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EMBRAER

SERVICES & SUPPORT


T E C H N I C A L P U B L I C AT I O N

E-JETS

FAMILY

114

JUNE/2016

114

E-JETS/INFO

EDITOR Rodrigo de Macedo


GRAPHIC PROJECT Marcell Marra
E-NEWS is a periodic publication aimed to provide technical information to Engineering and Maintenance personnel.
This edition and earlier ones can be found at eForum and also at FlyEmbraer Portal: www.flyembraer.com > Download_center > Commercial Jets >
Maintenance > Technical Support > E-JETS > E-JETS NEWS (Periodic Publication)
Should you need any additional information, do not hesitate to contact us: +55 12 3927-6693 / technical.support@embraer.com.br
PROPRIETARY NOTICE
The articles published in E-NEWS are for information only and are Embraer S/A property. This newsletter must not be reproduced or distributed in whole or in
part to a third party without Embraers written consent. Also, no article published should be considered authority-approved data, unless so specifically stated.

SERVICES & SUPPORT

E M B R A E R S E R V I C E S & S U P P O R T T E C H N I C A L P U B L I C AT I O N
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SUMMARY

SUMMARY
CALENDAR

Choose your
destination

TECHNICAL

E-Jets Structures
Workshop 2016

ACM
Water
Ingestion

Maintenance Cost
Reduction Project
Overview 2016

13th E-Jets
Optimization
GWG/ISC 2016

FOCUS ON

10

DID YOU
KNOW?

11

REMINDER

12

Engine Oil Pressure Indication

Installation of Cable
Guard Support on
Aileron Control Cables

Wave
Shaped
Contour

SNAPSHOT
OF THE MONTH

20

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CALENDAR

E V E N TS 2 0 1 6
21 - 22 JAN

03 - 04 FEB

25 - 26 FEB

MRO Latin America


Lima
Peru

MRO Dubai
Dubai
UAE

ATO MRO
Moscow
Russia

29 - 31 MAR

05 - 07 APR

WEBEX
E-Jets Technical
Workshops

MRO USA
Dallas
USA

02 - 03 MAY

02 - 06 MAY

15 - 18 MAY
05 - 20 APR

Webex E-Jets Technical


Workshops

26 - 27 APR

Field Issues Ranking


Support Tool Webex
(FIRST)

13th E-Jets
Optimization GWG/ISC
Fort Lauderdale
USA

13 - 29 SEP

Webex E-Jets
Technical Workshops

18 - 20 OCT

MRO Europe
Amsterdam
Netherlands

25 - 26 OCT

EOC/MCW WW E-Jets
Amsterdam
Netherlands

31OUT- 4 NOV

14th E-Jets
Optimization GWG/ISC
OGMA
Portugal

13 - 14 DEC

Field Issues
Ranking Support
Tool Webex (FIRST)

CCMA ALTA MRO


Fajardo
Puerto Rico

14 - 16 JUN

EOC China E-Jets


Guangzhou
China

30 - 31 AUG

Field Issues Ranking


Support Tool Webex
(FIRST)

07 - 10 MAR CF34-8E/10E GE

Operators Conference
New Orleans
USA

CAB Customer
Advisory Board
So Jos dos Campos
Brazil

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TECHNICAL

Jose Claudio S. Leal


Technical Support (EFTC)
Jose.leal@embraer.com.br

ACM Water Ingestion


Embraer is receiving reports
of ACM failures due to water
ingestion. Such cases are normally
found during the teardown of
machines with major traces of
water ingestion at journal bearing
air foil T1 turbine housing.
Although this is neither the main
cause for pack failures, nor an
increasing issue, there is a point
of attention to maintenance.
These cases are attributed to the
malfunction of the spray nozzle
(installed on the ram-air ducts, in
the aircraft underbelly, figure 1);
which may be either clogged or not
installed correctly.

(1) Water Collector


Installation

Water Collector (REF.)

