CFM56-7B Engine Testing Handbook PDF

CFM 56-7B
ENGINE TESTING
WARNING !!!
The present document must be considered STRICTLY CONFIDENTIAL. The information
contained in this document is for training purpose only and cannot to be a reference
in actual activity, this notice shall appear on any reproduction in whole or in part.
Document On By Ary whendra P

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CFM56-7B ENGINE TESTING – TABLE OF CONTENTS
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TABLE OF CONTENTS
Subject Page
CFM56-7B ENGINE TESTING – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 10

CFM56-7B ENGINE TESTING -- ON-WING ENGINE TESTING – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 12
SYSTEM REVIEW – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 13
AIRCRAFT SYSTEM REVIEW – FLIGHT COMPARTMENT – PANELS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 15
ENGINE RUN – AIRCRAFT SYSTEM REVIEW – FLIGHT COMPARTMENT – MAIN INSTRUMENT PANELS ,,,,,,,,,,,,, 18
AIRCRAFT SYSTEM REVIEW – FLIGHT COMPARTMENT – GLARSHIELD PANELS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 20
AIRCRAFT SYSTEM REVIEW – FLIGHT COMPARTMENT – P2 AND P9 PANELS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 22
AIRCRAFT SYSTEM REVIEW – FLIGHT COMPARTMENT – CONTROL STAND ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 24
AIRCRAFT SYSTEM REVIEW – FLIGHT COMPARTMENT – P8 AFT ELECTRONIC PANEL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 26
AIRCRAFT SYSTEM REVIEW – FLIGHT COMPARTMENT – P5 FORWARD OVERHEAD PANEL ,,,,,,,,,,,,,,,,,,,,,, 28
AIRCRAFT SYSTEM REVIEW – FLIGHT COMPARTMENT – P5 AFT OVERHEAD PANEL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 28
COMMON DISPLAY SYSTEM – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 33
GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 35
FLIGHT COMPARTMENT COMPONENT LOCATION – 1 ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 37
BRIGHTNESS CONTROLS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 39
ELECTRICAL POWER – OPERATION – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 42
POWER AND CONTROL – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 45
DISTRIBUTION – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 49
ELECTRICAL METERS, BATTERY, AND GALLEY POWER MODULE – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,, 51
GENERATOR DRIVE AND STANDBY POWER MODULE – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 55
AC SYSTEM, GENERATOR, AND APU MODULE – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 58

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LIGHTS – INSTRUMENT AND PANEL LIGHTS – MASTER WARNING AND CAUTION LIGHTS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 62
MASTER DIM AND TEST – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 64
FIRE PROTECTION – ENGINE FIRE EXTINGUISHING – OVERHEAT / FIRE PROTECTION PANEL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 67
FIRE PROTECTION – ENGINE FIRE EXTINGUISHING – ENGINE AND APU FIRE EXTINGUISHER TEST ,,,,,,,,,,,,,,,,,,,,,, 70
AIRBORNE AUXILIARY POWER – CONTROLS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 73

OPERATION – START ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 75
OPERATION – SHUTDOWN ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 77
ENGINE RUN – AIRCRAFT SYSTEM REVIEW – APU – PROTECTIVE SHUTDOWN ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 79
AIRBORNE AUXILIARY POWER – INDICATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 82
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – HYDRAULIC POWER – CONTROL AND INDICATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,, 85
AIRCRAFT SYSTEM REVIEW – HYDRAULIC POWER – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 88
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – HYDRAULIC BRAKES -- FUNCTIONAL DSCRIPTION ,,,,,,,,,,,,,,,,,,,,,,, 89
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – LANDING GEAR – PARKING BRAKE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 92
PNEUMATIC – FUNCTIONAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 95

PNEUMATIC – ENGINE BLEED SYSTEM – OPERATIONAL TEST ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 98
PNEUMATIC – DISTRIBUTION – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 100
ENGINE RUN – AIRCRFT SYSTEMS REVIEW – INLET COWL ANTI-ICE SYSTEM – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,, 103
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – FUEL – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 106
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – FUEL – STORAGE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 108

ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – FUEL – ENGINE AND APU FUEL FEED ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 110
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – FUEL – QUANTITY INDICATIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 113

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ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – COMMUNICATIONS – VHF SYSTEM – OPERATION ,,,,,,,,,,,,,,,,,,, 116
AIRPLANE SYSTEMS REVIEW – COMMUNICATIONS – FLIGHT INTERPHONE SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 118
ENGINE RUN – AIRCRAFT SYSTEM REVIEW – COMMUNICATIONS – SERVICE INTERPHONE – JACKS ,,,,,,, 121
ENGINE RUN – SAFETY – WIND CONDITIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 124

ENGINE RUN – SAFETY – ENGINE HAZARD AREAS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 126
ENGINE RUN – SAFETY – ENGINE NOISE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 129
ENGINE RUN – NOTES ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 131
ENGINE RUN – CAUTIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 132
ENGINE RUN – WARNINGS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 134
ENGINE RUN – ENGINE SYSTEMS LIMITS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 136
ENGINE RUN – OPERATION PARAMETERS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 140
737 WALK AROUND INSPECTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 144
ENGINE TESTS – TABLES ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 147
ENGINE TESTS -- ENGINE DATA AND RECORD SHEET ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 150

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CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 153
OFF-WING ENGINE TESTING – GENERAL TESTING (TEST 000) ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 159
TOOLS, EQUIPMENT AND CONSUMABLE MATERIAL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 161
MODUL REPLACEMENT TESTING ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 162
TEST EQUIPMENT, INSTRUMENTATION, AND MATERIALS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 164
PREPARATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 168
ENGINE TRANSPORT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 173
PRE-TEST INSPECTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 177
DATA RECORDING ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 180
PROCEDURE OF TESTING ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 182
ENGINE START PROCEDURE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 183
POWER SETTING PROCEDURES ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 184
ENGINE SHUTDOWN PROCEDURE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 185
COMPLETION OF TEST ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 186
OFF-WING ENGINE TESTING – OPERATING LIMITS (TEST 001) ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 189

GENERAL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 189
LIMITS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 189
ECU FAULT ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 205
OFF-WING ENGINE TESTING – ENGINE FUNCTIONAL TEST (TEST 002) ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 208
GENERAL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 208
LEAK INSPECTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 210
MOTORING CHECK ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 210
START TESTS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 211
FADEC SYSTEM TESTS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 212
FUNCTIONAL CHECK BREAK-IN, VIBRATION SIGNATURE, AND TRANSIENT CHECKS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 213

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OFF-WING ENGINE TESTING – ENGINE ACCEPTANCE TEST (TEST 003) ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 220
GENERAL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 220
ACCELERATION TIME CHECK AND ACCEPTANCE CALIBRATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 220
PERFORMNACE TROUBLE-SHOOTING ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 232
PERFORMANCE CALCULATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 233
OFF-WING ENGINE TESTING – FAN TRIM BALANCE (TEST 004) ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 238
GENERAL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 238
TOOLS, EQUIPMENT, AND CONSUMABLE MATERIALS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 239
DEFINITION OF TERMS AND SYMBOLS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 239
FAN TRIM BALANCE PROCEDURE (THREE-SHOT PLOT METHOD) ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 240
OFF-WING ENGINE TESTING – NO.4 BEARING DEFECTSCREENING (TEST 009) ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 247
GENERAL ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 247
TOOLS, EQUIPMENT AND MATERIALS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 247
PREPARATION TEST ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 248
TEST SEQUENCE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 249
DATA ACQUISITION TEST ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 250
DATA ANALYZING ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 251

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ENGINE SYSTEMS REVIEW – SPECIFICATION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 259
ENGINE RUN – ENGINE SYSTEM REVIEW – ENGINE – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 262
ENGINE RUN – AIRPLANE SYSTEMS REVIEW – ENGINE FUEL AND CONTROL – FUNCTIONAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,, 266
ENGINE FUEL AND CONTROL – FUEL INDICATING – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 269
ENGINE RUN – AIRPLANE SYSTEMS REVIEW – ENGINE IGNITION – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 273
ENGINE RUN – ENGINE SYSTEM REVIEW – ENGINE AIR – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 276
ENGINE SYSTEM REVIEW – ENGINE AIR – FUNCTIONAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 278
ENGINE RUN – AIRPLANE SYSTEM REVIEW – ENGINE CONTROLS – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 282
ENGINE INDICATING – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 285
ENGINE TACHOMETER SYSTEM – FUNCTIONAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 288
EXHAUST GAS TEMPERATURE (EGT) INDICATING SYSTEM – FUNCTIONAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 293
ENGINE RUN – AIRPLANE SYSTEMS REVIEW – AVM SYSTEM – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 297
ENGINE RUN – ENGINE SYSTEMS REVIEW – ENGINE OIL STORAGE AND DISTRIBUTION SYSTEM ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 299
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – ENGINE OIL INDICATING SYSTEM – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,, 303
ENGINE RUN – AIRPLANE SYSTEMS REVIEW – ENGINE STARTING – GENERAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 308
REFERENCE SOURCE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 310

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CFM56-7B ENGINE TESTING - INTRODUCTION

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CFM56-7B ENGINE TESTING – INTRODUCTION
General Course Structure:
The CFM56-7B Engine Testing gives you the information to start The engine test course has these parts:
and do test of the CFM56-7B Engine. The CFM56-7B Engine Testing - On-wing engine testing
course have two parts, classroom instruction and simulator - Off-wing engine testing
practice, for the simulator practice used the Aircraft base flight - Engine systems review
simulator or Engine Test Cell Simulator.
On-wing engine testing
This engine can be test on-wing in aircraft and off-wing in test cell,
This part will explain On-wing engine testing that similar with an
the different result testing of on-wing and off-wing is in the engine
Engine Run-Up 737-600/-700/-800/-900 training course module.
performance analysis. The Power Assurance Check is an engine
performance analysis of the engine on-wing test, The Power Off-wing engine testing
Assurance Check is not a good test for performance analysis of the
engine. Do not use only the Power Assurance Check to accept or This part given overview an on-wing engine testing which will be
reject an engine. The power assurance run is usually not sufficiently explained to be:
stable to accurately calculate the engine's health. You can get a - General (TEST 000)
more reliable performance analysis by doing an Engine Acceptance - Operating Limits (TEST 001)
Test in test cell operation or on-wing performance trend - Engine Functional Test (TEST 002)
monitoring. - Engine Acceptance Test (TEST 003)
- Fan Trim Balance (TEST 004)
It is not possible to cover all procedure, practices, equipment, and - Core Trim balance (TEST 005)
situations that occur when you run an engine. You must use your - No.4 Bearing Defect Screening (TEST 009)
experience and good judgment for non-normal conditions not
covered in this course. Engine system review
This manual is for training purposes only. The maintenance manual This part will review of engine system operation and the contains is
and your company policies and procedure have precedence over similar with an Engine Run-Up 737-600/-700/-800/-900 training
this training manual. course module.

