CFM56-7B Removal & Installation

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ENGINE REMOVAL AND INSTALLATION

TRAINING COURSE

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EFFECTIVITY 737-600/700/800/900/BBJ/C40A&B CFM PROPRIETARY INFORMATION

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CFM Proprietary Information

The 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 set forth 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 by

the U.S. export control laws. Unauthorized export or re-export is prohibited.

The Power

Of Flight

Removal & Installation Training Course

Document: GEK 112143

Revised: Jan. 2003

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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 Description

The CFM56-7 engine fan cowling and thrust reverser segments are hinged to the strut. To remove or

install an engine, the fan cowls need to be removed to provide access to the forward engine ground

handling points. The fan cowls are held in the open position by integral hold-open rods for engine

maintenance when the engine is installed on the strut. The forward fairing will need to be removed to

gain access to GSE bootstrap interface points. The forward fairing is held in place by 7 quick release

latches allowing easy access to GSE hard points for the bootstrap system. The thrust reverser is made

in two halves ("C"-Ducts) which are raised open with integral actuators by a hydraulic pump which must

be purchased as Ground Support Equipment (GSE). Once the "C"-Ducts are open, an automatic lock

in the actuators holds each "C"-Duct open. GSE actuator locks provide a backup for the locks in the

actuators. When removing an engine, the actuators are disconnected and GSE thrust reverser cowl

hold-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.

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ENGINE NACELLE

ALF

Thrust Reverser LH

(C-Duct)

Thrust Reverser RH

(C-Duct)

Engine Strut

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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 Cradle

for the CFM56-7 Engine

Additional Support Equipment

Note: Refer to GSE manual for more information

C78020 Equipment - Hold Open, Thrust Reverser Cowl,

C71020 Kit - Bootstrap, CFM56-7 Engine

C78005 Pump - Portable Hand, Thrust Reverser Cowl

C71022 Torque Wrench Equipment - CFM56-7 Engine Bolts

C71040 Inlet cowl sling

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ENGINE TRANSPORTATION STAND

Engine Stand

LH Fan Support

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ENGINE TRANSPORTATION STAND

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.

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ENGINE TRANSPORTATION STAND

Identification (1.A.a)

This section identifies the basic maintenance equipment

to support CFM56-7 engine change using the

engine 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

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ENGINE TRANSPORTATION STAND

ALF

AFT

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FAN COWLING

Identification (1.A.a)

The CFM56-7 engine fan cowling and thrust reverser

segments are hinged to the strut. To remove or

install an engine, the fan cowls need to be removed to

provide access to the forward engine ground

handling points. The fan cowls are held in the open

position by integral hold-open rods for engine

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FAN COWLING

HOLD OPEN ROD

FAN COWL PINS

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LH STRUT QUICK DISCONNECTS

Identification (1.A.a)

The CFM56-7 engine the quick disconnects must be

removed for fuel, air, electrical, and hydraulics.

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RH STRUT QUICK DISCONNECTS

Identification (1.A.a)

The CFM56-7 engine the quick disconnects must be

removed for fuel, air, electrical, and hydraulics.

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ENGINE FIRE EXTINGUISHING TUBE

Identification (1.A.a)

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ENGINE FIRE EXTINGUISHING TUBE

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PRE-COOLER LINES LH SIDE

Identification (1.A.a)

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PRE-COOLER LINES LH SIDE

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PRE-COOLER RH SIDE

Identification (1.A.a)

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PRE-COOLER RH SIDE

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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.

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LH FAN FRAME ENGINE SUPPORT

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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.

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RH FAN FRAME ENGINE SUPPORT

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LH FAN FRAME ENGINE SUPPORT

Identification (1.A.a)

The LH engine stand supports is installed into the fan

frame.

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LH FAN FRAME ENGINE SUPPORT

LH

SUPPORT

LH

SUPPORT

Detail A

Top View

Detail A

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LH FAN FRAME ENGINE SUPPORT

Identification (1.A.a)

The LH engine stand trunnion support is installed into

the fan frame safety ball pin and a beveled pin.