Spray Nozzle

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TECHNICAL

ACM WATER INGESTION

The recommended actions to


prevent such occurrences are as
follows:
Observe through the NACA
scoops proper water spray out of
the water spray nozzle (figure 2).
Ref. AMM 21-51-08-200-801-A.
Perform the spray nozzle test
with the syringe and water. Ref.
AMM 21-51-08-200-801-A.
Check for proper connection of
aircraft wiring to the temp sensors
condenser and the pack outlet
duct. Ref. SB 190-21-0051 (not
applicable to EMBRAER 170/175).
- Check that the drain line
between the water spray nozzle
and the water collector is
connected to correct drain boss
on the water collector. Ref. AMM
21-51-08-200-801-A.

(2) Water Collector Layout

VIEW FORWARD FROM AFT OF AIRCRAFT

Look for active CMC messages related


to any pack system internal components,
such as the add heat valve and the low
limit valve. Ref. AMM 45-45-00.
With the packs operating, check that
the condenser inlet temperature is

approx. 3 degrees C on the AMS status


page (figure 3).
SNL 170-21-0021 (190-21-0014) gives
detailed information about the ACM
failure prevention.

(3) Systems Diagnostics/ATA21/Temp


Control page for the channel in-Control
Example of conf in temp readouts out-of-limits at the LH PACK

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TECHNICAL

Joo Fernando F. Bacciotti


Technical Support (RTS)
joao.bacciotti@embraer.com.br

E-Jets Structures Workshop 2016


On May 12th and 13th, 2016
Embraer hosted the E-Jets
Structures Workshop and
the 14CFR Part 26 Subpart
C WFD / LOV Meeting in Fort
Lauderdale, Florida.
The Workshop counted on the
participation of:
14 Airlines Representatives
from North America, Europe,
Africa and China;
02 MROs Representatives
from North & Central America;
Total of 39 Airlines, MROs
and Embraers Representatives
attended the event.

The event was an excellent


opportunity for Embraer,
Customers, and MROs to
exchange information and
experience regarding Aircraft
Structures such as Structures
Repair Manual, Service Bulletins,
Airworthiness Regulations,
Embraer Policies for Structures
Support, Delegations from
ANAC (DER), EASA DOA, and
prioritization of the items that
Customers would like to have
included in the SRM based on
their needs and experience.
The Customers and MROs
feedback showed the event is
welcomed and they look forward

Embraer to continuing hosting


the Workshop.
Embraer would like to thank
all E-Jets Structures Workshop
attendees and count on
your participation in the next
Workshop in 2018.

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TECHNICAL

Fernando Forte Cobo


Maintenance Economics & MRO Services
maintenance.cost@embraer.com.br

Maintenance Cost Reduction Project Overview 2016


EMBRAER is making its best
efforts for the year of 2016,
with the focus on providing
the E-Jets operators with
technical and maintenance
solutions to reduce their Direct
Maintenance Cost - DMC.
Potential savings are at US$
0.68/FH (Flight Hours) for
the E170/175 family, and
US$ 1.31/FH for the
E190/195 family.
The results are so far below
our monthly goal for this year,
being the total saving for 2016
set at a target of US$ 8.00 10.00/FH. However, ongoing
product change requests
and commercial concessions
negotiations are expected
to improve DMC reductions
within the coming months.

The chart below, presents an


overview of the forecasted
total reduction on the aircraft
DMC based on Product
Performance, Maintenance
Plan Improvements, Spare
Parts Prices and Repair Costs
solutions foreseen to be
delivered to the E-Jets Fleet
this year.

