EF G C F M 5 6 BASIC ENGINE CFM56-7B February 2002 ATA level 3 CTC-223 EF G CFM56-7B TRAINING MANUAL BASIC ENGINE Published by CFMI CFMI Customer Training Center Snecma Services - Snecma Group Direction de l’Après-Vente Civile MELUN-MONTEREAU Aérodrome de Villaroche B.P. 1936 77019 - MELUN-MONTEREAU Cedex FRANCE EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION CFMI Customer Training Services GE Aircraft Engines Customer Technical Education Center 123 Merchant Street Mail Drop Y2 Cincinnati, Ohio 45246 USA GENERAL Page 1 Feb 02 EF G CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION GENERAL Page 2 Feb 02 EF G CFM56-7B TRAINING MANUAL This CFMI publication is for Training Purposes Only. The information is accurate at the time of compilation; however, no update service will be furnished to maintain accuracy. For authorized maintenance practices and specifications, consult pertinent maintenance publications. The information (including technical data) contained in this document is the property of CFM International (GE and SNECMA). It is disclosed in confidence, and the technical data therein is exported under a U.S. Government license. Therefore, None of the information may be disclosed to other than the recipient. In addition, the technical data therein and the direct product of those data, may not be diverted, transferred, re-exported or disclosed in any manner not provided for by the license without prior written approval of both the U.S. Government and CFM International. COPYRIGHT 1998 CFM INTERNATIONAL EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION GENERAL Page 3 Feb 02 EF G CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION GENERAL Page 4 Feb 02 EFG CFM56-7B TRAINING MANUAL TABLE OF CONTENTS EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION CONTENTS BASIC ENGINE Page 1 Feb 02 EFG CFM56-7B Chapter Section TRAINING MANUAL Page Table of Contents 1 to 2 Lexis 1 to 8 Intro 1 to 8 72-00-00 Engine General 1 to 10 72-20-00 Fan Section 1 to 26 72-00-02 Core Engine Major Module 1 to 4 72-30-00 High Pressure Compressor Section 1 to 6 72-40-00 Combustion Section 1 to 6 72-50-00 Turbine Section 1 to 12 72-60-00 Accessory Drive Section 1 to 10 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION CONTENTS BASIC ENGINE Page 2 Feb 02 EFG CFM56-7B TRAINING MANUAL ABBREVIATIONS & ACRONYMS EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION LEXIS Page 1 Feb 02 EFG A A/C AC ACARS ACMS ACS ADC ADEPT ADIRS AGB AIDS ALF ALT AMB AMM AOG APU ARINC ATA ATC ASM ATHR ATO AVM CFM56-7B AIRCRAFT ALTERNATING CURRENT AIRCRAFT COMMUNICATION ADRESSING and REPORTING SYSTEM AIRCRAFT CONDITION MONITORING SYSTEM AIRCRAFT CONTROL SYSTEM AIR DATA COMPUTER AIRLINE DATA ENGINE PERFORMANCE TREND AIR DATA AND INERTIAL REFERENCE SYSTEM ACCESSORY GEARBOX AIRCRAFT INTEGRATED DATA SYSTEM AFT LOOKING FORWARD ALTITUDE AMBIENT AIRCRAFT MAINTENANCE MANUAL AIRCRAFT ON GROUND AUXILIARY POWER UNIT AERONAUTICAL RADIO, INC. (SPECIFICATION) AIR TRANSPORT ASSOCIATION AUTO-THROTTLE COMPUTER AUTOTHROTTLE SERVO MECHANISM AUTO THRUST ABORTED TAKE OFF AIRCRAFT VIBRATION MONITORING EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC B BITE BMC BSI BSV BVCS C CAS CBP CCDL CCFG CCU CCW CDP CDS CFDIU CFDS CFMI Ch A Ch B CMC CMM CMS CG TRAINING MANUAL BUILT IN TEST EQUIPMENT BLEED MANAGEMENT COMPUTER BORESCOPE INSPECTION BURNER STAGING VALVE BLEED VALVE CONTROL SOLENOID CALIBRATED AIR SPEED (HP) COMPRESSOR BLEED PRESSURE CROSS CHANNEL DATA LINK COMPACT CONSTANT FREQUENCY GENERATOR COMPUTER CONTROL UNIT COUNTER CLOCKWISE (HP) COMPRESSOR DISCHARGE PRESSURE COMMON DISPLAY SYSTEM CENTRALIZED FAULT DISPLAY INTERFACE UNIT CENTRALIZED FAULT DISPLAY SYSTEM JOINT GE/SNECMA COMPANY (CFM INTERNATIONAL) channel A channel B CENTRALIZED MAINTENANCE COMPUTER COMPONENT MAINTENANCE MANUAL CENTRALIZED MAINTENANCE SYSTEM CENTER OF GRAVITY LEXIS Page 2 Feb 02 EFG CFM56-7B cm.g CHATV CIP(HP) CIT(HP) CODEP CPU CRT CSD CSI CTAI CSN Cu.Ni.In CW CENTIMETER X GRAMS CHANNEL ACTIVE COMPRESSOR INLET PRESSURE COMPRESSOR INLET TEMPERATURE HIGH TEMPERATURE COATING CENTRAL PROCESSING UNIT CATHODE RAY TUBE CONSTANT SPEED DRIVE CYCLES SINCE INSTALLATION COWL THERMAL ANTI-ICING CYCLES SINCE NEW CUPPER.NICKEL.INDIUM CLOCK WISE E EBU ECA ECAM D DC DCU DEU DFCS DFDAU DISC DIU DMC DMU DMS DPU DIRECT CURRENT DATA CONVERSION UNIT DISPLAY ELECTRONIC UNIT DIGITAL FLIGHT CONTROL SYSTEM DIGITAL FLIGHT DATA ACQUISITION UNIT DISCRETE DIGITAL INTERFACE UNIT DISPLAY MANAGEMENT COMPUTER DATA MANAGEMENT UNIT DEBRIS MONITORING SYSTEM DIGITAL PROCESSING MODULE EHSV EIS EIU EMF EMI EMU ESN EIU ENGINE BUILDUP UNIT ELECTRICAL CHASSIS ASSEMBLY ELECTRONIC CENTRALIZED AIRCRAFT MONITORING ENVIRONMENTAL CONTROL SYSTEM ELECTRONIC ENGINE CONTROL ERASABLE PROGRAMMABLE READ ONLY MEMORY ENGINE FLIGHT HOURS ELECTRONIC FLIGHT INSTRUMENT SYSTEM EXHAUST GAS TEMPERATURE ENGINE INDICATING AND CREW ALERTING SYSTEM ELECTRO-HYDRAULIC SERVO VALVE ELECTRONIC INSTRUMENT SYSTEM ENGINE INTERFACE UNIT ELECTROMOTIVE FORCE ELECTRO MAGNETIC INTERFERENCE ENGINE MAINTENANCE UNIT ENGINE SERIAL NUMBER ENGINE INTERFACE UNIT F FAA FEDERAL AVIATION AGENCY EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC TRAINING MANUAL CFMI PROPRIETARY INFORMATION ECS EEC EPROM EFH EFIS EGT EICAS LEXIS Page 3 Feb 02 EFG FADEC CFM56-7B FRV FWC FWD FULL AUTHORITY DIGITAL ENGINE CONTROL FUEL AIR RATIO FLIGHT DATA ACQUISITION & MANAGEMENT SYSTEM FLIGHT DATA RECORDING SYSTEM FIELD ENGINEERING INVESTIGATION MEMO FAN FRAME/COMPRESSOR CASE VERTICAL (VIBRATION SENSOR) FLIGHT IDLE (F/I) FORWARD LOOKING AFT FLEXIBLE TAKE OFF FLIGHT MANAGEMENT COMPUTER FLIGHT MANAGEMENT AND GUIDANCE COMPUTER FLIGHT MANAGEMENT SYSTEM FUEL METERING VALVE FOREIGN OBJECT DAMAGE FRONT PANEL ASSEMBLY FLUORESCENT PENETRANT INSPECTION FUEL RETURN VALVE FAULT WARNING COMPUTER FORWARD G GE GEM GI GENERAL ELECTRIC GROUND-BASED ENGINE MONITORING GROUND IDLE (G/I) FAR FDAMS FDRS FEIM FFCCV FI FLA FLX TO FMC FMGC FMS FMV FOD FPA