E NEWS

E-JETS

EMBRAER SERVICES & SUPPORT T E C H N I C A L P U B L I C AT I O N

80

AUGUST/2013

FAMILY

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Editor: Cristina Amato Cipola Editorial Designer: Marcell Marra

E-JETS/INFO

This edition and earlier ones can be found at Flyembraer Portal: www.flyembraer.com > Download_center > Commercial Jets > Maintenance > Technical Support > E-Jets NEWS. Should you need any additional information, do not hesitate to contact us: +55 12 3927-8495 / technical.support@embraer.com.br

Proprietary Notice

The articles published in E-NEWS are for information only and are the 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

SUMMARY

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

SUMMARY
CALENDAR TECHNICAL

Choose your destination

1
MAINTENANCE

Released SNLs - Update

Wings Balance Weights with Corrosion Reports

REMINDER DID YOU KNOW?

FOCUS ON

SNAPSHOT OF THE MONTH

Maintenance Cost Reduction Project

Behind E-Jets Structural Maintenance Plan Optimization

EJETS Main Landing Gear Shimmy Damper

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CALENDAR

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

CALENDAR E V E N TS

What will happen

In September 2013 Embraer Technical Support team will hold another session of the E-Jets Technical Workshop via WEBEX. This is a valuable opportunity for Embraer to share updated information with customers on the actions to address the on-going E-Jets fleet issues.

These workshops have the purpose of promoting discussions at the operational level, therefore the participation of Operator members directly involved on technical issues is highly recommended. Find below the agenda for each day separated by technology and meeting time based on different time zones.

10

E-Jets Workshop
GMT@5:00am
Interiors

11

E-Jets Workshop
GMT@5:00am
Interiors Electrical & Avionics

17

E-Jets Workshop
GMT@5:00am
Structures

18

E-Jets Workshop
GMT@5:00am
Structures Landing Gear & Hydraulic Systems

GMT@1:00pm
Electrical & Avionics

GMT@1:00pm

GMT@1:00pm

Landing Gear & Hydraulic Systems

GMT@1:00pm

24

E-Jets Workshop
GMT@5:00am
Propulsion

25

E-Jets Workshop
GMT@5:00am
Environmental Propulsion

26

E-Jets Workshop
GMT@5:00am
Flight Controls & Auto Flight Systems

TIME ZONES
GMT So Paulo, Brazil Fort Lauderdale, USA Paris, France Beijing, China @5:00am @2:00am @1:00am @7:00am @1:00pm @1:00pm @10:00am @9:00am @3:00pm @9:00pm

GMT@1:00pm

Flight Controls & Auto Flight Systems

GMT@1:00pm

GMT@1:00pm
Environmental

TECHNICAL

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

Jose Cludio S. Leal Technical Support (EFTC) jose.leal@embraer.com.br

Released SNLs - Update

As a complement of the article included in the Reminder section of this publication last edition, the EFTC AMS has released the following SNLs during the past week: SNL 170-35-0005 (190-35-0004) Crew Oxygen Discharge Indicator Disc with information on how to deal with cases of discolored discs. This subject was raised during the last FIRST Webex meeting. SNL 170-21-0035 (190-21-0031) Pack By-Pass Valve Filters instructions have been included to identify the new valve filters. SNL 170-36-0020 (190-36-0019) Fan-Air Valve Filters also with instructions to identify the new valve filters. It is important to highlight that the EFTC AMS has cleaned the SNL database and kept only the letters with updated in-service difficulties.

TECHNICAL

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

Wings Balance Weights with Corrosion Reports

Embraer received reports of unusual corrosion found at the wing tip tungsten balance weights (flutter mass). The manufacturing material of these masses is sintered tungsten. During the sintering process, paraffin is used to seal any porosity. After some time, the paraffin got loose and induced the primer displacement. This primer displacement associated with dirt, resulted in a bad visual aspect that has been reported as corrosion. As tungsten does not have serious corrosion issue, the only recommendation for these events is to weight the mass to check if it is within limits, to clean any dirt and loose primer and re-apply protection (Dinytrol). Embraer Service Newsletters 170-57-0005 and 19057-0007 released in July 2013, provide further information related to this subject. Wing Balance Weight Reported finding
Wing Balance Weight Reported finding

