Engine removal and installation cfm56 7 b

1EFFECTIVITY 737-600/700/800/900/BBJ/C40A/B/C/P8A/MMA/AWAC CFM PROPRIETARY INFORMATION 71-00-00Sept. 2006

CFM56-7B TRAINING MANUAL

ENGINE REMOVAL AND INSTALLATIONTRAINING COURSE

Document: GEK 112143R6

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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

Document: GEK 112143R6Revised: Sept. 2006

CFM56-7B Removal & Installation Training Course

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Table of Contents Page 05Power Plant Removal Preparation ………………………………………………..… Page 07Engine Preservation ………………………………………………………………..… Page 13Engine History Data, Tests And Inspections ………….……………………….… Page 15Airplane Preparation ……………………………………………………………….…. Page 33Static Grounding ………………………………..………………………………….…. Page 41Airplane Leveling …………………..……………………………………………….…. Page 43Engine Nacelle ……………………………………………………………………….… Page 47Fan Cowling …………………………………….……………………………………… Page 49Thrust Reverser Safety Tooling ……………………………………………………. Page 55Thrust Reverser Hold Open Tooling ………………………………………………. Page 59Fuel System Preparation …………………………………………..……………….… Page 69Engine Quick Disconnects ……………………………………………………….…. Page 71Engine Core Disconnects …………..……………………………………………..… Page 79Thumbnail Fairing …………………………………………………………………….. Page 89Forward Bootstrap Tooling …………………………………………………….…… Page 91AFT Bootstrap Tooling ……………………………………………………………..… Page 119Engine Transportation Stand …………………………………………………….…. Page 129Engine Mounts …………………………………………………………………….….. Page 139Engine Transportation ……………………………………………………………...… Page 163Thrust Reverser Tooling ……………………………………………………….……… Page 167Engine Inlet Tooling …………………………………………………………………… Page 189

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Power Plant Removal Preparation

General Description

Before power plant removal begins, read the procedures and understand them. Note carefully the warnings, cautions, tooling, inspections, checks and consumable products before you begin. A full overview is needed before beginning and after installation to save time and avoid possible oversights.

POWER PLANT REMOVAL PREPARATION

Power Plant Removal Preparation

General Description

Before power plant removal begins, many tasks

need to be considered, they are:

1. Engine history and recording faults

2. Data retrieval and storage

3. Engine preservation

4. Special Inspections

5. BITE tests

6. Ground tests

7. Erasing old faults and data

8. AVM checks

9. Other Front face BITE checks

10. Shop visit and engine history information

Power Plant Installation

General Description

After power plant installation, many tasks

1. Checking for current status of faults stored

2. Erasing EEC/DEU data fault check

3. Engine Serial number CDU input

4. FMC and EEC software status

5. ID plug verification status

6. Ground tests

7. BITE tests

8. Erasing faults and data status

10. Engine depreservation

POWER PLANT REMOVAL PREPARARTION

DFDRDFDR

QARQAR

ACARSACARS

CDUCDU

EAUEAU

AVMAVM

PRESERVATIONPRESERVATIONEEC BITEEEC BITE

BSIBSI

MCDMCD’’ss

DMSDMS

GROUND TESTSGROUND TESTS

DEUDEU’’ss

ID PLUGID PLUG

DFDAUDFDAU

PDLPDL

INPUT MONITORINGINPUT MONITORING

ENGINE MAGNETIC CHIP DETECTORS

General Description

1. Special Inspection MCD’S or DMS

MCDMCD’’ss

ENGINE MAGNETIC CHIP DETECTORS

Engine Preservation

General Description

This task is to dry the forward sump, aft sump, and the gearbox of the engine with hot air when the engine cannot be operated.

CAUTION: IF AN IN-FLIGHT SHUTDOWN OCCURRED ON THE APPLICABLE ENGINE AND THE ENGINE WILL NOT BE OPERATED FOR 24 HOURS AFTER A LANDING, YOU MUST DO THE ENGINE DRY-OUT PROCEDURE AS QUICKLY AS POSSIBLE. IF YOU DO NOT DO THE ENGINE DRY-OUT PROCEDURE IMMEDIATELY AFTER A LANDING, CONDENSATION CAN CAUSE CORROSION DAMAGE ON THE COMPONENTS WET WITH OIL.

