CFM56-7RI2003

Page 1EFFECTIVITY 737-600/700/800/900/BBJ/C40A&B CFM PROPRIETARY INFORMATION 71-00-00Jan. 2003

CFM56-7B TRAINING MANUAL

ENGINE REMOVAL AND INSTALLATION TRAINING COURSE

Document: GEK 112143

Revised: Jan. 2003



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CFM Proprietary InformationThe information contained in this document is CFM Proprietary Information and is disclosed in confidence. It is the property of CFM and shall not be used,disclosed to others, or reproduced without the express written consent of CFM International. If consent is given for reproduction in whole or in part, this notice and the notice setforth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled bythe U.S. export control laws. Unauthorized export or re-export is prohibited.

The Power Of Flight

CFM56-7B Removal & Installation Training Course

Document: GEK 112143Revised: Jan. 2003



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Table of Contents

Engine Nacelle………………………………………………………………………………….. Page 08

Engine Transportation Stand ……………………………………………………………….. Page 10

Fan Cowling …………………………………………………………………………………… Page 16

Engine Quick Disconnects ………………………………………………………………….. Page 18

Engine Support Tooling ……………………………………………………………………… Page 28

Engine Mounts ………………………………………………………………………………... Page 46

Thrust Reverser Hold Open Tooling ………………………………………………………. Page 52

Bootstrap Tooling …………………………………………………………………………….. Page 62



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ENGINE NACELLE

General DescriptionThe CFM56-7 engine fan cowling and thrust reverser segments are hinged to the strut. To remove orinstall an engine, the fan cowls need to be removed to provide access to the forward engine groundhandling points. The fan cowls are held in the open position by integral hold-open rods for enginemaintenance when the engine is installed on the strut. The forward fairing will need to be removed togain access to GSE bootstrap interface points. The forward fairing is held in place by 7 quick releaselatches allowing easy access to GSE hard points for the bootstrap system. The thrust reverser is madein two halves ("C"-Ducts) which are raised open with integral actuators by a hydraulic pump which mustbe purchased as Ground Support Equipment (GSE). Once the "C"-Ducts are open, an automatic lockin the actuators holds each "C"-Duct open. GSE actuator locks provide a backup for the locks in theactuators. When removing an engine, the actuators are disconnected and GSE thrust reverser cowlhold-open rods are the only means of holding the "C"-Ducts open.

With the thrust reverser halves held open, engine removal and installation is accomplished using a"bootstrap" hoisting system.



ENGINE NACELLE

ALF

Thrust Reverser LH(C-Duct)

Thrust Reverser RH(C-Duct)

Engine Strut



ENGINE TRANSPORTATION STAND

Purpose (2.B.b)The purpose of the engine stand, cradle or dolly is to support the engine during transportation to airport apron and shop. It may also be used for air or highway transportation with approval of CFMI. When using the stand for transportation, the two fan attach points and the aft right hand turbine attach point are required for support of the engine.

Equipment AM2563 Base Universal Transportation Cradlefor the CFM56-7 Engine

Additional Support EquipmentNote: Refer to GSE manual for more informationC78020 Equipment - Hold Open, Thrust Reverser Cowl, C71020 Kit - Bootstrap, CFM56-7 EngineC78005 Pump - Portable Hand, Thrust Reverser Cowl C71022 Torque Wrench Equipment - CFM56-7 Engine BoltsC71040 Inlet cowl sling




Engine Stand

LH Fan Support




Training Information Points (3.E.c)A series of Tie-down rings offer secure retainment during long distant hauling of the unit. When rolling engine under the wing, the top of the aft engine mount should not exceed 70.5 inches (179.09 cm) from the ground for ground clearance from the pre-cooler.

