CFM56-7B Removal & Installation

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

CFM56-7B TRAINING MANUAL

ENGINE REMOVAL AND INSTALLATION

TRAINING COURSE

Document: GEK 112143

Revised: Jan. 2003



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The Power

Of Flight

CFM56-7B

Removal & Installation Training Course

Document: GEK 112143

Revised: 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 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.



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 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




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 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

- Complete Stand




ALF

AFT

FWD



FAN COWLING


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.



FAN COWLING

HOLD OPEN ROD

FAN COWL

FAN COWL PINS



LH STRUT QUICK DISCONNECTS


The CFM56-7 engine the quick disconnects must be

removed for fuel, air, electrical, and hydraulics.



LH STRUT QUICK DISCONNECTS



RH STRUT QUICK DISCONNECTS


The CFM56-7 engine the quick disconnects must be

removed for fuel, air, electrical, and hydraulics.



RH STRUT QUICK DISCONNECTS



ENGINE FIRE EXTINGUISHING TUBE


The CFM56-7 engine the fire extinguishing tube location.



PRE-COOLER LINES LH SIDE


The CFM56-7 engine pre-cooler and lines locations.



PRE-COOLER LINES LH SIDE

PRE-COOLER LINES



PRE-COOLER RH SIDE


The CFM56-7 engine pre-cooler location.



PRE-COOLER RH SIDE

PRE-COOLER



LH FAN FRAME ENGINE SUPPORT


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


The engine stand supports tools are found on the engine

stand in boxes. This is the RH engine support for the fan

frame.





The LH engine stand supports is installed into the fan

frame.




LH

SUPPORT

LH

SUPPORT

Detail A

Top View

Detail 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





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


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


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


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


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.



AFT ENGINE MOUNT

AFT ENGINE

MOUNT

FWD



AFT ENGINE MOUNT


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


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





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.





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





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


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.



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


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


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


The forward boot strap tooling installed on the

CFM56-7 strut detail connections.



FWD BOOTSTRAP CONNECTIONS

FWD BOOTSTRAP

SUPPORT CONNECTIONS






CFM56-7 strut detail connections.




Safety Pin

Attachment Pin

Attachment Pins



FORWARD BOOTSTRAP INSTALLED



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

DYNAMOMETER RH CHAIN HOIST

FWD BOOTSTRAP

SUPPORT



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


DO NOT APPLY MORE THAN 3850 POUNDS (1750 KG)

TO THE FORWARD INBOARD DYNAMOMETER

-The forward outboard dynamometer should read 3200±100 pounds



TO THE FORWARD OUTBOARD DYNAMOMETER

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


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


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

CFM56-7B Removal & Installation

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