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INGLS TCNICO

Manual de Treinamento
PG

NDICE
VOCABULARY....................................................................3
AIRFRAME.......................................................................11
FLIGHT CONTROLS SYSTEMS.............................................20
ENGINE SYSTEMS.............................................................26
FUEL SYSTEM...................................................................35
VENTILATION SYSTEM.......................................................38
HYDRAULIC SYSTEM..........................................................39
AIR MANAGEMENT SYSTEM................................................44
ELECTRICAL SYSTEM.........................................................52
AVIONIC SYSTEM..............................................................58
CABIN.............................................................................65
MATERIAL HANDBOOK.......................................................70
EXERCISES......................................................................74

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INGLS TCNICO
Manual de Treinamento
AIRFRAME

PART I: VOCABULARY
Airframe

Estrutura ou clula

Alloy

Liga Metlica

Bulkhead

Caverna de Reforo/Principal, anteparo

Cargo

Bagagem, carga

Center Fuselage

Fuselagem Central

Compartment

Compartimento

Corner

Canto

Crew

Tripulao

Crossbeam

Barra /Viga Transversal

Edge

Bordo

Elevator

Profundor/leme de profundidade

Empennage

Empenagem

Fairing

Carenagem

Forward Fuselage

Fuselagem Dianteira

Frame

Caverna

Fuselage

Fuselagem

Horizontal Stabilizer

Estabilizador Horizontal

Rear Fuselage

Fuselagem Traseira

Rib

Nervura

Rudder

Leme de direco

Shape

Forma

Skin

Revestimento

Spar

Longarina

Stringer

Perfil

Stub

Caixo

Vertical Stabilizer

Estabilizador Vertical

Wing

Asa

Winglet

Aleta (da ponta de asa)

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Manual de Treinamento

AIRFRAME
Part II: Text Exercises
The Airframe is the basic structure of a plane, including fuselage, wings,
empennages, etc.

Right Wing

Emergency
Door

Rear Passenger
Door
Vertical
Stabilizer

Fuselage

Horizontal
Stabilizer

Forward Passenger
Door

Wing / Fuselage
Fairing

Engine

Left Wing

The fuselage is the main portion of the aircraft to which the wing, horizontal and
vertical stabilizers are attached.
The main function of the fuselage is to provide accommodation for the passengers
and crew, as well as room for baggage in the overhead bins and in the forward
and aft cargo compartments.
The fuselage contains several systems and main structural components.
The fuselage is divided basically in three parts:
Forward Fuselage
Center Fuselage
Rear Fuselage.

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Manual de Treinamento
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Forward Fuselage: it is the anterior part of the fuselage, and basically provides
accommodations for pilots to fly the aircraft.
Center Fuselage: it is the part of the fuselage that provides accommodations for
flight attendants and passengers.

Rear Fuselage: provides continuity to the fuselage, and connects the Center
Fuselage to aircrafts Tail Cone.

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There are other important structural parts at the Fuselage:

Frame

Stringer

Skin

Bulkhead

Stub
Crossbeam

Spar

Skin

The Frames are vertical rings that give shape to the aircraft.
The Skin is a metallic component that covers the external structure of the
aircraft and gives aerodynamics smooth.
The Crossbeam is the rigid beam that provides support to cabin floor.
The Spar is a reinforced part of the aircraft that provides longitudinal support
to aerodynamic efforts.

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The Stringer provides longitudinal complementary support to aerodynamics


efforts.
The Bulkhead is a structural component that divides the aircraft into two
different compartments, closes the pressurized compartment and provides
structural strength.
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EMPENNAGE

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The Empennage is installed at Rear Fuselage and provides stability and control to
Pitch and Yaw attitudes.
The Vertical and Horizontal tail structures can hold inertial and aerodynamic
loads, providing support to Rudder and Elevators.
The Vertical Stabilizer is stationary, while the Horizontal Stabilizer is movable and
operates as pitch trim.
The Elevators are hinged at the trailing edge of the Horizontal Stabilizer, and the
Rudder is hinged at the trailing edge of the Vertical Stabilizer.
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WING
The Wings are the main aerodynamic structure of an airplane. They create lifting
forces to sustain the airplane when flying.
The wings can also storage fuel and place components as landing gear, engine
and flight control surfaces.
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RIB

