CFM56-7B POWER PLANT REMOVAL & INSTALLATION

Transcription

1 Task No: NG Maint Prog Ref: BAL/BOE/11 Station: A/C Reg: Issue: 5 Date: NOV 2017 A.M.M. Ref: Check: Aircraft Type CAA App Ref. UK Scheduled / Unscheduled Delete as applicable Date: Operator ITEM TASK DESCRIPTION A PART NUMBER OFF. PART NUMBER ON SERIAL No. OFF:.. SERIAL No. ON:.. WORK ORDER No.:. POSITION:. AIRCRAFT HOURS:.. AIRCRAFT CYCLES.. B RECORD REASON FOR REMOVAL BELOW: C IDENTIFY ADDITIONAL WORK REQUIRED FOR OFF-GOING ENGINE PRIOR TO REMOVAL: D CHECK PRESERVATION REQUIRED FOR OFF-GOING ENGINE: NOTE: CONTACT TUI POWERPLANT IF UNSURE OF PRESERVATION REQUIREMENTS E VERIFY IF OFF GOING ENGINE IS TO BE REMOVED SERVICABLE F MAKE SURE THAT THE CONFIGURATION OF THE ON-GOING ENGINE IS COMPATIBLE WITH THE AIRPLANE AND THRUST REVERSERS : AMM SUBTASK F00 Note: only if on-going engine is known. If unknown this step may be N/A G MAKE SURE THE CONFIGURATION OF THE ON-GOING EXHAUST NOZZLE AND THE AIRPLANE STRUT ARE COMPATIBLE: SUBTASK F00 Note: only if on-going engine is known. If unknown this step may be N/A H IDENTIFY ADDITIONAL TASKS REQUIRED ON REPLACEMENT ENGINE DURING/FOLLOWING INSTALLATION: NOTE: CHECK TRANSIT / CARRIED FORWARD SHEETS Note! Issue Task Cards , , 71-TOM-001/002 and /02 with this form. FORM No NG - ISSUE 5 - PAGE 1 of 21

2 ITEM TASK DESCRIPTION I J TUI CHECK THE PART NUMBER OF THE ON GOING ENGINE AND THE OPPOSITE ENGINE ARE THE SAME. IF THEY ARE DIFFERENT PERFORM THE APPLICABLE INTERMIX SB: SUBTASK F00 Note: the P/N of the engine can be CFM56-7B27, CFM56-7B27/3 or CFM56-7B27E, if any of these P/N are intermixed an SB will be required IN THE FLIGHT COMPARTMENT CHECK THE FMC MEDB CONGIURATION NUMBER BEFORE STARTING ENGINE REMOVAL RECORD THE MODEL/ENGINE CONFIG NUMBER HERE FORM No NG - ISSUE 5 - PAGE 2 of 21

3 POWER PLANT REMOVAL - AMM Task F00 ITEM TASK DESCRIPTION 1 Subtask F00 Ensure that the aircraft attitude is correct i.a.w. MM. Tasks Subtask F00 Static Grounding i.a.w. MM Task page block Subtask F00 Make sure Engine Start Lever is in CUTOFF position and install DO NOT OPERATE label. 4 Subtask F00 Supply Electrical Power i.a.w. MM Task Subtask F00 Close Fuel Valve. 6 Subtask F00 Open the Circuit Breakers and attach DO NOT CLOSE label:- For No. 1 Engine; Panel P6-3 Panel P Subtask F00 Open the Circuit Breakers and attach DO NOT CLOSE label:- For No. 2 Engine; Panel P6-3 Panel P6-2 8 Subtask F00 Remove power from Hydraulic System A or B i.a.w. MM Task page block 200 and attach DO NOT OPERATE label. 9 Subtask F00 Put the HYD PUMPS ENG switch on P5 Panel in the OFF position. FORM No NG - ISSUE 5 - PAGE 3 of 21

