480-010-P00

WARNING









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FOR REFERENCE ONLY









SUBTASK 72-00-00-016-717-P00


SUBTASK 72-00-00-046-718-P00

WARNING



F. Procedure A - Borescope Access through the Fan Air Manifold Inlet Ports.

SUBTASK 72-00-00-296-712-P00

(1) Insert a flexible borescope into the fan air manifold inlet ports at the 4:30 and 7:30 o'clockpositions on the fan exit case (Figure 685).

NOTE: The ports are between the large fan exit struts, aft of the 2.5 bleed exit ports. Note thedifference in the port size and the location depending on the fan case configuration.

SUBTASK 72-00-00-296-713-P00

(2) Inspect the housing and the retaining bolts for these conditions:

(a) Make sure all three bolts are in place and have not backed off.

(b) Look for cracks on the housing on or near the housing mount ears.

(c) Look for missing bolt heads (Figure 686).

NOTE: There are three retaining bolts. Two of the bolts can be seen from the left side ofthe engine and will appear to be at the end of the housing. The bolt seen from theright side will appear to be in the middle of the housing.

SUBTASK 72-00-00-366-730-P00

(3) If abnormal conditions are found, the conditions must be corrected.

G. Procedure B - Borescope Access through the Boltholes in the Intermediate Case Fan AirManifold Cover.

NOTE: A 6 mm or smaller flexible borescope, preferably a 4 mm borescope, is required to gainaccess through the boltholes.



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FOR REFERENCE ONLY

SUBTASK 72-00-00-026-715-P00

(1) Remove the left and the right bolt from the top row of three bolts which secure the intermediatecase fan air manifold cover to the intermediate case.

NOTE: The cover is located on the rear of the intermediate case at the 6 o'clock location,adjacent to the 14th stage bleed converter valve (Figure 687).

SUBTASK 72-00-00-296-716-P00

(2) Insert a flexible borescope through one of the accessible boltholes to inspect the condition ofthe housing and the three retaining bolts.

(a) One retaining bolt is visible through the right side bolthole.

1) This retaining bolt is located 4.5 inches (114.3 mm) forward of the cover.

(b) Two retaining bolts are visible through the left side bolthole.

1) One bolt is located 2.0 inches (50.8 mm) forward of the cover and slightly to theright.

2) The second of the two bolts is located 6.5 inches (165.1 mm) forward of the cover.

SUBTASK 72-00-00-296-722-P00


(a) Make sure all three bolts are in place and have not backed off.

(b) Look for cracks in the housing on or near the housing mount ears.

(c) Look for missing bolt heads.

SUBTASK 72-00-00-366-731-P00

(4) If abnormal conditions are found, the condition must be corrected.

SUBTASK 72-00-00-306-724-P00

(5) Replace the bolts which were removed to gain access for the inspection.

(a) Apply anti-seize paste, D50124 [P06-054] to the bolt threads per SPOP 146.

1) Wipe off excess paste.

(b) Torque the bolts to 62 - 72 pound-inches (7.007 - 8.135 newton-meters).

H. Procedure C - Borescope Access through the EEC Speed Transducer (N1) Mounting Port.

NOTE: Use this procedure if only a rigid borescope is available. However, a flexible borescope ispreferred to better view the housing retaining bolts.

SUBTASK 72-00-00-026-725-P00

(1) Remove the EEC speed transducer (N1) (PAGEBLOCK 73-21-06/401).

NOTE: The transducer is located on the rear of the intermediate case at the 5 o'clock position(Figure 688).

SUBTASK 72-00-00-296-726-P00

(2) Insert the borescope into the cavity created by the removal of the EEC speed transducer.

NOTE: Only one retaining bolt can be seen if a rigid borescope is used. A flexible borescopewill provide better visibility.

SUBTASK 72-00-00-296-727-P00


(a) Make sure all visible bolts are in place and have not backed off.

(b) Look for cracks in the housing on or near the housing mount ears.

(c) Look for missing bolt heads.



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FOR REFERENCE ONLY

SUBTASK 72-00-00-366-732-P00

(4) If abnormal conditions are found, the condition must be corrected.

SUBTASK 72-00-00-426-729-P00

(5) Install the EEC speed transducer (PAGEBLOCK 73-21-06/401).

I. Put the airplane back to its initial condition.

SUBTASK 72-00-00-046-720-P00


SUBTASK 72-00-00-016-721-P00


END OF TASK



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FOR REFERENCE ONLY

2

1

2

1

ASEE

A

A

L-98436 (0998)

FAN EXIT

GUIDE

VANES

INSERT BORESCOPE

IN THIS PORT

INSERT BORESCOPE

IN THIS PORT

2.5 BLEED PORT

2.5 BLEED PORT

TITANIUM

STRUT

TITANIUM

STRUT

COMPOSITE

STRUT

FAN CASE CONFIGURATION POST-PW-SB 72-143 (POST-PIP)

FAN CASE CONFIGURATION PRE-PW-SB 72-143 (PRE-PIP)

H90586 S00061276067_V1

Borescope Access Through the Fan Air Manifold Inlet PortsFigure 685/72-00-00-990-907-P00



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ASEE

A

(3 LOCATIONS)

BOLT AND WASHERMOUNT LOCATION)

(TYPICAL FOR ANY

CRACK LOCATION

HOUSING

BUMPER BEARING

LOCATING PIN HOLE

POSITION

LOCATED AT THIS

EAR AND BLOT

RIGHT SIDE HOUSING

FROM THE REAR

THIS FLANGE IS VISIBLE

ON AN ASSEMBLED ENGINE

CASE

INTERMEDIATE

THIS FLANGE IS NOT VISIBLE

ON AN ASSEMBLED ENGINE

FWD

L-98437

(0998)H90592 S00061276068_V1

Towershaft Bumper Bearing Housing InspectionFigure 686/72-00-00-990-908-P00



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FOR REFERENCE ONLY

B

SEE B

A

ASEE

FAN AIR MANIFOLD COVER

THE HOUSING

FOR BRESCOPE ACCESS TO

REMOVE THESE COVER BOLTS

CASE

INTERMEDIATE

L-98438 (0998)H90593 S00061276069_V1

Borescope Access through the Boltholes in the Intermediate Case Fan Air Manifold CoverFigure 687/72-00-00-990-909-P00



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FOR REFERENCE ONLY

FWD

(POST-PW-SB 73-72)

BRACKET

BRACKET

BOLTBOLT

(N1)

TRANSDUCER

EEC SPEED

PACKING

L-98439 (0998)

H90595 S00061276070_V1

Borescope Access Through the EEC Speed Transducer (N1) Mounting PortFigure 688/72-00-00-990-910-P00



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Documents

Altitude Globalcbt.altitudeglobal.aero/Files/B757 PW Borescope.pdf · 2020. 3. 3. · FOR REFERENCE ONLY Introduction Borescope . inspection is an important practice on any aircraft