Ignition Starting

B737NG/74&80/301 Ignition & Starting

Boeing B737-600/700/800/900

Ignition & Starting CMF56-7B

Training manual For training purposes only LEVEL 3

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Table of Contents. 1. IGNITION..................................................................................................6 1.1. General Description................................................................................8 1.2. Engine Component...............................................................................10 1.3. Flight Compartment Component Locations...........................................12 1.4. Ignition Exciter......................................................................................14 1.5. Ignition Leads and Spark Igniters...........................................................16 1.6. Functional Description..........................................................................18 1.7. Operation.............................................................................................20 2. ENGINE STARTING.................................................................................24 2.1. General Description..............................................................................26 2.2. Engine Component Locations...............................................................28 2.3. FLT Compartment and EE Compartment Components..........................30 2.4. Start Valve............................................................................................32 2.5. Starter...................................................................................................34 2.6. Maintenance Practices..........................................................................36 2.7. Engine Starting - Functional Description................................................38 3. IGNITION & STARTING OPERATION......................................................40 3.1. Engine Starting Operation.....................................................................40 4. IGNITION & STARTING - TRAINING INFORMATION POINT..................42

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List of Illustrations. ENGINE COMPONENT LOCATIONS.......................................................................................... 11 ENGINE STARTING.................................................................................................................. 43 ENGINE STARTING COMPONENT LOCATIONS......................................................................... 29 ENGINE STARTING - FUNCTIONAL DESCRIPTION..................................................................... 39 ENGINE STARTING - GENERAL DESCRIPTION........................................................................... 27 ENGINE STARTING - INTRODUCTION....................................................................................... 25 ENGINE STARTING OPERATION............................................................................................... 41 FLIGHT COMPARTMENT AND EE COMPARTMENT COMPONENTS........................................... 31 FLIGHT COMPARTMENT LOCATIONS...................................................................................... 13 IGNITER EXCITER.................................................................................................................... 15 IGNITION................................................................................................................................ 42 IGNITION FUNCTIONAL DESCRIPTION..................................................................................... 19 IGNITION - GENERAL DESCRIPTION........................................................................................... 9 IGNITION - INTRODUCTION....................................................................................................... 7 IGNITION LEADS AND SPARK IGNITERS................................................................................... 17 IGNITION - OPERATION........................................................................................................... 21 IGNITION - TRAINING INFORMATION POINT............................................................................ 23 STARTER................................................................................................................................. 35 STARTING SERVICING............................................................................................................. 37 START VALVE.......................................................................................................................... 33

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Abbreviations and Acronyms AGB ALF AMM CDS CDU CONT DEU EEC FLT FMC FMCS GRD IGN L R

Accessory GearBox Aft Looking Forward Airplane Maintenance Manual Common Display System Control Display Unit Continuous Display Electronics Unit Electronic Engine Control Flight Flight Management Computer fFlight Management Computer System Ground Ignition Left Right

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1. IGNITION. The ignition systems supply electrical sparks in the combustion chamber for combustion. Each engine has two ignition systems that operate independently. The ignition system usually operates manually. However, the ignition systems operate automatically when the electronic engine control (EEC) sees a possible engine flameout condition. You use ignition during these times : - Ground start, - Takeoff and landings, - In-flight (during heavy turbulence or bad weather), - In-flight start.

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IGNITION - INTRODUCTION

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1.1. General Description. These components control ignition : - Start levers, - Start switches, - Ignition selector switch, - Electronic engine control (EEC). The start lever controls ignition system power to the EEC. The start switch and the ignition selector switch supply inputs to the EEC. The EEC uses these inputs to supply power to the ignition exciters. The ignition exciters supply power to the spark igniters. The engine starting system also uses the switch positions for control. See the engine starting chapter for more information.(AMM PART I 80) ELectrical Power. The engine 1 ignition systems receive 115v ac from ac transfer bus 1 and the ac standby bus. The EEC has internal switches that control the 115v ac to the ignition exciters. The ignition exciters change the 115v ac input to a dc voltage of approximately 15,000 to 20,000v for the spark igniters. The spark igniters give a spark for combustion. The ignition systems of engine 2 receive ac power from ac transfer bus 2 and the ac standby bus.