(1) Targets & Follow up of


the E-Jets Maintenance Cost
Reduction
LEGEND
(Project Status)
On Time
Delayed, trends to reach the goals
Delayed, trends to not reach the goals

Direct Maintenance Cost (DMC) Potential Savings

Target U$D 8.00 - 10.00/FH


5

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TECHNICAL

MAINTENANCE COST REDUCTION PROJECT OVERVIEW 2016

Gains in DMC driven by products can be seen below:


Product Solutions (All E-Jets)

(4) MCW2016 - Save the Date

Documents

Date

Potential Savings
(US$/FH)

New Toilet Flush Valve

SB-170-38-0020
SB-190-38-0020

Jan -16

0.10

Reinforcement of TCAS module Rack

SB 170-53-0112
SB 190-53-0074

Feb -16

0.09

New TAT Sensor

AIPC 34-15-02-01

Mar - 16

0.49

(2) Product Results

Gains in DMC driven by maintenance program can be seen below:


Maintenance Solutions (E190/195)

Documents

Restoration of Flap / Slat Actuators

MRB-1928 Rev 10

Date

April -16

Potential Savings
(US$/FH)

0.63

(3) Maintenance Program Results


Remarks:
The potential DMC savings reflect product modifications (SB, AMM, SRM, FIM, AIPC, CMM etc.) and/or
maintenance plan improvements (MRBR, MPD, EMM, etc.), spare parts and repair solutions that have been
made available to operators. Embraer measures and assesses the efficacy of the solutions that have been
provided to the field. In the case where a specific solution has been deemed not-effective, Embraer is able
to track back and omit the gains associated with that solution from the E-Jets cost reduction results.

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TECHNICAL

Rodrigo Manzioni Corra


Maintenance Programs Engineering
rodrigo.correa@embraer.com.br

13th E-Jets Optimization


GWG/ISC 2016
Embraer hosted the 13th E-Jets
Optimization GWG/ISC 2016 in
Fort Lauderdale last May 2016,
where the GWG and ISC covered
the Maintenance Plan Evolution
Program (MPEP), such as MRBR
changes due to design changes
and field data evaluation of
Systems, Structural and Zonal
tasks, related to the Basic 3
check.
We had the participation of
17 airlines (21 customers), 4
Authorities (ANAC, FAA, EASA and
TCCA) and 1 supplier (GE). The
favorability of the event, according
to satisfaction survey was 97%.

During this meeting, Embraer,


operators, authorities, and
suppliers reviewed Basic 3 tasks
field data and MSG-3 analysis, in
order to establish the optimum
interval.
The ISC agreed to propose a MRB
TR with the results reached during
this meeting which allowed the
Embraer Maintenance Program
Engineering to publish those
changes for operators, supporting
them to update their own
maintenance programs, thus taking
advantage of the optimized tasks.
The next GWG/ISC will be held in
Portugal at OGMA facilities from
October 31st to November 4th. We
encourage operators to share data

and participate in the GWG/ISC


activities.
Besides that, GWG/ISC Embraer
published the EMBRAER 170 MRB1621 revision 12 and EMBRAER 190
MRB-1928 Revision 10 last April,
including the Flap/Slat restoration
task interval updated from
30000FH/156MO to 35000FH.

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TECHNICAL

Cristina Amato Cipola


Technical Support (EFTC)
cristina.cipola@embraer.com.br

Installation of Cable Guard Support


on Aileron Control Cables
To begin with a background
information, it has been
identified premature wear
in some specific points of
stainless steel cables, during
the inspection of the wing
control cables. To address this
issue, Service Bulletins 17057-0048 and 190-57-0038 were
issued to replace the grommet
configuration to pulleys.
However, the then current
solution did not achieve the
expected results, thus preventing
the MRB escalation. In order to
improve the cables durability,
Embraer released a new solution
that consisted in new cables

manufactured of carbon steel


material. The bench tests showed
positive results with regard to the
wear of the carbon steel cables
when compared with stainless
steel cables. The solution is
available on Service Bulletins 17027-0049 and 190-27-0037.
After some findings in the
fleet, Service Bulletins 170-570048 and 190-57-0038 were
revised last month, to include
the replacement of the pulley
support with a new cable guard
support. This solution was flighttested early this year and showed
good results.

In a nutshell, the final action


that addresses the aileron cable
wear in the wing region is the
implementation of the pulleys
and cable guard support, in place
of the original grommets, along
with the new carbon steel cables.

