737 MAX / LEAP-1B

APAC & China WTT Meeting

April 17-18, 2018
Xi’an

Engine Change Lessons Learned

CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma (Safran group) and GE. The information in this document is CFM Proprietary Information and is disclosed in confidence. It is the
property of CFM International and its parent companies, and shall not be used, disclosed to others or reproduced without the express written consent of CFM. If consent is given for reproduction in whole or in part, this notice shall appear in any such
reproduction in whole or in part. The information contained in this document may also be controlled by the U.S. and French export control laws. Unauthorized export or re-export is prohibited.
Agenda

• Background
• Process
• Lessons Learned / Recommendations
• Summary

2 / CFM Proprietary Information subject to restrictions on the cover

737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Background

• 10 LEAP-1B engine changes performed in the field:

• 4 engines removed to incorporate SB 72-0080
• 2 lease engine removed after being used during SB 72-0080 quickturn
• 4 engines removed due to unserviceable findings per SB 72-0163

• 4 customers affected
• Engine changes executed by:
• 7 by GE On-Wing Support
• 3 by Customers

• 4 Functional Check Flight performed as required per AWL (Low

Pressure Spool Rotorlock)
3 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process

• Spare engines condition

• Typically the engines had full QEC installed except for: Inlet Cowl, Exhaust Nozzle Assy, IDG, Hydraulic
EDP, Duct Vent Valve (DVV) and Engine Anti-Ice Valve (EAIV).
NOTE: IDG and EDP QAD were installed on spare engine.
• Step-by-step (example)
• Inflate main and nose landing gear struts per AMM recommendations
NOTE: Only required when using G01 engine stand, but it can save time even if using G02 engine stand
• Remove inlet cowl and install it on spare engine
• Engine to remove
• Remove fan cowls
• Install Thrust Reverser Cowl Hold Open Tool C78033-1
• Remove Exhaust Nozzle Assy, IDG, EDP, DVV
• Remove thumbnail fairing (37 bolts covered with paint)
• Install FWD and AFT bootstraps
• Remove engine
• Remove EAI Valve
NOTE: The removal/installation of the EAIV is easier to perform while the engine is off-wing, because there’s much
improved access
4 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process

• Step-by-step (cont)
• Engine to install
• Install EAIV
• Install engine
• Finish inlet cowl installation (lower attachment)
• Install Exhaust Nozzle Assy, IDG, EDP and DVV
• Remove AFT and FWD bootstraps
• Install thumbnail fairing
• Install fan cowls
• Depreserve the engine
• Service engine
• Service Air Turbine Starter

• Timing and manpower

• Total: 12 hour per engine change (engine removal, installation and QEC swap)
• Manpower: 10 men
• All the engine changes went globally very smoothly
5 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process - Photos

Engine stand
weight and CG
information

Engine stand
6 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process - Photos

Fan
Spare Frame
Engine

C78033-1

Inlet Cowl swap Thrust Reverser Cowl Hold Open Tool C78033-1

7 / CFM Proprietary Information subject to restrictions on the cover

737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process - Photos
The installation of the TR Cowl Hold Open Tool C78033-1 requires removal of the TR insulation blankets that
cover the tool attachment points and the No. 1 compression rod and bracket for clearance
C78033 is being redesigned so it is not necessary to remove No. 1 compression rod bracket (removal of
compression rod will still be required)

TR Insulation Blankets No. 1 Compression Rod

8 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process - Photos

37 fasteners

Removal of thumbnail fairing to

install FWD bootstrap FWD bootstrap
9 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process - Photos

AFT bootstrap installation AFT bootstrap installed

10 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process - Photos

Access to FWD mount bolts Access to AFT mount bolts Removing the engine
11 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process - Photos

Pushing the engine forward

Removing the engine Engine removed

12 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Process - Photos

Precooler Thrust Reverser

Cowl Hold Open
Tool C78033-1

Thrust link

Precooler clearance to Thrust Links

Clearance to precooler Removing the EAIV

13 / CFM Proprietary Information subject to restrictions on the cover

737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Lessons Learned / Recommendations

Preparation
• Preparation is critical. Prepare well your expendables, tooling and consumables:
• Reference list prepared – contact your CFM FSE
• Minimal equivalence of expendables and tooling with the CFM56-7B
• Know the level of equipment installed on your spare engine
• A more equipped engine can save several hours during the engine change
• A full QEC swap can take 24H x 6 men
• Consider all the tasks that need to be performed and their needs in terms of expendables, tooling and consumables:
• QEC swap
• Engine preservation
• End of lease checks
• Test after engine installation
• Engine transportation
• Recommended to have an engine change kit prepared in advance
• Inventory expendables, tooling and consumables before starting the work
• On the MAX, the thumbnail fairing is secured by 37 fasteners, instead of the 7 latches on the NG. The fasteners head is
covered with paint which will make them hard to remove and will result in damaged heads
• The LEAP-1B engine stand is more complex than the CFM56-7B. Get familiar with it. Refer to the TDS available on
myCFM Portal
14 / CFM Proprietary Information subject to restrictions on the cover
737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Lessons Learned / Recommendations