ENGINE PRESERVATION

856A2659

856A3620

856A1480 HMU FMV

ENGINE DATA VERIFICATION

General Description

6. Ground tests

7. BITE tests

ID PLUGID PLUGCDUCDU

ENGINE DATA PLATEENGINE DATA PLATE

ENGINE DATAGeneral Description

5. BITE tests

6. Ground tests

8. AVM checks

Power Plant Installation

General Description

6. Ground tests

7. BITE tests

10. Engine depreservation

ENGINE DATA

General Description

Check the necessary electronic units for fault information. Do the necessary BITE CHECKS to validate repairs after an engine change. Input data as serial number of the engine in the required areas of the CDU.

ENGINE DATA VERIFICATIONGeneral Description

Engine History Data, Tests And Inspections

General Description

2. Data retrieval and storage (PDL)3. CAUTION:

MAKE SURE THAT YOU MAKE WORKING COPIES OF THE MASTER DISC. DO NOT USE THE MASTER DISC TO RETRIEVE THE NVM DATA FROM THE EEC. DURING THE STEPS THAT RETRIEVE THE NVM DATA FROM THE EEC, THE DATA LOADER WILL WRITE TWO NVM FILES TO THE DISC. IF YOU WANT TO SAVE THE TWO NVM FILES, YOU MUST USE A DIFFERENT WORKING COPY FOR EACH EEC NVM THAT YOU RETRIEVE.

IT IS RECOMMENDED THAT YOU LOOK FOR ANY EEC SYSTEM FAULTS BEFORE YOU RETRIEVE THE NVM DATA FROM THE EEC. TO LOOK FOR SYSTEM FAULTS, DO THE EEC TEST BEFORE YOU RETRIEVE THE NVM DATA FROM THE EEC.

Tests and inspections

5. BITE tests

6. Ground tests

8. AVM checks

EAU DMS/MCD’s

ENGINE HISTORY DATA, TESTS AND INSPECTIONS

PDL NVM DOWNLOADING

FLIGHT DATA RECORDER SYSTEM -INTRODUCTION

Purpose (2.A.a)The flight data recorder system (FDRS) stores airplane parameters and system data for the last 25 hours of operation.The flight data recorder (FDR) protects the parameters and the system data. If there is an airplane incident, these parameters supply data on flight conditions and airplane systems operation. Airline personnel can also use the data to make an analysis of system performance during airplane maintenance.

FLIGHT DATA RECORDER SYSTEM

EEC BITE - IDENT/CONFIG - CDU

General DescriptionThe IDENT/CONFIG pages show engine and EEC configuration and identification data. There are two pages of this data.

IDENT/CONFIG Page 1The IDENT/CONFIG page 1 gives this data: CFM ALL•AIRPLANE MODEL (737-600/700/800) •ENGINE MODEL (7Byy where yy X 1000 is the base thrust rating) •BUMP (hot day thrust cutback point increase) •N1 TRIM (N1 trim setting) •EEC P/N (EEC part number) •EEC S/W VER (EEC software version) •START MODE (engine start mode) •ENG S/N (engine serial number). •Page 2•Page 2 gives this data:•PMUX INSTALLED (shows YES with optional condition monitoring sensors installed) •DMS KIT INSTALLED (shows YES with optional electronic chip detector installed) •IGNITION MODE (STANDARD or AUTOMATIC).

EEC BITE - IDENT/CONFIG CONTROL DISPLAY UNIT

ANNUNCIATION LIGHTS

General DescriptionThe WARNING LIGHTS show engine status. There are two pages of this data.

P5 PANELThe warning lights are:•ENGINE CONTROL light •REVERSER lights•ALTN MODE lights

ANNUNCIATION LIGHTS

Airplane Preparation

General Description

1. Level Airplane

2. Main landing gear strut servicing

3. Static grounding

4. Electrical supply

5. Hydraulic systems

6. Pneumatic systems

7. Fuel systems

8. Thrust reverser systems

9. Airplane configuration

10. Tooling and alternate procedures

11. Cautions and warnings

12. Flight compartment configuration and tagging

General Description

1. Safety and danger areas must be known ahead of time.

2. Refer to the AMM for the current updates for the procedures. Check service bulletins, commercial engine service memorandums, etc., for airplane, CFM, and tooling issues effecting the procedure methods used.