(1) Aileron Control


Cables Configurations

Pulleys

Pulleys
Configuration
Configuration

Affected Region

Affected Region
Figure 1 Aileron Control Cables Configurations

Figure 1 Aileron Control Cables Configurations

Cable Guard
Configuration

Cable Guard
Configuration

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TECHNICAL

Juliana Born
Technical Support (EFTC)
juliana.born@embraer.com.br

Wave-shaped Contour
What is the difference
between the wave-shaped
contour and finger design
concept used in the E-Jets
structures?
During the aircraft design
development, it is necessary to
combine many aspects, such
as: authorities requirements,
market and customer
demands. To guarantee its
competitiveness, commercial
aircraft need to be able to carry
passenger and cargo on long
range flights with fuel efficiency.
With that in mind, aircraft
designers are always pursuing
optimization of the aircraft
project.

In order to have a design that


combines economic aspects
and performance, different
concepts of weight relief are
developed. The wave-shaped
contour used in the splices,
shear clips and other structures
is one of these concepts. Its
design is slightly similar to the
fingers used on the external
doubler repairs, however, the
wave-shaped contour has a
smoother contour and reduced
dimensions. The reason for the
differences of their designs is
related to the purpose of those
structures. While the fingers
of the doublers main purpose
is to facilitate maintainability
- its design allows an external

inspection, the waves on the


wave-shaped contour main
objective is to lighten the
structure.
If you are interested in more
details on the fingers in
the doubler repair, E-News
Ed. 112 has a whole article
focused on its purpose. Also,
EMBRAER offers a Structural
Repair Training where more
information of structural
concepts and repairs are
provided. For details, please
contact your Account Manager.

(1) Wave-shaped
contour Splice
detail

REMINDER & DID YOU KNOW?

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Hugo Valrio Dutra


Technical Support (EFTC)
hdutra@embraer.com.br

Did you know?


...that LOT Airlines has
hosted the third Flight
Control No Dispatch
Workshop in Warsaw,
Poland?
This event is part of the
FCND Tiger Team efforts and
happened from May 10th to
12th with the presence of
operators from Europe and
Asia. Forty-five attendees
from fifteen operators
spent three days at the LOT
facilities under training,
presentation sessions and
dedicated meetings to
discuss and improve the way
of dealing with FCND events.

The picture was taken during


the LOT Aircraft Maintenance
Services (LOT AMS) facilities
visit, where the E170 MSN
17000073 can be seen under
heavy maintenance.

10

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REMINDER & DID YOU KNOW?

Eder Rodrigues de Almeida


Technical Support (EFTC)
eder.almeida@embraer.com.br

Reminder

Embraer recommends that this


bulletin be accomplished in the
next 7500 FH from the first issue
date of the referred Service
Bulletins. This modification
was factory incorporated in
the aircraft serial numbers
presented in the following table.

Aircraft Models

Aircraft Serial Numbers

E170/175

17000526, 17000558 and on

E190/195

19000711 and on

11
Drain Tube

SPDA Cover

Source: The Telegraph UK

Embraer released Service


Bulletins 170-21-0061 and
190-21-0053 in Feb/2016 to
address the installation of a
water protection cover and
a drain tube in the forward
avionics compartment, to
prevent liquid ingression on
SPDA #1.

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FOCUS ON

Engine Oil Pressure Indication


Duplex Oil Pressure System Improvement (LOPS Activation)

Erick Aguiar Carvalho


Technical Support (EFTC)
erick.carvalho@embraer.com.br

ENGINE OIL SYSTEM


The purpose of Engine Oil System is to
provide lubrication and cooling to the
turbine engine main shaft bearings
and the accessory gearbox bearings.
Each CF34 engine has an independent
lubrication supply system, which
provides an appropriate quantity of oil
at a temperature not above that safe
for continuous operation, utilizes an
engine driven positive displacement
vane type pump element to supply
oil to the various engine components
that require cooling and lubrication.
The lubrication system is a selfcontained pressurized full-flow
system.