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CFM56-7B ENGINE TESTING – ON WING ENGINE TESTING

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CFM56-7B ENGINE TESTING -- ON-WING ENGINE TESTING –
INTRODUCTION
The engine CFM56-7B that installed on B737-600/-700/-800/-900
Limitation can be testing On-wing, that commonly known as Engine Ground
Run (EGR).
This section reviews the operating limits of the engine system that
you used when running an engine To explain the Chapter CFM56-7B On-wing engine testing which will
be used an Engine Ground Run B737-600/-700/-700/-800/-900
Operating procedure
training module because it is similar.
The operating procedures show how to start and stop the engine.
Engine test
Note: See on the Engine Shop Manual or Aircraft Maintenance
This section is an introduction to the engine tests. You will do some Manual to know the complete data used for engine testing.
of the engine tests in Aircraft simulator.
Ground safety
Ground safety review engine hazards and safety procedure that

help you safely do the engine starts and engine test
Simulator
You practice engine starts and engine tests in the simulator. In this
section you will monitor an engine limitation used Aircraft
simulator parameter.

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ENGINE RUN – AIRCRAFT SYSTEM REVIEW – FLIGHT
COMPARTMENT – MAIN INSTRUMENT PANELS

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COMMON DISPLAY SYSTEM – INTRODUCTION
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COMMON DISPLAY SYSTEM – INTRODUCTION
The common display system (CDS) shows performance, navigation,

and engine data in many different formats on 6 display units in
flight compartment.

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ELECTRICAL POWER – OPERATION – GENERAL DESCRIPTION

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LIGHTS – INSTRUMENT AND PANEL LIGHTS – MASTER WARNING
AND CAUTION LIGHTS

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FIRE PROTECTION – ENGINE FIRE EXTINGUISHING – OVERHEAT /
FIRE PROTECTION PANEL

66
67
68
69
70
71
AIRBORNE AUXILIARY POWER – CONTROLS

72
73
74
75
76
77
78
79
80
81
82
83
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – HYDRAULIC POWER –
CONTROL AND INDICATIONS

84
85
86
87
88
89
90
91
92
93
PNEUMATIC – FUNCTIONAL DESCRIPTION

94
95
96
97
98
99
100
101
ENGINE RUN – AIRCRFT SYSTEMS REVIEW – INLET COWL ANTI-ICE
SYSTEM – GENERAL DESCRIPTION

102
103
104
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – FUEL – GENERAL
DESCRIPTION

105
106
107
108
109
110
111
112
113
114
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – COMMUNICATIONS –
VHF SYSTEM – OPERATION

115
116
117
118
119
120
121
122
ENGINE RUN – SAFETY – WIND CONDITIONS

123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
737 WALK-ARROUND INSPECTION

143
144
145
ENGINE TESTS – TABLES

146
147
148
ENGINE TESTS -- ENGINE DATA AND RECORD SHEET

149
150
151
CFM56-7B ENGINE TESTING – OFF WING ENGINE TESTING

152
CFM56-7B ENGINE TESTING – OFF-WING ENGINE TESTING – Preparation Area
INTRODUCTION
This preparation area is used to prepare the engine before and
after the testing
Engine testing off-wing can be doing in “TEST CELL FACILITY this area has an equipment to support the engine testing below;
EQUIPMENT” this building is Aerodynamic construction design to
- Preparation bay
facilitate the engine testing and for the engine testing this building
- Lifting platform
can provide;
- Crane
- Provide stable airflow (constant velocity)
- Mono rail
- Provide uniform airflow (low distortion)
- Meet neighborhood noise requirements
- Provide protected environment for people and equipment
- Productivity (monorail delivery, lift platform, lighting…) Fuel Farm
This building is divided in to three main buildings; Fuel farm is a fuel supporting area for support engine testing, there
- Test cell is a fuel tank, fuel pump system, piping, etc.
- Preparation area
- Fuel farm
Test Cell
Test cell is a large aerodynamic room and as a place the engine to
test.
Test cell is divided into sub buildings;
- Inlet stack
- Exhaust stack
- Test chamber
- Control room

153
CFM56-7B ENGINE TESTING – OFF WING ENGINE TESTING – INTRODUCTION – TEST CELL FACILITY BUILDING

154

155

156
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING –
CONTROL ROOM

157
GENERAL (TEST 000)

158
GENERAL (TEST 000)
When you do functional checks, such as a start, monitor and keep

General a record of these parameters:
Some of general data is required during engine testing that follows;

 The conditions for the starter air supply
 Time necessary for the engine to get to idle
• Tests CFMI recommends after module replacements  Peak EGT
• Equipment, instrumentation, and materials necessary to do all of  Fuel flow during start
the Testing Sections  EGT (at all speeds except minimum idle)
• Procedures to prepare the engine for test  Vibration indications (which include amplitude and
• Procedures for inspections before you start the tests frequency)
 T2
• The types of data you must keep records of during the tests
 Oil pressure
• Engine motoring procedures
 N1 and N2 speeds
• Engine start procedures
• Power setting procedures
• Engine shutdown procedures
When you do the performance points for steady-state operation,
keep a record of the indications from all of the instruments. Do not
include the indications from the instruments that measure
When you operate the engine, monitor it closely. Keep a record of
all important events and of these parameters: transient conditions
• T2
• Fuel Flow
• Time
• N1 and N2 speeds
• Oil pressure
• Exhaust Gas Temperature (EGT)

159
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000)

160
GENERAL (TEST 000) -- TOOLS, EQUIPMENT AND CONSUMABLE
Referenced Procedures
MATERIAL
ATA No Description
Tools and Equipment
72-00-00 Storage 001
 Borescope tool set 72-00-00 Testing 001
 Borescope guide tube for HPT and Shroud 72-00-00 Testing 002
 Motor, Drive - Core Engine Rotation 72-00-00 Testing 003
 Cart, Stator Actuator (actuator cart) 72-00-00 Testing 004
 Probe, Pilot Static Pressure - Bellmouth (Bellmouth
pressure probe) Expendable Parts
 Sensor, Temperature - T54 (temperature sensor)
 Sensor, Pressure - PT54 (pressure sensor)  Packing set (see on applicable manual)
 Cover Kit Blank-off - Engine Test Cell (blank-off covers)
Note; for the details tools, equipment and procedures refer to last
Standard Tools and Equipment revision shop manual.
 Adapter - Drain, CFM56-7 Engine
Consumable Materials
 Oil – Engine
 Fuel

161
GENERAL (TEST 000) -- MODULE REPLACEMENT TESTING
The engine testing requirement can be follow from the

specification module replacement vary
 FUNCTIONAL TEST - TEST 002

 ACCEPTANCE TEST - TEST 003
Functional Test – TEST 002
In engine functional test the engine will be check for;

- Fuel and oil leaks
- Vibration
- Idle speed
- Variable Stator Vane (VSV) tracking
- Variable Bleed Valve (VBV) tracking
- Full Authority Digital Electronic Control (FADEC) operation
- Other mechanical functions
Acceptance Test - TEST 003
Engine acceptance test is used to compare the performance data to

the engine certified performance levels. During testing the engine
will be operating at vary different power settings to collect engine
performance data.

162
Testing 002 Testing 003
Module
Functional Test Acceptance Test
Fan Major Module X X
Core Engine Major Module X X
LPT Major Module X X
Accessory Drive Major Module X
Fan and Booster Module X X
No. 1 & 2 Brg Support Module X X
Compressor Rotor Module X X
Compressor Front Stator Module X X
Compressor Rear Stator Module X X
Combustion Chamber Module X X
HPT Nozzle Module X X
HPT Rotor Module X X
HPT Shroud/Stg 1 LPT Nozzle Module X X
Inlet Gearbox & No. 3 Brg Module X X
Transfer Gearbox Module X
Accessory Gearbox Module X
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) -- TOOLS, EQUIPMENT AND CONSUMABLE MATERIAL -
- RECOMMENDED TESTS FOR MODULE REPLACEMENT

163
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – - Print set, Identification – Magnetic Chip Detector
GENERAL (TEST 000) --TEST EQUIPMENT, INSTRUMENTATION, AND Debris
MATERIALS
Test Equipment
Facility Instrumentation Requirements
The test cell must be approved and correlated and have the
 All Speed sensor N1 / N2
equipment that follows:
 All Temperature sensor oil, EGT, air inlet, HP rotor, cowl,
 Engine Test Adapter assembly, Interface, design, and etc.
construction  All pressure sensor Oil, sump, scavenge, air, etc.
- An engine adapter assembly is necessary to support  Stator and rotor sensor position VBV, VSV, etc.
and interface the engine with the test facility thrust  Vibration sensor HP, LP, bearing, CCFFV, etc.
frame, wiring, and services system.  And all other equipment sensor supporting that can see in
 The engine mounts Shop manual
 A CFM56-7B Engine Cowling Kit
- Bellmouth
- Bifurcated duct Note; Calibrate all instruments regularly per intervals established
 Engine Cowling Kit Component Storage Dollies with the applicable Regulatory Agency. Regular calibration
 Engine Dress Equipment makes sure each instrument recording system is in the correct
- The Bellmouth pressure probe limits.
- P17 rake
- Blank – off covers
 Test Tooling, drain connections and instrumentation Note; RPM and EGT limits are given as steady-state and transient. All
- CFM56 Multi-Engine Trim Balance program other limits are given as steady-state only
- Trim Balance Kit
- Actuator cart
- Borescope set Test Materials
- Portable Data Loader and assembly cable
- A Bellmouth Sling See the CFMI recommendation fuel and oil specification in shop
- An Exhaust Nozzle Lifting Sling manual

164
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) –
TEST EQUIPMENT, INSTRUMENTATION, AND MATERIALS
ENGINE MOUNTING

165
TEST EQUIPMENT, INSTRUMENTATION, AND MATERIALS --
ENGINE TEST ADAPTER

166
CART – STATOR ACTUATOR
ENGINE TEST COWLING KIT
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) --TEST
EQUIPMENT, INSTRUMENTATION, AND MATERIALS

167
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING –  Service Engine Oil Tank and Starter.
GENERAL (TEST 000) -- PREPARATION
Final Inspection
Preparation for Test
 Do the engine induction test with essential EBU (Engine Perform a final shakedown inspection of preparation efforts and
Buildup) hardware installed such as but not limited to; complete necessary process paperwork sign-offs
- Forward and Aft Mounts
- Engine Essential Wiring Harness  Inlet and exhaust areas for presence of foreign
- Starter/Ducting objects/materials and damage. Bellmouth and exhaust
- Fire and Overheat Detectors elements for security.
- Speed Sensors  All engine to adapters service connections for security and
- Oil Pressure/Differential Pressure Switches safety-wire.
- Temperature Sensors  Test cowling security and integrity ensuring seals and latch
- Fuel Lines
mechanisms are in satisfactory condition/properly
- IDG and Harnesses (as applicable)
- Hydraulic Pump (as applicable) adjusted.
 Installation test adapter, bifurcated duct in the test
preparation area
 Removal the engine transportation-stand.
 Installation test Bellmouth and slave exhaust nozzle and Note; Should additional EBU hardware be required for facility
plug. and adaptation interface, it shall be installed per
 Complete the connections, engine to adapter applicable airframe/item manufacturer instructions
- Engine starter ducting to control valve.
- Fuel line. Note; Prepare the engine for test per following instructional
- Hydraulic oil supply (as applicable). summary in shop manual and equipment supporting per
- Fire detection. manufacture manual
- Electrical harnesses.
- Pressure measurements.
- Drain connections.
 Installation necessary blank-off plugs and covers.
 Installation applicable engine dress kit pressure and
temperature probes.