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

MAINTENANCE

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

Maintenance Cost Reduction Project

Due to the E-Jets success worldwide and to their role as a key asset for our Customers business, Embraer is focused on a Maintenance Cost Reduction Product as part of the continuous improvement of its product. The goal of this Project is to reduce the E-Jets Direct Maintenance Costs (DMC) by USD20.00/FH in 2013, considering four pillars below: - Maintenance Performance - Product Performance - Repair Cost - Parts Price So far, Embraer has made available to the Customers improvements in two pillars and the result so far is a reduction of USD11.35/FH. The main improvements for each pillar are described:

Eduardo Rodrigues Alves Maintenance Economics maintenance.support@embraer.com.br

Pillar Maintenance Performance: Reduction of USD 7.95/FH

The DMC reduction initiatives under the Maintenance Performance pillar include: MaIntenance Program EVolutIon - Check of the surfaces control backlash from 4,000 flight hours for the horizontal stabilizer and from 6,000 flight hours for other surfaces control to 7,500 flight hours; - The interval to restore the landing gear restoration for E190 model increased from 8 years to 10 years; Best PractIces Maintenance Access Optimization, which resulted in an Access Optimization Tool (AOT). The AOT is available on FlyEmbraer to use in accesses opened during the Basic Check (B-2) and that are reopened during the Basic Check (B-3). With the tool, operators will be able to optimize their B-3 check by transferring these tasks from the B3 to B2, taking advantage of the opened accesses without the need to reopen them. This reduces the man power for accesses and it will consequently reduce the downtime. For operators that already performed Basic Check (B-2), AOT can be used for further checks, with the same advantage of accesses opened during even checks (B-2, B-4, ) and reducing man power and downtime for odd checks (B-3, B-5, ).
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MAINTENANCE

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

Maintenance Cost Reduction Project

Pillar Product Performance: Reduction of USD3.40/FH

The cost reduction initiatives under this pillar are focused on changes in the product, including among others: - New HS-ACE (Horizontal Stabilizer - Actuator Control Electronic) part number for E170 model to increase the robustness of the Horizontal Stabilizer System by preventing nuisance faults; - New EDP (Engine Driven Pump) part number for E190 model to reduce the events of external leakage through the EDP split line region; - Profile diverter installation in front of the forward passenger and service door deflectors for E190 model to improve the crew and passengers comfort and to prevent some failures that may occur in the forward passenger and service door deflectors.

Finally, SAVE THE DATE for the E-Jets MCW 2013. It will take place on October 16th, 2013 in Rio de Janeiro, Brazil. It is the best opportunity to discuss and share experiences about maintenance costs, best practices and knowledge among the community of Embraer Customers.

WEBEX Presentation on FlyEmbraer

For more information, please visit us on FlyEmbraer and consult the WEBEX presentation (held on June 25th, 2013) to reach the list of improvements aiming at the direct maintenance cost reduction.

MCW 2013 - Save the Date

Download center Commercial Jets Maintenance Maintenance Cost E-Jets Cost Reduction Project Online Conferences

Knowing the Customers point of view is a key factor for this Maintenance Cost Reduction Project. For this reason we kindly ask the operators to keep in touch with Embraer account team, sharing information and questions related to maintenance cost.

MAINTENANCE

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

Behind E-Jets Structural Maintenance Plan Optimization

As part of the E-Jets Maintenance Program Optimization Process, all maintenance requirements must be reassessed taking into account the operational experience from the worldwide E-Jets fleet to reach a confidence level equal to or above than 95%. Field data related to unscheduled and scheduled maintenance actions are being collected for intervals optimization analysis and discussing the task effectivity in MRB process events. However, the optimization process for the Structural Maintenance Plan is also focused on other actions in addition to the interval optimization. The purpose of this text is to present the activities and targets resulted from discussions on structures. The Structural and Zonal Working Groups are managing the technical proposals of the Structures Optimization Process to the following activities: Harmonization of structural tasks between E-Jets 170/175 and 190/195; Transference of the Maintenance requirements from Corrosion and Prevention Control Program (CPCP) to the Zonal Program; Definition of optimum Threshold and Intervals for maintenance requirements of CPCP; For the harmonization of structural tasks, field data are being used to reassess the MSG-3 analysis for E-Jets 170/175 and 190/195 to propose an optimized common interval for both mo-