AIRPLANE PREPARATION

Safety Preparation

General Description

1. Safety equipment use as harnesses when on top of the engine.

SAFETY HARNESS

General Description

1. Wind milling prevention outside

AIRPLANE PREPARATION

Wind milling prevention outside, use covers or an approved safe method.

General Description

1. Perform the lockout procedures for the leading edge slats, flaps and TR’s

FOLLOW LOCKOUT PROCEDURES

Thrust Reverser Lockout

Leading Edge Lockout

STATIC GROUNDING

Identification (1.A.a)

When static grounding is recommended in a detailed procedure, the airplane must be statically grounded to a common, approved, identified ground. The location is in the landing gear main wheel wells grounding studs.

STATIC GROUNDING

LEVELING AIRPLANE

METHODS

1. Level the airplane with a plumb bob 1.5 degrees nose down or as close as possible and level laterally. Jacks may be used if necessary.

2. Level the airplane using GSE attitude leveling gage, F70043.

AIRPLANE LEVELING

General Description

1. Level Airplane

2. Main landing gear strut servicing

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

Thrust Reverser LH(C-Duct)

Thrust Reverser RH(C-Duct)

Engine Strut

FAN COWL PANEL REMOVAL

SLING METHOD

Unlatch the fan cowl panel latches. Install the C71026-2 sling at the GSE attach point on the fan cowl panel. Remove the GSE plug in the fan cowl panel and install the sling eye bolt. Torque to value installed on the sling strap or AMM (15-30 INCH POUNDS.)

Note: Before opening the fan cowl panels and thrust reversers the airplane must be configured correctly to avoid damage to the airplane wing devices, refer to the AMM.

FAN COWL PANEL SLING METHOD

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 - Removal Pins

HOLD OPEN ROD

FAN COWL

FAN COWL PINS

FAN COWL PANEL REMOVAL (CONT.)

SLING METHOD

Use the hoist and sling to open and hold the fan cowl panel.

Release the quick-release pin with the button on the end and remove the pin. Install the drift pin from the sling kit at the hinge. Continue till the all pins are removed, then remove all temporary pins.

MANUAL METHOD

Using 3-4 people manually remove the 96 pound fan cowl panel.

Note: Re-install lock pins in strut holes after the removal of the fan cowl panels to avoid damage to the lanyards during removal of the engine.

FAN COWL PANEL QUICK RELEASE PINS

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.

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.

EquipmentC78005-21 Pump - Portable Hand, Thrust Reverser Cowl Opening System

Manual Method

The thrust reverser using 4 people open after unlatching T/R. Secure actuator safety lock on to the actuator with the 2 pins.

THRUST REVERSER ACTUATOR TOOLING

THRUST REVERSER SAFETY ACTUATOR TOOLING

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

THRUST REVERSER ACTUATOR SAFETY TOOLING

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.

EquipmentC78019-15 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

THRUST REVERSER COMPRESSION RODSIdentification (1.A.a)The TR compression rods consists of:-3 compression rods

-They support the top of the T/R when closed by resting in cups in the T/R that provide tension loads.

THRUST REVERSER COMPRESSION ROD

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

FUEL SYSTEM PREPARATION

Identification (1.A.a)Drain the fuel supply line at the fuel filter drain plug.

FUEL SYSTEM PREPARATION

LH 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

Identification (1.A.a)The CFM56-7 engine the quick disconnects must be removed.

CORE DISCONNECTSPRE-COOLER LINES LH AND RH SIDES

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

CORE DISCONNECTS - PRE-COOLER LINES

RH SIDELH SIDE

FWDFWD

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 SEAL

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

PRE-COOLER SEAL

ENGINE FIRE EXTINGUISHING TUBE

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

ENGINE FIRE EXTINGUISHING TUBE

PRE-COOLER RH SIDE

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

PRE-COOLER RH SIDE

PRE-COOLER

FORWARD THUMBNAIL FAIRING

The CFM56-7 engine forward thumbnail fairing location.

FORWARD THUMBNAIL FAIRING

BOOTSTRAP TOOLING

Identification (1.A.a)This section identifies the basic maintenance equipment C71020 – 76 bootstrap kit 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.

BOOTSTRAP TOOLING IN SHIPPING CONTAINER

FWD BOOT STRAP 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

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

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.

