Engine Start Student Guide
Engine Start Student Guide
SEPTEMBER 2004
STUDENT GUIDE
FOR
THIS PACKAGE HAS BEEN DEVELOPED FOR USE BY: Black Hawk (UH-60) Helicopter Maintenance Test Pilot
Training Program
PROPONENT FOR THIS TSP IS: U.S. Army Maintenance Test Pilot School AVIATION
TRAINING BRIGADE ATTN: ATZQ-ATB-CA Ft. Rucker,
Alabama 36362-5000
FOREIGN DISCLOSURE RESTRICTIONS: Unclassified: This product/publication has been reviewed
by the product developers in coordination with the
USAALS foreign disclosure authority. This product is
releasable to students from foreign countries on a case-
by-case basis..
SEPTEMBER 2004
UH-60 ENGINE START SYSTEM
TABLE OF CONTENTS
Page
SECTION I. - INTRODUCTION .................................................................................................................... 3
SECTION II. - PRESENTATION................................................................................................................... 4
A. ENABLING LEARNING OBJECTIVE ELO No. 1 ............................................................... 4
B. ENABLING LEARNING OBJECTIVE ELO No. 2 ............................................................... 9
SECTION III. - SUMMARY.......................................................................................................................... 62
C. ENABLING LEARNING OBJECTIVE ELO No. 3 ............................................................. 63
SECTION IV. - SUMMARY ......................................................................................................................... 66
APPENDIX A..............................................................................................................................................A-1
APPENDIX B..............................................................................................................................................B-1
2
SECTION I. - INTRODUCTION
3
SECTION II. - PRESENTATION
4
b. Auxiliary Power Unit
Frame #0030 (Auxiliary Power Unit)
(1) There are several methods of providing air for engine starts. The first
method is the Auxiliary Power Unit (APU).
(2) The APU supplies air to the engine selected for engine start.
(3) The Turbomach and Garrett are the two types of APUs.
5
c. Cross Bleed Starting
Frame #0035 (Cross Bleed Starting)
6
d. Ground Source
Frame #0040 (Ground Source)
(1) Another way to start the engines is with the Auxiliary Ground Power Unit
(AGPU).
(2) The AGPU is an external air source used for engine starting.
7
e. Buddy Start
Frame #0040A (Buddy Start)
(1) The Buddy Start system (aircraft to aircraft) is another method of starting
the engines.
(2) Procedures for this method are found in the TM1-1520-237-MTF.
8
B. ENABLING LEARNING OBJECTIVE ELO No. 2
(1) The pneumatic tubing and manifold used during the engine start
sequence, extends from the left side of the transmission section
throughout the cabin section upper deck area forward to the heater.
9
(a) Nipple Check Valve
Frame #0045A (Nipple Check Valve)
10
(b) Lower Tube
Frame #0045B (Lower Tube)
11
(c) Middle Tube
Frame #0045C (Middle Tube)
12
(d) Rear Tube
Frame #0045D (Rear Tube)
13
(e) Front Tube
Frame #0045E (Front Tube)
14
(f) APU Compartment Front Tube
Frame #0045F (APU Compartment Front Tube)
15
(g) Oil Cooler Compartment Tubes
Frame #0045G (Oil Cooler Compartment Tubes Uninstalled)
1) This is the cross bleed tube and the connection for the
rear bleed-air tube.
16
Frame #0045G (Oil Cooler Compartment Tubes Installed)
2) This is the cross bleed tube and the connection for the
rear bleed air tube.
17
(h) Pneumatic Tubing Description
Frame #0050 (Pneumatic Tubing Description)
18
(i) Tubing Maintenance Aspects
Frame #0055 (Tubing Maintenance Aspects)(0055)
19
b. Start Control Valves
Frame #0060 (Start Control Valves Location)
(1) The start control valves are located inside the oil cooler compartment,
inboard of each respective engine's firewall.
20
(a) Start Control Valves Description
Frame #0065 (Start Control Valves Description)
21
Frame #0065 (Start Control Valves Description)
22
(b) Start Control Valves Operation
Frame #0070 (Start Control Valves Operation)
23
Frame #0070 (Start Control Valves Operation2)
24
(c) Start Control Valves Power Source
Frame #0075 (Start Control Valves Power Source)
25
Frame #0075 (DC ESNTL BUS)
26
(d) No. 2 DC PRI BUS CIRCUIT BREAKER PANEL
Frame #0075 (No. 2 DC PRI BUS)
27
(e) Start Control Valves Maintenance Aspects
Frame #0080 (Start Control Valves Maintenance Aspects)
28
c. Bleed-Air Shutoff Valves
Frame #0085 (Bleed-Air Shutoff Valves Location)
(1) The bleed-air shutoff valves are located inside the oil cooler
compartment below the start control valves.