4 ITEM TASK DESCRIPTION 10 Subtask F00 Remove the Fan Cowl Panel i.a.w. MM F Subtask F00 read the WARNING notes regarding electrical power and leading edge devices then open the Thrust Reverser i.a.w. MM F00 12 Subtask F00 read the WARNING note then Remove Electrical Power i.a.w. MM and attach DO NOT OPERATE label to the BAT switch on P5 panel. 13 Subtask F00 Install the Thrust Reverser Hold Open Tool C after reading & complying with the CAUTION and WARNING notes. 14 Subtask F00 Disconnect the Thrust Reverser Opening Actuators. 15 Subtask F00 If the number 2 engine is removed then secure the Thrust Reverser Latches. Note : This will give clearance for the engine stand on the left hand side. 16 Subtask F00 Read & comply with the WARNING then apply the protective covers around the fire seals. FAN CASE DISCONNECTS ON THE LEFT HAND SIDE Read the note related to this task 17 Subtask F00 Drain the fuel supply line. 18 Subtask F00 Disconnect the 2 Electrical Connectors. FORM No NG - ISSUE 5 - PAGE 4 of 21

5 ITEM TASK DESCRIPTION 19 Subtask F00 Disconnect the Starter Duct. TUI 20 Subtask F00 Disconnect the Hydraulic Lines. 21 Subtask F00 Disconnect the Fuel Supply Line at the Fan Cowl Support Beam. 22 Subtask F00 Disconnect the DP0502 connector from the Fuel Flow Transmitter. FAN CASE DISCONNECTS ON THE RIGHT HAND SIDE Read the note related to this task. 23 Subtask F00 Disconnect the eight Electrical Connectors. 24 Subtask F00 Disconnect the Strut Drain Line and ensure that the CAUTION note is complied with. ENGINE CORE DISCONNECTS ON THE LEFT HAND SIDE 25 Subtask F00 Disconnect the Pressure Sensing Line from the Precooler ensuring that the CAUTION note is complied with. 26 Subtask F00 Disconnect the 450 degrees F Temperature Sensing Line. FORM No NG - ISSUE 5 - PAGE 5 of 21

6 ITEM TASK DESCRIPTION 27 Subtask F00 Disconnect the five extinguishing tube from the strut and left side of the precooler. ENGINE CORE DISCONNECTS ON THE RIGHT HAND SIDE 28 Subtask F00 Disconnect the 390 degrees F Temperature Sensing Line. 29 Subtask F00 Disconnect the Pneumatic Duct from the Precooler. REMOVE THE POWER PLANT 30 Subtask F00 Remove Forward Thumbnail Fairing i.a.w. MM Subtask F00 Put the Fan Cowl Panel Pins in the Strut. 32 Subtask F00 Install the Forward Bootstrap Equipment paying attention to and complying with the notes and WARNING. 33 Subtask F00 Attach the Forward Bootstrap Equipment to the Engine. 34 Subtask F00 Install the Aft Bootstrap Equipment paying attention to and complying with the notes and WARNING. FORM No NG - ISSUE 5 - PAGE 6 of 21

7 ITEM TASK DESCRIPTION 35 Subtask F00 Attach the Aft Bootstrap Equipment to the Engine. 36 Subtask F00 / F00 / F00 Identify stand manufacturer. Read and comply with the CAUTION and other notes and prepare the Cradle & the Dolly for Engine Removal. Note: AGSE cradle P/N start with AM, Frank brown cradle P/N start with FB and Stanley Aviation cradle P/N starts with Subtask F00 Position the Cradle and Dolly below the Power Plant paying attention to and complying with notes and CAUTION. If necessary raise aircraft by extending the main & nose landing gear i.a.w. MM Task Subtask F00 Set Dynamometers to Zero position. 39 Subtask F00 Read and comply with the CAUTION & other notes then apply correct load to the lever hoists. 40 Subtask F00 Disconnect the Forward Engine Mounts. Note: route removed bolts to stores for NDT inspection. 41 Subtask F00 Disconnect the Aft Engine Mount. Note: route removed bolts to stores for NDT inspection. 42 Subtask F00 Read and comply with the CAUTION, WARNING & other notes then Lower the Power Plant. 43 Subtask F00 Disconnect the Bootstrap Equipment from the Power Plant. 44 Subtask F00 Remove the Seal from the top of the Engine Pneumatic Duct and the Starter Duct. Note: these seals may be reused if serviceable. FORM No NG - ISSUE 5 - PAGE 7 of 21