MAINTENANCE TIP 737-MT-71-003 R1

SUBJECT: ENGINE REMOVAL AND INSTALLATION USING BOOTSTRAP EQUIPMENT

APPLICABILITY All 737-600/700/800/900 airplanes when using engine bootstrap equipment P/N C71020-80 (banana fitting at forward engine locations) with revised multi-purpose fitting. CONDITION: The fuel flow meter connector can be damaged when using the revised bootstrap equipment P/N C71020-80 and multi-purpose fitting.

RECOMMENDED ACTION

Disconnect the fuel flow meter (T435) connector DP0502 prior to attaching the bootstrap to the engine multi-purpose fitting on the left hand side of the fan case.

BACKGROUND

During an engine change, the engine was dropped due to failed bolts that attach the multi-purpose fitting to the left hand side of the fan case. Upon inspection of these bolts in other engine change kits, several stretched and necked bolts were found. The bolts were over stressed while the multi-purpose fitting was being engaged in the engine cradle. To prevent over stressing the bolts, the multi-purpose

fitting, engine cradle and the bootstrap equipment were modified to move the bootstrap interface point toward the engine centerline approximately 2 inches. The straight fitting between the dynamometer and the multi-purpose fitting was replaced by a longer “banana” fitting. The “banana” shaped fitting is required to avoid contact with the inline fuel filter(nozzle filter). The top of the “banana” fitting can come in contact with the fuel flow meter connector.

MAINTENANCE MANUAL ACTION

A step will be added in the 10 June 2003 revision of AMM 71-00-02, Power Plant – Removal/Installation procedure, to disconnect the Fuel Flow Meter connector DP0502 before the bootstrap is connected to the engine multi-purpose fitting.

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.

Before turning jam nut be sure to loosen set screw or damage to the threads of the RH trunnion may occure.

RH Trunnion set screw

BOOTSTRAP CONNECTIONS

Training Information Points (3.E.c)Zero the dynamometers once fully installed with no load.

- 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 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.

Inspect bolts for necking with a micrometer and other possible damage.

RH BOOTSTRAP CONNECTION

RH FWD TRUNNION BOLTS

RH CONNECTION TO FAN FRAME

ADJUSTABLE JAM NUT

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

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±100pounds (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 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

Attach points

AFT BOOTSTRAP TOOLING

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 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..

DYNAMOMETER

AFT CHAIN HOIST

AFT BOOTSTRAP SUPPORT

AFT BOOTSTRAP LH CONNECTION

The aft engine bootstrap support..

ENGINE TRANSPORTATION STAND

Training Information Point (3.E.c)The thrust reverser latches may interfer with the engine transportation stand for the engine position #2 or #1.

Using the approved tape secure the latches to avoid interference with the engine shipping and maintenance stand. Use tape around the fire seals to avoid injury to hands.

THRUST REVERSER LATCHES

ENGINE STAND FWD

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.

EquipmentAM2563-227 Base, Universal Transportation Cradle for the CFM56-7 Engine and has three sections.- Engine Dolly Base- Cradle- Complete Stand

Tow Bar Storage

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 approvalof 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.

EquipmentAM2563 Base Universal Transportation Cradlefor the CFM56-7 Engine

Additional Support EquipmentNote: Refer to GSE manual for more informationC78020-1 Equipment - Hold Open, Thrust Reverser Cowl, C71020 – 76 Kit - Bootstrap, CFM56-7 EngineC78005 Pump - Portable Hand, Thrust Reverser Cowl C71022 Torque Wrench Equipment - CFM56-7 Engine BoltsC71040-2 Inlet cowl sling

Safety Pin

Arm Support Storage

Turning Bar

Training Information Points (3.E.c)AM2563-227 Base, Universal Transportation Cradle has 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 casterassembly 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 locksand 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)The LH engine stand supports is installed into the fan frame.

LH SUPPORT

Detail ATop View

Detail A

FORWARD ENGINE MOUNT

Identification (1.A.a)The forward engine mount has four bolts, washers and barrel nuts which secure the front engine mount to the strut. The bolts and barrel nuts must be inspected before each installation.

Identification (1.A.a)The engine is attached to the strut with barrel nuts and bolts. Shear pins align the mounts and give support to the engine attachment.

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

FWD ENGINE MOUNT

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.

AFT ENGINE MOUNT

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

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.

AFT BOOTSTRAPCONNECTION

TR HOLD OPENCONNECTION

AFT ENGINE MOUNT

AFT BOLT

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

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

NEW FAN FRAME ENGINE SUPPORTS

Identification (1.A.a)The LH and RH engine stand trunnion supports are installed into the fan frame.