168
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) -- PREPARATION

169

170

171

172
GENERAL (TEST 000) -- ENGINE TRANSPORT
Transport of the Engine
 Transport the prepared engine and adapter to the test

chamber and install it into the facility thrust frame
 Slowly maneuver the engine and adapter into the test
chamber and directly beneath the thrust frame.
 Lift the engine and adapter to the thrust frame and secure.
Ensure once the engine is properly positioned and engaged
in the thrust frame that all safe operation interlock signals
are verified received and complete.
Note; Follow the reference facility supplier and vendor

component literature for recommendations specific to the
facility and engine handling equipment.

173
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) -- ENGINE TRANSPORT –
TEST CHAMBER

174
THRUST FRAME
THRUST FRAME, ADAPTER, AND MONO RAIL TRANSPORTATION
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) -- ENGINE TRANSPORT

175
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) -- ENGINE TRANSPORT -
-THRUST FRAME AND ADAPTER INTERLOCK MECHANISM

176
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING –  When you operate engines without accessories on the
GENERAL (TEST 000) -- PRE-TEST INSPECTION customer pads, make sure the plugs are installed on the gear
shafts.
 Make sure the test cell thrust and support mounts are
Pre-test Inspection serviceable as follows:
- Examine the mounts for cracks
NOTE: - Make sure the mounts are tightly attached
This is a sample checklist to be accomplished prior to - Make sure the mounts are installed correctly
and concurrent with engine test preparation. It is
important to carefully make an inspection of the test
 Make sure the drain hoses are correctly installed
facility and engine before each test. Make sure all  Make sure the starter air pipes and leads are correctly
operations necessary are complete before test starts. installed
 Make sure all the electrical connections are tight
 Read the engine log or cards. Make sure all necessary  Make sure all vibration leads, sensors, and instruments are
inspections have been made on work that is complete. Make correctly installed
sure the engine has been released for test.  Make sure the throttle operates correctly
 Make sure the engine lubrication system is correctly serviced.  Make sure the shut-off solenoid valve on the HMU is OFF
 Make sure the starter is primed with oil.  Set the ignition switch to OFF (AUTO Mode position).
 Make sure the fuel supply is the correct type, and there is an  Examine the fan and core inlets and exhaust for unwanted
adequate quantity for the test materials
 Make a check of the basic engine piping as follows:  Make sure the test cell floor is clean
- Make sure the piping is correctly installed  Start the electrical power supply for the engine, test cell, and
- Set the fuel boost pumps to ON panel
- Examine the fuel piping connections for leaks
- Set the fuel boost pumps to OFF CAUTION: IF THE STARTER IS RUN WITHOUT OIL, IT WILL
BE SEVERELY DAMAGED
 Make sure the basic engine rigging is correct
 Make a visual inspection of VSV linkages for correct
installation and serviceable condition CAUTION: EXAMINE THE ENGINE AND TEST CELL THRUST
AND SUPPORTMOUNTS BEFORE EACH ENGINE
RUN TO PREVENT INJURIESAND DAMAGE TO
THE ENGINE AND TEST CELL.

177
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) -- PRE-TEST INSPECTION --
AIR TURBINE STARTER

178
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) -- PRE-TEST INSPECTION --
THRUST STAND AND EQUIPMENTS

179
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING –  Absolute humidity (in grains).
GENERAL (TEST 000) -- DATA RECORDING  Engine operation time.
 Time of day when you did test.
Recorded Data
 Transient thrust data:
NOTE: Keep a record of this minimum data on the test log - Maximum N1 and N2 speeds.
sheets for each engine installation: - Maximum EGT.
- The time necessary for the engine to get to 95 percent
of takeoff thrust.
 Date.
- The time necessary for the engine to get to maximum
 Serial number of the engine.
EGT.
 Number of the test cell.
 Specific comments about the problems that occur during
 The type of oil used in the engine.
the tests.
 The serial numbers of the major pieces of test equipment
 Readings of all engine instruments at each steady-state
(Bellmouth, test cowlings, etc.).
data point.
 Fan nozzle area.
 Primary nozzle area.
 The lower heating value (LHV) of the fuel during the last
NOTE: CFMI recommends you make a record of all ARINC
analysis. output during the tests. The ARINC output will help you
 The specific gravity of the fuel. do troubleshooting if you have engine problems.
 The temperature of the fuel at the flow meter.
 Fuel and oil leakage as specified (fuel quantity and oil
quantity, measured separately).
 Data from starts:
- T12 (fan inlet temperature).
- Maximum EGT.
- The pressure and temperature of the starter air.
- The time necessary for the engine to get to minimum
idle after you energize the starter.
- The fuel flow during start and the peak fuel flow.
 Barometric pressure, adjusted to 32°F (0°C).

180
DATA RECORDING – ARINC OUTPUT BUS DATA

181
GENERAL (TEST 000) -- PROCEDURE OF TESTING
Engine Testing Procedure

CAUTION: DO NOT MOTOR THE ENGINE WITHOUT A
POSITIVE FUEL INLET PRESSURE. THE FUEL
PUMP AND HMU ARE LUBRICATED BY FUEL AND
DAMAGE TO THESE COMPONENTS CAN OCCUR.
 Dry-Motor the engine as follows:

(1) Set the Throttle Lever to IDLE.
(2) Set the Mode Selector to NORMAL.
(3) Set the Master Lever to OFF.
(4) Set the electrical power to ON and wait for the engine
parameters to come on the screen.
(5) Set the Manual Start Switch to ON.
(6) Set the Mode Selector to CRANK.
(7) Permit the engine to become stable at approximately
4000 rpm N2 speed. Monitor the oil pressure for a
positive indication.
(8) Obey the starter limits. Refer to shop manual TASK
[TASK 72-00-00-760-001].

182
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – HIGHER PEAK EGT AND UNUSUAL LENGTHS OF
GENERAL (TEST 000) -- ENGINE START PROCEDURE TIME TO GET TO IDLE.
CAUTION: DO NOT OPERATE THE ENGINE ABOVE MINIMUM
Engine Start Procedure IDLE WITH THE COWL OPEN TO PREVENT
DAMAGE TO THE COWLS.
CAUTION: DRY-MOTOR THE ENGINE FOR THE SPECIFIED
TIME TO PREVENT ENGINE DAMAGE.
(3) Start the engine as follows:
(a) Set the manual start switch to ON.
Do a manual start procedure as follow: (b) Set the Mode Selector to IGNITION.
(c) Set the Master Lever to ON when the engine gets to 20
(1) If the engine was operated during the previous 2 hours, dry- percent N2.
motor the engine for approximately 90 seconds. Refer to TASK (d) Move the Mode Selector to NORMAL when the engine gets
to do engine dry motoring in shop manual. to idle.
(e) Monitor the fuel flow indications until the engine is stable at
(2) Do this checklist before you start the engine: minimum idle.
(a) Set the Master Lever to OFF. (f) Monitor the EGT indications until the engine becomes stable
at minimum idle.
(b) Set the Throttle to IDLE.
(g) Carefully monitor the oil pressure until the engine becomes
(c) Set the Mode Selector to NORMAL. stable at minimum idle.
(d) Set the electrical power to ON. - You must get an indication of oil pressure before the
(e) Make sure a sufficient fuel supply is available. engine becomes stable at minimum idle.
(f) Set the Fuel Boost Pump to ON. - High oil pressure can occur in cold weather because of
(g) Make sure there is sufficient fuel pressure. high oil viscosity. When the temperature of the oil
(h) Make sure there is sufficient starter inlet air pressure. CFMI increases, the oil pressure decreases.
- If the oil pressure is not in the limits after the oil
recommends 25 psig (172 kPa) with the start valve open.
temperature becomes stable, stop the engine and do
(i) Make sure the engine oil quantity is correct. troubleshooting. Refer to TASK [TASK 72-00-00-760-001]
in shop manual
CAUTION: CAREFULLY MONITOR THE START CYCLE WHEN
YOU USE LOWER STARTER INLET AIR- CAUTION: OBEY THE OIL PRESSURE LIMITS. IF THE ENGINE
PRESSURE THAN WE RECOMMEND. LOW AIR OPERATES AT LOW OIL PRESSURES, BEARING
PRESSURE AT THE STARTER INLET CAN CAUSE DAMAGE CAN OCCUR.

183
GENERAL (TEST 000) -- POWER SETTING PROCEDURES
E. Use these procedures when you move the throttle during
Power Setting Procedures decelerations:
A. Set all power settings to the N1 referenced in TASK [TASK 72-00- (1) Use a minimum of one minute to move the throttle when
00-760-002] in shop manual, or as limited by EGT. you decelerate to minimum idle from stable operation
(more than 20 seconds) at or above maximum continuous
B. Move the throttle slowly and smoothly when you set the power.
power.
Move the throttle quickly only when it is specified in a
procedure. (2) You can make a short (one second) deceleration to minimum
idle from non-stabilized operation (not greater than 20
C. Let the engine become stable at idle power:
seconds) at conditions up to take-off power.
(1) After an engine start, let the engine be stable at minimum
idle for a minimum of 5 minutes before you try to operate at
a higher power setting.
(2) After a deceleration from higher power to minimum idle, let

the engine be stable at minimum idle for a minimum of 5
minutes before you return to higher power or do a shutdown
procedure.
D. Use a minimum of one minute to move the throttle from

minimum idle to maximum continuous power or higher unless
given different instructions.

184
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – CAUTION: DRY-MOTOR THE ENGINE FOR THE SPECIFIED
GENERAL (TEST 000) -- ENGINE SHUTDOWN PROCEDURE TIME TO PREVENT ENGINE DAMAGE.
Engine Shutdown Procedure

(9) Dry-motor the engine for a minimum of 2 minutes after
 If you used high power settings, operate the engine at
the core stops. Or, dry-motor the engine until the EGT is
minimum idle for 5 minutes to permit the engine to
less than 100°C. Refer to TASK 72-00-00-760-000-005 for
become cool.
the engine dry-motoring.
 Set these controls and monitor these parameters:
(1) Set the Throttle Lever to IDLE.
(2) Set the Master Lever to OFF.
(3) Set the Mode Selector to NORMAL.
(4) Set the Manual Start Switch to OFF.
CAUTION: MAKE SURE THE EGT CONSTANTLY DECREASES

TO PREVENT DAMAGE TO THE ENGINE.
(5) Carefully monitor the EGT. If it does not decrease (or if

you get a tailpipe fire) motor the engine until the fire
stops. Refer to TASK 72-00-00-760-000-005 for “Dry-
Motor the engine”
(6) Monitor the N2 speed.
(7) Monitor the fuel flow indication to make sure the fuel
flow stops.
(8) Set the fuel supply to OFF.