FPI EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC g.in GMT GPU GSE TRAINING MANUAL GRAM X INCHES GREENWICH MEAN TIME GROUND PPOWER UNIT GROUND SUPPORT EQUIPMENT H HCF HMU HP HPC HPCR HIGH CYCLE FATIGUE HYDROMECHANICAL UNIT HIGH PRESSURE HIGH PRESSURE COMPRESSOR HIGH PRESSURE COMPRESSOR ROTOR HPSOV HIGH PRESSURE SHUTOFF VALVE HPT HIGH PRESSURE TURBINE HPTC HIGH PRESSURE TURBINE CLEARANCE HPT(A)CC HIGH PRESSURE TURBINE (ACTIVE) CLEARANCE CONTROL HPTCCV HIGH PRESSURE TURBINE CLEARANCE CONTROL VALVE HPTR HIGH PRESSURE TURBINE ROTOR Hz HERTZ (CYCLE PER SECOND) I IDG INTEGRATED DRIVE GENERATOR ID PLUG IDENTIFICATION PLUG IFSD IN FLIGHT SHUT DOWN IGB INLET GEARBOX IGN IGNITION IGV INLET GUIDE VANE LEXIS Page 4 Feb 02 EFG in. I/O IOM IR K K L lbs. LCF LE (L/E) L/H LP LPC LPT LPTC LPT(A)CC LPTR LRU LVDT M MO MCD MCDU MCL MCT MDDU CFM56-7B INCH INPUT/OUTPUT INPUT OUTPUT MODULE INFRA RED mm. MMEL MTBF MTBR 1000 X N N1 (NL) POUNDS, WEIGHT LOW CYCLE FATIGUE LEADING EDGE LEFT HAND LOW PRESSURE LOW PRESSURE COMPRESSOR LOW PRESSURE TURBINE LOW PRESSURE TURBINE CLEARANCE LOW PRESSURE TURBINE (ACTIVE) CLEARANCE CONTROL LOW PRESSURE TURBINE ROTOR LINE REPLACEABLE UNIT LINEAR VARIABLE DIFFERENTIAL TRANSFORMER AIRCRAFT SPEED MACH NUMBER MAGNETIC CHIP DETECTOR MULTIPURPOSE CONTROL AND DISPLAY UNIT MAXIMUM CLIMB MAXIMUM CONTINUOUS MULTIPURPOSE DISK DRIVE UNIT EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION TRAINING MANUAL MILLIMETERS MAIN MINIMUM EQUIPMENT LIST MEAN TIME BETWEEN FAILURES MEAN TIME BETWEEN REMOVALS N2ACT NVM LOW PRESSURE ROTOR ROTATIONAL SPEED ACTUAL N1 DEMANDED N1 COMMANDED N1 TARGETED FAN SPEED HIGH PRESSURE ROTOR ROTATIONAL SPEED ACTUAL N2 NON VOLATILE MEMORY O OAT OGV OSG OUTSIDE AIR TEMPERATURE OUTLET GUIDE VANE OVERSPEED GOVERNOR N1ACT N1DMD N1CMD N1TARGET N2 (NH) P P0 P25 PCU AMBIENT STATIC PRESSURE HP COMPRESSOR INLET TOTAL AIR TEMPERATURE PRESSURE CONVERTER UNIT LEXIS Page 5 Feb 02 EFG PLA PMC PMUX PS12 PS13 PS3HP PSI PSIA PSID PSM PSS PSU PT PT2 CFM56-7B POWER LEVER ANGLE POWER MANAGEMENT CONTROL PROPULSION MULTIPLEXER FAN INLET STATIC AIR PRESSURE FAN OUTLET STATIC AIR PRESSURE COMPRESSOR DISCHARGE STATIC AIR PRESSURE POUND PER SQUARE INCH POUND PER SQUARE INCH ABSOLUTE POUND PER SQUARE INCH DIFFERENTIAL POWER SUPPLY MODULE PRESSURE SUB-SYSTEM POWER SUPPLY UNIT TOTAL PRESSURE FAN INLET TOTAL AIR PRESSURE (PRIMARY FLOW) Q QAD QTY QWR QUICK ATTACH DETACH QUANTITY QUICK WINDMILL RELIGHT R RACC RAM R/H RPM RTD ROTOR ACTIVE CLEARANCE CONTROL RANDOM ACCESS MEMORY RIGHT HAND REVOLUTION PER MINUTE RESISTIVE THERMAL DEVICE EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC RTV RVDT TRAINING MANUAL ROOM TEMPERATURE VULCANIZING (MATERIAL) ROTARY VARIABLE DIFFERENTIAL TRANSFORMER S SAV SB SCU SDI STARTER AIR VALVE SERVICE BULLETIN SIGNAL CONDITIONING UNIT SOURCE/DESTINATION IDENTIFIER (BITS) (CF ARINC SPEC) SDU SOLENOID DRIVER UNIT SER SERVICE EVALUATION REQUEST SFC SPECIFIC FUEL CONSUMPTION SG SPECIFIC GRAVITY SLS SEA LEVEL STANDARD (CONDITIONS : 29.92 in. Hg/59 F) SMM STATUS MATRIX SMP SOFTWARE MANAGEMENT PLAN S/N SERIAL NUMBER SNECMA SOCIETE NATIONALE D’ETUDE ET DE CONSTRUCTION DE MOTEURS D’AVIATION SOL SOLENOID S/R SERVICE REQUEST S/V SHOP VISIT SVR SHOP VISIT RATE SW SOFTWARE LEXIS Page 6 Feb 02 EFG T T12 T25 T3 T49.5 T5 TAT TBD TBV T/E T/C TC TCase TCC TCJ TEO TGB Ti TLA TM TMC TO/GA T/O T oil CFM56-7B FAN INLET TOTAL AIR TEMPERATURE HP COMPRESSOR INLET AIR TEMPERATURE HP COMPRESSOR DISCHARGE AIR TEMPERATURE EXHAUST GAS TEMPERATURE LOW PRESSURE TURBINE DISCHARGE TOTAL AIR TEMPERATURE TOTAL AIR TEMPERATURE TO BE DETERMINED TRANSIENT BLEED VALVE TRAILING EDGE THERMOCOUPLE HP TURBINE CASE TEMPERATURE HP TURBINE CASE TEMPERATURE TURBINE CLEARANCE CONTROL TEMPERATURE COLD JUNCTION ENGINE OIL TEMPERATURE TRANSFER GEARBOX TITANIUM THROTTLE LEVER ANGLE TORQUE MOTOR TORQUE MOTOR CURRENT TAKE OFF/GO AROUND TAKE OFF OIL TEMPERATURE EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION TPU T/R TRA TRDV TRAINING MANUAL TSI TSN TTL TRANSIENT PROTECTION UNIT THRUST REVERSER THROTTLE RESOLVER ANGLE THRUST REVERSER DIRECTIONAL VALVE THRUST REVERSER PRESSURIZING VALVE TIME SINCE INSTALLATION (HOURS) TIME SINCE NEW (HOURS) TRANSISTOR TRANSISTOR LOGIC U UER UNSCHEDULED ENGINE REMOVAL TRPV V VAC VBV VDC VDT VRT VSV VOLTAGE, ALTERNATING CURRENT VARIABLE BLEED VALVE VOLTAGE, DIRECT CURRENT VARIABLE DIFFERENTIAL TRANSFORMER VARIABLE RESISTANCE TRANSDUCER VARIABLE STATOR VANE W WDM WFM WOW WTAI WATCHDOG MONITOR WEIGHT OF FUEL METERED WEIGHT ON WHEEL WING THERMAL ANTI-ICING LEXIS Page 7 Feb 02 EFG CFM56-7B TRAINING MANUAL ENGLISH/METRIC CONVERSIONS METRIC/ENGLISH CONVERSIONS 1 mile = 1.609 km 1 km = 0.621 mile 1 foot = 0.3048 m or 30.48 cm 1 m = 3.281 ft. or 39.37 in. 1 in. = 0.0254 m or 2.54 cm 1 cm = 0.3937 in. 1 mil. = 25.4 10-6 m or 25.4mm 1 mm = 39.37 mils. 1 lb. = 0.454 kg 1 kg =2.205 lbs 1 psi. = 6.890 kPa or 6.89 10-2 bar 1 Pa = 1.45 10-4 psi. 1 kPa = 0.145 psi or 0.01 bar 1 bar = 14.5 psi °F = 1.8 x °C + 32 °C = ( °F - 32 ) /1.8 1 sq.in. = 6.45 cm² 1 m² = 10.76 sq. ft. 1 USG = 3.785 l ( dm³ ) 1 cm² = 0.155 sq.in. 1 cu.in. = 16.39 cm³ 1 m³ = 35.31 cu. ft. 1 dm³ = 0.264 USA gallon 1 cm³ = 0.061 cu.in. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC LEXIS Page 8 Feb 02 EF G CFM56-7B TRAINING MANUAL INTRODUCTION TO THE CFM56 FAMILY EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION INTRO BASIC ENGINE Page 1 Feb 02 EF G CFM56-7B TRAINING MANUAL INTRODUCTION TO THE CFM56 FAMILY The CFM56 engine, a high by-pass, dual rotor, axial flow advanced technology turbofan, was designed in the mid 70’s. It is a product of CFMI. CFM International is a company jointly owned by GENERAL ELECTRIC (GE) of the USA, and SOCIETE NATIONALE D’ETUDE ET DE CONSTRUCTION DE MOTEURS D’AVIATION (SNECMA) of France. CFMI, with the full backing of parent companies holding equal shares, has a dual function: - Overall program management, on behalf of both GE and SNECMA - Single interface with customers for marketing and product support EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC INTRO BASIC ENGINE Page 2 Feb 02 EF G CFM56-7B TRAINING MANUAL DESIGN DEVELOPMENT MANUFACTURING ASSEMBLY Jointly owned company Uses all GENERAL ELECTRIC and SNECMA resources... ...With work split 50/50 One program manager One customer interface MARKETING PRODUCT SUPPORT CUSTOMER SATISFACTION CTC-223-001-00 CFM INTERNATIONAL ORGANIZATION EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION INTRO BASIC ENGINE Page 3 Feb 02 EF G CFM56-7B TRAINING MANUAL INTRODUCTION TO THE CFM56 FAMILY Engine Applications The following chart shows the various engine models for the Boeing B737-600/-700/-800/-900/-BBJ/COMBI/C40A aircraft. The engine used on these aircraft is the CFM56-7B, which has several different thrust ratings. Ranging from 19500 to 27300 lbs of thrust, the CFM56-7B is offered by CFMI as the common power source for the Boeing 737 Next Generation Versions. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC INTRO BASIC ENGINE Page 4 Feb 02 EF G CFM56-7B CFM56-7B18 (19,500 lbs) CFM56-7B20 (20,600 lbs) CFM56-7B22 (22,700 lbs) TRAINING MANUAL 737-600 CFM56-7B20 (20,600 lbs) CFM56-7B22 (22,700 lbs) CFM56-7B24 (24,200 lbs) 737-700 CFM56-7B24 (24,200 lbs) CFM56-7B26 (26,300 lbs) CFM56-7B27 (27,300 lbs) 737-800 CFM56-7B24 (24,200 lbs) CFM56-7B26 (26,300 lbs) CFM56-7B27 (27,300 lbs) 737-900 737-BBJ / COMBI CFM56-7B26 (26,300 lbs) CFM56-7B24 (24,200 lbs) CTC-223-002-00 CFM56-7B FOR BOEING APPLICATIONS EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC C40A CFMI PROPRIETARY INFORMATION INTRO BASIC ENGINE Page 5 Feb 02 EF G CFM56-7B TRAINING MANUAL CFM56-7B MAIN CHARACTERISTICS Type of engine Turbo fan Performance (*figures depend on engine model) Arrangement Two spool axial flow - Take-off thrust (SLS) *19500 - 27300 lbs Rotation Clockwise (ALF) - Take-off flat rated Temperature °F/°C *86/30 Compressors - Fan - LP Compressor - HP Compressor Single stage Four stages Nine stages - Max climb thrust *5960 lbs - By-pass ratio *5.1:1 to 5.5:1 Combustion chamber Annular SAC (option DAC) - EGT red line 950°C - 100% N1 (Low Pressure Rotational Speed) 5175 rpm - N1 speed limit (red line) 104% - 100% N2 (High Pressure Rotational Speed) 14460 rpm - N2 speed limit (red line) 105% Turbines - HP Turbine - LP Turbine Single stage Four stages Weight 2384 kg (5257 lbs) Overall dimensions - Length - Height - Width 2.51m (98.72 ins) 1.83m (72.00 ins) 2.12m (83.40 ins) EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC INTRO BASIC ENGINE Page 6 Feb 02 EF G CFM56-7B CFM56-7B CTC-223-003-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC TRAINING MANUAL CFMI PROPRIETARY INFORMATION INTRO BASIC ENGINE Page 7 Feb 02 EF G CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC INTRO BASIC ENGINE Page 8 Feb 02 EFG CFM56-7B TRAINING MANUAL ENGINE GENERAL EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-00-00 BASIC ENGINE Page 1 Feb 02 EFG CFM56-7B TRAINING MANUAL ENGINE GENERAL CONCEPT The CFM56-7B engine is a high by-pass, dual rotor, axial flow, advanced technology turbofan. It is supported by the wing pylon and streamlined by cowlings. Air is sucked into the intake by the fan blades and split into two flow paths, the Primary and the Secondary. The primary airflow passes through the inner portion of the fan blades and is directed into a booster (LPC). The flow path then enters a High Pressure Compressor (HPC) and goes to a combustor. Mixed with fuel and ignited, the gas flow provides energy to a High Pressure Turbine (HPT) and a Low Pressure Turbine (LPT). The secondary airflow passes through the outer portion of the fan blades, the Outlet Guide Vanes (OGV’s) and exits through the nacelle discharge duct, producing approximately 80 % of the total thrust. It also plays a role in the thrust reverser system. At static take-off power, the engine by-pass ratio is between 5.1:1 and 5.5:1, depending on the engine model, which means that the secondary airflow takes in between 5 and 6 times more air than the primary airflow. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-00-00 BASIC ENGINE Page 2 Feb 02 EFG CFM56-7B TRAINING MANUAL SECONDARY FLOW PRIMARY FLOW THRUST REVERSER SYSTEM DESIGN AND OPERATION CTC-223-004-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-00-00 BASIC ENGINE Page 3 Feb 02 EFG CFM56-7B TRAINING MANUAL ENGINE GENERAL CONCEPT The CFM56-7B engine uses a maintenance concept called ‘On Condition Maintenance’. This means that the engine has no periodic overhaul schedules and can remain installed under the wing until something important occurs, or when lifetime limits of parts are reached. For this reason, to monitor and maintain the health of the engine, different tools are available, which are: - Engine performance trend monitoring, to evaluate engine deterioration over a period of use: engine parameters, such as gas temperature, are recorded and compared to those initially observed at engine installation on the aircraft. - Spectrometric oil analysis program (S.O.A.P.): oil is sampled from the oil tank, and an analysis is made of all microscopic (smaller than 10 microns) metal particles it contains. The nature and concentration of metal found indicates the beginning of parts damage. - Engine vibration monitoring system: sensors located in various positions in the engine, send vibration values to the on-board monitoring system. When vibration values are excessive, the data recorded can be used to take remedial balancing action. - Borescope inspection, to check the condition of engine internal parts: when parts are not accessible, they can be visually inspected with borescope probes inserted in ports located on the engine outer casing. - Lubrication particles analysis: while circulating in the oil system, lubrication oil is filtered, and large, visible-to-the-eye particles (larger than 10 microns) coming from worn engine parts are collected in filters and magnetic chip detectors, for visual inspection and analysis. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-00-00 BASIC ENGINE Page 4 Feb 02 EFG CFM56-7B TRAINING MANUAL TREND MONITORING VIBRATION MONITORING BORESCOPE INSPECTION LUBE PARTICLE ANALYSIS CONDITION MONITORING CTC-223-005-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC S.O.A.P. CFMI PROPRIETARY INFORMATION 72-00-00 BASIC ENGINE Page 5 Feb 02 EFG CFM56-7B TRAINING MANUAL ENGINE GENERAL CONCEPT The CFM56-7B engine consists of two independent rotating systems: - The low pressure system rotational speed is designated N1. - The high pressure system rotational speed is designated N2. The engine rotors are supported by 5 bearings, identified in manuals as numbers 1 thru 5, where No. 1 is the most forward and No. 5 the most aft. These bearings are housed in 2 dry sump cavities provided by the fan and turbine frames. Engine structural rigidity is obtained with short lengths between two main structures (frames). The accessory drive system uses energy from the high pressure compressor rotor to drive the engine and aircraft accessories. It also plays a major role in starting. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-00-00 BASIC ENGINE Page 6 Feb 02 EFG CFM56-7B TRAINING MANUAL 5 BEARINGS LP SYSTEM ACCESSORY DRIVE 2 FRAMES HP SYSTEM 2 SUMPS ENGINE GENERAL CONCEPT CTC-223-006-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-00-00 BASIC ENGINE Page 7 Feb 02 EFG CFM56-7B TRAINING MANUAL ENGINE GENERAL CONCEPT The CFM56-7B is a modular concept design engine. It has 17 different modules that are enclosed within three major modules and an accessory drive module. The 4 modules are: - The Fan Major Module - The Core Engine Major Module - The Low Pressure Turbine Major Module - The Accessory Drive Module EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-00-00 BASIC ENGINE Page 8 Feb 02 EFG CFM56-7B FAN MAJOR MODULE TRAINING MANUAL CORE ENGINE MAJOR MODULE LOW PRESSURE TURBINE MAJOR MODULE ACCESSORY DRIVE MODULE MODULAR DESIGN CTC-223-007-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-00-00 BASIC ENGINE Page 9 Feb 02 EFG CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-00-00 BASIC ENGINE Page 10 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 1 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION The fan section is at the front of the engine downstream from the air inlet cowl. It includes the fan and booster module, and the fan frame module. Fan and booster The purposes of the fan and booster are : - to accelerate air overboard to generate thrust - to increase the pressure of the air directed to the High Pressure Compressor (HPC) After entering the air inlet cowl, the total engine airflow passes through the fan rotor, which increases the air’s kinetic energy. Most of the airflow is ducted overboard producing approximately 80% of the total thrust. The remainder is directed through the booster, where it is pressurized before entering the HPC. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 2 Feb 02 EFG CFM56-7B TRAINING MANUAL AIR INLET COWL FAN SECTION MODULE AIR OVERBOARD AIR TO THE BOOSTER FAN AND BOOSTER MODULE CTC-223-008-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 3 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Fan and booster (Cont’d) The fan and booster is located at the front of the engine, downstream from the air inlet cowl, and consists of : - a spinner front cone - a spinner rear cone - a single stage fan rotor - a three stage axial booster Its rotating assembly is mounted on the fan shaft and its fixed assembly is secured to the fan frame. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 4 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN ROTOR 3 - STAGE BOOSTER SPINNER REAR CONE SPINNER FRONT CONE FAN AND BOOSTER DESIGN CTC-223-009-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 5 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Spinner front cone The spinner front cone is designed to minimize ice buildup. It is made of black sulfuric anodized aluminium alloy. It is a hollow cone-shaped structure, which is attached on its rear flange to the spinner rear cone. The attachment is an interference fitting. The rear flange has 6 mounting screw locations and 3 threaded inserts, located every 120°, for installation of jackscrews used in removal procedures. An offset hole, identified by an indent mark, ensures correct installation and centering onto the rear cone front flange. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 6 Feb 02 EFG CFM56-7B TRAINING MANUAL 6 MOUNTING SCREW LOCATIONS INDENT MARK MOUNTING SCREW 3 JACKSCREW LOCATIONS SPINNER FRONT CONE CTC-223-010-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 7 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Spinner rear cone The rear cone smoothes airflow at the inlet of the engine and provides anti-rotation of the fan retaining ring. It also accomodates the fan retaining flange and balancing screws used in fan trim and static balance procedures. It is a hollow elliptical structure that is mounted on interference fit flanges between the spinner front cone and the fan disk. It is made of aluminium alloy and protected by sulfuric anodization. The fan retaining flange is installed on the inner rear flange of the spinner rear cone through an interference fit. There are 6 threaded holes for the installation of jackscrews used if it is necessary to remove the fan retaining flange. Both front and rear flanges have an offset hole to ensure correct installation and they are identified by indent marks. On the front flange of the rear cone, the indent mark is next to the offset hole. The other indent mark is on the outer rim of the rear cone, facing fan blade No.1. The front flange has 6 line replaceable, crimped, selflocking nuts. The inner rear flange has 12 mounting screw holes for installation onto the fan disk. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 8 Feb 02 EFG CFM56-7B TRAINING MANUAL SPINNER REAR CONE ATTACHMENT AREA BALANCING SCREW SELF - LOCKING NUTS SPINNER REAR CONE CTC-223-011-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 9 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Spinner rear cone (cont’d) Balance procedures use various weights which are in the form of balancing screws installed on the rear cone’s outer diameter. The balancing screws are used in two cases : - Fan static balance following fan blade replacement, for example after FOD. - Fan trim balance, when vibration levels are higher than the limits. There are two sets of balancing screws available and the screws in each set are identified as either P01 to P07 or, P08 to P14. The numbers, which are engraved on the screw heads, are equivalent to various weights. There are 36 threaded inserts on the outer rim of the rear flange which accommodate the balance screws. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 10 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN BLADES INDENT MARK FAN DISK SPINNER REAR CONE SPINNER REAR CONE BALANCING SCREWS FAN DISK BALANCING SCREWS BALANCING SCREWS CTC-223-012-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 11 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Fan disk The fan disk is a titanium alloy forging. The outer front flange provides attachment for the rear cone and the retaining flange. The outer rim of the fan disk has 24 curved dovetails slots designed for fan blade retention. It also has a flange designed for the attachment of the fan blade platforms. The fan disk provides attachment for the fan shaft on its inner rear flange and its outer rear flange is bolted to the booster spool. Balance weights are riveted on the forward flange for dynamic module balancing. The inner front flange has an imprint to identify an offset hole for rear cone installation. There are also two identification marks engraved on either side of blade recesses No 1 and 5. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 12 Feb 02 EFG CFM56-7B SPHERICAL IMPRINT OFFSET HOLE 1 1 5 5 FAN BLADE SLOTS TRAINING MANUAL BALANCE WEIGHT PROVISIONS FAN DISK FRONT FLANGE CTC-223-013-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 13 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Fan blades The 24 wide-cord fan blades form the first stage of the Low Pressure Compressor (LPC) and accelerate the air entering the engine through the air inlet cowls. They are made of titanium alloy, and are 20.67ins. (0,52m) long. Each blade has a dovetail base that slides into a recess on the fan disk outer rim. A retainer lug, machined at the rear end of the blade root, engages the forward flange of the booster spool and limits axial movements. 24 platforms, made of forged aluminium, are installed between the blades, to prevent their axial movement. Axial disengagement of the shims is prevented by a retaining ring installed on the front of the fan disk through a bayonet system. Radial and axial movement of the platforms is prevented by a retaining flange, fitted with pins that engage in the platforms front face. Both retaining ring and flange are held in position by the spinner rear cone. 24 shims, made of titanium alloy covered with elastomer strips, are installed under the fan blade roots, to limit their radial movement. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 14 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN BLADE PLATFORM PIN FAN BLADE LPC SHIM FAN DISK RETAINING RING FAN RETAINING FLANGE FAN BLADE INSTALLATION CTC-223-014-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 15 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Fan blades (cont’d) Each blade has specific indications engraved on the bottom of the root. - Part number - Serial number - Momentum weight - Manufacturer code The fan blade root faces have an anti-friction plasma coating (Cu-Ni-In) and a top coat of cured molybdenumbase film varnish, which acts as a lubricant. Lubrication of blade roots is further improved by the application of solid molybdenum-base lubricant before installation on the fan disk. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 16 Feb 02 EFG CFM56-7B MANUFACTURER CODE PART NUMBER MOMENTUM WEIGHT TRAINING MANUAL VIEW A F0301 337-000-114-0 206740 F0491 J023493 SERIAL NUMBER SUB-CONTRACTOR NUMBER EXAMPLE SPECIFIC INDICATIONS MOLYDAG COATING VIEW B Cu-Ni-In AND MOLYDAG COATING A B SPECIFIC INDICATIONS FAN BLADE ROOT CTC-223-015-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 17 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Fan frame module The fan frame module is the forward structure for mounting the engine onto the airframe, and supports the fan and booster module, the HPC and cowls. It consists of the following major assemblies : - The containment case, - The Outlet Guide Vane (OGV) assembly, - The fan frame assembly (shroud and 12-strut hub), - The radial drive shaft housing. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 18 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN FRAME SHROUD 12-STRUT HUB CONTAINMENT CASE RADIAL DRIVESHAFT HOUSING OUTLET GUIDE VANE (OGV) ASSY FAN FRAME MODULE CTC-223-016-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 19 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Containment case The containment case is a single part made of aluminium alloy. Its outer surface has flanges and ribs to give more strength to the case during engine operation and to provide attachment for equipment brackets. It has 2 hoisting points, at the 2 and 10 o’clock positions for ground handling devices, and is equipped with mount fittings at the 9 o’clock position, for the AGB/TGB. Its inner surface houses an abradable liner, located radially in line with the fan rotor blades. The outer shrouds of the OGV’s are bolted at the rear of the containment case. The front flange provides attachment for the air inlet cowl. The rear flange bolts onto the frame shroud front flange. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 20 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN FRAME SHROUD MOUNTING FLANGE OGV OUTER SHROUD ATTACHMENT POINTS 2 HOISTING POINTS OUTLET GUIDE VANES (OGV) FAN FRAME SHROUD FWD AGB / TGB MOUNT FITTINGS ABRADABLE LINER CONTAINMENT CASE FAN INLET COWL MOUNTING FLANGE CONTAINMENT CASE CTC-223-017-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 21 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Outlet Guide Vane (OGV) assembly The OGV assembly is housed at the rear of the containment case. Its purpose is to direct and smooth the secondary airflow to increase thrust efficiency. The assembly consists of the fan OGV inner shroud and 76 vanes, made of aluminium alloy. The OGV inner shroud rear flange is attached to the front of the 12-strut hub with bolts. Its forward outer surface features 76 apertures, containing composite seals, which house the OGV inner platforms and retain them axially in place. The vane outer platforms are bolted to the containment case. A splitter fairing, which separates the primary and secondary airflows, is bolted onto the fan OGV inner shroud forward flange. A borescope port in the inner shroud allows for inspection of stg 3 and 4 booster blades. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 22 Feb 02 EFG CFM56-7B TRAINING MANUAL OUTER PLATFORM FAN FRAME SHROUD CONTAINMENT CASE OGV OGV INNER SHROUD INNER PLATFORM OGV SEAL FAN OUTLET GUIDE VANES CTC-223-018-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 23 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN SECTION Fan frame assembly The fan frame assembly consists of : - the fan frame shroud. - the 12-strut hub. - the radial drive shaft housing. The 12 hollow struts house various equipment and lines. Compartments formed between the struts, house variable bleed valves (VBV). The secondary airflow is ducted rearward between the fan frame shroud and the mid-box structure. The primary airflow from the booster is ducted to the HPC between the center hub and the mid-box structure. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 24 Feb 02 EFG CFM56-7B TRAINING MANUAL FAN FRAME SHROUD VBV COMPARTMENTS SECONDARY AIRFLOW RADIAL STRUTS HUB PRIMARY AIRFLOW FORWARD LOOKING AFT MID-BOX STRUCTURE FAN FRAME ASSEMBLY CTC-223-019-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-20-00 BASIC ENGINE Page 25 Feb 02 EFG CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-20-00 BASIC ENGINE Page 26 Feb 02 EFG CFM56-7B TRAINING MANUAL CORE ENGINE MAJOR MODULE EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-00-02 BASIC ENGINE Page 1 Feb 02 EFG CFM56-7B TRAINING MANUAL CORE ENGINE MAJOR MODULE The core engine is a high pressure, high speed, gas generator that produces the power to drive the engine. Fan discharge air is compressed in the High Pressure Compressor (HPC), heated and expanded in the combustion chamber. It is then directed by the High Pressure Turbine (HPT) nozzles onto the HPT rotor. Energy not extracted from the gas stream by the HPT rotor is used to drive the Low Pressure Turbine (LPT), fan rotors and booster. The forward end of the core is supported by the No 3 ball and roller bearings, located in the fan frame. The aft end is supported by the No 4 roller bearing, located in the HPT rotor rear shaft. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC The core engine consists of the following : The HPC. - HPC rotor. - HPC front stator. - HPC rear stator. The combustion section. - Combustor casing. - Combustion chamber. The HPT. - HPT nozzle. - HPT rotor. - HPT shroud & Stage 1 LPT nozzle. 72-00-02 BASIC ENGINE Page 2 Feb 02 EFG CFM56-7B TRAINING MANUAL COMBUSTION CASE HIGH PRESSURE COMPRESSOR STATOR COMBUSTION SECTION HPT SECTION STAGE 1 LPT NOZZLES HIGH PRESSURE COMPRESSOR ROTOR #3 BEARING #4 BEARING HPC SECTION CORE ENGINE MAJOR MODULE CTC-223-020-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-00-02 BASIC ENGINE Page 3 Feb 02 EFG CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-00-02 BASIC ENGINE Page 4 Feb 02 EFG CFM56-7B TRAINING MANUAL HIGH PRESSURE COMPRESSOR SECTION EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-30-00 BASIC ENGINE Page 1 Feb 02 EFG CFM56-7B TRAINING MANUAL HIGH PRESSURE COMPRESSOR (HPC) SECTION The HPC, which has 9 stages, increases the pressure of the air as it passes from stage to stage, to supply the combustor section. It is mounted between the fan frame and the combustor case. The HPC also has pipe connections that duct 4th, 5th, and 9th stage bleed air for both engine and aircraft use. It consists of the following modules : - The compressor rotor - The compressor front stator - The compressor rear stator EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-30-00 BASIC ENGINE Page 2 Feb 02 EFG CFM56-7B TRAINING MANUAL HIGH PRESSURE COMPRESSOR FRONT STATOR HIGH PRESSURE COMPRESSOR REAR STATOR HIGH PRESSURE COMPRESSOR ROTOR 4TH STAGE BLEED AIR 9TH STAGE BLEED AIR HP COMPRESSOR SECTION CTC-223-021-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC 5TH STAGE BLEED AIR CFMI PROPRIETARY INFORMATION 72-30-00 BASIC ENGINE Page 3 Feb 02 EFG CFM56-7B TRAINING MANUAL HPC SECTION Borescope ports There are 9 plugged borescope ports on the lower stator case, at approximately the 5 o’clock position, and they are numbered S1 thru S9, where S1 is the most forward. S7, S8 and S9 plugs have a particular design. They are double plugs. The inner thread engages the HPC rear stator case, while the outer thread is tightened on the HPC case. A spring-loaded system enables the outer plug to drive the inner plug. Both the inner and outer plugs have specific torque values. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-30-00 BASIC ENGINE Page 4 Feb 02 EFG CFM56-7B S6 S5 TRAINING MANUAL S4 FWD S3 S2 S1 TOP VERTICAL S9 S1 TO S9 S8 AFT LOOKING FORWARD S7 S6 BORESCOPE PLUG ( S1 TO S6 ) S9 BORESCOPE PLUG ASSEMBLY ( S7 TO S9 ) S7 S9 S8 S6 S5 S4 S3 S2 S1 HPC BORESCOPE PORTS CTC-223-022-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-30-00 BASIC ENGINE Page 5 Feb 02 EFG CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-30-00 BASIC ENGINE Page 6 Feb 02 EFG CFM56-7B TRAINING MANUAL COMBUSTION SECTION EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-40-00 BASIC ENGINE Page 1 Feb 02 EFG CFM56-7B TRAINING MANUAL COMBUSTION SECTION The combustion section is located between the High Pressure Compressor (HPC) and the Low Pressure Turbine (LPT). Air from the HPC is mixed with fuel, supplied by 20 fuel nozzles. The mixture is ignited by 2 igniter plugs, located at the 4 and 8 o’clock positions. The front face of the combustor is attached to the rear of the compressor module. The rear section of the combustion case houses the HPT module. The combustion section also supplies HPC 9th stage bleed air for both aircraft and engine use. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-40-00 BASIC ENGINE Page 2 Feb 02 EFG CFM56-7B TRAINING MANUAL COMBUSTION CASE HPC 9TH STAGE BLEED AIR COMBUSTION CASE REAR FLANGE COMBUSTION CASE FRONT FLANGE HP TURBINE SECTION COMBUSTION CHAMBER COMBUSTION SECTION CTC-223-023-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-40-00 BASIC ENGINE Page 3 Feb 02 EFG CFM56-7B TRAINING MANUAL COMBUSTION SECTION Borescope ports There are 4 plugged borescope ports (S12, S13, S14, S15) around the combustion case, which enable inspection of the combustion chamber. Two other ports are available, using the spark igniter ports S10 and S11, which can also be used to inspect the High Pressure Turbine (HPT) blades. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-40-00 BASIC ENGINE Page 4 Feb 02 EFG CFM56-7B TRAINING MANUAL BORESCOPE PORT LOCATIONS (ALF) S12 S15 S14.5 (DAC ONLY) COMBUSTION CASE S13 S10 IGNITER S11 IGNITER S14 BORESCOPE PLUG S12, S13, S14, S14.5 (DAC ONLY), S15 CTC-223-024-00 IGNITER (S10, S11) COMBUSTION CHAMBER BORESCOPE PORTS EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC FWD CFMI PROPRIETARY INFORMATION 72-40-00 BASIC ENGINE Page 5 Feb 02 EFG CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-40-00 BASIC ENGINE Page 6 Feb 02 EFG CFM56-7B TRAINING MANUAL TURBINE SECTION EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-50-00 BASIC ENGINE Page 1 Feb 02 EFG CFM56-7B TRAINING MANUAL TURBINE SECTION The turbine section provides the necessary power to drive the compressor rotors. It consists of the : - High Pressure Turbine (HPT) - Low Pressure Turbine (LPT) High Pressure Turbine (HPT) The HPT module is housed in the combustion case and consists of a single stage nozzle that directs the gas flow from the combustion chamber to the HPT rotor blades that drive the HPC rotor. The LPT stage 1 nozzle is also housed in the combustion case. Engine cooling Air from the 4th stage of the HPC is ducted through 4 pipes, to cool down the LPT stage 1 nozzle and the front cavity. Air from the 4th and 9th stage of the HPC goes through the HPTCC valve and is ducted through 2 pipes, to cool down the cavity that surrounds the HPT shroud. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-50-00 BASIC ENGINE Page 2 Feb 02 EFG CFM56-7B HPC 4TH/9TH STAGE COOLING AIR TRAINING MANUAL HPC 4TH STAGE COOLING AIR COMBUSTOR CASE STAGE 1 LPT NOZZLE HPT NOZZLE HPT ROTOR HPT SHROUD HPTCC VALVE CTC-223-025-00 HPT & STAGE 1 LPT NOZZLE ASSEMBLY EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-50-00 BASIC ENGINE Page 3 Feb 02 EFG CFM56-7B TRAINING MANUAL TURBINE SECTION HPT borescope ports Borescope ports S16 and S17, at the aft of the combustion case at approximately the 5 and 8 o’clock positions, are used to inspect the trailing edge of the HPT blades. Igniter ports S10 and S11 (and combustion chamber ports S12 thru S15) can be used to inspect the HPT front sections. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-50-00 BASIC ENGINE Page 4 Feb 02 EFG CFM56-7B TRAINING MANUAL BORESCOPE PORT LOCATIONS (ALF) S17 S11 IGNITER S10 IGNITER S16 FWD FWD S16, S17 BORESCOPE PLUG S16 OR S17 HPT BORESCOPE PORTS CTC-223-026-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-50-00 BASIC ENGINE Page 5 Feb 02 EFG CFM56-7B TRAINING MANUAL TURBINE SECTION Low Pressure Turbine (LPT) The LPT module converts the energy of gasses from combustion into the necessary torque to drive the fan and booster rotor. The LPT is a 4-stage axial flow turbine that consists of a rotor and stator assembly. The LPT module front flange is mounted onto the rear flange of the combustor module. Its rear flange is attached onto the LPT frame and its inner flange is secured onto the LPT shaft. Fan discharge air is ducted through cooling manifolds that are provided with orifices, to direct cooling air onto the LPT outer case. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-50-00 BASIC ENGINE Page 6 Feb 02 EFG CFM56-7B TRAINING MANUAL LPT MODULE LPT ROTOR LPT STATOR LPT REAR FRAME MODULE AIR MANIFOLD COOLING MANIFOLDS LPT SHAFT MODULE CTC-223-027-00 LOW PRESSURE TURBINE MODULE EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-50-00 BASIC ENGINE Page 7 Feb 02 EFG CFM56-7B TRAINING MANUAL TURBINE SECTION LPT borescope ports There are 5 borescope ports for inspection of the LPT blades. Ports S16 and S17, which are located at the 5 and 8 o’clock positions respectively, are used to examine the LPT stage 1 blade leading edge. Ports S18, S19 and S20, at the 5 o’clock position, are located between all stages. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-50-00 BASIC ENGINE Page 8 Feb 02 EFG CFM56-7B TRAINING MANUAL S16, S17 BORESCOPE PLUGS S16, S17 S18 S18, S19, S20 BORESCOPE PLUGS S19 S20 LPT BORESCOPE PORTS CTC-223-028-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-50-00 BASIC ENGINE Page 9 Feb 02 EFG CFM56-7B TRAINING MANUAL TURBINE SECTION Turbine frame module The turbine frame module is the engine rear structural assembly, and is bolted to the rear flange of the LPT case. It is made up of an outer casing and a hub. The outer casing is equipped with mounts for rear engine installation on the airframe. The hub outer flange is equipped with studs which provide attachment for the exhaust plug. The hub inner flange provides support and attachment for the flange assembly and, at its center, the flame arrestor. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-50-00 BASIC ENGINE Page 10 Feb 02 EFG CFM56-7B TRAINING MANUAL TANGENT STRUT ENGINE MOUNTS EXHAUST PLUG ATTACHMENT STUDS FLAME ARRESTOR FLANGE ASSEMBLY OIL SUPPLY TUBE FLANGE ASSEMBLY SCAVENGE TUBE OUTER CASE DRAIN TUBE OIL SUPPLY TUBE FLAME ARRESTOR TURBINE REAR FRAME CTC-223-0029-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-50-00 BASIC ENGINE Page 11 Feb 02 EFG CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-50-00 BASIC ENGINE Page 12 Feb 02 EFG CFM56-7B TRAINING MANUAL ACCESSORY DRIVE SECTION EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-60-00 BASIC ENGINE Page 1 Feb 02 EFG CFM56-7B TRAINING MANUAL ACCESSORY DRIVE SECTION At engine start, the accessory drive system transmits external power from the engine air starter to drive the core engine. When the engine is running, the accessory drive system extracts part of the core engine power and transmits it through a series of gearboxes and shafts in order to drive the engine and aircraft accessories. For maintenance tasks, the core can be cranked manually through the Accessory Gearbox. The accessory drive system is located at the 9 o’clock position (ALF) and consists of the following components : - The inlet Gearbox (IGB), that takes power from the HPC front shaft. - The radial Drive Shaft (RDS), that transmits the power to the Transfer Gearbox. - The transfer Gearbox (TGB), which redirects the torque. - The horizontal Drive Shaft (HDS), that transmits power from the Transfer Gearbox to the Accessory Gearbox. - The accessory Gearbox (AGB), that supports and drives both engine and aircraft accessories. EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-60-00 BASIC ENGINE Page 2 Feb 02 EFG CFM56-7B TRAINING MANUAL INLET GEARBOX (IGB) INNER RADIAL DRIVE SHAFT (RDS) OUTER RADIAL DRIVE SHAFT HORIZONTAL DRIVE SHAFT (HDS) ACCESSORY GEARBOX (AGB) CTC-223-030-00 TRANSFER GEARBOX (TGB) ACCESSORY DRIVE SECTION DESIGN EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-60-00 BASIC ENGINE Page 3 Feb 02 EFG CFM56-7B TRAINING MANUAL ACCESSORY DRIVE SECTION Accessory gearbox The accessory gearbox supports and drives both aircraft and engine accessories. The AGB assembly is mounted on the left hand side of the fan frame at the 9 o’clock position and is secured by 2 clevis mounts with shouldered bushings. The housing is an aluminium alloy casting. Its rear face connects with the HDS sleeve and provides mounting pads for : - The lubrication unit - The scavenge oil filter - The fuel pump and Hydromechanical Unit (HMU) Some of the accessories are installed on the AGB through Quick Attach/Detach (QAD) rings. The AGB consists of a gear train that reduces and increases the rotational speed to meet the specific drive requirements of each accessory. The AGB’s front face has mounting pads for the following equipment : - The Hydraulic pump - The Integrated Drive Generator (IDG) - The Starter - The Hand-cranking drive - The Control alternator (FADEC Power supply) EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-60-00 BASIC ENGINE Page 4 Feb 02 EFG CFM56-7B TRAINING MANUAL FRONT VIEW FLANGED BUSHING FWD CONTROL ALTERNATOR DRIVE PAD TGB TO AGB INPUT DRIVE PAD SPEED SENSOR HANDCRANKING DRIVE PAD FUEL PUMP DRIVE PAD STARTER DRIVE PAD REAR VIEW IDG DRIVE PAD FWD HYDRAULIC PUMP DRIVE PAD LUBRICATION UNIT DRIVE PAD FLANGED BUSHING ACCESSORY GEARBOX HOUSING CTC-223-031-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-60-00 BASIC ENGINE Page 5 Feb 02 EFG CFM56-7B TRAINING MANUAL ACCESSORY DRIVE SECTION Sealing Sealing of the AGB is provided by 2 configurations of carbon-contact seals : - Magnetic type - Spring-loaded type Magnetic type seals The magnetic-type seal consists of : - A non-magnetic seal housing, which contains a magnetized mating ring with a polished face and a retaining ring - A rotating seal held in a rotating ring This seal type can be used on the following pads : - Integrated Drive Generator (IDG) - Hydraulic pump - Fuel pump EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-60-00 BASIC ENGINE Page 6 Feb 02 EFG CFM56-7B TRAINING MANUAL (DISASSEMBLED) (ASSEMBLED) NON MAGNETIC SEAL HOUSING MAGNETIZED RING RETAINING RING O-RING SEALS STATIC PART ROTATING PART CARBON CONTACT FACE O-RING SEAL MAGNETIC SEAL CTC-223-032-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC LAPPED OR POLISHED CONTACT FACE CFMI PROPRIETARY INFORMATION 72-60-00 BASIC ENGINE Page 7 Feb 02 EFG CFM56-7B TRAINING MANUAL ACCESSORY DRIVE SECTION Spring-loaded seals The spring-loaded seal is made up of carbon packing and a rotating mating ring with a polished face. The rotating mating ring has 4 lugs that engage in 4 corresponding slots machined in the gear shaft bearing. A housing, which contains the spring-loaded seal, ensures constant contact between the polished face of the rotating mating ring and the carbon seal element. This seal type can be used on the following drive pads : - Integrated Drive Generator (IDG) - Hydraulic pump - Starter - Fuel pump EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-60-00 BASIC ENGINE Page 8 Feb 02 EFG CFM56-7B TRAINING MANUAL CARBON CONTACT FACE (ASSEMBLED) (DISASSEMBLED) SPRING WASHER O-RING SEAL O-RING SEALS STATIC PART MATING RING ROTATING PART LUGS LAPPED OR POLISHED CONTACT FACE SPRING LOADED SEAL CTC-223-033-00 EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL TOC CFMI PROPRIETARY INFORMATION 72-60-00 BASIC ENGINE Page 9 Feb 02 EFG CFM56-7B TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B737-600, -700, -800, -900, -BBJ, COMBI, C40A/ALL CFMI PROPRIETARY INFORMATION TOC 72-60-00 BASIC ENGINE Page 10 Feb 02
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