The transport base unit consists of a frame supported by four dual wheel caster assemblies. Each caster assembly has a 5 inches (13 mm) wide by 10 inches (25 mm) diameter wheel for easy mobility and a weight capacity of 5000 lbs (2266 kg) each. Shock absorbing polyurethane tread wheels, position locks and face brakes are standard. All four caster assemblies are designed to pin in a retracted position for air/truck transport of the entire unit, with engine. The towbar stows on the base frame when not in use. The maximum towing speed of the unit is 3 MPH (5Km/h). Built-in shock absorbing mounts cushion all transport movements.







Identification (1.A.a)This section identifies the basic maintenance equipment to support CFM56-7 engine change using theengine transportation stand called a shipping dolly or cradle on the 737-600/-700/-800/-900/C40/BBJ airplane.

Equipment AM2563-227 Base, Universal Transportation Cradle for the CFM56-7 Engine and has three sections.- Engine Dolly Base- Cradle- Complete Stand




ALF

AFT

FWD



FAN COWLING

Identification (1.A.a)The CFM56-7 engine fan cowling and thrust reverser segments are hinged to the strut. To remove orinstall an engine, the fan cowls need to be removed to provide access to the forward engine groundhandling points. The fan cowls are held in the open position by integral hold-open rods for enginemaintenance when the engine is installed on the strut.



FAN COWLING

HOLD OPEN ROD

FAN COWL

FAN COWL PINS



LH STRUT QUICK DISCONNECTS

Identification (1.A.a)The CFM56-7 engine the quick disconnects must be removed for fuel, air, electrical, and hydraulics.



LH STRUT QUICK DISCONNECTS



RH STRUT QUICK DISCONNECTS

Identification (1.A.a)The CFM56-7 engine the quick disconnects must be removed for fuel, air, electrical, and hydraulics.



RH STRUT QUICK DISCONNECTS



ENGINE FIRE EXTINGUISHING TUBE

Identification (1.A.a)The CFM56-7 engine the fire extinguishing tube location.







PRE-COOLER LINES LH SIDE

Identification (1.A.a)The CFM56-7 engine pre-cooler and lines locations.



PRE-COOLER LINES LH SIDE

PRE-COOLER LINES



PRE-COOLER RH SIDE

Identification (1.A.a)The CFM56-7 engine pre-cooler location.



PRE-COOLER RH SIDE

PRE-COOLER



LH FAN FRAME ENGINE SUPPORT

Identification (1.A.a)The engine stand supports tools are found on the engine stand in boxes. This is the LH engine support for the fan frame.

Purpose (2.B.b)

The purpose of the engine supports are to maintain the stand to the engine fan frame and the aft engine turbine rear frame during transportation.







RH FAN FRAME ENGINE SUPPORT

Identification (1.A.a)The engine stand supports tools are found on the engine stand in boxes. This is the RH engine support for the fan frame.








Identification (1.A.a)The LH engine stand supports is installed into the fan frame.




LH SUPPORT

LH SUPPORT

Detail ATop View

Detail A




Identification (1.A.a)The LH engine stand trunnion support is installed into the fan frame safety ball pin and a beveled pin.




LH SUPPORT

LH Trunnion

Beveled Pin

Ball Lock Pin




Identification (1.A.a)The LH engine stand trunnion support is installed into the fan frame safety ball pin and a beveled pin.




RH SUPPORT

RH Trunnion

Beveled Pin

Ball Lock Pin



AFT LPT ENGINE SUPPORT

Identification (1.A.a)The AFT LPT engine support is installed to the turbine rear frame of the LPT.



AFT LPT ENGINE SUPPORT

AFT CRADLE ARM SUPPORT

FWD




Training Information Point (3.E.c)The thrust reverser latches may interfer with the engine transportation stand for the RH engine position #2.




THRUST REVERSER LATCHES

ENGINE STAND FWD



THRUST REVERSER ACTUATOR TOOLING

Identification (1.A.a)The thrust reverser actuator tooling is a hand pump and safety equipment used on the thrust reverser actuator.

The tool safety feature is the u-channel tool with two quick disconnect pins.