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Manual de Treinamento

The Wing main structure is made from aluminum alloy, and includes Spars, Ribs,
Leading Edge and Trailing Edge.
The Winglets are structural parts installed at wing tips, to prevent the creation of
vortex.
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WING STUB
The wings of an aircraft have many structural interfaces:

The Wing Stub is a structural box at Center Fuselage, where the wing is installed
at the aircraft.
The Stub can be divided in two parts:
The Main Box provides Wing-to-Fuselage interface, and can storage extra fuel.
The Rear Box is the Main Landing Gear Compartment.

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Wing to Fuselage Fairings (WFF) consist in many composite panels, which
give a better aerodynamic shape to the wing-to-fuselage junction.

They round wings corners and close the gaps. They also protect the systems and
components attached to the wing stub-fuselage lower region.
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DOORS
There are many doors at Embraer aircrafts:

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The Main Door is the one where the passengers and the crew enter the aircraft.
At E-Jets Family, we have two main doors: the Forward Passenger Door and the
Afterward Passenger Door.
The Service Door is the door where the ground service team fills the galleys with
food and drink. At Embraer 170 / 190 Family, we have two service doors either.
The Baggage Door is the door that closes the Baggage Compartment. We have
the Forward Baggage Door that closes the Forward Baggage Compartment, and
the Afterward Baggage Door, for the Afterward Baggage Compartment.
The Emergency Door is the door where, in case of emergency, the passengers can
leave the aircraft quickly. At E-Jets Family, the Emergency Doors are both Main
Doors and both Service Doors.
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INGLS TCNICO
Manual de Treinamento

FLIGHT CONTROLS SYSTEMS


Part I: Vocabulary
Aileron

Aileron

Attitude

Atitude

Axis

Eixo

Bellcrank

Guinhol

Cable

Cabo

Corner

Canto

Crew

Tripulao

Device

Dispositivo

Disconnection Mechanism

Mecanismo de desconexo

Dumping

Reduo, Amortecimento

Elevator

Profundor, leme de profundidade

Flap

Flape, Aba (do bordo de fuga)

Flight Controls

Comandos de Vo

Groove, to

Fazer sulcos, ranhuras

Handle

Manche, volante

Length

Extenso, comprimento

Lift

Sustentao

Main

Principal

Mechanism

Mecanismo

Pitch

Arfagem

Pulley

Roldana

Roll

Rolagem

Rope

Corda

Rudder

Leme (de direco)

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Secondary

Secundrio

Shape

Formato, forma

Slat

Slat,Flape (do Bordo de Ataque)

Spoiler

Travo aerodinmico

Stick

Coluna do Manche

Stop

Batente

Tension

Tenso

Torque Tube

Tubo torque, Tubo de aperto

Torque Tube

Barra de Toro

Travel

Curso

Trim Tab

Compensador

Turnbuckle

Esticador

Yaw

Guinada

Part II: Text Exercises


The Flight Control is the system that allows controlling the aircraft at any attitude,
safely, through different turbulence conditions during the flight time. It is divided
in main controls, secondary controls, hyper lifting surfaces, and aerodynamic
braking surfaces.
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Manual de Treinamento

The Main Flight Controls are developed to control the aircraft at the three flight
axis: longitudinal, lateral and vertical.
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The Secondary Flight Controls are composed basically by Trim Tabs, located at
ailerons, elevators and rudder. They help Main Flight Controls to control the
aircraft and to remove undesirable flight tendencies.
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The Hyper Lifting Surfaces provide lifting for the aircraft, even in low speeds. They
are basically composed by Flaps and Slats.
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Slat Outboard
Slat Inboard

