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737 Bleed Air Test Guide PDF
737 Bleed Air Test Guide PDF
1. Precooler System----Precooler, precooler valve, precooler sensor, wing thermal anti-ice solenoid
(WTAI). Controls the bleed delivery temperature to 390 degrees by varying the amount of air
blowing through the precooler from the fan duct.
2. PRSOV System----PRSOV (pressure regulating and shutoff valve), bleed air regulator (remote mount
regulator), 450
degree overtemp sensor, and 490 degree overtemp switch. Functions to shut engine
bleed air on and off. Also regulates bleed delivery pressure to 40 to 50 PSI through modulation of
the PRSOV. Provides bleed air overtemp protection.
3. High Stage System----High stage valve, high stage regulator. Augments bleed pressure from the 9th
stage to provide adequate flow at low power settings.
NOTE: For normal operation the following duct pressures will be observed on a correctly functioning system.
TAKEOFF & CLIMB 42-52 PSI
CRUISE 35-40 PSI
IDLE & DESCENT 15-20 PSI
NOTE: When you remove lines from the engine components for test purposes be sure to use anti-seize
compound on the treads when re-connecting. These lines are known to gall and lock up tight.
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A. BLEED TRIP AT TAKEOFF POWER – bleed parameters otherwise normal
CAUSE – excessive pressure sensed in engine ducting upstream of PRSOV causing bleed air regulator over
pressure switch to trip bleed off.
PRIMARY SUSPECTS – high stage valve, high stage regulator, bleed air regulator.
B. BLEED TRIP AT CLIMB, CRUISE, OR DESCENT – bleed pressure low prior to trip or
unknown.
CAUSE – excessive duct temperature being sensed by 490 degree overtemp switch.
SECONDARY SUSPECTS – 450 degree sensor, high stage valve, high stage regulator, PRSOV, bleed air
regulator.
C. HIGH DUCT PRESSURE AT HIGH POWER SETTINGS – (climb, cruise, & takeoff)
CAUSE – PRSOV restricting bleed air to downstream system because bleed air is to hot. Excessive bleed temp
is caused by insufficient fan air through precooler. Low duct pressure can also be caused buy insufficient
regulated pressure from bleed air regulator to PRSOV.
PRIMARY SUSPECTS – precooler valve, precooler sensor, 450 degree sensor, bleed air regulator, PRSOV.
E. LOW DUCT PRESSURE AT LOW POWER SETTING – high power settings duct pressure is
normal.
CAUSE – high stage valve not open far enough, or PRSOV not regulating properly.
CAUSE – PRSOV is stuck or valve is failing to get a proper control signal from bleed air regulator.
CAUSE – PRSOV hunting due to internal binding or erratic control signal from bleed air regulator.
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PRECOOLER SYSTEM TEST
Note: With the engine shut down and the APU bleed valve in the “OFF” position the precooler control valve
should be spring loaded to the “OPEN” position. If it is not fully open, replace the valve.
INDICATOR
SENSE LINE
SUPPLY LINE
SENSOR PORT
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PRECOOLER SYSTEM TEST
1. Manually wrench the precooler control valve position indicator through full range of motion in both directions. If
valve does not operate smoothly, replace the precooler control valve.
2. Disconnect supply line from precooler control valve supply pressure port located on L/H side of engine.
3. Connect test hose between the precooler control valve supply pressure port and regulator Ps of the test box.
4. With 130 PSI supplied to test box, slowly increase pressure at regulator Ps while observing valve position
indicator. Precooler valve should be within 30 degrees of full closed when regulator Ps pressure gauge reaches
12 PSI.
a. If valve is not within 30 degrees of full closed, disconnect sense line from R/H side of
precooler control valve and plug the precooler sensor port on the valve.
b. Repeat above steps. If the valve still does not close, replace the precooler control valve. If valve
closes, there is a leak in the sense line, WTAI solenoid valve, or the precooler sensor.
6. Disconnect the sense line from the precooler control valve sensor port located on R/H side of the valve.
7. Connect test hose between the sensor port on the precooler control valve and gauge Pc of the test box.
9. Slowly increase pressure at regulator Ps to 55 PSI (+/-5 PSI). Pressure on gauge Pc should stabilize between 6 &
13 PSI. Precooler control valve should move to within 30 degrees of full closed.
10. Slowly open regulator (Bleeder Valve) Pc on the test box. Precooler control valve must begin to open when
pressure on gauge Pc reaches a minimum of 7 PSI. Precooler control valve must be full open when gauge Pc
reaches 3 PSI.