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IGNITION - GENERAL DESCRIPTION

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1.2. Engine Component. Each engine has a right and a Left ignition system. These are the components of each ignition system : - ignition exciter, - Ignition lead, - Air manifold, - Spark igniter. Component Locations. The ignition exciters are on the right side, lower portion, of the fan case. The ignition leads go from the ignition exciters to the spark igniters on the right and left sides of the engine. The air manifold goes around the ignition leads. The air manifold starts in the 6:00 strut and goes to the igniters. The spark igniters are just forward of the fuel manifold, at the 4:00 position and the 8:00 position.

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ENGINE COMPONENT LOCATIONS EFFECTIVITY ALL

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1.3. Flight Compartment Component Locations. These components which control the ignition system are in the flight compartment : - Engine start switches, - Ignition selector switch, - Start levers. Component Location. The ignition selector switch and engine start switches are on the forward overhead panel (P5). The start levers are on the control stand.

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FLIGHT COMPARTMENT LOCATIONS EFFECTIVITY ALL

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1.4. Ignition Exciter. The ignition exciters supply power to spark igniters. General. The ignition exciters change 115v ac to 20,000v dc. The output of the ignition exciter is 14.5 to 16 joules. The spark igniter uses this power to ignite the fuel/ air mixture in the combustion chamber. Usually, only one ignition exciter per engine operates at a time. PhysicaL Description. A 115v ac electrical connector attaches to the forward face of the ignition exciter. The ignition Lead attaches to the aft face of the ignition exciter. The ignition exciters attach to the fan case with four shockmounts. Each ignition exciter has a bond jumper that attaches to the engine. Training Information Point. WARNING : MAKE SURE THE IGNITION EXCITERS ARE DE-ENERGIZED BEFORE YOU START WORK ON THE IGNITION SYSTEM. THE IGNITION SYSTEM VOLTAGE IS DANGEROUSLY HIGH. DO NOT TOUCH THE IGNITION SYSTEM COMPONENTS UNTIL YOU DO THE PROCEDURE THAT FOLLOWS. THIS PROCEDURE WILL RELEASE THE HIGH VOLTAGE FROM THE IGNITION EXCITER. IF YOU DO NOT OBEY THIS PROCEDURE, INJURY TO PERSONS CAN OCCUR. W1ZN-K1M 4- IGNITION LEADS AND SPARK IGNITERS

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IGNITER EXCITER

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1.5. Ignition Leads and Spark Igniters. The spark igniters supply an electrical spark to ignite the fuel/air mixture in the combustion chamber. The ignition leads transmit power from the ignition exciters to the spark igniters. General Description. Each spark igniter has its own ignition lead. Air goes around each ignition lead to decrease the temperature of the lead. Ignition Lead Cooling. Each ignition lead goes into an air manifold at the 6:00 position at the aft end of the fan case. Booster air (low pressure compressor exhaust air), makes each ignition lead cool. The booster air goes into the air manifold and moves around the inner part of the ignition lead shroud. Booster air comes out of the spark igniter end of the ignition Lead to cool the spark igniter. Spark Igniters. Each spark igniter installs into an adapter at the 4:00 and 8:00 positions on the engine. The spark igniter electrode is inside the combustion chamber.

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IGNITION LEADS AND SPARK IGNITERS

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1.6. Functional Description. These are the components that operate the ignition system : - Start levers, - Engine start switches, - Ignition selector switch, - EEC. The ac transfer bus 1 supplies 115v ac electrical power to the EEC for the left ignition exciter. The ac standby bus supplies 115v ac electrical power to the EEC for right ignition exciter. The left ignition exciter for engine 2 uses power from ac transfer bus 2. The right ignition exciter uses the ac standby bus. The EEC controls power to the ignition exciters. Input from the flight compartment components give manual control. The EEC has internal logic for automatic ignition system control. Manual Control. The EEC and the CDS/DEUs monitor positions of these flight compartment components : - Ignition selector switch, - Engine start switches, - Start levers.