Paulo Roberto de Freitas Diniz Maintenance Support paulo.diniz@embraer.com.br

dels if their structures are identical. This initiative is focused on the need of the reassessment of the original certification assumptions of the MSG-3 analysis to allow the development of a simpler maintenance planning mainly for operators with 170 and 190 in their fleet.

regulatory authorities the reliability of the Zonal Program to address inspections in such structures. Through this decision the CPCP may result in a reduction of maintenance requirements by at least 25%. Such reduction will minimize the paperwork for maintenance planning and controlling and The transfer of structural tasks from task accomplishments, therefore inCPCP to the Zonal Program will provicreasing the aircraft overall availability. de even further optimization, given the good reliability of most of the CPCP Given the amount of field data shared by tasks that were analyzed so far. The CPCP sampling program was used as a the operators with Embraer along with reference to the Working Group. CPCPs the Sampling Program assessments world wide fleet experience is allowing and operators experience, the goal to the CPCP maintenance program op- increase those tasks intervals was estatimization with excellent reliability to blished after the evaluation of all tasks provide the new thresholds and inter- with intervals lower than 72 months and vals periods and to transfer tasks to the 7000 FC considering the Basic 1 package Zonal Program. Therefore, the assess- escalation from 6,000 FH to 7,500 FH and ment proved to the working group and fleet utilization parameters worldwide.

MAINTENANCE

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

Behind E-Jets Structural Maintenance Plan Optimization

Preliminary results of the first two Structural Working Groups show that the Structural Program is going through a deep modification which led to threshold increase, intervals increase beyond 25% and transference of maintenance requirements to the Zonal Program along with the harmonization of Embraer 170 and Embraer 190 maintenance programs. The technical proposals to be assessed by the next Working Group meetings will address optimization of other structural tasks with higher Threshold and Interval following the same target herein mentioned: Harmonization analysis, transference analysis from structural to Zonal Program and Threshold and Intervals optimization. We are confident that the current CPCP Sampling Program and field data collection from Basic check will give all means to the Working Group improve the current structural program and reduce maintenance costs.

MSG-3 Analysis Reassessment and Interval Optimization Report

REMINDER & DID YOU KNOW?

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

Rodrigo de Macedo Technical Support (EFTC) rodrigo.macedo@embraer.com.br

Rodrigo de Sousa Frutos Technical Support (EFTC) rodrigo.frutos@embraer.com.br

Reminder
The SB 190-32-0054 was recently revised in order to include the on-wing modification procedure for the introduction of new RSA floating piston seal. The covered Liebherr SB with offwing instructions also had a modification introduced. The main advantage of on-wing task is the possibility to remove only the sliding tube removal, instead of the complete MLG assembly. This eliminates the need of shop tooling such as trolley PN 53377A0000-01 and Beam PN 53377A2500-01. Nevertheless, in both methods the new GSEs will be necessary (GSE 427 and GSE 494). It is worth mentioning that during the field evaluation of the new seal it was observed an accommodation period of up to 2 months within which a small internal nitrogen leakage is normal.

Did you know?

...that the AMM Task 34-13-01-06 (Integrated Pitot/Static/ AOA sensor Inspection/Check) was recently revised to include procedures to do damage assessment of the Air Data Smart Probes (ADSP)? This task provides instructions to avoid unnecessary ADSP removals due to erosion or corrosion before cross-checking its effect with the specific steps of the referred AMM task.
8

AOA PORTS

STATIC PORTS

ADSP Static Ports inspection

FOCUS ON

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

EJETS Main Landing Gear Shimmy Damper

The Main landing gear provides ground-rolling capability to the aircraft, thus enabling take-off, landing and taxi operations. Due to size of the MLG and its tires, as on all landing gear with similar design, a Shimmy Damper was required for shimmy stability. In Ejets the Shimmy Damper was designed to be attached to the union of upper and lower torque links by an axle. All these components provide the aircraft proper alignment on landing and take-off, as well disable the wheels rotation around the sliding tube axle. The Shimmy Damper is installed on LH/RH Main Landing Gear of the E170 and E190 models. See Figure 1 and 2. This article provides information about the Shimmy Damper and describes its evolution over the years.
Main Fitting Upper Torque Link Torque Link Damper Brake Torque Pin Nitrogen Valve