Flap Outboard

Flap Inboard

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The Flaps are surfaces installed at wing trailing edge, used to generate lift in low
speeds. The Slats are surfaces installed at wing leading edge, used to elevate
wing critical angle of attack when the aircraft angle of attack is high.
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The Spoilers are hinged surfaces installed at wing upper part. They can be used to
reduce airspeed (Speed Brake Function) by activating the Multi Function Spoilers.
The Spoilers can also be used to eliminate lift (Lift Dumping Function), by
activating the Ground Spoilers.
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Speed Brake

Lift
Dumping

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There are many components at the Flight Control System:
The Bellcrank is a device used to change the direction of an applied force.
The Cables are metal ropes used in control systems.
The Pulley is a grooved wheel used to change the direction of a moving cable.
The Stop is the device that prevents excessive movement of a control.
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Tension is the degree of tightness to which a cable is stretched.
The Travel is the movement or the extension of movement of the control
surfaces.
The Turnbuckle is a device inserted in a length of cable to adjust its tension.
The Handle is a device used by pilots to change aircraft attitude during the
flight, in pitch and roll commands.
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ENGINE SYSTEMS
PART I: VOCABULARY
Accessory

Acessrio

Backward

Para Trs

Bearing

Mancal; rolamento

Blade

Combustion

Combusto

Cowling

Capot, capota

Crankcase

Bloco

Crankshaft

Eixo da Manivela (cambota)

Cylinder

Cilindro

Dispatch, to

Despachar, liberar para vo

Drag

Arrasto, Atrito

Exhaust

Escapamento, Escape

Feather

Embandeiramento (Hlice)

Forward

Para a frente

Gearbox

Caixa de velocidade (dos acessrios)

Governor

Governador

Ground Speed

Velocidade Relativa do solo

Hub

Cubo

Idle

Marcha Lenta, ralenti

Jet Engine

Motor a Jato

Lift

Sustentao

Load

Carga

Manifold

Bloco de distribuio

Nacelle

Nacele

Piston

Pisto

Pitch

Passo

Plug

Vela

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Propeller

Hlice

Pylon

Pilone

Ratio

Razo, Relao, Rcio

Reciprocating Engine

Motor Convencional (recproco, alternativo, a


pisto)

Reliability

Credibilidade, fiabilidade

Reverse

Inverso

Revolutions per Minute

Rotaes por Minuto

Rod

Biela

Safety

Segurana

Shell

Concha

Spark

Fasca

Thermal

Trmico

Throttle

Manete, Acelerador

Traction

Trao

Turbo

Turbinado, Acionado por Turbina

Waste

Resduos

Weight

Peso

Part II: Text Exercises


To make an aircraft fly, it is necessary a Traction Force, opposite to a Drag Force.
This traction is generated by an engine that, by internal combustion, converts
thermal energy into mechanical energy.
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There are two types of aeronautical internal combustion engines: jet engines and
reciprocating or propeller engines.
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The propeller engine imposes a low acceleration at a large mass of air. The jet
engine imposes a high acceleration at a low quantity of air.
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The Engine Reverse System consists in a kit of doors in the shape of a shell.
When activated, the doors change the escaping gases direction to forward,
producing a backwards reaction.
This system helps the aircraft to decrease ground speed after landing.
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The Nacelle is the compartment where engines are installed at the aircrafts.
The Pylon is the structure that holds the engine. At Embraer E-Jets Family, pylons
are installed at the wings. At Regional Family, pylons are installed at Rear
Fuselage.
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Engine System general components and characteristics are:


The Accessory Gearbox is a component that drives equipments such as
pumps and generators.
The Bearing is a mechanical device that reduces friction and carries the weight
of moving mechanical parts.
Compression is the pressure created when the air volume is reduced in a
cylinder.