8 ITEM TASK DESCRIPTION 45 Subtask F00 Remove the Power Plant from the work area complying with the CAUTION notes. 46 Subtask F00 Remove the two Lock pins and remove the Engine Attach Bracket from the turbine rear frame. 47 Subtask F00 If necessary; remove the Bootstrap Equipment from the Strut. 48 Subtask F00 AGSE cradle: Install the eye-bolt and diagonal brace on the forward cradle arms once engine is clear from airplane. 49 If the Left engine is removed Inspect the Left Strut Forward and Aft Engine Mount Assemblies Task Card If the Right engine is removed Inspect the Right Strut Forward and Aft Engine Mount Assemblies. Task Card Make sure that all of the protective caps/covers have been installed on electrical connectors, hoses, tubes, ducts, VBV louvers, open gearbox lines (gearbox LRUs removed) and any other openings where contamination can occur. MM TASK F00 POWER PLANT INSTALLATION Preparation 52 Refer to step : Subtask F00 Make sure the configuration of the engine to be installed is compatible with the airplane and the thrust reversers. Refer to Item E 53 Refer to step : Subtask F00 Make sure that the configuration of the primary exhaust nozzle and the airplane strut are compatible. Refer to Item F FORM No NG - ISSUE 5 - PAGE 8 of 21

9 ITEM TASK DESCRIPTION 54 Subtask F00 Ensure that the compression rod assembly is properly installed. 55 Subtask F00 Replace the bolts at the forward and aft engine mountings with serviceable bolts. Note: if serviceable bolts are not available removed bolts must be NDT inspected by Florescent Penetrant Inspection method. 56 Subtask F00, Do a check of the self locking feature of the four barrel nuts of the forward engine mount on the ongoing engine. 57 Subtask F00, Do a check of the self locking feature of the four barrel nuts of the aft engine mount. 58 Subtask F01 Do a check of the aft engine mount for the correct Installation of the centre link. Ref: AD para (n), Boeing SB A1462, and task cards 71-TOM-001/ Subtask F00, Do a visual check for worn wires at the forward transponder of the upper engine fire detector on the ongoing engine. FORM No NG - ISSUE 5 - PAGE 9 of 21

10 POWERPLANT INSTALLATION AMM TASK F00 ITEM TASK DESCRIPTION 60 Subtask F00 Lubricate the Shear Pin on the Strut Interface of the Aft Engine Mount. 61 Subtask F00 Lubricate the two Shear Pins on the Forward Engine Mount. 62 Subtask F00 Install the Bootstrap equipment on the strut if it is not already installed. 63 Subtask F00 Temporarily remove the three dynamometers if they are still attached to the lever hoists. 64 Subtask F00 Disconnect the Diagonal Braces from the left and right forward cradle arms on the dolly if this has not already been done. 65 Subtask F00 AGSE Cradle: Read the CAUTION note then remove the Eye-bolts from the arms of the cradle. 66 Subtask F00 / F00 / F00 Identify engine cradle and position the replacement Power Plant installed in its cradle and dolly, paying attention to the notes, below the Strut. Note: AGSE cradle P/N start with AM, Frank brown cradle P/N start with FB and Stanley Aviation cradle P/N starts with Subtask F00 Read the WARNING note before making sure that the Chains on the three Lever Hoists are not twisted. 63 Subtask F00 Attach the Dynamometers to the Lever Hoists on the Forward Bootstrap Equipment. FORM No NG - ISSUE 5 - PAGE 10 of 21