(1) Typical Engine


Oil System

12

Oil Tank

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FOCUS ON

ENGINE OIL PRESSURE INDICATION

ENGINE OIL INDICATING


SYSTEM (MFD)
The oil indicating system gives
an indication of oil quantity, oil
pressure, oil temperature and
metal debris in the oil.
As shown in figure 2, a positive
oil quantity indicator is provided
to each engine oil tank and is
available to the flight crew on the
MFD display. Also, oil pressure
and oil temperature indicators are
given to each engine via a digital
display on EICAS.

13

(2) Indicating System

(2) Indicating System

FOCUS ON

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ENGINE OIL PRESSURE INDICATION

ENGINE OIL INDICATING SYSTEM (MFD)


The oil system CAS messages are listed below:
ENG 1(2) OIL LO PRESS > Message Type: Warning
ENG 1(2) OIL LO LEVEL > Message Type: Caution
ENG 1(2) OIL SW FAIL > Message Type: Advisory
ENG 1(2) OIL IMP BYPASS > Message Type: Advisory

SWITCHES AND SENSORS


The original design of CF34-8E/-10E
Engine Oil Pressure Indication System
contains an Oil Pressure Transducer (OPT)
and a Low Oil Pressure Switch (LOPS),
located on the aft side of the Accessory
Gear Box, as shown in the figure 4.
THE OIL PRESSURE TRANSMITTER
(OPT)
The OPT signal is read by the Aircraft MAU
(Modular Avionics Unit) and its function
is to provide a signal to the aircraft
indicating the oil pressure display.
THE LOW OIL PRESSURE SWITCH
(LOPS)
The purpose of the low oil pressure
switch is to provide a signal to the aircraft
indicating and warning systems when oil
pressure is low.

(3) EICAS

(4) OPT and LOPS


location

Oil Pressure XMitter

Oil Pressure Switch

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FOCUS ON

ENGINE OIL PRESSURE INDICATION

OPERATION
The Low Oil Pressure EICAS
warning indication alerts the
crew to an engine low oil
pressure condition. ENG 1(2)
OIL LO PRESS CAS is displayed
when low pressure is detected
in the engine lube oil system.
When the pressure falls below
the minimum limit, which is
a function of the engine core
speed, the pressure indication
will turn to red in the EICAS.
As per QRH (Quick Reference
Handbook), an in-flight engine
shutdown is required by the
crew.

(5) EICAS Warning


Indication

ENG 1(2) OIL LO PRESS

EICAS Indication: OIL pressure indication in red or amber may be presented.


OIL PRESSURE INDICATION ABNORMAL?
YES

ENGINE SHUTDOWN (NAP1-21)


Procedure..................Accomplish

END

NO

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FOCUS ON

ENGINE OIL PRESSURE INDICATION

BACKGROUND
In 2008, the LOPS feedback was
disabled through MAU Software
EPIC LOAD 21.4 (EMB SB 170-310034/190-31-0024) deployed in
Sept/2008 and the current oil
system logic takes all of its input
(digital oil pressure readout and
EICAS warning) from the OPT.

(5) EICAS Warning Indication

Engine oil pressure indication


relies solely on OPT signal and
LOPS signal not used anymore.

Affected Fleet:
- 600 engines delivered to the field with
no LOPS installed
- 200 A/C with no LOPS A/C wiring
installed

AFFECTED FLEET
On the CF34-10E engines, LOPS
and aircraft wiring were eliminated
from production to improve
maintainability and reduce
complexity.

2008

LOPS FEEDBACK
DISABLED
VIA MAU 21.4

On the CF34-8E engines, LOPS


feedback was disabled, but no
hardware was eliminated from
production aircraft.

2010

CEASED LOPS IN
PRODUCTION
E190/E195

JUN/2013

RETURNED LOPS
IN PRODUCTION
E190/E195

ISSUE DESCRIPTION
False Low oil pressure indications have
caused field issues, delays and cancellations,
and commanded in-flight engine shutdowns.
CORRECTIVE ACTION
Re-introduction of Low Oil Pressure Switch
(LOPS) feedback to provide duplex oil
pressure indication system.