ignition on/off switch, for an ignition exciter, works at a time. The other EEC channel is in the standby mode. 115v ac power goes to the EEC when you move the start lever to the idle position. The 115v ac power goes through the start lever switches that are in the closed position. The ignition exciters receive power and supply 15,000 to 20,000v dc of electrical power to the spark igniters. The voltage goes across the electrodes of the spark igniter to make sparks. Automatic Control. The EEC turns on both ignition systems of an engine automatically if one of these conditions are true : - The engine start lever is in the IDLE position, the start switch is in the FLT position, - The engine start lever is in the IDLE position, start switches in GRD or CONT position, N2 less than idle and the airplane is in flight, - The engine start lever is in the IDLE position, engine speed decreases uncommanded or N2 is Less than 57% and N2 is greater than 50%. For this condition only, both ignition systems are energized for 30 seconds, - The engine start lever is in the IDLE position, the airplane is in flight, start switch is in the OFF position, N2 speed is Less than idle and N2 speed is greater than 5%. The EEC turns ignition off when these conditions are true :

Each CDS/DEU sends a digital data signals to the EEC with switch position information. The EEC looks at the CDS/DEU digital data signal and the analog signal. The EEC compares the two signals. If the CDS/DEU 1 or CDS/DEU 2 digital data signal to the EEC logic stops, the EEC uses the analog signal as the flight compartment input. The EEC uses switch position data to control four internal EEC ignition on/off switches. These switches control the 115v ac power to the ignition exciters. Each EEC channel (A and B) controls one ignition on/off switch to each ignition exciter. Only one EEC channel is active at a time. Therefore, only one EFFECTIVITY ALL

- The engine start switches are not in a position that command ignition operation, - Hot start on the ground, - Wet start on the ground, - The engine start lever is in the IDLE position, airplane is on the ground, the engine completed a start, N2 speed goes less than 50% and EGT is greater than the start limit - Ignition system energized because of N2 less than idle or uncommanded decrease in N2 and engine speed goes back to normal.

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IGNITION FUNCTIONAL DESCRIPTION EFFECTIVITY ALL

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1.7. Operation General These are the flight compartment controls you use to operate the engine ignition: * Start lever * Ignition selector switch * Engine start switch. Start Lever The start lever controls ignition electrical power to the EEC. The EEC receives 115v ac power for ignition when the start lever is in the idle position. Ignition Selector Switch There are three ignition selector switch positions: * IGN L (Left spark igniter) * IGN R (right spark igniter) * BOTH (both spark igniters). Engine Start Switch There are four engine start switch selection positions: * GRD (ground start) * OFF * CONT (continuous ignition) * FLT (flight).

You use the GRD position to start the engine on the ground. See the engine starting chapter for more information. (CHAPTER 80) Engine Start Switch Position (OFF) Usually the igniters do not operate when the start switch is in the OFF position. However, the EEC turns on the ignition system automatically if the EEC sees a possible engine flameout condition. See the functional description page in this section for more information about this function. Engine Start Switch Position (CONT) The flight crew may turn the engine start switch to the CONT position at these times: * Takeoff * Approach * Landing * Bad Weather. The spark igniters, as selected by the ignition selector switch, turn on and operate continuously when the switch is in this position. Engine Start Switch Position (FLT) Both spark igniters operate continuously when you turn the engine start switch to FLT position. The EEC does not use the ignition selector switch position information.

Engine Start Switch Position (GRD) The engine starter engages and turns the engine when you put the engine start switch to the GRD position. You supply ignition and fuel to the engine combustor when you move the start lever to the idle position.