185
GENERAL (TEST 000) -- COMPLETION OF TEST
Do the preservation procedures in line with the schedule that
Completion of the Test. follow:
EFFECT -7B Classic SAC Commercial.7B DAC.7B Non- (1) Up to 30 days - operable and inoperable engines.
Commercial.7B/3 Commercial.7BE Commercial
(2) 30-365 days - operable engine.
 After all of the engine tests are complete, do an engine
(3) 30-365 days - on stand, operable engine.
preservation procedure. Refer to TASK [72-00-00-500-001]
(72-00-00, Storage 001). (4) 30-365 days - inoperable engine.
 Do this preservation procedure if:
(1) The engine is sent back to the shop.
(2) The engine will not be operated for a long time. NOTE: There is no limit to the number of times a 30-365 days’
preservation procedure can be done as long as one is
done at least every 365 days.
Engine preservation is a flexible program. Do it in the way that is
best for the applicable weather and storage conditions at the time.
The preservation program for spare and/or stored engines must be

planned in advance to do the preservation renewal correctly. You
must monitor the program to make sure the necessary action is
taken before the preservation period expires.

186
CFM56-7B ENGINE TESTING --OFF-WING ENGINE TESTING – GENERAL (TEST 000) -- COMPLETION OF TEST --
TYPICAL PRESERVATION OIL SYSTEM

187
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING –
OPERATING LIMITS (TEST 001)

188
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – is limited to 5 minutes of operation with 10 minutes of no
OPERATING LIMITS (TEST 001) -- GENERAL operation before a new motoring.
Remarks: Do not engage the starter when the core speed is

more than 55 percent (N2 > 55%)
NOTE: this limitation is for training purposes only, refer to engine
shop manual to know the engine limitation.
NOTE: The operator must know all of these limits before engine B. Engine Start Time:
operation.
(1) Time to light-off
Remarks: Light-off should occur in 2 to 3 seconds after the

master lever is turned on during an enhanced manual start. If
light-off does not occur within 10 seconds, place fuel shut-off
lever to OFF, continue to motor the engine with starter for 60
OPERATING LIMITS (TEST 001) -- LIMITS
seconds, then de-energize starter. Refer to [TASK 72-00-00-760-
A. Starter limits: 000-006] (72-00-00, Testing 000)
(1) Start attempts (2) Start to minimum idle
Requirements: Multiple attempts are permitted, 2 minutes Requirements: Corrected Start Time (CST) must be less than
each, maximum Specification Start Time (SST).
Remarks: 10 seconds of no operation between attempts to Remarks: Do troubleshooting if the CST is more than the SST
permit the starter rotor to be lubricated again.
(2) Extended motoring
Requirements: 2 consecutive extended motorings, 15 minutes

each, maximum
Remarks: 2 minutes of no operation between the first two

extended motorings. After 2 extended motorings, the starter

189
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – OPERATING LIMITS (TEST 001) – LIMITS --
START TIME CORRECTION TABLE

190

191

192
OPERATING LIMITS (TEST 001) – LIMITS (continue)
(2) Core (N2): Core seized because of seal or shroud interference,
C. Ignition System: or starter shaft is sheared
(1) Duty cycle Remarks: Do not try to start the engine until core rotor turns
freely. If engine is cold, troubleshoot starter
Requirements: Continuous use is permitted
Remarks: Use one system first, and then the other system.
Make a minimum of one start on each system during the test
schedule. The maximum ignition unit environmental
temperature must not be more than 400°F (204°C) with
continuous ignition
D. Rotors Do Not Rotate:
(1) Fan (N1): Core engine operation with fan rotor or low
pressure turbine (LPT) rotor seized
Requirements: Maximum permitted core engine speed is the

maximum motoring speed
Remarks: Do not operate the engine without an N1 rotation

indication. Set the master lever to OFF and the mode selector
to NORMAL. Do not try to start the engine. Do troubleshooting
to find the cause

193
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – Where correction factor = correction factors derived using
OPERATING LIMITS (TEST 001) – LIMITS (continue) physical core speed in RPM (Label 344) and the oil
temperature in deg C (TEOSEL .. Label 316).
E. Lubrication System:
(a) During start
CAUTION: SHUT DOWN THE ENGINE IF THERE IS ANY OIL
Requirements: Positive indication before 2000 rpm (N2)
PRESSURE CHANGE OF 5 PSI (34 kPa) DURING
STEADY-STATE OPERATION. DO (b) At stabilized minimum idle
TROUBLESHOOTING TO FIND THE CAUSE.
ENGINE DAMAGE CAN OCCUR IF THE ENGINE IS Requirements: Type 1 oil: 13 psid (90 kPa) min. indicated
OPERATED WITH THIS DEFECT.
Remarks: If not in limits, examine and correct the cause before
operation at higher speeds
(1) Oil Pressure
NOTE: The corrected oil pressure equals oil supply pressure Requirements: Type 2 oil: 13 psid (90 kPa) min. indicated
(lube pump discharge) minus the sump internal (TGB (c) Above approach idle
internal) pressure (FADEC parameterߪ.PEOFILTR Requirements: Type 1 oil For all models except -7B27A, -7BA/3, -
(ARINC Label 317)) plus the oil correction factor. 7B27AE .. 43.7 - 65.4 psid (301 - 451 kPa)For -7B27A, -7BA/3, -
COP = OSP – OSIP + OFC 7B27AE .. 74.7 - 112.4 psid (515 - 775 kPa)
Remarks: If corrected oil pressure is not in limits, examine and

correct the cause
The oil correction factors are derived using the physical core
speed (ARINC Label 344) and the selected engine oil Requirements: Type 2 oil For all models except -7B27A, -7BA/3, -
temperature (TEOSELߪ ARINC Label 316). 7B27AE .. 47.3 - 69.0 psid (326 - 476 kPa)For -7B27A, -7BA/3, -
7B27AE .. 80.5 - 118.2 psid (555 - 815 kPa)
The correction factor is shown in the following equation:
Corrected oil pressure (PEOFILTRC) = PEOFILTR (Label 317) +

correction factor
COP = PEOFILTR + FC

194
For TYPE 2 Oils
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – OPERATING LIMITS (TEST 001) – (CONTINUE) –
OIL PRESSURE CORRECTION for TYPE 2 OIL

195
(3) Facility flow verification
E. Lubrication System: (continue)
Requirements: Both facility fuel flow meters must not be
(2) Oil Temperature more than 0.5 percent different
(a) At lube pump discharge
Requirements: 285°F (140°C) maximum
Remarks: The normal oil supply temperature to the engine is G. Under-Cowl Air Temperature Limits:
150-285°F (66 to 140°C)
(1) All test operations
(3) Oil consumption Requirements: 400°F (204°C) maximum forward of station
Requirements: Less than 0.1 gal/hr (0,38 liters/hr) 221 and 500°F (260°C) maximum aft of station 221
Remarks: This limit is necessary to make sure the engine will Remarks: You must monitor under-cowl temperatures during
not use more than the operational consumption rate when it break-in and all test operations. If temperatures are not in
is installed limits, examine the engine for air leaks. Correct all air leaks
and continue the test run
F. Fuel System:
(1) Fuel flow H. Exhaust Gas Temperature (EGT):

Requirements: 400-680 pph (182-308 kg/h) during start
Remarks: Fuel flow more than 680 pph (308 kg/h) can cause (1) Start
you to go above the EGT limits Requirements: 1337°F (725°C) maximum
(2) All other operations

(2) Fuel inlet Requirements: Not more than the limits
Requirements: 10-50 psig (69-345 kPa gage)
Remarks: At the inlet to the fuel pump during all test modes
to include transients I. Vibration levels.
Apply the vibration limits.

196
EGT Temperature Limits (Except Starts)

197
Vibration Limits

198
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – (3) Main fuel pump
OPERATING LIMITS (TEST 001) – LIMITS (continue) Requirements: Maximum 120 ml/h
Remarks: Replace the main fuel pump
J. Oil Leakage:
(1) Main oil/fuel heat exchanger
(4) Main oil/fuel heat exchanger
Requirements: Maximum 7 cc/hr
Requirements: Maximum 20 ml/h
Remarks: Replace the main oil/fuel heat exchanger
Remarks: Replace the main oil/fuel heat exchanger
(2) AGB IDG pad
(5) HMU
Remarks: Replace the magnetic seal or sealol seal
(3) Aft sump
Remarks: Replace the HMU
Requirements: Oil puddle in the exhaust or on the ground is
permitted if oil consumption is in limits
(6) HPTACC
(4) Hydraulic pump
Remarks: Replace the HPTACC valve
Remarks: Replace the magnetic seal or sealol seal
(5) Forward sump
(7) LPTACC
Remarks: Repair the engine
Remarks: Replace the LPTACC valve
(6) Oil tank scupper
Requirements: Oil flows from oil tank servicing only
(8) Burner staging valve
K. Fuel Leakage:
Remarks: Replace the burner staging valve
(1) VSV actuator
(9) Transient bleed valve
Remarks: Replace the defective component
(2) VBV actuator
Remarks: Replace the transient bleed valve
Remarks: Replace the VBV actuator

199
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – M. Rotor Speeds.
(1) High pressure rotor (N2):
L. Idle Stabilization Time:
(a) Minimum idle.
(1) After a start Requirements: N2 ± 25 rpm. N2R25 = 8300 ± 25 rpm
Requirements: 5 minutes minimum Remarks: Minimum idle is set to one of the following criteria:
Min. PS3 = PS3 ± 1 psig. Refer to [Figure 2] for PS3.
Remarks: Do an engine shutdown procedure immediately if
Min. Corrected N2R25 = 8300 ± 25 rpm. Refer to
an emergency occurs. Refer to [TASK 72-00-00-760-000-008]
[Figure 1] to calculate N2R25. Min. physical N2 =
(72-00-00, Testing 000). It is not necessary to permit the
physical core speed ± 25 rpm. Refer to [Figure 1]
engine to become stable first.
for N2.
Engage the starter at 2000 N2 rpm and motor the engine to
NOTE: When the engine runs to one of the minimum criteria,
equally cool it if the engine was operated at high power
the other two parameters will exceed the minimum
settings. Refer to [TASK 72-00-00-760-000-005] (72-00-00,
values.
Testing 000).
(b) Maximum physical speed
Do not motor the engine if it will cause more damage
Requirements: 15183 rpm (100 percent = 14460 rpm)
(2) After operation at more than 2100 N1 rpm before you
accelerate again Remarks: Do an overspeed inspection if your speed is
Requirements: 5 minutes minimum more than this limit
(3) Before shutdown

Requirements: 5 minutes minimum
(2) Low pressure rotor (N1):
(a) Maximum physical speed
Requirements: 5382 rpm
Remarks: Repair the cause if your speed is more than this

limit

200
Figure 1 - Minimum Idle Corrected Core Speed

201
Figure 2 – PS3 Minimum Schedule

202
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – Q. Ratings:
OPERATING LIMITS (TEST 001) – LIMITS (continue) (1) Takeoff power setting
Remarks: Maximum of 5 minutes
N. Variable Stator Vane (VSV) schedule
Requirements: Monitor ARINC output
(2) Maximum continuous
Remarks: If the VSV did not track correctly, refer to [TASK 72-00-
Remarks: Continuous
00-760-000] (72-00-00, Testing 000)
R. Nozzle Areas (Test):