Marcos Silveira Technical Support (EFTC) msilveira@embraer.com.br

WOW Sensors Sliding Tube Grease Niples

Wheel Axe

Brake Harness Lower Torque Link Brake Hydraulic Lines

Figure 1 MLG, Shimmy Damper

Figure 2 MLG, Upper/Lower Torque Links and Shimmy Damper

FOCUS ON

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

MLG Shimmy Damper

MLG Shimmy Damper
General Information
Its function is to reduce the translation of lateral movement from the lower torque link to the upper torque link due to the shimmy behavior or any other movement which may be induced during rolling on the ground. See Figure 3.

Functional Information
The component is a disc spring, energized, hydraulic fluid damper. The damper housing is connected to the upper torque link; the shaft is connected to the lower torque link via a ball bearing. Each torque link has a grease point to keep the axle lubricated. The shimmy damper contains a housing and a hollow, flanged shaft with a reservoir of Hydraulic Fluid SAE AS1241. The oil-filling valve is protected by a nut with longer cylinder shape. The shimmy damper housing is attached to the upper torque link with six screws (connections bores) and the damper shaft is attached to the lower torque link with a flanged bearing and a support assembly. See Figure 4 and Figure 4.1.

Support Shaft

Upper Torque Link

Oil Reservoir

Damping Once

Protection Nut

Oil Filling Valve Lower Torque Link Housing Disc Springs

10

Torque Link Damper Bleed Point Upper Torque Link Oil Filling Valve

Figure 4.1 Shimmy Damper Cut View

Bleeder Plug Cap Housing Assembly Connection Bores to Upper Torque Link Shaft Assembly

Support

Lower Torque Link

Tappet Valve

Figure 3 Shimmy Damper (typical)

Figure 4 Shimmy Damper

The Shimmy Damper is effective during ground operation, such as taxing, take-off and landing. The damping effect is primarily a result of the hydraulic fluid passing through the restrictors in the shaft piston. The disc springs installed inside the shimmy damper return the shaft to the center position. See Figure 4.1. The shimmy damper operates when the sliding tube tries to rotate, thus transmitting the torque from the lower torque link to the upper torque. This causes the shimmy damper shaft to move, and the oil in the shaft reservoir is forced to go through the orifices of the restrictors in the shaft causing damping movement.

FOCUS ON

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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

MLG Shimmy Damper

Component Modifications Details
Several PNs were released since the beginning of Ejets operation, find below detailed characteristics, differences and changes according to each PN and its respective fleet application:
Protection bush

visualization. The red color was kept to the indicate reservoir low level. The shimmy damper has present words MAX (do not overfill) and MIN (refill) engraved on the cover and MAX and MIN lines will be printed on the glass. See Figure 6 and Figure 6.1.

PN 2244A0000-03 (E170/175 fleet)

On this configuration the shaft material was changed. Additionally, the shimmy damper protection shield was replaced by a protection bush installed in the upper torque link. See Figure 5. This allows the protection bush to better prevent the shimmy damper stroke against fine particles and impacts. This modification was introduced with the MLG shock strut PN 190-70031-401/-402.

Internal Shaft, Material: Marval X12H

Figure 5 - Shimmy Damper P/N 2244A0000-03 corrosion resistant steel material and an improved service indicator lines for better visualization. On these configurations, the following changes were performed to update components addressing different issues: A. As the indication in the level of the shimmy damper would cause a fluid level misinterpretation (Figure 6), there was a change of the indication concept, replacing the green indication area by a black line to facilitate the oil level

MAX Line grinded inside the sight glass MIN Line grinded inside the sight glass Black Line chem. oxidised on piston Width of indication window increased to 9,8mm (was 8mm) Engraved MIN - MAX indication on Reservoir Cover (on both sides of windows)

11

PN 2244A0000-04 (E170/175 fleet) / PN 2265A0000-01 (E190/195 fleet)

These PNs had the same modification of -03 in addition to replacement of the plug bleeder with a

Figure 6 New indication of the oil level

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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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

MLG Shimmy Damper

of the seal groove to increase the seal squeeze, replacement of the seal from O-Ring with an AGT-Ring and the inclusion of a second seal (Silicon O-Ring) on the reservoir piston to improve the sealing at low temperature. See Figure 7.