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IGNITION - OPERATION EFFECTIVITY ALL

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Training information point The control display unit (CDU) helps you do troubleshooting of the ignition system. You can also use the CDU to do a ground test of the ignition system. See the engine indicating chapter for more information. (CHAPTER 77)

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IGNITION - TRAINING INFORMATION POINT EFFECTIVITY ALL

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2. ENGINE STARTING. The engine starting system uses pneumatic power to turn the engine’s N2 rotor during a start or motor procedure. Pneumatic power comes from one of these sources : - APU, - Pneumatic ground equipment, - Opposite engine. These components control the engine start system : - Flight compartment switches, - Display electronics unit (DEU), - Electronic engine control (EEC). The engine starting system operates on the ground and in flight.

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ENGINE STARTING - INTRODUCTION EFFECTIVITY ALL

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2.1. General Description. The engine-starting system uses these airplane and engine systems or components : - Pneumatic power, - Electrical power, - Flight compartment switches, - Engine fuel control system, - Engine control system, - Common display system (CDS). Engine Start Switch. You put the engine start switch to the GRD position to turn the engine with the starter. The switch automatically moves to the OFF position at starter cutout.


Start Valve and Starter. The start valve opens to supply power to the starter. Usually, this valve opens when you put the engine start switch to the GRD position. You can manually open the valve. The starter turns the engine N2 rotor through the engine accessory gearbox (AGB). EEC. The EEC protects the engine during start. The EEC shuts off fuel supply to the engine when it finds the engine parameters are out of limits during a start. Display Electronics Units (DEU). The DEUs are components of the common display system (CDS). The DEUs supply start valve position information to the CDS. The DEUs monitor N2 and let the engine start switch go back to the OFF position at starter cutout.

With electrical and pneumatic power available, this happens when you put the switch to the GRD position : - The electronic engine control (EEC) receives a start signal, - The APU receives an engine start signal, - The start valve opens and the pneumatic starter turns the engine. The crew uses the FLT position to start the engine in flight when the starter is not necessary. The CONT position supplies continuous ignition. See the engine ignition chapter for more information on the ignition system. (AMM PART I 74)

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2.2. Engine Component Locations. The engine starting system has these components on the left side of the engine : - Pneumatic starter ducts, - Start valve, - Starter. You open the left fan cowl to get access to these components. The electronic engine control (EEC) is on the right side of the engine fan case at the 2:00 position, aft looking forward (ALF). You open the right fan cowl to get access to the EEC. Pneumatic Starter Ducts. There are two pneumatic starter duct assemblies. The upper assembly has two tubes and two flexible joints. One end connects to a pneumatic duct at the strut. The other end attaches to the start valve. The assembly attaches to the fan case. The lower assembly has one tube. The assembly connects to the start valve and to the starter. The assembly attaches to the fan case. Start Valve. The start valve is above the starter on the fan case. Starter. The starter is on the forward face of the engine accessory gearbox (AGB) at the 8:00 position.

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2.3. FLT Compartment and EE Compartment Components. Flight Compartment. The engine.start switches and the ignition selector switch are on the P5 forward overhead panel. The upper center display unit is on the P2 main panel center. The engine parameters usually show on this display. The parameters can also show on the lower center display unit. The engine start levers are on the control stand, aft of the thrust Levers. Electrical Equipment Compartment. The display electronics units (DEU)s are on the E3 rack.

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FLIGHT COMPARTMENT AND EE COMPARTMENT COMPONENTS EFFECTIVITY ALL

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2.4. Start Valve. The start valve controls pneumatic power to the starter. The valve opens for these engine operations : - Ground start, - In flight starts which require starter assist, - Motoring. Physical Description. The valve is a butterfly shutoff valve. It is electrically controlled and pneumatically operated. The valve is spring-loaded closed. The primary components are the valve body assembly and the actuator assembly. The valve body assembly has these components : - Butterfly valve, - Valve shaft, - Shaft bearings - External position indicator. The actuator assembly has these components : - Torsion spring, - Pneumatic actuator, - Solenoid valve assembly, - Valve position switch, - Manual override provision.