11 ITEM TASK DESCRIPTION 64 Subtask F00 Attach the Dynamometer to the Lever Hoist on the aft Bootstrap Equipment. 65 Subtask F00 Attach each Forward Dynamometer to the Cradle-to-engine Attach Bracket. 66 Subtask F00 Attach the Aft Dynamometer to the Engine Attach Bracket. 67 Subtask F00 Make sure that the Forward and Aft Bootstrap and all engine Attach Brackets are installed correctly. 68 Subtask F00 Set all of the Dynamometers to Zero position. 69 Subtask F00 / F00 / F00 Comply with the CAUTION note and Disconnect the engine from the cradle. 70 Subtask F00 Slowly increase the load on the three dynamometers to raise the engine. 71 Subtask F00 Use the forward outboard lever hoist to roll the engine until it is parallel to the engine mounts on the strut (approximately 6 degrees). 72 Subtask F00 As you continue to raise the engine, raise the aft end slightly higher than the forward end. This will keep the above interference areas to a minimum. 73 Subtask F00 As you engage the shear pins make sure the engine mount surfaces are parallel with the strut. FORM No NG - ISSUE 5 - PAGE 11 of 21

12 ITEM TASK DESCRIPTION TUI 74 Subtask F00 Record the applied engine load from each dynamometer:- Forward inboard:.. Forward outboard:. Aft:. 75 Subtask F00 Continue to raise the engine Until the engine mounts are inches below the strut. Make sure that the aft mount surfaces are parallel to the mating strut surface. If they are not refer to AMM. 76 Subtask F00 If the rear shear pin does not fully engage and a clearance of approximately 0.3 inches is visible you must verify that the exhaust nozzle is compatible with the strut. 77 Subtask F00 Slowly raise the two forward lever hoists equally until the forward mount is engaged with the mating strut surfaces. 78 Subtask F00 Examine the strut fire seal to make sure that it is seated correctly and does not protrude over the engine fan case. 79 Subtask F00 Read the CAUTION and other notes then apply a preload to the lever hoists greater than the dynamometer loads recorded against Subtask F00 (item 75) but below the maximum allowable limits. 80 Subtask F00 If after the preload there is a clearance between the forward or aft mounts, follow the AMM subtask F00 to remove it. 81 Subtask F00 ENGINES WITH THE SHORT EXHAUST NOZZLE AND PLUG Make sure that the pin at the 12 o clock position on the exhaust nozzle is centred in the mating receptacle on the strut. 82 Subtask F00 Attach the power plant to the strut using the bolts, washers & barrel nuts installed and checked against Subtask F00, F00 & F00 (Item_55-57). 83 Subtask F00 Apply the initial torque to the engine mount bolts. FORM No NG - ISSUE 5 - PAGE 12 of 21

13 ITEM TASK DESCRIPTION TUI 84 Subtask F00 Apply the final torque to the engine mount bolts and record torque applied:- Inb d fwd mount bolts:.inb d aft mount bolts:... Outb d fwd mount bolts:.outb d aft mount bolts:.. Record the number of the Torque Wrenches used:. 85 Carry out a duplicate inspection of the engine mount bolt installation. 86 Subtask F00 Remove the cradle from the work area and reinstall any removed components ready for shipping. 87 Subtask F00 Remove the load from the Lever Hoists. 88 Subtask F00 Disconnect the Bootstrap equipment from the Power Plant. 89 Subtask F00 Remove the Forward Bootstrap Equipment from the Strut. 90 Subtask F00 Install the Forward Thumbnail Fairing i.a.w. MM Task page block Subtask F00 Remove the Aft Bootstrap Equipment from the Strut. 92 Subtask F00 If the main & nose landing gear have been extended retract them to their usual service band limits i.a.w. MM Task FORM No NG - ISSUE 5 - PAGE 13 of 21