O. Variable Bleed Valve (VBV) schedule
(1) Primary (Core) Nozzle Area - A8
Requirements: Monitor ARINC output
Requirements: 462.83 sq in. (2986,0 sq cm) ± 1.5 percent
Remarks: If the VSV did not track correctly, refer to [TASK 72-00-
Remarks: Measured cold
00-760-000] (72-00-00, Testing 000)
(2) Fan Nozzle Area - A18
P. High Pressure Compressor (HPC) Discharge Pressure: Requirements: 1217.86 sq in. (7857,1 sq cm) ± 0.75 percent
Remarks: Measured cold
(1) Minimum Idle. Refer to Rotor Speed Minimum Idle
Requirements: Min. PS3 = PS3 ± 1 psig. Refer to [Figure 2] for S. Nozzle Areas (Test):
PS3 (1) Primary (Core) Nozzle Exit (A9) Plane Area
Remarks: Minimum idle is set to one of the following Requirements: 469.52 sq in. (3029,2 sq cm) ± 1.5 percent
criteria:Min. PS3 = PS3 ± 1 psigMin. corrected N2R25 = 8300 ± Remarks: Measured cold
25 rpmMin. physical N2 = N2 ± 25 rpm Refer to [Figure 1] for
N2. Refer to [Figure 2] for PS3 (2) Fan Nozzle Exit Plane Area (A19)
NOTE: When the engine runs to one of the minimum criteria, Requirements: 1226.39 sq in. (7912,2 sq cm) ± 0.75 percent
the other two parameters will exceed the minimum value Remarks: Measured cold
shown.
(2) Takeoff
Requirements: 507 psia (3495 kPa) maximum at takeoff power

203
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – (2) Shutdown
Requirements: Dry-motor for a minimum of 2 minutes after
T. ECU Temperature the core stops or until the EGT is less than 100°C
Requirements: 221°F (105°C) maximum Remarks: Obey the starter limits. Refer to Subtask 72-00-00-760-
062 (paragraph 2.A.)
Remarks: Remove power to the ECU when the engine is not in
operation
U. Fault Monitoring
Requirements: Monitor channels A and B of the ECU ARINC

output bus. Refer to TASK [72-00-00-760-000] (72-00-00, Testing
000)
Remarks: Correct the faults before you continue the test
V. Dry-motoring for engine cooling:
(1) Start
Requirements: Dry-motor for approximately 90 seconds

before start if the engine was operated during the previous 2
hours
Remarks: Obey the starter limits. Refer to Subtask 72-00-00-

760-062 (paragraph 2.A.)

204
OPERATING LIMITS (TEST 001) – ECU FAULTS
1. ECU Faults
a. CFMI recommends you make a record of all ARINC output

during the test. The ARINC output will help you do
troubleshooting if you have engine problems. The data
available from the ARINC output bus is found in TASK [72-00-
00-760-000] (72-00-00, Testing 000).
 Minimum Idle Corrected Core Speed

 PS3 Minimum Schedule
 Start Time Correction Table
 Oil Pressure Corrections (psig) for Type 1 Oils
 Oil Pressure Corrections (psig) for Type 2 Oils
 Temperature Limits (Except Starts)
 Vibration Limits

205
CFM56-7B ENGINE TESTING -- OFF-WING ENGINE TESTING – OPERATING LIMITS (TEST 001)
ECU FAULTS

206
OFF-WING ENGINE TESTING – ENGINE FUNCTIONAL TEST
(TEST 002)

207
(TEST 002)
NOTE;
1. General.
- Before you start the functional test, be sure you know the
a. The functional check gives instructions to make checks of the operating limits. Refer to TASK72-00-00-760-001 (72-00-
engine for: 00, Testing 001, Version 7001) for the correct limits.
 Fuel and oil leaks

- Monitor all of the parameters for changes during the test
 Vibration procedure. You must do this if the parameters are in
 Idle speed normal limits or not. A change in the parameters can be
 Variable Stator Vane (VSV) tracking an indication of a problem.
 Variable Bleed Valve (VBV) tracking
 Full Authority Digital Electronic Control (FADEC) operation - Before you do this test, make sure the engine is correctly
 Other mechanical functions prepared for operation. Refer to TASK72-00-00-760-000-
002 (72-00-00, Testing 000).
b. The recommended acceptance test schedule is represented in
Figure 1301.
- Before you operate the engine, do a pre-test inspection.
The schedule has been designed to combine all tests into one Refer to TASK72-00-00-760-000-003 (72-00-00, Testing
procedure, but can be modified as required for any type 000).
maintenance performed.

208
OFF-WING ENGINE TESTING – ENGINE FUNCTIONAL TEST (TEST 002) –
Acceptance Test Schedule Figure 1301

209
OFF-WING ENGINE TESTING – ENGINE FUNCTIONAL TEST (4) Make sure the VSV are closed (38.7 degrees plus or minus 1
(TEST 002) (continue) degree).
2. Leak Inspection. (5) Make sure the VBV are fully open.
a. If necessary, open the cowling doors. (6) Make sure there is no leakage from the oil system tubes or
components.
b. Start the fuel supply to the engine. Set the fuel supply to 10-
50 psig (69-345 kPa gage).
c. Examine all fuel components and tubes for leaks. If leaks are NOTE: When engine operates, some oil leak can occur at the aft
found, stop the fuel supply and correct them. Do the leak sump rotating seal. After operation, an oil puddle in
inspection again after you correct the leaks. the exhaust is usual. When engine operations are done
d. If the leak inspection is complete, close the cowling doors. one after the other, it can cause a large oil puddle in
the exhaust.
3. Motoring Check.
D. If necessary, start the fuel supply to the engine.
NOTE: Do this check before you start the engine.
CAUTION: DO NOT TRY TO MODULATE THE FUEL FLOW WITH
A. If necessary, open the cowling doors. THE MASTER LEVER. HIGH FUEL FLOWS WILL PUT
TOO MUCH FUEL INTO THE ENGINE.
B. Motor the engine. Refer to TASK72-00-00-760-000-005 (72-00-
00, Testing 000). E. Make sure there is an indication of fuel flow as follows:
(1) Set the Master Lever to ON for a maximum of 15 seconds.
C. Let the engine be stable at the maximum motoring rpm and
monitor these items: (2) Monitor the fuel flow indicator for a positive indication. If
the fuel flow indication is more than 680 pph (308 kg/h),
(1) Make sure there is a positive indication of oil pressure.
immediately set the Master Lever to OFF.
(2) Make sure the N2 indication is approximately 4000 rpm.
(3) Set the Master Lever to OFF. When you do this, the fuel flow
(3) Make sure there is an N1 indication. indication must decrease to 0.

210
OFF-WING ENGINE TESTING – ENGINE FUNCTIONAL TEST E. Do an engine shutdown procedure. Refer to TASK72-00-00-
(TEST 002) (continue) 760-000-008 (72-00-00, Testing 000).
F. Continue to dry-motor the engine for 60 seconds to remove F. Fill the oil tank to full. Refer to TASK72-00-00-760-000-002 (72-
the fuel from the combustor. 00-00, Testing 000).
G. Set the Mode Selector to NORMAL. G. Do a normal start. Refer to TASK72-00-00-760-000-006 (72-00-
00, Testing 000).
H. Listen for unusual noises from the engine during the coast-
down period. H. Operate the engine at or near minimum idle before you
accelerate to a higher power setting.
I. If necessary, do an engine shutdown procedure. Refer to

4. Start Tests.
TASK72-00-00-760-000-008 (72-00-00, Testing 000).
A. Do a normal start. Refer to TASK72-00-00-760-000-006 (72-00
00, Testing 000).
B. Let the engine become stable at minimum idle and make an

inspection for leaks or other unusual conditions.
C. If you find problems, do an engine shutdown procedure and

correct them before you continue with the test. Refer to
TASK72-00-00-760-000-008 (72-00-00, Testing 000).
D. Make a check of the minimum-to-approach idle transition as

follows:
(1) Set the throttle to APPROACH IDLE and make sure the
transition is smooth.
(2) Set the throttle to MINIMUM IDLE and make sure the
transition is smooth.

211
OFF-WING ENGINE TESTING – ENGINE FUNCTIONAL TEST (3) If no faults were generated, continue to the next step. If a
(TEST 002) (continue) fault is generated, perform necessary trouble-shooting to
clear the fault, and repeat this test.
5. FADEC System Test.
H. Do an engine shutdown procedure. Refer to TASK72-00-00-
A. Perform an engine shutdown procedure. Refer to TASK72-00-
760-000-008 (72-00-00, Testing 000).
00-760-000-008 (72-00-00, Testing 000).
I. Make sure that the stand-by channel (from the first time
B. Remove power to both channels of the ECU (off for at least 30
through the test) becomes active. This is to make sure that the
seconds).
FADEC system test is done on both channels of the ECU.
C. Energize both channels of the ECU.
J. Repeat Subtask72-00-00-760-084 (paragraph 5.D.) through
NOTE: One channel will become active, the other channel will
Subtask72-00-00-760-085 (paragraph 5.H.).
be in stand-by. Assuming equivalent health on both
channels, the channel in control will alternate on each
engine shutdown.
D. Make sure that there are no FADEC faults indicated on the

ARINC output. If a fault is generated, perform necessary
troubleshooting and clear the fault.
E. Do an engine start procedure. Refer to TASK72-00-00-760-000-

006 (72-00-00, Testing 000).
F. Let the engine become stable at minimum idle.
G. Make sure of the integrity of the FADEC System as follows:
(1) Slowly accelerate the engine to 11,100 rpm N2, and allow it
to become stable.
(2) Decelerate the engine to minimum idle. Let the engine

become stable for 5 minutes.

212
(TEST 002) (continue)
(5) Refer to Figure 1302 for an engine tested at multiple ratings
6. Functional Check Break-in, Vibration Signature, and Transient in one test run (26K and 24K ratings).
Checks.
(a) Break-in and mechanical check-out at the highest rating
A. General.
(26K) for this example.
(1) You can do these checks at the same time.
(2) This procedure conditions the surfaces of these seals to help
keep clearance deterioration to a minimum in normal service:
. Low Pressure Turbine (LPT) shrouds
. LPT interstage seals
. Compressor discharge seals
. Balance piston seals
(3) Carefully monitor the fan vibration levels during all
accelerations and decelerations. Do a fan trim balance
procedure if the fan vibrations are not in the limits. Refer to
TASK72-00-00-760-004 (72-00-00, Testing 004).
(4) Carefully monitor the core vibration levels during all
accelerations and decelerations. Send the engine to the

shop if the core vibrations are not in the limits.