ADDITIONAL
IMPROVEMENT RELEASED

High Temp OPT


PN412OT16P02
-8E: GE SB 72-0148;
-10E: GE SB 72-0258;
New LOPS PN 4120T17P03
-8E: GE SB 77-0003;
-10E: GE SB 72-0127;

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FOCUS ON

ENGINE OIL PRESSURE INDICATION

DUPLEX OIL PRESSURE


INDICATION SYSTEM
IMPROVEMENT
GE released CF34-8E FADEC software
version 5.60 and CF34-10E FADEC
software version 5.50 which include
the logic that provides a duplex
oil pressure indication system.
These FADEC software versions in
conjunction with MAU Load 25.3
(Pentium II) or 25.5.0.1 and on
(Pentium II or M) activate feedback
from the LOPS.
With the duplex system, MAU uses the
OPT signal for oil pressure indication,
in psi, on the EICAS display. LOPS
provides indication of low oil pressure
for the FADEC to compare with the
OPT readings and accommodate the
low oil pressure CAS message.
complexity.

(6) LOPS active configuration


Low Oil
Pressure
Switch

Oil Pressure
Transmitter

DUPLEX OIL PRESSURE


SYSTEM POST-MOD LOPS
ACTIVATION
The next figures show the duplex
oil pressureTransmitter
accommodation
Oil Pressure
fault scenarios.

(7) Low Oil Pressure Switch (LOPS) Fault


Flight Phase EICAS Message
In Flight

No EICAS Message
Annunciated

On Ground

ENG X OIL SW
EICAS MESSAGE
DISPLAYED

Hardwire

Hardwire

Note

LOPS is deferrable
per MMEL CAT C
(10 Days)

MAU
17
ARINC 429
ASCB

FADEC

FADEC

ASCB

ARINC 429
MAU

EICAS
OPT
LOPS

TRUE

Example: LOPS SIGNAL


FAULT IN FLIGHT

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FOCUS ON

ENGINE OIL PRESSURE INDICATION

(9) Oil Pressure Transmitter (OPT) AND


Low Oil Pressure Switch Faults

(8) Oil Pressure Transmitter (OPT) Fault


Flight Phase EICAS Message

Note

Flight Phase EICAS Message

In Flight

0 PSI (IN RED) IS DISPLAYED

In Flight

On Ground

No EICAS Message Annunciated


ENG X NO
DISPATCH CAUTION DISPLAYED

LOPS is not deferrable, FIM Troubleshooting


required for Dispatch

On Ground

Note

ENG X OIL LO EXPRESS EICAS


MESSAGE DISPLAYED

Both OPT&LOPS INDICATE OIL


PRESSURE, ENGINE SHUTDOWN
REQUIRED PER QRH

18

FADEC

ARINC 429
0V

FADEC

ASCB

ARINC 429
0V

MAU

OPT

OPT

LOPS

LOPS

Example: LOPS OF OPT


SIGNAL IN FLIGHT

TRUE

ASCB
MAU

Example: LOPS
AND LOPS FAULT

E M B R A E R S E R V I C E S & S U P P O R T T E C H N I C A L P U B L I C AT I O N
E - J E T S F A M I LY - N U M B E R 1 1 4 - J U N E 2 0 1 6

FOCUS ON

ENGINE OIL PRESSURE INDICATION

CONCLUSION
With the duplex oil pressure system
implementation, QRH will instruct
the crew to only perform an engine
shutdown in case of both OPT and
LOPS indicate low oil pressure (real
oil leak or dual sensors failed).

19

(10) Field Implementation


LOPS Activation

Note: LOPS may be activated


independently on engines on
same aircraft.

SNAPSHOT
OF THE MONTH

Amazing view of Mount Kilimanjaro - the highest mountain in Africa - from Kenya Airways E190 flight.
Credits to Francisco Moraes - EMBRAER Sales Director

Should you need any additional information, do not hesitate to contact us: +55 12 3927-6693 / technical.support@embraer.com.br

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