Purpose (2.B.b)The purpose of the thrust reverser actuator tooling is to open the thrust reverser by a hand pump , which uses engine oil. Using this system provides a backup safety feature inside the actuator that lowers slowly the thrust reverser in 11.5 seconds. The actuator when fully opened holds the thrust reverser in the open position by a locking collar another safety feature. The additional safety feature is the u-channel tool with two quick disconnect pins that prevents the thrust reverser from closing until them are removed.

Equipment C78005-21 Pump - Portable Hand, Thrust Reverser Cowl Opening System



THRUST REVERSER ACTUATOR TOOLING

FWD



TORQUE WRENCH

Purpose (2.B.b)

The purpose of the torque wrench is to correctly torque the engine mount bolts and obtain access to them with the swivel head feature in the strut area.



TORQUE WRENCH

ENGINE MOUNT BOLTS



FORWARD ENGINE MOUNT

Identification (1.A.a)The engine is attached to the strut at two locations. The forward engine mount system and the AFT engine mount.



FORWARD ENGINE MOUNT

FWD ENGINE MOUNT

FWD



AFT ENGINE MOUNT

Identification (1.A.a)The engine is attached to the strut at two locations. The forward engine mount system and the AFT engine mount.

The aft engine mount system consists of a mount assembly which is attached to the turbine rear frame, by four bolts. The Aft Mount Assembly includes a left, right center Link, and an evener bar assembly.

In conjunction with the engine mounts, a forward thrust link system is utilized to absorb fore and aftengine loads. The two forward arms of the thrust links are located on both sides of the fan frame. The aft linkage attaches to the strut.



AFT ENGINE MOUNT

AFT ENGINE MOUNT

FWD



AFT ENGINE MOUNT

Identification (1.A.a)The aft engine mount system consists of a mount assembly which is attached to the turbine rear frame, by four bolts.

In conjunction with the engine mounts, are attachment points for the AFT boot strap kit and hold open tooling that connect to the strut.



BOLT

AFT BOOTSTRAP CONNECTION

TR HOLD OPEN CONNECTION

FWD

AFT ENGINE MOUNT



THRUST REVERSER HOLD OPEN TOOLING

Identification (1.A.a)The thrust reverser is made in two halves ("C"-Ducts) which are raised open with integral actuators by a hydraulic pump. Once the "C"-Ducts are open, an automatic lock in the actuators holds each "C"-Duct open. The thrust revers actuator locks provide a backup for the locks in the actuators. When removing an engine, the actuators are disconnected and thrust reverser cowl hold-open rods are the only means of holding the "C"-Ducts open.

Equipment C78019-15 Equipment - Hold Open, Thrust Reverser Cowl, CFM56-7







Training Information Points (3.E.c)

WARNING: DO THESE SPECIFIED TASKS IN THE CORRECT SEQUENCE BEFORE YOU OPEN THE THRUST REVERSER: RETRACT THE LEADING EDGE, DO THE DEACTIVATION PROCEDURES FOR THE THE LEADING EDGE AND THE THRUST REVERSERS (FOR GROUND MAINTENANCE), AND OPEN THE FAN COWL PANEL. IF YOU DO NOT OBEY THE ABOVE SEQUENCE, INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.

NOTE: The hold-open equipment consists of a strut attach beam , two arm supports , two beam assemblies , two retention pins and lock pins and the hold-open equipment is symmetrical between the inboard and outboard sides.

WARNING: MAKE SURE YOU CORRECTLY ENGAGE EACH ARM SUPPORT INTO THE STRUT ATTACH BEAM. IF YOU DO NOT, THE HOLD-OPEN RODS WILL NOT HOLD THE WEIGHT OF THE THRUST REVERSER. INJURIES TO PERSONS CAN OCCUR.

NOTE: Make sure the longer side of the beam assembly faces forward.







Identification (1.A.a)The TR hold open tooling is installed to support the thrust reversers before the actuators are disconnected.