Note: If the valve does not open as outlined it can cause the bleed air temp to be excessively high which
will cause the 450 degree sensor to modulate the PRSOV towards the closed position.
11. If the valve does not open as outlined in step #10, replace the precooler control valve.
6
PRSOV SYSTEM TEST
Note: With engine shut down and APU bleed valve in “OFF” position the PRSOV should be spring loaded to the
“CLOSED” position. If it is not fully closed, replace the valve.
Turn on aircraft power and assure bleed switch for test engine is “ON”.
450 Degree
Sensor
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PRSOV SYSTEM TEST
It is normal for a small amount of air to come out of the “T” fitting.
a. Pressurize pneumatic ducting to the engine using either APU or ground cart.
b. Disconnect both bleed air regulator control line and 450 degree sense line from “T” fitting located on the
R/H side of the PRSOV. If large amount of air (jet blast) is coming from the “T” fitting, replace the
PRSOV.
With the engine shut down the high stage valve is spring loaded to the “CLOSED” position. If it is not
closed, replace the valve.
INDICATOR
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HIGH STAGE SYSTEM TEST
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AIRCRAFTS WITHOUT REVERSE FLOWPROTECTION
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AIRCRAFTS WITHOUT REVERSE FLOW PROTECTION AIRCRAFTS WITH REVERSE FLOW PROTECTION
PRE-SB 36-1016
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FOR INFORMATION ONLY. UNCONTROLED DATA. ALWAYS USE YOUR OFFICIAL MANUALS.
1. Precooler System----Precooler, precooler valve, precooler sensor, wing thermal anti-ice solenoid
(WTAI). Controls the bleed delivery temperature to 390 degrees by varying the amount of air
blowing through the precooler from the fan duct.
2. PRSOV System----PRSOV (pressure regulating and shutoff valve), bleed air regulator (remote mount
regulator), 450
degree overtemp sensor, and 490 degree overtemp switch. Functions to shut engine
bleed air on and off. Also regulates bleed delivery pressure to 40 to 50 PSI through modulation of
the PRSOV. Provides bleed air overtemp protection.
3. High Stage System----High stage valve, high stage regulator. Augments bleed pressure from the 9th
stage to provide adequate flow at low power settings.
NOTE: For normal operation the following duct pressures will be observed on a correctly functioning system.
TAKEOFF & CLIMB 42-52 PSI
CRUISE 35-40 PSI
IDLE & DESCENT 15-20 PSI
NOTE: When you remove lines from the engine components for test purposes be sure to use anti-seize
compound on the treads when re-connecting. These lines are known to gall and lock up tight.
2
A. BLEED TRIP AT TAKEOFF POWER – bleed parameters otherwise normal
CAUSE – excessive pressure sensed in engine ducting upstream of PRSOV causing bleed air regulator over
pressure switch to trip bleed off.
PRIMARY SUSPECTS – high stage valve, high stage regulator, bleed air regulator.
B. BLEED TRIP AT CLIMB, CRUISE, OR DESCENT – bleed pressure low prior to trip or
unknown.
CAUSE – excessive duct temperature being sensed by 490 degree overtemp switch.
SECONDARY SUSPECTS – 450 degree sensor, high stage valve, high stage regulator, PRSOV, bleed air
regulator.
C. HIGH DUCT PRESSURE AT HIGH POWER SETTINGS – (climb, cruise, & takeoff)
CAUSE – PRSOV restricting bleed air to downstream system because bleed air is to hot. Excessive bleed temp
is caused by insufficient fan air through precooler. Low duct pressure can also be caused buy insufficient
regulated pressure from bleed air regulator to PRSOV.
PRIMARY SUSPECTS – precooler valve, precooler sensor, 450 degree sensor, bleed air regulator, PRSOV.
E. LOW DUCT PRESSURE AT LOW POWER SETTING – high power settings duct pressure is
normal.
CAUSE – high stage valve not open far enough, or PRSOV not regulating properly.
CAUSE – PRSOV is stuck or valve is failing to get a proper control signal from bleed air regulator.