29
(a) Bleed-Air Shutoff Valves Description
Frame #0090 (Bleed-Air Shutoff Valves Description)
30
(b) Bleed-Air Shutoff Valves Operation
Frame #0095 (Bleed-Air Shutoff Valves Operation)
31
(c) Bleed-Air Shutoff Valves Power Source
Frame #0100 (No. 1 DC PRI BUS CIRCUIT BREAKER PANEL)
32
Frame #0100 (Overhead Console)
33
(d) Bleed-Air Shutoff Valves Maintenance Aspects
Frame #0105 (Bleed-Air Shutoff Valves Maintenance Aspects)
34
d. APU Check Valve
Frame #0110 (APU Check Valve Location)
(1) The Auxiliary Power Unit (APU) check valve is located on the lower left
hand side of the APU just forward of the firewall for the APU.
(2) The APU check valve is a one-way check valve that allows the APU to
pressurize the pneumatic manifold, but prevents air from being forced
back through the APU when it is not operating.
35
e. APU Check Valve Maintenance Aspects
Frame #0125 (APU Check Valve Maintenance Aspects)
(1) If the flapper valve separates from the APU check valve, the flapper
valve must be located prior to replacement with a new check valve.
(2) TM 1-1520-237-23-4, Chapter 7, procedures for removal, inspection,
cleaning, and installation.
(3) The APU check valve is a spring-loaded flapper type valve.
(4) Pressurized air opens the valve and it is spring-loaded closed.
36
f. APU Start Bypass Valve Location
Frame #0130 (APU Start Bypass Valve Location)
(1) The APU start bypass valve is located on the lower left hand side of the
APU combustion chamber on the Turbomach APUs.
(2) They are not required on the Garret APUs due to a better fuel control on
the Garret APU.
37
(a) APU Start Bypass Valve Description
Frame #0135 (APU Start Bypass Valve Description)
38
(b) APU Start Bypass Valve Operation
Frame #0140 (APU Start Bypass Valve Operation)
39
(c) APU Start Bypass Valve Power Source
Frame #0145 (APU Start Bypass Valve Power Source)
40
Frame #0145 (ESU)
41
(d) APU Start Bypass Valve Maintenance Aspects
Frame #0150 (APU Start Bypass Valve Maintenance Aspects)
42
g. Air Turbine Starter
Frame #0155 (No.1 Engine Starter Location)
(1) The No. 1 engine starter is located on the accessory gearbox inner side
near the firewall.
Frame #0155 (No. 2 Engine Starter Location)
(2) The No. 2 engine starter is located on the accessory gearbox outer side.
43
(a) Air Turbine Starter Description
Frame #0160 (Air Turbine Starter Description)
44
(b) Air Turbine Starter Operation
Frame #0165 (Air Turbine Starter Operation)
45
Frame #0165 (Impeller)
46
(c) Air Turbine Starter Maintenance Aspects
Frame #0170 (Turbine Starter Maintenance Aspects)
47
h. Speed Sensor
Frame #0157 (Speed Sensor)
(1) The speed sensor is located on the engine starter and provides an ac
signal, proportional to engine speed, to the engine starter speed switch,
which equates to 52%-65% Ng speed.
(2) The speed sensor switch can be replaced at the AVUM.
48
i. Engine Control Quadrant Location
Frame #0175 (Engine Control Quadrant Location)
(1) The engine control quadrant is centered on the upper console and
permits either the pilot or the copilot to select engine speed, stopcock
fuel, select engine fuel supply, start engine, abort start, and control the
engine fire extinguisher.
49
(a) Engine Control Quadrant Switches
Frame #0225 (Engine Control Quadrant Switches)
50
Frame #0225 (Abort Switch)
51
j. Starter Speed Switch
Frame #0230 (Starter Speed Switch)
(1) The starter speed switch is located in the upper cabin area above the
left-hand gunners station.
(2) As engine speed increases, the speed pickup sensor (mounted on and
driven by the air turbine starter) produces an ac signal that electrically
energizes the starter speed switch, holding the engine start relay in the
energized position.
(3) When engine speed reaches 52%-65% Ng, the starter speed switch
deactivates, closing the engine start control valve.
52
(a) Starter Speed Switch Operation
Frame #0240 (Starter Speed Switch Operation)
53
k. Keylock Ignition Switch
Frame #0250 (Keylock Ignition Switch)
(1) The keylock ignition switch is located on the instrument panel, below the
Central Display Unit (CDU).
(2) The keylock ignition switch is a two-position switch, (OFF or ON). The
switch serves both engines.
(3) If the switch is in the OFF position, neither engine can be started,
however, motoring capability remains.