213
OFF-WING ENGINE TESTING – ENGINE FUNCTIONAL TEST (TEST 002) --
Multiple Ratings Acceptance Test Schedule Figure 1302

214
OFF-WING ENGINE TESTING – ENGINE FUNCTIONAL TEST (TEST (8) Stay at 4600 rpm N1K for 3.5 minutes, and write the
002) (continue) indications.
B. Do the checks as follows: (9) Slowly accelerate (30 seconds) to takeoff rpm N1. Hold for 5
seconds. Decelerate (10 seconds) to maximum continuous
NOTE: Set the engine speeds for the power settings in this test
rpm N1.
to 10 rpm. Unless constrained by the FADEC N1 maximum
limit (5356 rpm - ARINC 429 LABEL 342-) and the ambient (10) Stay at maximum continuous rpm N1 for 5 minutes, and
temperature is below hot day conditions. Refer to Figure write the indications.
1303 and Figure 1304.
(11) Make a rapid deceleration (1 second) to minimum idle.
(1) Do a normal start. Refer to TASK72-00-00-760-000-006 (72-00- (12) Stay at minimum idle for 9 minutes, and write the
00, Testing 000). indications.
If shutdown is necessary, do it only after 9 minutes of
(2) Keep the engine at minimum idle MI for 5 minutes, and write
stabilization at minimum idle.
the indications after 5 minutes.
(12).A. Accelerate to approach idle AI. Hold for 5 minutes and
(3) Slowly accelerate (30 seconds) to 3500 rpm N1K, hold for 5 write the indications.
seconds, then decelerate (10 seconds) to 3300 rpm N1K. (12).B. Decelerate to minimum idle. old for 5 minutes and
write the indications.
(4) Stay at 3300 rpm N1K for 3.5 minutes, and write the
indications. (13) Review data obtained and compare limits. Refer to
TASK72-00-00-760-001 (72-00-00, Testing 001, Version 7001).
(5) Slowly accelerate (30 seconds) to 4600 rpm N1K, hold for 5
If vibration data is beyond limits at any speed, return to that
seconds, then decelerate (10 seconds) to 4200 rpm N1K. speed, write additional vibration data, and make sure of the
results.
(6) Stay at 4200 rpm N1K for 3.5 minutes, and write the
indications.
(7) Slowly accelerate (30 seconds) to maximum continuous rpm CAUTION: THE FAN MUST BE BALANCED PRIOR TO PROCEEDING
N1. Hold for 5 seconds. Decelerate (10 seconds) to 4600 rpm TO THE NEXT STEP. REFER TO TASK 72-00-00-760-004
N1K. (72-00-00, TESTING 004).

215
(14) Slowly accelerate (2 minutes) to takeoff rpm N1. Hold for

5 seconds, then slowly decelerate (2 minutes) to minimum
idle power.
(15) Stay at minimum idle for 5 minutes, and write the

indications on the third minute.
(16) Make sure the minimum idle speed is correct.
C. Do an engine shutdown procedure. Refer to TASK72-00-00-760-

000-008 (72-00-00, Testing 000).
NOTE: You can continue without an engine shutdown if more

tests are scheduled.
NOTE: Refer to Figure 1302 and TASK 72-00-00-760-002 (72-00-

00, Testing 002) for testing multiple ratings.
D. Examine all filters, screens, and magnetic chip detectors.

216
Power Level Chart Figure 1303

217
Power Setting Chart Figure 1304

218
OFF-WING ENGINE TESTING – ENGINE ACCEPTANCE TEST
(TEST 003)

219
(TEST 003)
2. Acceleration Time Check and Acceptance Calibration.
1. General
NOTE: Thee checks are made to be done at the same time.
a. This session will explain for the Engine Acceptance Test.
During the test, you will operate the engine at different a. This test makes sure the indicated EGT and N2 are in the
power settings (fan speeds) for the ambient conditions and performance limits. It also makes sure that when you set the
collect performance data. You will then compare the N1, the engine produces the correct thrust at the applicable
performance data to the engine's certified performance power setting.
levels.
b. Monitor the fuel flow (WF) and exhaust gas temperature
b. The engine must meet the minimum thrust requirements. In (EGT) carefully. These parameters can help find possible
addition, the engine should also demonstrate positive EGT problems and control quality.
and N2 margins relative to the maximum EGT and N2 limits
given in Figure 1301. c. Do the test as follow:
c. Characteristics of operation for N2, Engine Pressure Ratio (1). Start the engine. Refer to TASK 72-00-00-760-000-006 (72-
(EPR), and Fuel Flow (WF) are provided to help you control 00-00, Testing 000).
engine quality. You can also use this data to do
troubleshooting if the performance of the engine is marginal.
But, do not use the characteristics of operation to accept or (2). Record the corrected time to MI and peak EGT. Set N1 for
reject an engine. the power settings in this test to plus or minus 5 rpm.
Unless constrained by the FADEC N1 maximum limit (5356
d. During this test, refer to TASK 72-00-00-760-001 (72-00-00, rpm – ARINC 429 LABEL 342-) and the ambient
Testing 001, Version 7001) for the applicable operating limits. temperature is below hot day conditions.

220
OFF-WING ENGINE TESTING – ENGINE ACCEPTANCE TEST (TEST 003) -- General
Performance Acceptance Checks Figure 1301

221
(8) Quickly accelerate (one second) to the throttle stop
calculated in Subtask72-00-00-760-088 (paragraph
c. Do the test as follow: (continue) 2.C.(5)) to produce a stable TO power N1,
(3). Do the following warming-up procedure: and at the same time record the elapsed acceleration
time to 95 percent maximum TO power. Refer to Figure
NOTE: Repeat the warm-up procedure each time the
1312.
engine is shutdown during the test.
Keep the engine at TO power N1 for 30 seconds, then do
(a) Keep the engine at MI for 5 minutes.
a quick deceleration (one second) to MC. Keep the engine
(4). Record the oil quantity indication at 5 minutes. See Figure at MC for 8 minutes.
1303 for correction.
(a) The elapsed acceleration time must not be more than
(5). Determine the TO power. Refer to Figure 1302. 5 seconds. If the acceleration time is more than 5
seconds, do troubleshooting for the cause.
NOTE: This test must be done with all customer bleed

off and no customer power extraction. NOTE: For engines to be tested at multiple ratings, the
acceleration check should be done at highest
rating of the multiple ratings.
(6). Slowly accelerate to the TO power calculated in
Subtask72-00-00-760-088 (paragraph 2.C.(5)) and set the NOTE: The following steady state data points are
throttle stop at that position. necessary to complete the acceptance test
requirements. Conduct these data points with a
(7). Do a slow deceleration to 15 percent TO power. Refer to fan speed modifier level of zero.
Figure1313. Keep the engine at 15 percent TO power for
5 minutes.

222
OFF-WING ENGINE TESTING – ENGINE ACCEPTANCE TEST (13) Record the oil quantity indication at 5 minutes.
(14) Subtract oil quantity recorded in from oil quantity
recorded in Subtask72-00-00-760-090 (paragraph
c. Do the test as follow: (continue) 2.C.(4)).
(9) Record the indications after maintaining the required (15) If oil quantity used is out of limits, do the servicing of the
engine stabilization time shown at each power setting. engine oil system, then do a penalty run. Refer to Figure
1305 Sheet 1.
(10) Accelerate to TO power. Keep the engine at TO power
for 5 minutes. Record the indications. a. If oil quantity used is out of limits, perform an oil
consumption penalty run. Refer to Figure 1305 (Sheet
(11) Decelerate to MC power. Keep the engine at MC power
1) for engines that have been shutdown after
for 3 minutes. Record the indications.
performance cycle or Figure 1305 (Sheet 2) for
engines that have not been shutdown after
NOTE: Refer to Figure 1313 for an engine test at multiple performance cycle.
ratings in one test run (example: 26K and 24K
ratings).
NOTE: The engine oil consumption obtained by calculation
with oil level indications must be considered for
(a) Break-in and mechanical check-out at highest rating information only, as the tolerance of the indicator can be
(26K for this example). equal to the oil consumption limit.
(b) Acceptance test at 26K and 24K settings.
(12) Slowly decelerate (2 minutes) to MI. Keep the engine at (16) If oil quantity increased, examine fuel/oil heat exchanger
MI for 7 minutes. Record the indications. and servo fuel heater for fuel in the oil system.
NOTE: Also use the AI power setting test indications taken

during break-in test sequence for acceptance test.

223
OFF-WING ENGINE TESTING – ENGINE ACCEPTANCE TEST (TEST 003) (continue)
Oil Quantity Correction Versus Temperature (⁰ C) Figure 1303

224
Power Setting Chart Figure 1302

225
Acceptance Test Schedule Figure 1312

226
NOTE: Initial production engine configuration will be the first
information listed on the nameplate, until all lines on
c. Do the test as follow: (continue) the nameplate have been filled and the nameplate is
replaced. CFMI recommends that the customer, for
(17) Do an engine shutdown procedure. Refer to TASK 72-
record keeping purposes, retain removed nameplates.
00-00-760-000-008 (72-00-00, Testing 000).
NOTE: You must run all of the acceptance steady state test
points with a fan speed modifier level (N1 Trim Level)
of zero.
(18) Find a fan speed modifier (FMN1) based on the takeoff

thrust margin of the engine model. Refer to Figure
1320.
(19) Install the FMN1 plug onto the engine. Do an electronic

test.
(20) Engrave updated information on the nameplate. Refer

to Figure 1307. Fill the next available blank line on the
nameplate with the applicable engine configuration
information. Mark the part to a depth of 0.07-0.10 inch
(1,8-2,5 mm). Refer to TASK 70-10-12-350-005 (70-10-
12, Vibro-Peen Marking), or equivalent method
maintaining legibility and depth.