Purpose (2.B.b)The two adjustment pins of the, (C78005-21), are placed in the compression rod receiver cups on the thrust reversers which holds the TR in the open position.




LH SUPPORT TOOLING RH SUPPORT TOOLING

FWD FWD




Identification (1.A.a)The TR hold open tooling consists of:-2 Beam Assembly-2 Arm Support-2 adjustment pins-Strut Attach Beam Assembly-Pins for attachment







Purpose (2.B.b)The purpose of the thrust reverser hold open tooling is to support the thrust reverser during engine change when the actuators are disconnected. The adjustment pins provide the mechanical support of the TR.



TR HOLD OPEN TOOL ADJUSTMENT PINS




BOOTSTRAP TOOLING

Identification (1.A.a)This section identifies the basic maintenance equipment to support CFM56-7 engine change using the bootstrap method on the 737-600/-700/-800/-900 airplane. Engine installation/removal is most commonly performed using a "bootstrap" hoist assembly and various other ground support equipment items. The engine as removed from the airplane is in the QEC configuration with the inlet cowl, exhaust sleeve and plug attached. Access to the bootstrap hard points is gained through the strutforward thumbnail fairing. The forward fairing has been designed with easy access in mind, there are 7quick release latches, which secure the fairing to the strut. There is in addition a forward strut accesspanel located on the aft portion of the forward fairing, this allows access to the starter ducts andpneumatic tubing located on the forward section of the strut.



BOOTSTRAP TOOLING IN SHIPPING CONTAINER

FWD BOOT STRAP TOOLING



BOOTSTRAP TOOLING

Purpose (2.B.b)The purpose of the bootstrap system is for installation/removal of the engine. The bootstrap equipment is used for removal and installation of the CFM56-7 engine and is used with the cradle. This system is a particular asset where an engine is changed at a remote site. The system includes a forward and an aft arm with lever hoists, dynamometers and engine attach brackets as integral components.



BOOTSTRAP TOOLING



FORWARD BOOTSTRAP TOOLING

Identification (1.A.a)The forward boot strap tooling consists of the following pieces:-inboard dynamometer-outboard dynamometer-2 chain hoists-Support beam 2 pieces-2 braces-7 Attachment Pins -2 shackles-Dynamometer attachment adapters and pins



FORWARD BOOTSTRAP TOOLING



FORWARD BOOTSTRAP ATTACHMENT POINTS

Identification (1.A.a)The forward boot strap tooling attachment points.

The strut thumbnail fairing is removed to access the attachment points.



FORWARD BOOTSTRAP ATTACHMENT POINTS



FORWARD BOOTSTRAP CONNECTIONS

Identification (1.A.a)The forward boot strap tooling installed on the CFM56-7 strut detail connections.



FWD BOOTSTRAP CONNECTIONS

FWD BOOTSTRAPSUPPORT CONNECTIONS




Identification (1.A.a)The forward boot strap tooling installed on the CFM56-7 strut detail connections.




Safety Pin

Attachment Pin

Attachment Pins



FORWARD BOOTSTRAP INSTALLED

Identification (1.A.a)The forward boot strap tooling installed on the CFM56-7 strut.



FORWARD BOOTSTRAP INSTALLED



RH BOOTSTRAP CONNECTION


NOTE: After the bootstrap equipment is installed on the airplane, you must use all four persons to remove the power plant. Apply a load to the lever hoists as follows:

NOTE: The load values given below include the necessary preload force and the weight of the engine.

1) The forward inboard dynamometer reads 3700±100 pounds (1682±45 kilograms).

2) The forward outboard dynamometer reads 3200±100 pounds (1454±45 kilograms).

3) The aft dynamometer reads 1100±100 pounds (500±45 kilograms).

4) During installation of the engine, a total preload of 200 pounds (91 kilograms) is required to compress the seal on the engine to the strut.

NOTE: Use an 11/16-inch or 15/16 socket to loosen the bolts.