NEW FAN FRAME ENGINE SUPPORTS

LHRHRH

AFT LPT ENGINE SUPPORT

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

AFT CRADLE ARM SUPPORT

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

MAINTENANCE STAND

Remove the power plant from the work area.CAUTION: BE CAREFUL WHEN YOU MOVE THE POWER PLANT AWAY FROM THE AIRPLANE. DAMAGE TO THE THRUST REVERSERS AND POWER PLANT CAN OCCUR IF THE POWER PLANT HITS THE THRUST REVERSERS.

To remove the power plant, move it forward until it is free of the thrust reversers. Remove the two lockpins and remove the engine attach bracket from the turbine rear frame. If it is necessary, remove the bootstrap equipment from the strut.

If you move the engine, do these steps:

Install the eye-bolt for the diagonal brace on the forward cradle arms. Install the diagonal brace on the forward cradle arms.

ENGINE TRANSPORTATION

If you use a semi-trailer with two or more engines installed on the trailer, both the tractor and the trailer must have pneumatic suspension.

Cradle and engine data

Length 171.5 inches (435.6 cm)

Length (Casters up) 169.5 inches (430.5 cm)

Width 96 inches (243.8 cm)

Height (Casters up) 87.6 inches (222.5 cm)

Height (Casters down) 91.1 inches (231.4 cm)

Weight 10,850 pounds (4922 kg)

MAINTENANCE STAND

ENGINE COVERGeneral

This section is a supplement to the engine removal and installation training.

Engine cover views.

Overview of the thrust reverser and engine inlet cowl tooling. Refer to the AMM for details.

Engine Cover LH View

RH View

AFT View

FWD View

RH THRUST REVERSER

Identification (1.A.a)The RH thrust reverser can be removed with the C78018 tool.

RH THRUST REVERSER

LH THRUST REVERSER

Identification (1.A.a)The LH thrust reverser can be removed with the C78018 tool.

LH THRUST REVERSER

THRUST REVERSER TOOLING

Identification (1.A.a)The C78018 tooling.

Sling equipment (C78018) is required for the installation/removal of the thrust reverser cowl.

In addition, customer supplied overhead lift is required to raise or lower the thrust reverser afterdetachment from the strut.NOTE: THE TOOL WEIGHS APPROXIMATELY 225 POUNDS

Identification (1.A.a)The C78018 tool.

During installation/removal of the thrust reverser cowl, movement of the cowl is controlled by using achain hoist either powered or unpowered. The strong back attaches to the thrust reverser at two hardpoints located on the hinge beams, and two hard points located on the thrust reverser latch beam.show the location of the hard points. A dynamometer is placed between the eyebolt and the chain hoist to prevent excessive pre-loads, the thrust reverser is then removed using acustomer supplied overhead lifting device. The sling utilized to install/remove thethrust reverser. After removing a thrust reverser cowl, it may be stored and transported on theC78011 thrust reverser dolly.

The C78026 is used with tool C78018 (Thrust reverser sling equipment) and interfaces withthe tool utilizing the lift rotate plate located on the strongback main beam.

GeneralThe torque is 20-50 in. LBS for the bottomattachment bolts for the GSE.

After the thrust reverser segments have been reinstalled on the strut, they must be closed and locked.As the segments are closed, seals located at the upper bifurcation of the segments are compressedproviding resistance to the closure. To help overcome this resistance, a latching tool C78020 has beendeveloped that attaches to the locking latch on the reverser segment and helps draw the segmentstogether for locking.

ENGINE INLET COWL TOOLING

The inlet cowl may be installed/removed using a sling with an overhead hoist B71040 and dynamometer. Refer to the AMM TASK 71-11-01-000-801-F00 for removal of the inlet cowl. There is more than 1 tool to remove the inlet cowl.

Using this method of installation/removal requires caution to prevent damage to engine components,accessories and fittings. The EEC cooling hose, TAI duct and T12 sensor must be removed.

The inlet cowl and ground handling points and the sling and how it attaches to the inlet cowl.CAUTION: ADJUST THE SLING TO HOLD ONLY THE WEIGHT OF THE INLET COWL. MORE FORCE CAN CAUSE DAMAGE TO THE INLET COWL. THE INLET COWL WEIGHS 310 LBS.

ENGINE INLET COWL TOOLING

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