227
* * * * * FOR ALL * * * * *
OFF-WING ENGINE TESTING – ENGINE ACCEPTANCE TEST (TEST 003) – General (continue) --
CFM56-7B FADEC N1 Modifier Levels Figure 1320

228
* * * * * FOR ALL * * * * *
OFF-WING ENGINE TESTING – ENGINE ACCEPTANCE TEST (TEST 003) – General (continue) --
Nameplate Figure 1307

229
1. Testing with full authority digital engine control
(FADEC) 2 type EEC (P/N 1853M33PXX).
c. Do the test as follow: (continue)
The test cell connector must not be used with
(21) Calculate engine performance (thrust, EGT, fuel flow, FADEC 2 type EEC and the following software:
and N2 at takeoff power only). Calculate on both a
Software P/N Version Reference
modified and unmodified fan speed basis. Refer to
1853M78P27 7.B. R3F2 (7B67)
Figure 1308.
1853M78P28 7.B.SF2 (7B70)
(a) Alternative Procedure Available. All engines can be 1853M78P31 7.B. U1F2 (7B8A)
tested with its own rating plug (set the fan speed 1853M78P29 7.B.TF2 (7B79)
modifier/N1 trim level to zero), with the exception of
the following ratings: 7B26/3F, 7B26E/F, 7B26/3B2F,
Engines in these configurations must be tested
7B26E/B2F, 7B27/3F,7B27E/F, 7B27/3B1F, 7B27E/B1F
with a 27K nameplate rating plug (P/N 390-660-
and 7B27AE. These engine ratings must be tested
501-0) in lieu of the test cell connector. Set the fan
with the appropriate test cell connector.
speed modifier (N1 Trim level) to zero. However,
To help testing the engine at more than one thrust the test cell connector can be used for engines
rating. If the electronic engine control (EEC) is with 7.B. V2 and up software.
configured with P/N 1853M78P16 or higher versions
of EEC software, do the engine test with a test cell
2 Testing with FADEC 3 Type EEC (P/N 2042M67PXX)
connector installed on the EEC. Enter the aircraft
application as 737-800 model in the test cell input to The test cell connector can be used with any
the EEC. version of software P/N 2044M25P03 or higher.
See in engine manual for the applicable test cell
connector’s P/N

230
TEST CELL CONNECTOR CONFIGURATION

231
D. Performance Troubleshooting.
(1) If the engine fails any performance test point, examine the
test data for instrumentation faults, and then repeat the test
point, if necessary.
(2) Some of the possible reasons for poor component

performance are:
Fan Too much dirt

Blended too much
Large tip clearance
Leading edge contour
Fan duct Damage to flowpath
surfaces (steps and
gaps)
HPC Large tip clearances
Stator schedule error
Too much dirt
Too much damage
Blended too much
HPT Large tip clearances
High parasitics (seal
leaks)
Large HPT nozzle area
LPT Large tip clearance
Large LPT nozzle area
Parasitics (internal cooling flow Increased seal
and seal leaks) clearance
Blocked passages

232
E. Performance Calculations.
(1) General. NOTE: Use these derivatives to adjust the data for
tests done at inlet temperatures higher than the
Correct FN, EGT, N2, WF, and EPR to the Standard Day flat-rated temperature. Also use the derivatives to
conditions with the applicable parameter adjustments adjust off-speed data because of errors when you set
referenced in this procedure (refer to Figure 1306 and Figure the necessary N1 test speed.
1308). Compare the results to the applicable power setting
specifications. Refer to Figure 1301.
(2) Do the performance calculation corrections in the sequence

that follows: (3) Calculations.
(a) Standard Day correction factors for PT2/PS2, T2, humidity, Correct the applicable data to standard day conditions. Include
and clearance control effects. condensation and humidity factors. Use the equations that
follow in Figure 1306 and Figure 1308.
(b) Condensation correction factors.
(c) Test cell correlation facility modifiers, unique to each

customer facility. You can get these from the applicable Test
Cell Correction Report.
NOTE: The facility modifiers are multipliers as function of

corrected dry thrust, prior to applying the facility-
modifier for thrust (FMFN).
(d) Adjustments for the test cell Bellmouth.
(e) Derivatives to adjust parameters from N1R ACTUAL to N1K

RATED for appropriate power setting.

233
OFF-WING ENGINE TESTING – ENGINE ACCEPTANCE TEST (TEST 003) – Performance Calculation
Performance Acceptance Checks Figure 1301

234
Condensation and Humidity Corrections (Theta 2 and T2)
Figure 1306

235
(Facility Modifiers and Installation Effects)
Figure 1308

236
OFF-WING ENGINE TESTING – FAN TRIM BALANCE
(TEST 004)

237
(TEST 004)
(a) Find the quantity of the initial imbalance.
1. General. (b) Compare this initial quantity with the quantity of the
imbalance caused by test weights which are put at three
A. This procedure gives the instructions to trim balance the Fan
locations, 120 degrees apart.
Rotor and the Low Pressure Turbine (LPT) Rotor.
(c) Put the data on a graph to find the position and quantity
B. The trim balance procedure is done when the low pressure
of the weights necessary for the final trim balance.
rotor assembly vibration levels exceed the limits defined in
Testing 001.
C. The function of the trim balance procedure is to balance the

fan rotor and, if necessary, the LPT rotor, to get the No. 1
bearing and the FFCCV (Fan Frame Compressor Case Vertical)
vibration levels within the limits defined in Testing 001.
D. For imbalance correction calculation, the trim balance

procedure uses the vibration data recording of the vibration
given by the No. 1 bearing and FFCCV vibration sensors.
E. Trim Balance Method.
(1) Three-Shot Plot Method.
NOTE: This method is used when there is no equipment

available to find the phase angle of the imbalance; the
steps are as follows:

238
OFF-WING ENGINE TESTING – FAN TRIM BALANCE 3. Definition of Terms and Symbols.
A. Symbols.
2. Tools, Equipment, and Consumable Materials.
A - Phase angle.
NOTE: You can use equivalent alternatives for tools,
R and AW - Resultant.
equipment, and consumable materials.
S - Sensitivity: The ratio of the imbalance weight (g-cm)
to the vibration amplitude (mils) caused
A. Tools and Equipment. by a given imbalance weight for a given
speed and sensor.
(1) Special Tools. None.
U – Vibration amplitude or displacement vector.
(2) Standard Tools and Equipment. None.
W – Balance correction weight.
(3) Locally Manufactured Tools. None.
X - Angle.
B. Consumable Materials.
B. Terms.
Code No. Description
(1) Displacement vector:
CP5062 MoS2 Dry Film Lubricant (dry film
(a) The displacement vector (U) is expressed in Mils
lubricant)
Double Amplitude (DA).
C. Referenced Procedures.
(b) The angular direction is given by the phase angle
ATA No. Description (A) expressed in degrees.
72-00-00 Testing 002 (2) Balance weights:

(a) Balance weights are screws of different lengths,
72-00-00 Assembly 006, Effect D attached radially on the spinner rear cone.
72-00-00 Assembly 006, Effect C (3) Engine run:
(a) The engine run is the operation of the engine.

239
4. Fan Trim Balance Procedure (Three-Shot Plot Method).

B. Record of the Initial Conditions.
A. Connection of the equipment.
(1) Write the type and location of the balance screws
(1) Connect the cables to the following equipment’s. which are installed radially in the spinner rear cone.
Refer to Figure 1302 and Figure 1303.
(a) N1 speed sensor output connector.
(2) Find and make a record of the conditions that follow.
(b) No. 1 bearing vibration sensor output connector.
(a) Ambient air temperature (outside air temperature
NOTE: If the vibration sensor for the No. 1 bearing
(OAT)).
does not operate, use the FFCCV vibration
sensor. (b) Barometric pressure.
(c) FFCCV vibration sensor output connector.
NOTE: If, during an engine run with test weights CAUTION: MAKE SURE THAT YOU GET THE LOCAL
installed, the engine becomes balanced (the BAROMETRIC PRESSURE (NOT CORRECTED
Fan and LPT vibration levels at the different TO SEA LEVEL). THIS CAN HELP PREVENT
speeds become lower than the recommended ANINCORRECT TRIM TARGET SELECTION.
level on the test cell indication), the trim
balance procedure is completed. The test
weights stay installed, and the engine is
serviceable.

240
(c) Increase the speed of the engine slowly to the
C. Engine Runs. correct takeoff target % N1.
CAUTION: DO NOT RUN THE ENGINE AT TAKEOFF (d) Continue to operate the engine for a minimum of
POWER FOR MORE THAN 5 MINUTES. ENGINE 5 seconds but a maximum of 30 seconds while you
DETERIORATION MAY RESULT. write the No. 1 bearing and FFCCV vibration
indications (U0) on a 3-shot plot worksheet.
(1) Determine rating specific maximum permissible
takeoff N1, refer to TASK 72-00-00-760-002 (72-00- (e) If the vibration level is more than 7 mils, do as
00, Testing 002). follows. 1 Decrease the speed of the engine slowly
and continuously while you monitor the No. 1
(2) Do the engine run as follows.
bearing and FFCCV vibrations indications. 2
CAUTION: DO NOT EXCEED 14,700 RPM N2 PHYSICAL. Continue to decrease the speed until the correct
vibrations levels are at 7 mils or lower.
(a) Start the engine and hold at Minimum Idle (MI).
NOTE: This will make sure that the vibration levels will
(b) Continue to operate the engine at MI for a not be more than 8.0 mils during the balance
minimum of 5 minutes to make the temperature procedure.
of the engine stable.
(f) Decrease the speed of the engine slowly to the
NOTE: The time to make the temperature stable can be subsequent lower N1 speed.
decreased to a minimum of 3 minutes if the
engine was operated less than 15 minutes (g) Write the No. 1 bearing and FFCCV vibration
before this procedure. This 3-minutes time is indications (U0) while you make the engine stable for
not necessary if the trim balance procedure is a minimum of 5 seconds but a maximum of 30
started less than 5 minutes after the engine was seconds at each lower N1 speed.
operated at high power and was not stopped.
(h) Decrease the speed to minimum power.
(i) After 5 minutes, when the engine becomes stable, do

the engine shutdown procedure.

241
OFF-WING ENGINE TESTING – FAN TRIM BALANCE (10) Replace the three P05 weights from the second
(TEST 004) (continue) location with the initial P07 screws lubricated with
dry film lubricant (CP5062).
(3) Look at the chart of the installed balance screws
(other than P07). (11) Install the three P05 balance screws lubricated with
dry film lubricant (CP5062) in the third location that
(4) Find three locations, that are apart 120⁰, where
you found (240⁰). Refer to TASK 72-00-00-430-006-A
three P05 balance screws can be installed without
(72-00-00, Assembly 006, Effect D) or TASK 72-00-00-
the removal of other balance screws. Example: (2, 1,
430-006-C (72-00-00, Assembly 006, Effect C)
36), (24, 25, 26), and (12, 13, 14).
(12) Do a third engine run.
(5) Install three P05 balance screws lubricated with dry
film lubricant (CP5062) at the first location that you (a) Write the U3 values.
found. Refer to TASK 72-00-00-430-006-A (72-00-00,
(13) Use the 3-shot procedure to calculate the angle and
Assembly 006, Effect D) or TASK 72-00-00-430-006-C
balance weight
(72-00-00, Assembly 006, Effect C)
(6) Obey the related WARNING and CAUTION while you

do the first engine run.
(a) Write the U1 values.
(8) Install the three P05 balance screws lubricated with

dry film lubricant (CP5062) in the second location
that you found (120⁰). Refer to TASK 72-00-00-430-
006-A (72-00-00, Assembly 006, Effect D) or TASK 72-
00-00-430-006-C (72-00-00, Assembly 006, Effect C)
(9) Obey the related WARNING and CAUTION while you

do a second engine run.
(a) Write the U2 values.