54
(a) Keylock Ignition Switch Operation
Frame #0260 (Keylock Ignition Switch Operation)
55
(b) Keylock Ignition Switch Maintenance Aspects
Frame #0265 (Keylock Ignition Switch Maintenance Aspects)
56
l. Starter Relays
Frame #0270 (Relay Panels)
(1) The No. 1 engine starter relay (K45) is located in the left relay panel.
(2) The No. 2 engine starter relay (K26) is located in the right relay panel.
57
m. Circuit Breaker Panels
Frame #0275 (Circuit Breaker Panels)
(1) The NO. 1 ENG START circuit breaker is located on the DC ESNTL
BUS. The DC ESNTL BUS (No. 1 Start system) provides voltage
through the NO. 1 ENG START circuit breaker to K45 relay in the left
relay panel, to energize the No. 1 engine start control valve.
(2) The NO. 2 ENG START circuit breaker is located on the NO. 2 DC PRI
BUS.
(a) The No. 2 DC PRI BUS (No. 2 Start system) provides voltage
through the NO. 2 ENG START CONTR circuit breaker to K26
relay in the RIGHT RELAY PANEL to energize the No. 2 engine
start control valve.
(3) The CAUTION/ADVISORY panel is located on the center instrument
panel. When the start button is pressed, air from the selected source is
directed through the start control valve to the engine starter.
(a) The #1 ENGINE STARTER or #2 ENGINE STARTER caution
light will go on at this time and remain on until the starter drops
out.
58
n. Prime Shutoff Valves
Frame #0271 (Prime Shutoff Valves)
(1) The prime shutoff valves are located on the top inboard center of the
main fuel cells.
(2) When the starter switch is pressed, the start control valve is opened and
the relay is energized.
(3) This also opens the prime shutoff valve.
(4) The engine fuel system is primed when the prime shutoff valve is
opened.
59
o. Prime Boost Pump
Frame #0272 (Prime Boost Pump)
(1) The prime boost pump is located on top of the right main fuel cell.
(2) When the toggle switch on the upper console marked FUEL PUMP,
FUEL PRIME, OFF, and APU BOOST, is in the FUEL PRIME position,
the prime boost pump is energized and the prime shutoff valve to each
main engine fuel supply line is opened.
(3) This mode will illuminate the PRIME BOOST PUMP ON capsule on the
CAUTION/ADVISORY panel.
60
CHECK ON LEARNING
61
SECTION III. - SUMMARY
2. REVIEW/SUMMARIZE:
You have completed the UH-60 Engine Start System components topic.
The key points to remember are:
• The three methods of providing air for engine starts are:
- APU
- Crossbleed starting from the other engine.
- Ground source
• The main components of the Engine Start System are:
- Pneumatic tubing
- Start control valves
- Bleed-air shutoff valves
- APU check valve
- APU start/bypass valve
- Air turbine starter
- Speed sensor
- Engine control quadrant switches
- Starter speed switch
- Keylock ignition switch
- Starter relays
- Circuit breaker panels
- Prime shutoff valve
- Prime boost pump
62
C. ENABLING LEARNING OBJECTIVE ELO No. 3
(1) The following scenario is with the APU online, and the FUEL PRIME
switch in the OFF position.
(2) Placing the AIR SOURCE HEAT/START switch to the APU position
sends 28 V dc to energize relay K22, and causes the contacts of relay
K22 to close.
(3) (K22 controls the Start/Bypass Valve).
(4) Positioning the ENGINE IGNITION switch to the ON position, removes
one of the two shorting points from the alternator output.
(5) The other shorting point is removed as relay K45 is energized, after the
start switch has been pressed.
(6) Pressing the ENGINE START button routes 28 V dc to the left relay
panel, energizing relay K45.
(7) Simultaneously, 28 V dc is routed from the starter speed switch to relay
K45, creating a holding circuit and allowing the ENGINE START button
to be released.
63
(8) Power (28 V dc) is then routed to the No. 1 Engine Prime Shutoff Valve,
opening the valve and allowing fuel flow to the engine.
(9) Power (28 V dc) is also routed to the No. 1 Engine Start Control Valve,
energizing the relay and opening the valve, allowing bleed-air from the
APU to flow to the engine starter.
(10) The closed contacts of the NO. 1 Engine Start Control Valve, routes 28 V
dc to the starter speed switch, to the relay K67 holding circuit, and
illuminates the #1 ENGINE STARTER capsule on the
CAUTION/ADVISORY panel.
(11) The engine speed pickup sensor sends a signal to the starter speed
switch, and as the engine spools up the alternator, produces an output to
the ignition exciter which fires the igniter plugs.
(12) When the engine Ng reaches 52-65%, the starter speed switch removes
power to holding circuit for relay K45, effectively closing the No. 1 Engine
Start Control Valve, shorting out the alternator output, removing the
ignition source.