RH TRUNNION

DYNAMOMETERRH CHAIN HOIST

FWD BOOTSTRAPSUPPORT



FORWARD RH BOOTSTRAP CONNECTION


The forward outboard dynamometer should read 3200±100 pounds (1454±45 kilograms).

Engine position number 2, trunnion, is bolted to the fan frame.




RH FWD TRUNNION BOLTS

RH CONNECTION TO FAN FRAME

FWD

ADJUSTABLE JAM NUT



BOOTSTRAP CONNECTIONS


- The forward inboard dynamometer reads 3700±100 pounds (1682±45 kilograms). DO NOT APPLY MORE THAN 3850 POUNDS (1750 KG) TO THE FORWARD INBOARD DYNAMOMETER

-The forward outboard dynamometer should read 3200±100 pounds (1454±45 kilograms).

DO NOT APPLY MORE THAN 3350 POUNDS (1520 KG) TO THE FORWARD OUTBOARD DYNAMOMETER

- The aft dynamometer reads 1100±100 pounds (500±45 kilograms). DO NOT APPLY MORE THAN 1300 POUNDS (590 KG) TO THE AFT DYNAMOMETER.

WARNING:

IF YOU APPLY MORE THAN THE LIMITS, DAMAGE TO THE POWER PLANT, WING AND STRUT CAN OCCUR.

MAKE SURE THERE ARE NO SPIRAL TWISTS IN THE LEVER HOIST CHAIN BETWEEN THE LEVER HOIST.

HOUSING AND ITS LOWER BLOCK (THE ATTACH POINT FOR THE DYNAMOMETER). IF YOU SEE A TWIST IN THE CHAIN, YOU MUST REMOVE IT. IF YOU DO NOT REMOVE IT, INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.

Note: During installation of the engine, a total preload of 200 pounds (91 kilograms) is required to compress the seal on the engine to the strut.



BOOTSTRAP CONNECTIONS

LH DYNAMOMETER CONNECTION RH DYNAMOMETER CONNECTION

LH DYNAMOMETER CONNECTION

LH TRUNNION

RH DYNAMOMETER CONNECTION

RH TRUNNION



FORWARD LH BOOTSTRAP CONNECTION


The forward inboard dynamometer should read 3700 ±100 pounds (1454±45 kilograms).

Engine position 2 is shown.



FWD LH BOOTSTRAP CONNECTION

DYNAMOMETER

LH TRUNNION



FORWARD LH BOOTSTRAP CONNECTION


The forward inboard dynamometer should read 3700 ±100 pounds (1454±45 kilograms).

Engine position 2 is shown.



FWD LH BOOTSTRAP CONNECTION



AFT BOOTSTRAP CONNECTIONS


The aft engine bootstrap system consists of a tooling assembly which is attached to the strut by two pins.




LH AFT BOOTSTRAP CONNECTION AFT BOOTSTRAP CONNECTIONS

FWD FWD

Attach point Attach points



AFT BOOTSTRAP TOOLING

Identification (1.A.a)

The aft engine bootstrap system consists of a tooling assembly which is attached to the strut by:

- Lock pins

- Center Beam

- Forward support brace

- AFT support brace



AFT BOOTSTRAP TOOLING





The aft engine bootstrap system tooling assembly which is attached turbine rear frame Engine 2 on the RH side support, engine 1 LH side.



ENGINE 1 AFT BOOTSTRAP CONNECTION


ENGINE 2 AFT BOOTSTRAP CONNECTION



AFT BOOTSTRAP RH CONNECTION


The aft engine bootstrap support has a dynamometer and chain hoist to support the aft end of the engine..



AFT BOOTSTRAP RH CONNECTION

DYNAMOMETER

AFT CHAIN HOIST

AFT BOOTSTRAP SUPPORT

CFM56-7RI2003

Documents

engine fan

b training manual cfm56

fan cowling page engine

engine maintenance

page thrust reverser

page bootstrap tooling

aft engine mount

gse manual