242
OFF-WING ENGINE TESTING – FAN TRIM BALANCE (TEST 004)
Balance Screw Specifications
Figure 1302

243
Figure 1303

244
Figure 1303

245
OFF-WING ENGINE TESTING – NO.4 BEARING DEFECTSCREENING
(TEST 009)

246
OFF-WING ENGINE TESTING – NO.4 BEARING DEFECTSCREENING (2) No.4 Bearing Passed, Code Analysis
(TEST 009)
(a) The testing did not identify No.4 bearing signature levels
that are considered strong indicators of a defect in the
1. General. bearing outer race, but levels were measured that are
higher than typical. Product Support Engineering may
A. CFM has developed a screening tool to aid in the detection of
provide additional assistance in interpreting the results
No.4 bearing defects. The tooling can identify some defects
of this test outcome.
that occur in the No.4 bearing outer race. This type of damage
may be the result of previous engine operation, (3) No.4 Bearing Defect Detected, Bearing Inspection
contamination, or assembly damage. The purpose of the Recommended
testing and the use of the tool to screen No.4 bearings at the
(a) The testing identified No.4 bearing signature levels that
overhaul shop is to reduce the likelihood that a No.4 bearing
are considered strong indicators of a defect in the
failure will occur in service. The tool uses the standard engine
bearing outer race. CFM recommends to inspect and
vibration sensors and rotor speed signals to perform the
change the bearing if required.
analysis.
D. This test procedure is recommended by CFM to be performed
B. The test procedure may be performed for an engine inbound
during all outbound testing for the CFM56-7B engines, and
to the shop or outbound during final Functional Testing
requires CFM tooling.
(Testing 002) and Acceptance Testing (Testing 003). No special
engine run time is required beyond typical outbound testing to
complete the bearing signature analysis.
2. Tools, Equipment and Materials.
C. At the completion of the testing, the CFM tooling will provide
one of the following three recommendations: A. Tools and Equipment
(1) No.4 Bearing Passed Tool No. Description
(a) The testing did not identify a defect in the No.4 bearing 856A2679G11
and the engine has satisfactorily completed testing. Or CFM56 No.4 Bearing Screening Tool
856A2679G12
856A2680G03 CFM56 No.4 Bearing Screening Software

247
OFF-WING ENGINE TESTING – NO.4 BEARING DEFECTSCREENING for the FFCC vibration sensor. The output of the charge
(TEST 009) (continue) amplifier must be in units of acceleration (mV / g's peak).
B. Initiate the software.

3. Test Preparation.
(1) Turn the No. 4 bearing screening tool, 856A2679G12 power
NOTE: Read the CFM56 MULTI-ENGINE VIBRATION ANALYZER supply “ON”
Manual, to become familiar with the operation of the tooling.
(2) Enter your user ID (Figure 1303)
A. Install the No.4 bearing screening tool as follows. Refer to
(3) Enter password
Figure 1301 and the CFM56 MULTI-ENGINE VIBRATION
ANALYZER Manual. (4) Cell Number is optional
(1) Install the No. 4 bearing screening tool, 856A2679G12 (5) OK

vibration analyzer in a location that can be accessed by (6) Enter ESN (Figure 1304)
the engine operator during the engine test.
(7) Time Since New TSN - optional
(2) Connect wire “N1” from the ADC / Input Box “RE4
INTERCONNECTION BOX” to the test cell N1 SPEED signal (8) Cycles Since New CSN - optional
(30 pulses / rev with high tooth). (9) CALIBRATION (Figure 1305)
(3) Connect wire “N2” from the ADC / Input Box “RE4 (10) Check Sensitivity Boxes for correct mV/g values
INTERCONNECTION BOX” to the test cell N2 SPEED signal.
(a) Valid Button Saves Changes
(4) Connect wire “ACC1” from the ADC / Input Box “RE4
INTERCONNECTION BOX” to the test cell Charge Amplifier (b) Cancel if no changes made
for the No.1 Bearing (BRG) vibration sensor. The output
of the charge amplifier must be in units of acceleration
(mV / g's peak).
(5) Connect wire “ACC2” from the ADC / Input Box “RE4
INTERCONNECTION BOX” to the test cell Charge Amplifier

248
(5) Accelerate to TAKEOFF. Stabilize for 1 minute. Slowly
4. Engine Test Sequence. decelerate the engine to the following N2 physical speeds
and stabilize the engine at each speed for 1 minute:
A. The tooling acquires data during the complete engine test
sequence below: (a) 14,000, 13,750, 13,500, 13,250, 13,000, 12,750, 12,500,
12,000, 11,000
- The Typical Functional Testing (TASK72-00-760-002 (72-
00-00, Testing 002)), (6) Slowly decelerate the engine to minimum idle
- Acceptance Testing (TASK72-00-00-760-003 (72-00-00,
(7) Stabilize the engine at minimum idle for 5 minutes
Testing 003)),
- Fan Trim Balance (TASK72-00-00-760-004 (72-00-00, NOTE: A command must be provided to the tooling prior to
Testing 004)) the next throttle movement. Refer to Subtask 72-00-
00-760-004
test sequences are the recommended engine operation for
the use of the tooling. (8) Vibration Signature:
B. If a specific engine test run is to be performed for No.4 (a) Slowly and continuously accelerate the engine from
bearing signature analysis only, the following test sequence is minimum idle to TAKEOFF power. The engine
recommended: acceleration should be performed for 2 minutes
(1) Perform a normal start to idle (b) Stabilize the engine at TAKEOFF power for 30 seconds
(2) Stabilize the engine at minimum idle for 5 minutes (c) Slowly and continuously for 2 minutes, decelerate the
engine from TAKEOFF to minimum idle
(3) Slowly accelerate from minimum idle to 80 percent N1. (d) Let the engine stabilize at minimum idle for 5 minutes
Let the engine stabilize at 80 percent N1 for 5 minutes
(e) Perform a normal engine shutdown.
(4) Slowly accelerate from 80 percent N1 to MAXCON power.
Let the engine stabilize at MAXCON for 1 minute

249
5. Data Acquisition During Engine Test.

C. The lap top vibration analyzer switches automatically to
A. Prior to engine start, select START ACQUISITION on the steady state (SS) measurement after the deceleration portion
tooling. Refer to Figure 1302. of the transient has been detected and stored.
(1) The tooling will begin to acquire data automatically after

the engine is started.
B. Prior to starting the Vibration Signature, with the engine at

idle, select “TRANS MEAS” on the No. 4 bearing screening
tool., 856A2679G12 Refer to Figure 1302.
NOTE: A series of messages will appear in the journal window

during the transient measurement. If the tool is
gathering data correctly the following messages will be
found in the journal. If not, some portion of the transient
has been missed.
: “Transient Measurement Started”

: ”Transient Acceleration Waited”
: ”Transient Acceleration Stored”
: ”Transient Deceleration Waited”
: ”Transient Deceleration Stored”
: ”Steady Measurement Started”
If the messages do not appear, the transient data was not

collected. Make sure the tooling and input signals are installed
correctly. Refer to No.4 bearing screening tool, 856A2679G12
Tooling Manual.

250
(3) If the analysis results indicate “No.4 BEARING DEFECT
6. Analyze Data After Engine Test. DETECTED”:
A. After the acceptance test or inbound test and prior to engine (a) The testing identified No.4 bearing signature levels that
removal, select the “EXIT MONITORING” Stop Sign Button on are considered strong indicators of a defect in the bearing
the lap top vibration analyzer. Refer to Figure 1302. outer race. CFM recommends to inspect and, if necessary,
to replace the bearing.
B. Select the RESULTS button at the top of the screen to start the
No.4 bearing analysis. Refer to Figure 1302. NOTE; In the event that the results message indicates
there was insufficient data to complete the
C. Assuming all three data types are captured, three analyses
analysis, an additional engine run should be
will be performed by the tooling: SS, Transient Accelerate, and
acquired and processed.
Transient Decelerate.
D. After the analysis is completed, a report is displayed to the

screen. Refer to Figure 1306.
(1) If the analysis results indicate “No.4 BEARING PASSED”:
(a) The testing did not identify a defect in the No.4 bearing
and the engine has satisfactorily completed testing.
(2) If the analysis results indicate “No.4 BEARING PASSED,

Code Analysis”:
(a) The testing did not identify No.4 bearing signature

levels that are considered strong indicators of a defect in
the bearing outer race, but levels were measured that are
higher than typical. CFM Product Support Engineering may
provide additional assistance in interpreting the results of
this test outcome.

251
OFF-WING ENGINE TESTING – NO.4 BEARING DEFECTSCREENING (TEST 009)
Figure 1302

252
Figure 1303

253
Figure 1304

254
Figure 1305

255
Figure 1306

256
Figure 1306 a
257
CFM56-7B ENGINE TESTING – ENGINE SYSTEMS REVIEW

258
259
260
ENGINE RUN – ENGINE SYSTEM REVIEW – ENGINE – GENERAL DESCRIPTION

261
262
263
264
ENGINE RUN – AIRPLANE SYSTEMS REVIEW – ENGINE FUEL AND CONTROL – FUNCTIONAL DESCRIPTION

265
266
267
ENGINE FUEL AND CONTROL – FUEL INDICATING – GENERAL DESCRIPTION

268
269
270
271
ENGINE RUN – AIRPLANE SYSTEMS REVIEW – ENGINE IGNITION – GENERAL DESCRIPTION

272
273
274
ENGINE RUN – ENGINE SYSTEM REVIEW – ENGINE AIR – GENERAL DESCRIPTION

275
276
277
278
279
280
ENGINE RUN – AIRPLANE SYSTEM REVIEW – ENGINE CONTROLS – GENERAL DESCRIPTION

281
282
283
ENGINE INDICATING – INTRODUCTION

284
285
286
ENGINE TACHOMETER SYSTEM – FUNCTIONAL DESCRIPTION

287
288
289
290
291
EXHAUST GAS TEMPERATURE (EGT) INDICATING SYSTEM – FUNCTIONAL DESCRIPTION

292
293
294
295
ENGINE RUN – AIRPLANE SYSTEMS REVIEW – AVM SYSTEM – GENERAL DESCRIPTION

296
297
298
ENGINE RUN – ENGINE SYSTEMS REVIEW – ENGINE OIL STORAGE AND DISTRIBUTION SYSTEM

299
300
301
ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – ENGINE OIL INDICATING SYSTEM – GENERAL DESCRIPTION

302
303
304
305
ENGINE RUN – AIRPLANE SYSTEMS REVIEW – ENGINE STARTING – GENERAL DESCRIPTION

306
307
308
309
REFERENCE SOURCES
ARTICLES;
 CFM56-7B Engine Shop Manual, Rev. Jan’15’2017
 B737-600/700/800/900 Aircraft Maintenance Manual,
Rev.62
MATERIALS;
 B737-6/7/8//9ER Engine Run - Up Training Manual
(ALTEON), LTC
 ASE documentation – Anatomy of a Test Cell
 ASE documentation - ASE 2000LX Control &
Instrumentation System
SURVEY, INTERNAL INFORMATION, AND CONFIRMATION SOURCE;

 GE Engine Service Malaysia – testing engine witness, March
2017

310

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CFM56-7B ENGINE TESTING – INTRODUCTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 10

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AIRBORNE AUXILIARY POWER – CONTROLS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 73

PNEUMATIC – FUNCTIONAL DESCRIPTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 95

ENGINE RUN – AIRCRAFT SYSTEMS REVIEW – FUEL – STORAGE ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 108

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ENGINE RUN – SAFETY – WIND CONDITIONS ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 124

737 WALK AROUND INSPECTION ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 144

ENGINE TESTS – TABLES ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 147

ENGINE TESTS -- ENGINE DATA AND RECORD SHEET ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 150

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OFF-WING ENGINE TESTING – OPERATING LIMITS (TEST 001) ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 189

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General Course Structure:

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Ground safety review engine hazards and safety procedure that

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The common display system (CDS) shows performance, navigation,

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Test cell is divided into sub buildings;

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