(13) It also closes the No. 1 Prime Shutoff Valve, and the #1 ENGINE
STARTER capsule goes out.
64
CHECK ON LEARNING
3. During engine start, ignition will continue until the ENGINE IGNITION switch is
moved to the OFF position or:_____.
65
SECTION IV. -SUMMARY
1. REVIEW/SUMMARIZE:
You have completed the UH-60 Engine Start System troubleshooting lesson.
Key points to remember are:
• Placing the AIR SOURCE HEAT/START switch to the APU position
sends 28 V dc to relay K22 and causes the contacts to close.
• Positioning the ENGINE IGNITION switch to the ON position, removes
one of two shorting points from the alternator output. The other shorting
point is removed as relay K45 is energized.
• Pressing the ENGINE START button routes 28 V dc to the left relay
panel, energizing relay K45. Simultaneously, 28 V dc is routed from the
starter speed switch to relay K45, creating a holding circuit and allowing
the ENGINE START button to be released.
- Power (28 V dc) is then routed to the No. 1 engine prime shutoff
valve, opening the valve and allowing fuel flow to the engine.
- Power is also routed to the start control valves, energizing the
relay and opening the valve and allowing bleed-air from the APU
to flow to the engine starter.
• The closed contacts of the No. 1 Engine Start Control Valve, routes 28 V
dc to the starter speed switch, to the relay K67 holding circuit, and
illuminates the #1 ENGINE STARTER capsule on the
CAUTION/ADVISORY panel.
• The engine speed pickup sensor sends a signal to the starter speed
switch, and as the engine spools up the alternator, produces an output to
the ignition exciter, which fires the igniter plugs.
• When the engine Ng reaches 52-65%, the starter speed switch removes
power to holding circuit for relay K45, effectively closing the No. 1 Engine
Start Control Valve, shorting out the alternator output, removing the
ignition source. It also closes the No. 1 Prime Shutoff Valve, and the #1
ENGINE STARTER capsule goes out.
66
APPENDIX A
ILLUSTRATION LISTING
FRAME # FRAME TITLE
0020 Engine Start System
0030 Auxiliary Power Unit
0035 Cross Bleed Starting
0040 Ground Source
0040A Buddy Start
0045 Pneumatic Tubing Location
0045A Nipple Check Valve
0045B Lower Tube
0045C Middle Tube
0045D Rear Tube
0045E Front Tube
0045F APU Compartment Front Tube
0045G Engine Compartment Tubes (Uninstalled)
0045G Engine Compartment Tubes (Installed)
0050 Pneumatic Tube Description
0055 Tubing Maintenance Aspects
0060 Start Control Valves Location
0065 Start Control Valves Description
0065 Start Control Valves Description (Exploded)
0070 Start Control Valves Operation
0070 Start Control Valves Operation2
0075 Start Control Valves Power Source
0075 DC ESNTL BUS
0075 NO 2 DC PRI BUS
0080 Start Control Valve Maintenance Aspects
0085 Bleed-Air Shutoff Valves Location
0090 Bleed-Air Shutoff Valves Description
0090 Bleed-Air Shutoff Valves Description (Exploded)
0095 Bleed-Air Shutoff Valves Operation
0100 NO 1 DC PRI BUS
0100 Overhead Console
0105 Bleed-Air Shutoff Valves Maintenance Aspects
0110 APU Check Valve Location
0125 APU Check Valve Maintenance Aspects
0130 APU Start Bypass Valve Location
0135 APU Start Bypass Valve Description
0140 APU Start Bypass Valve Operation
0145 APU Start Bypass Valve Power Source
0145 ESU
0150 APU Start Bypass Valve Maintenance Aspects
0155 NO. 1 Engine Starter
0155 NO. 2 Engine Starter
0157 Speed Sensor
0160 Air Turbine Starter Description
0165 Air Turbine Starter Operation
0165 Impeller
0170 Air Turbine Starter Maintenance Aspects
0175 Engine Control Quadrant Location
0225 Engine Control Quadrant Switches
0230 Starter Speed Switch
A-1
0240 Starter Speed Switch Operation
0250 Keylock Ignition Switch
0260 Keylock Ignition Switch Operation
0265 Keylock Ignition Switch Maintenance Aspects
0270 Relay Panels
0271 Prime Shutoff Valves
0272 Prime Boost Pump
0275 Circuit Breaker Panels
0290 Engine Start System Schematic
A-2
APPENDIX B
TEST AND TEST SOLUTIONS
1. This appendix is only used when the test and solutions are internal to the POI file.
2. When the test and solutions are internal to the POI file, then the POI file becomes a FOR
OFFICIAL USE ONLY document.
B-1