PN 2244A0000-04 / PN 2265A0000-01
O-Ring

Correct filled damper: Black Indication line in between MIN-MAX range. Chem. anodized red marking - covered by the reservoir piston at correct filled shimmy damper. Chem. anodized red marking - visible only at low oil level or at Reservoir empty.

Relief Valve

The relief valve (Figure 7) installed on the shimmy damper was changed. Its two main functions are: To open in case of internal oil leakage allowing the oil to flow to the environment; To work as unidirectional valve to avoid water or other contamination getting into the shimmy damper; PN 2244A0000-05 / PN 2265A0000-02
O-Ring(2 seal) AGT-Ring

12

Figure 6.1 - Oil level indication Cut View

B. Also, the previous shimmy damper would present leakage on the reservoir piston seal at low temperatures after some period of use. The solution for this issue was the modification

In a condition that the relief valve was not opening when there was an internal oil leakage due to the high cracking pressure. The oil that cannot flow to the environment will be therefore deposited in the indication chamber. This issue was due to excessive amount of hydraulic fluid in the unit.

Relief Valve

Figure 7 - Modification of the seal and Relief Valve

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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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

MLG Shimmy Damper

C. The attachment bolts that attach the shimmy damper to the torque links have presented surface corrosion (Figure 8). The current protection on bolts is black oxide. For the shimmy damper PN 2244A0000-05 / PN 2265A0000-02 the bolts have cadmium plating protection. age on the reservoir at low temperature. The relief valve was replaced with a new improved one designed to operate at a lower pressure due to its six new attachment screws with improved anticorrosive properties. piston and ring in the overlapped position. When there is less hydraulic fluid in the reservoir, the oil pressure is less. The spring forces overcome the oil pressure and force the indicator piston to go apart making only the red colored part of the ring to be visible, which indicates insufficient oil level. The red indication means the damper needs servicing. Although the main function of the shimmy damper is to mitigate shimmy / vibration of MLG on the ground, whenever the pilot reports an aircraft vibration, event if it is addressed to Nose Landing Gear, it is highly recommended to perform the AMM Task 05-50-24-200-801-A to troubleshoot the aircraft, taking special attention to MLG shimmy damper servicing and installation, including the gaps of upper and lower torque links. It is very difficult to the crew distinguish the source of vibration, thus a NLG vibration report may be related to MLG. Remember that other facts may be the root-cause of such reports, like tire pressure, tire wear, nose wheel not well aligned, among others. We published this month, specifically to E170 the SNL170-32-0032 bringing the importance of identifying a shimmy condition when it occurs, proper actions after a shimmy event and how to mitigate it.

Reservoir indication changed from colored rings to *MIN (refill) / MAX (do not overfill)* indication Modification of the seals Presented Surface Corrosion Modified Use

13

Figure 8 - Attachment bolts D. It was noticed that the shimmy damper cover part painted has been stripped during operation. But cover does not need to be painted, because the base metal is stainless steel. Summarizing these configurations PN 2244A0000-05 / PN 2265A0000-02 contains a new sight glass and color indication display to prevent misinterpretation. A new cap and piston with associated ring, seal and O-rings have been installed in order to prevent leak-

Replacement of Relief Valve: Decreasing of Relief pressure from 3 bar to 0.3bar

Replacement of Reservoir Cover: Removal of Paint

Figure 9 - Lastest Modifications of the Shimmy Damper

Aspects during Operation

When the hydraulic fluid level and the oil pressure are correct, the oil pressure in the reservoir neutralizes the spring force and keeps the indicator

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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 TS F A M I LY - N U M B E R 8 0 - A U G U S T 2 0 1 3

MLG Shimmy Damper

ZONES 731 741

Shimmy Damper

Upper Torque Link

14

Oil Indication Level A

Lower Torque Link B

Figure 10 Main-Landing-Gear and Doors Shimmy Damper

SNAPSHOT OF THE MONTH

E190 parked at Conviasa Hangar in Venezuela. Photo taken by Adriano Carvalho - Embraer Technical Support Engineer

Should you need any additional information, do not hesitate to contact us: +55 12 3927-8495 / technical.support@embraer.com.br Proprietary Notice
The articles published in E-NEWS are for information only and are the 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