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Functional Description The valve solenoid energizes when you put the engine start switch to the GRD position. This permits air pressure to the pneumatic actuator. The pneumatic actuator force is more than the torsion spring force and the start valve opens. The DEUs use the valve position switch to supply indication in the flight compartment. You use a 3/8 inch square drive tool to manually open the valve. A visual indicator on the valve body shows valve position. A small hole in the left fan cowl gives you access to the manual override. A placard is near the hole. Training Information Point. WARNING : REMOVE PNEUMATIC POWER FROM THE AIRPLANE BEFORE YOU REMOVE THE START VALVE. AIR PRESSURE IN THE PNEUMATIC STARTER DUCT COULD CAUSE INJURY. CAUTION : DO NOT OPERATE THE MANUAL DRIVE WITHOUT PNEUMATIC POWER AVAILABLE. YOU MUST SUPPLY PNEUMATIC POWER TO THE VALVE TO PREVENT DAMAGE TO THE ACTUATOR DIAPHRAGMS. IF YOU DO NOT OBEY PRECAUTIONS, DAMAGE TO THE VALVE CAN OCCUR.

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2.5. Starter. The starter turns the engine for engine starting or motoring procedures. The starter changes air pressure into mechanical energy. Physical Description. The starter has a single-stage, axial-flow, turbine air motor. The starter uses reduction gears and a sprag clutch to turn the output shaft to the engine accessory gearbox (AGB). The starter has one port for oil drain and fill. This port also has a magnetic chip detector. A coupling attaches the starter to the AGB. A coupling attaches the lower pneumatic starter air duct assembly to the top of the starter. Functional Description. Pneumatic power goes through an open start valve to turn the turbine air motor in the starter. The turbine turns the reduction gears and engages the clutch. The clutch transmits torque to the output shaft of the starter. The reduction gears engage the clutch as long as pneumatic power turns the turbine.

The starter receives a continuous flow of oil from the AGB when the engine turns. The oil cools and lubricates the starter : - Clutch, - Gears, - Bearings. Oil returns to the AGB. A small quantity of oil stays in the starter. Training Information Point. It is not necessary to add oil to the starter after installation. But, you must supply a new starter with a small quantity of oil. Refer to chapter 12 of the airplane maintenance manual (AMM) part II for oil quantity requirements and procedures. After installation, the AGB maintains the starter oil level. WARNING : DO NOT LET ENGINE OIL STAY ON YOUR SKIN. FLUSH THE OIL FROM YOU SKIN WITH WATER. THE OIL IS POISONOUS. CAUTION : DO NOT HANG THE STARTER BY THE DRIVE SHAFT. INTERNAL STARTER DAMAGE CAN OCCUR.

The starter output shaft turns the AGB. The AGB turns the engine N2 rotor through shafts and other gears. At approximately 55 percent N2, the start valve closes and removes pneumatic power from the starter. The turbine and reduction gears slow and the clutch disengages. The starter output shaft then turns with the gearbox and engine. The turbine and reduction gears continue to slow until they stop.

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STARTER EFFECTIVITY ALL

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2.6. Maintenance Practices. The folling is a summarization of the maintenance practices required for CFM56-7 starter servicing. This is only a summarization and still requires the use of the aircraft maintenance manual (AMM) for detailed information that is critical to this procedure. Servicing of the starter is required only if a new starter has been installed. A summarization of the servicing procedure is as follows : - Safety the aircraft & obtain access to the starter. - Place a container on the ground under the starter. - Remove the bayonet type magnetic plug from the magnetic plug housing on the lower side of starter & discard the plug seal. - Install a TEDECO DB-75 adapter & pressure service the starter using same approved engine oil that is used in the accessory gearbox (AGB). Refer to the AMM to determine the correct amount of oil required for servicing. - Remove the adapter & replace the magnetic plug with a new seal.