14 ITEM TASK DESCRIPTION FAN CASE CONNECTIONS ON LEFT SIDE 93 Subtask F00 Connect the Harness Connectors DP1234 to the Strut Receptacles. 94 Subtask F00 Do the AMM steps to connect the harness connector D30038 to the strut receptacle. 95 Subtask F00 Connect the Starter Duct to the Strut. 96 Subtask F00 Connect the Hydraulic Lines. 97 Subtask F00 Examine and connect the Fuel Supply Line. 98 Subtask F00 Connect the DP 0502 connector to the fuel flow transmitter. FAN CASE CONNECTIONS ON RIGHT SIDE 99 Subtask F00 Connect the 8 Electrical Harness Connectors to their mating receptacles. 100 Carry out a duplicate inspection of the Electrical Harness Connections. FORM No NG - ISSUE 5 - PAGE 14 of 21

15 ITEM TASK DESCRIPTION 101 Subtask F00 Connect the Strut Drain Line. TUI CORE AREA CONNECTIONS ON THE LEFT SIDE. 103 Subtask F00 Connect the Pressure Sense Line on the side of the Precooler complying with the CAUTION notes. 104 Subtask F00 Connect the 450 degree F Temperature Sense Line on the side of the Precooler complying with the CAUTION notes. 105 Subtask F00 If previously disconnected or removed, install the fire extinguishing to be the strut. CORE AREA CONNECTIONS ON THE RIGHT SIDE 106 Subtask F00 Connect the Engine Pneumatic Duct to the Precooler. 107 Subtask F00 Connect the 390 degree F Temperature Sense Line on the side of the Precooler complying with the CAUTION notes. PUT THE AIRCRAFT BACK TO IT S USUAL CONDITION 108 Subtask F00 Connect the Opening Actuators for the Trust reversers. FORM No NG - ISSUE 5 - PAGE 15 of 21

16 ITEM TASK DESCRIPTION TUI 109 Subtask F00 remove the equipment from the Thrust Reverser and the Strut whilst complying with the WARNING note. 110 Subtask F00 If No. 2 Engine was installed, remove the tape from the edges of the Thrust Reverser. 111 Subtask F00 Remove the protective covers or tape from the Fire Seals on the top aft location on the Thrust reverser inner surface. 112 Subtask F00 Carry out the engine De-preservation procedure if necessary i.a.w. MM Task F Subtask F00 ENGINES WITH BLEED AIR CHECK VALVE P/N : Do the Bleed Air Check Valve Inspection task Note: This task is not required if the valve is a newly installed valve or was overhauled at the engine shop visit. 114 Subtask F00 Make sure the engine oil system is serviced correctly i.a.w. MM Task Subtask F00 Make sure the oil system for the IDG is serviced correctly i.a.w. MM Task Subtask F00 Make sure the oil system for the starter is serviced correctly i.a.w. MM Task F00. NOTE: The oil service of the starter is not necessary if you re-install the removed engine. 117 Subtask F00 Pay attention to the WARNING note and close the Thrust Reverser i.a.w. MM Task F Subtask F00 Install the Fan Cowl Panel i.a.w. MM Task F00. FORM No NG - ISSUE 5 - PAGE 16 of 21

17 ITEM TASK DESCRIPTION TUI 119 Make sure that the Starter Air Valve manual override socket is aligned with the starter override access hole on the fan cowls. If misaligned, then realign the starter valve. 120 Subtask F00 Pay attention to the CAUTION note and remove all objects from the Engine Inlet and work area around the power plant. 121 Subtask F00 Remove DO NOT CLOSE labels and close the Circuit Breakers:- For No. 1 Engine; Panel P6-3 Panel P Subtask F00 Remove DO NOT CLOSE labels and close the Circuit Breakers:- For No. 2 Engine; Panel P6-3 Panel P Subtask F00 Remove the DO NOT OPERATE labels from the Start Levers. 124 Subtask F00 Remove the DO NOT OPERATE labels from the HYD PUMPS ENG Switch. 125 Subtask F00 Supply Electrical Power i.a.w. MM Task page block Subtask F00 Reset the FMCS CDU, paying attention to all of the CAUTION notes. 127 Subtask F00 Make sure the engine thrust rating shown on the IDENT/CONFIG screen is correct. Make sure the EEC software version of the 2 EECs is compatible. Refer to SL Subtask F00 For the replaced engine clear any engine excendences on the Engine Excedence page. FORM No NG - ISSUE 5 - PAGE 17 of 21