CAUSE – PRSOV hunting due to internal binding or erratic control signal from bleed air regulator.
3
WTAI
Solenoid
Valve
(WTAI)
To Precooler Control
Valve Sensor
4
PRECOOLER SYSTEM TEST
Note: With the engine shut down and the APU bleed valve in the “OFF” position, the precooler control valve
should be spring loaded to the “OPEN” position. If it is not fully open, replace the valve.
WTAI SOLENOID
VALVE
5
PRECOOLER SYSTEM TEST
1. Manually wrench the precooler control valve position indicator through full range of motion in both directions. If
valve does not operate smoothly, replace the precooler control valve.
2. Disconnect supply line from precooler control valve supply pressure port located on L/H side of engine.
3. Connect test hose between the precooler control valve supply pressure port and regulator Ps of the test box.
4. With 130 PSI supplied to test box, slowly increase pressure at regulator Ps while observing valve position
indicator. Precooler control valve should be within 30 degrees of full closed when regulator Ps pressure gauge
reaches 14 PSI.
a. If valve is not within 30 degrees of full closed, disconnect control line from R/H side of
precooler control valve and plug the precooler control pressure port on the valve.
b. Repeat above steps. If the valve still does not close, replace the precooler control valve. If valve
closes, there is a leak in the control line, WTAI solenoid valve, or the precooler sensor.
6. Disconnect the control line from the precooler control valve control pressure port located on R/H side of the
valve.
7. Connect test hose between the control pressure port on the precooler control valve and gauge Pc of the test box.
9. Slowly increase pressure at regulator Ps to 55 PSI (+/-5 PSI). Pressure on gauge Pc should stabilize at 9 PSI (+/-3
PSI). Precooler control valve should move to within 30 degrees of full closed.
10. Slowly open regulator (Bleeder Valve) Pc on the test box. Precooler control valve must begin to open when
pressure on gauge Pc reaches a minimum of 7 PSI. Precooler control valve must be full open when gauge Pc
reaches 3 PSI.
Note: If the valve does not open as outlined it can cause the bleed air temp to be excessively high which
will cause the 450 degree sensor to modulate the PRSOV towards the closed position.
11. If the valve does not open as outlined in step #10, replace the precooler control valve.
6
PRSOV SYSTEM TEST
Note: With engine shut down and APU bleed valve in “OFF” position, the PRSOV should be spring loaded to the
“CLOSED” position. If it is not fully closed, replace the valve.
Turn on aircraft power and assure bleed switch for test engine is “ON”.
7
PRSOV SYSTEM TEST
1. Bleed Air Regulator Test:
Note: Leakage from the bleed air regulator honest orifices is not abnormal.
a. Disconnect both supply and control lines from the bleed air regulator pressure ports.
b. Connect test hose between the bleed air regulator supply pressure port and regulator Ps of the test box.
c. Connect test hose between the bleed air regulator control pressure port and gauge Pc of the test box.
d. Make sure regulator(Bleeder Valve) Pc is fully closed.
e. With 130 PSI supplied to test box, slowly increase pressure on regulator Ps to 65 PSI (+/-5 PSI). The
control pressure on gauge Pc should stabilize at 24 PSI (+/- 4PSI).
f. Continue to increase supply pressure on regulator Ps to 120 PSI, control pressure should remain at 24 PSI
(+/-4 PSI). If control pressure is significantly higher or lower than 24 PSI, replace the bleed air regulator.
g. Reduce regulator Ps pressure to zero and open regulator (Bleeder Valve) Pc.
h. Disconnect test hose from bleed air regulator control pressure port and reconnect control line to the
bleed air regulator pressure port.
It is normal for a small amount of air to come out of the PRSOV control pressure fitting.
a. Pressurize pneumatic ducting to the engine using either the APU or ground cart.
b. Disconnect control pressure sense line from the PRSOV. If large amount of air (jet blast) is coming
from the PRSOV, replace the PRSOV.
8
HIGH STAGE SYSTEM TEST
Note: This test will verify control function of the high stage system only. It will not test leakage past the butterfly
in the valve. This is common cause for over pressure bleed trips at takeoff power settings.
With the engine shut down the high stage valve is spring loaded to the “CLOSED” position. If it is not
closed, replace the valve.
9
HIGH STAGE SYSTEM TEST
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