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STARTING SERVICING EFFECTIVITY ALL

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2.7. Engine Starting - Functional Description. Starting Control. Electrical power for engine starting control comes from the battery bus. The engine start switch and the DEUs control the starting system. Indication. The DEUs use input data to show engine parameters and start valve position on the common display system (CDS). Start Switch. This occurs when you put the engine start switch to the GRD position when electrical and pneumatic power are available : - The EEC receives an engine start signal, - The APU electronic control unit receives a signal to open the APU inlet guide vanes, - The start valve solenoid energizes and the vaLve opens, - The starter clutch engages and the engine N2 rotor turns, - A solenoid in the P5 panel energizes to hold the switch in the GRD position. Fuel and Ignition. You move the engine start Lever to the idle position to add fuel and ignition during the start. See the engine fuel and control chapter for more information. (AMM PART I 73) See the ignition chapter for more information. (AMM PART I 74) Starter Cutout. At approximately 55 percent N2 this occurs : - The DEUs remove the electrical ground for the start switch solenoid, - The engine start switch goes to the OFF position, - The start valve solenoid deenergizes and the valve closes. EFFECTIVITY ALL


Engine Wet Start. The EEC stops the engine start if the EGT does not rise in 15 seconds after you move the engine start lever to the idle position. The EEC stops fuel flow and turns off ignition. You can find a fault message on the control display unit (CDU). See the TRAINING INFORMATION POINT page in this section for more information. Engine Hot Start. The EGT digital display flashes when the EEC sees a possible hot start. If the EGT starting limit is exceeded, the EEC immediately stops fuel flow and ignition. The EGT digital display continues to flash until you move the engine start lever to the cutoff position. This system operates on the ground only. NOTE : Persons who operate engines should know normal engine starting parameters. They should also know the maximum and minimum limits for each parameter. The engine operator should stop a hot engine start before the EEC does. In Flight Start. The crew puts the engine start switch to the FLT position for a windmill start. A windmill start does not use the starter. The crew uses the starter in flight if the airplane is out of windmill start limits. For example, the airplane airspeed may be too slow. See the flight operation manual for more information about these limits. The CDS tells the crew that the airplane is out of limits to windmill start the engine. The message X-BLEED START shows above the engine’s N2 digital indicator. In this situation, the flight crew uses the starter to start the engine. The OPERATION page in this section shows this message on the display. Automatic Relight. The EEC can automatically turn on ignition in flight. See the engine ignition chapter for more information. (AMM PART I 74)

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ENGINE STARTING - FUNCTIONAL DESCRIPTION EFFECTIVITY ALL

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3. IGNITION & STARTING OPERATION. 3.1. Engine Starting Operation. These are the flight compartment controls you use to start the engine : - Engine start switches, - Ignition select switch, - Engine start levers. Pneumatic power must be available to start the engine on the ground. See chapter 71 of the airplane maintenance manual (AMM) part II for the minimum pressure. You must monitor these engine parameters during engine starting : - N2, - Oil pressure, - N1, - Fuel flow, - EGT.

Engine Start. This is a summary of the engine start procedure : - Follow safety procedures and airplane and engine limitations found in chapter 71 of the AMM part II, - Set the ignition select switch to IGN L or IGN R, - Put the engine start switch to the GRD position, - Look for start valve open indication, - Monitor N2, - Make sure oil pressure increases, - Check with ground personnel to make sure N1 begins to turn counterclockwise, - Move the engine start lever to the idle position (forward) at a minimum of 25 percent N2, - Make sure fuel flow is in limits, - Make sure EGT increases, - Monitor EGT and N2 increase until starter cutout at approximately 55 percent N2, - Make sure engine start switch goes back to the OFF position at approximately 55 percent N2, - Monitor all engine parameters as engine speed increases to idle. Training Information Point. Usually, the engine requires only one igniter for starting. You should use a different igniter selection for each start.

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ENGINE STARTING OPERATION EFFECTIVITY ALL

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4. IGNITION & STARTING - TRAINING INFORMATION POINT. The control display unit (CDU) helps you do troubleshooting of the ignition system or troubleshoot problems when the engine does not start. The EEC keeps maintenance messages in its non-votatile memory. The EEC keeps a message during an engine start if the EGT does not increase in 15 seconds after you move the start lever to the idle position. You use the CDU to see this message. You can also use the CDU to do a ground test of the on system. See the engine indicating chapter for more information about engine troubLeshooting with the CDU. (AMM PART I 77)

IGNITION

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