18 ITEM TASK DESCRIPTION TUI 129 Subtask F00 Do a check of the fuel control module P5-2 and the ongoing HMU for the correct operation of the ENG VLV closed light. 130 Subtask F00 Do a check of the Fan Balance Screws on the engine and in the AVM (VIBRO-METER) to make sure they agree i.a.w. MM Task F Subtask F00 if the engine was replaced with a different engine, erase the Advanced AVM (if installed, Advanced AVM P/N is ). REPLACEMENT ENGINE TEST 132 Subtask F00 Do the tests listed in the Power Plant Test reference table for engine replacement. Determine if engine is pretested or untested. A pretested engine is an engine that has been tested on a test cell since the last separation of a major or minor module flange. REPLACMENT ENGINE TEST PRETESTED ENGINE TEST 9 AMM F Subtask F00 Erase all EEC faults i.a.w. MM Task F Subtask F00 Carry out EEC test i.a.w. MM Task F Subtask F00 Make sure the Engine Thrust Rating shown on the IDENT/CONFIG screen is correct (ref item ). 136 Subtask F00 Carry out EEC discretes check i.a.w MM Task F00. FORM No NG - ISSUE 5 - PAGE 18 of 21

19 ITEM TASK DESCRIPTION 137 Subtask F00 Do the Engine Fire Detection Operational Test i.a.w. MM Task Subtask F00 Leak Check of the Bleed Air Regulator and PRSOV i.a.w. MM Task page block 400 & Subtask F00 Perform Test 12 Actuator Test i.a.w. MM Task F Subtask F00 Perform Test 3A - Idle Power Leak Check i.a.w. MM Task F Subtask F00 Verify that there is more than 10 psi bleed pressure from the newly installed engine. 142 Subtask F00 Ensure that there is no obvious fuel leak from the fuel inlet hose. Note: It is not necessary to approach the engine whilst it is running to carry out this check. 143 Subtask F00 Check the Hydraulic System A or B Pressurisation with an Engine Driven Pump i.a.w. MM Task Subtask F00 Operational Test for No.1 Engine IDG i.a.w. MM Task (as applicable). 145 Subtask F00 Operational Test for No.2 Engine IDG i.a.w. MM Task (as applicable). 146 Subtask F00 Operational Test of the Inlet Cowl Anti-Icing i.a.w. MM Task FORM No NG - ISSUE 5 - PAGE 19 of 21

20 ITEM TASK DESCRIPTION TUI 147 Subtask F00 After the engine has stopped, examine the Engine Drains for signs of Leakage i.a.w. MM Task F Subtask F00 Re-connect the IDG (ensure N2 has stopped rotating before re-connecting). 149 Subtask F00 Look for the EEC BITE TEST RECENT FAULTS i.a.w. MM Task F Subtask F00 If any maintenance message(s) have been corrected then repeat the applicable section of the engine test. 151 Replace fan blade damage chart in tech log. Place off going chart with removed engine documentation. 152 Record engine change details in the Aircraft Technical Log. FORM No NG - ISSUE 5 - PAGE 20 of 21

21 PART RECORD: Component Change / Materials Used ITEM PART NUMBER OFF SERIAL NUMBER OFF PART NUMBER ON SERIAL NUMBER ON BATCH NO. CERTIFICATE OF RELEASE TO SERVICE: CERTIFIES THAT THE WORK SPECIFIED EXCEPT AS OTHERWISE SPECIFIED, WAS CARRIED OUT IN ACCORDANCE WITH EASA PART 145 AND IN RESPECT TO THAT WORK THE AIRCRAFT/ AIRCRAFT COMPONENT IS CONSIDERED READY FOR RELEASE TO SERVICE. EASA REF No. UK SIGNATURE: DATE: AUTHORITY:... FORM No NG - ISSUE 5 - PAGE 21 of 21