Preparation (cont)
• The LEAP-1B is bigger than the CFM56-7B. A different forklift may be required:
• Higher load capacity
• Longer fork
Refer to the table below, extract of LEAP Transportation Manual Version V2.0 (January 2017). Available on myCFM
Portal, through the myDownload widget

Height with Width with Length with Length Weight Weight Weight
LEAP Engine Shipping Stand (Base + Cradle)
Assembly P/N engine engine Bare engine with QEC Stand only with Bare with QEC
Model engine engine engine
96 98 193 228 5 250 11 378 12 916
LEAP-1B 956A8600G01
(2450) (2490) (4912) (5799) (2381) (5161) (5859)
NOTE 1:
DIMENSIONS ARE GIVEN IN INCHES WITH MILLIMETERS IN PARENTHESES.
WEIGHTS ARE GIVEN IN POUNDS WITH KILOGRAMMES IN PARENTHESES.
NOTE 2:
HEIGHT WITH ENGINE IS GIVEN WITHOUT AIR INLET AND WITH WHEELS IN "STOW WITH ENGINE" POSITION
NOTE 3:
WEIGHT WITH QEC ENGINE IS GIVEN WITHOUT AIR INLET WEIGHT

15 / CFM Proprietary Information subject to restrictions on the cover

737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Lessons Learned / Recommendations

Processual
• The LEAP-1B is bigger than the CFM56-7B.
Clearance between engine and precooler, Thrust Reverser and stand must be considered:
• Inflate both the main and nose landing gear. Make sure the airplane is leveled. Refer to the AMM engine
replacement task for details.
• Control the clearance between the thrust links and the precooler, when removing and installing the engine. The
precooler is located in between the thrust links. It’s recommended wrapping the thrust links with a layer of foam or
rubber.
• It is easier to untorque and torque the aft mount bolts without the engine stand under the engine, because access will be
improved. Use a small ladder, instead of stepping on the stand
• If the EAIV needs to be swapped, do it while the engines are off-wing. This improves access and saves time.
• The forward and aft mount bolts and barrel nuts require a dye penetrant inspection (AMM TASK 71-21-03-200-801-
G00) prior to re-use.
• This inspection requires a Level 3 NDT Inspector
• The required emulsifier is a hazardous material and cannot be hand carried on a commercial flight

16 / CFM Proprietary Information subject to restrictions on the cover

737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Lessons Learned / Recommendations

Processual (cont)
• Considerations when using the Engine Mount Bolt Torque Equipment (C71040-1):
• Exercise caution when torqueing the aft mount bolts. The tool can easily slip off, causing damage to the mount and
surrounding parts
• Get familiar with the instructions on the tool placard for torque wrench settings. The following settings are
required:
• Setting for the 4 Fwd mount bolts – No calculation required
• Setting for the 2 Front bolts on Aft mount – Calculation required
• Setting for 1 Rear inboard bolt on Aft mount – Calculation required
• Setting for 1 Rear outboard bolt on Aft mount – Calculation required
• If you need to preserve the removed engine:
• Do it while the engine is on-wing. It’s simpler
• When performing AMM TASK 71-00-03-630-801-G00 “Preservation of an Engine on Wing for 30 Days to 1 Year”
make sure you pull the Fuel Spar Valve circuit breakers, before running Test 25 - Fuel System Preservation. AMM
will be revised to add this instruction

17 / CFM Proprietary Information subject to restrictions on the cover

737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Lessons Learned / Recommendations

Processual (cont)
• PRSOV, HPSOV, EAI faults may appear during engine testing. This may be caused by the Integrated Air Systems
Controller (IASC) that latches these faults if the engine-pylon connections are disconnected while A/C power in ON
• If the faults are present, they cannot be cleared if there is any duct pressure present. The APU can provide 5psi duct
pressure, i.e. the APU must be turned off and ground power provided in order to clear these faults
• Recommendations:
• Pull the IASC circuit breakers prior to disconnecting pylon connections during an engine removal
• If latched faults appear, ensure the APU is shut down and A/C is on ground power. Then, the faults should be
able to be cleared
• AMM is being revised to pull IASC circuit breakers (as a precaution), and to add instructions to clear IASC
latched faults (if they occur). Revision date TBD

Manuals
• If QEC is being swapped make sure you have the latest copy of the Powerplant Build-Up Manual

18 / CFM Proprietary Information subject to restrictions on the cover

737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
Lessons Learned / Recommendations

Other considerations
• Lockout / tagout certified people identified
• Tooling calibration up to date.
• Tooling locations identified, with plan to move to outstation if required
• Engine dolly / engine stand identified for all stations, or plan to move equipment when needed
• NDT inspectors identified for each site, along with plan to move them and equipment
• On-site badging-who issues it, what is the procedure, etc?
• Are escorts needed on site, especially for out station AOG’s?

Stress test your plan!

19 / CFM Proprietary Information subject to restrictions on the cover

737 MAX / LEAP-1B WTT APAC & China, Xi’an, Apr.17-18, 2018
 Thank You

20 / CFM Proprietary Information subject to restrictions on the cover