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LH FAN FRAME ENGINE SUPPORT

LH SUPPORT

LH Trunnion

Beveled Pin

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RH FAN FRAME ENGINE SUPPORT

Identification (1.A.a)

The LH engine stand trunnion support is installed into

the fan frame safety ball pin and a beveled pin.

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RH FAN FRAME ENGINE SUPPORT

RH SUPPORT

RH Trunnion

Beveled Pin

Ball Lock Pin

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AFT LPT ENGINE SUPPORT

Identification (1.A.a)

The AFT LPT engine support is installed to the

turbine rear frame of the LPT.

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AFT LPT ENGINE SUPPORT

AFT CRADLE ARM

SUPPORT

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ENGINE TRANSPORTATION STAND

Training Information Point (3.E.c)

The thrust reverser latches may interfer with the

engine transportation stand for the RH engine

position #2.

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ENGINE TRANSPORTATION STAND

THRUST REVERSER LATCHES

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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

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THRUST REVERSER ACTUATOR TOOLING

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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.

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TORQUE WRENCH

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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.

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FORWARD ENGINE MOUNT

FWD ENGINE MOUNT

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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 aft

engine 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.

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AFT ENGINE MOUNT

AFT ENGINE

MOUNT

FWD

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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.

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BOLT AFT BOOTSTRAP CONNECTION TR HOLD OPEN CONNECTION FWD

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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

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THRUST REVERSER HOLD OPEN TOOLING

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

.

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THRUST REVERSER HOLD OPEN TOOLING

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.

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THRUST REVERSER HOLD OPEN TOOLING

LH SUPPORT TOOLING

RH SUPPORT TOOLING

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THRUST REVERSER HOLD OPEN TOOLING

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

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THRUST REVERSER HOLD OPEN TOOLING

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.

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TR HOLD OPEN TOOL ADJUSTMENT PINS

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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 strut

forward thumbnail fairing. The forward fairing has

been designed with easy access in mind, there are 7

quick release latches, which secure the fairing to the

strut. There is in addition a forward strut access

panel located on the aft portion of the forward

fairing, this allows access to the starter ducts and

pneumatic tubing located on the forward section of

the strut.

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BOOTSTRAP TOOLING IN SHIPPING CONTAINER

FWD BOOT STRAP

TOOLING

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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.

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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

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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.

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FORWARD BOOTSTRAP CONNECTIONS

Identification (1.A.a)

The forward boot strap tooling installed on the

CFM56-7 strut detail connections.

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FWD BOOTSTRAP CONNECTIONS

FWD BOOTSTRAP

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FORWARD BOOTSTRAP CONNECTIONS

Identification (1.A.a)

The forward boot strap tooling installed on the

CFM56-7 strut detail connections.

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FORWARD BOOTSTRAP CONNECTIONS

Safety Pin

Attachment Pin

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FORWARD BOOTSTRAP INSTALLED

Identification (1.A.a)

The forward boot strap tooling installed on the

CFM56-7 strut.

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RH BOOTSTRAP CONNECTION

Training Information Points (3.E.c)

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:

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RH BOOTSTRAP CONNECTION

RH TRUNNION

DYNAMOMETER

RH CHAIN HOIST

FWD BOOTSTRAP

SUPPORT

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FORWARD RH BOOTSTRAP CONNECTION

Training Information Points (3.E.c)

The forward outboard dynamometer should read

3200

±

100 pounds (1454

±

45 kilograms).

Engine position number 2, trunnion, is bolted to the

fan frame.

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RH BOOTSTRAP CONNECTION

RH FWD TRUNNION BOLTS RH CONNECTION TO FAN FRAME

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Training Information Points (3.E.c)

- 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.

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BOOTSTRAP CONNECTIONS

LH DYNAMOMETER CONNECTION

RH DYNAMOMETER CONNECTION

LH DYNAMOMETER CONNECTION LH TRUNNION RH DYNAMOMETER CONNECTION RH TRUNNION