The Connecting Rod connects the piston to the crankshaft, providing its
power.
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The Cowling is a removable metal cover that protects the engine from outside
elements.
The Crankcase is the part of the reciprocating engine that holds the
crankshaft.
The Crankshaft is the part of a reciprocating engine that receives power from
connecting rods.
The Cylinder is the chamber in which a piston of a reciprocating engine moves.
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The Idle is the position of the throttles when the engines are running smoothly.
The Ignition System supplies the spark to fire the fuel-air mixture in the
cylinder.
The Manifold Pressure is a measure of the power of an engine.

The Mixture Ratio is the measure comparing the weight of fuel with the weight
of air, supplied to the combustion chamber of an engine.

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The Reduction Gearbox is a component to reduce the speed of the propeller.
The Spark Plug is a device inserted in the cylinder head, used to produce a
spark for igniting the fuel-air mixture.
The Tachometer is the instrument for measuring engine revolutions per
minute
(rpm).
The Thermocouple is a device that converts heat into electricity for driving
instruments.
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The Compressor is the component of a jet engine that causes great quantities
of air to be taken in.
The Engine Exhaust System carries the hot waste gases from the cylinders to
the outside air.
The Piston moves inside the Cylinder.
The Throttle is a device for regulation the output power of an engine.

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There are two main interface systems that help to run and control the engines
operations:
The APU (Auxiliary Power Unit) is a jet engine designed to supply electrical
and pneumatic power to aircraft systems, in flight or on ground conditions.
The APU is located at the tail cone and its fuel is furnished by aircrafts fuel
system.
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The FADEC (Full Authority Digital Electronic Controller) is the engine main
controller.
It can flexibly engine operations and reduce pilots work loads with high level of
reliability and safety. The FADEC can control and monitor engine main functions
and indicates failures that allow maintenance specialist to dispatch the aircraft on
time.
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The Propeller is the most important part of a reciprocating engine.

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In a transversal view, the propeller can be compared to a wing that produces


lifting in horizontal direction, or traction. When the propeller pulls back the air,
there will be a reaction on opposite direction. This reaction produces the aircraft
forward movement.
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The Propellers general components and characteristics are:
The Propeller Blades are the components that cause the lifting effects on a
reciprocating engine.
To Feather is to turn the edges of the propeller blades of a dead engine into the
wind to reduce drag.
The Hub is the central part of a propeller that secures the blades.
Overspeed occurs when a propeller RPM are above the desired setting.
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The Propeller Governor is a device for adjusting the angle of the propeller
blades to hold a constant engine speed.
Synchronize: To operate at the same speed.
Turbo-Props: Airplanes powered by turbo-prop engines.
Pitch: The angle of the propeller blades.
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FUEL SYSTEM
PART I: VOCABULARY

Allow, to

Permitir

Arrester

Supressor

Booster

Reforo, aumento

Carburettor

Carburador

Cross feed

Alimentao Cruzada

Defuel (to)

Esvaziar

Differential Pressure

Presso Diferencial

Ejector

Ejetor

Failure

Falha,avaria

Feed Line

Linha de Abastecimento

Feed, to

Alimentar, Abastecer

Flame

Chama

Flow line

Linha de Fluxo

Fuel

Combustvel

Inlet

Entrada

Manifold

Bloco de distribuio

Pump

Bomba

Refuel

Reabastecimento

Relief

Alvio

Shutoff

Corte

Sprinkle

Asperso, Pulverizao, Chuvisco

Storage, to

Armazenar

Strainer

Filtro

Surge

Pico, excesso

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Part II: Text Exercises


The aircraft Fuel System is designed to storage and feed engines and APU with
fuel.
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The Fuel System is divided into the following subsystems:
The storage subsystem includes tanks with ventilation.
The distribution subsystem allows the operations of engine refuel and defuel.
The indication subsystem gives information of fuel quantity and system failures.
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The Fuel System general components and characteristics are:


The Booster Pump supplies fuel to engine-driven pump, the Ejector Pump
maintains the collector tank always full and feeds the engine, and the Auxiliary
Pumps help the main ones to feed the engine continuously.
The Carburettor is a device that mixes and regulates the flow of fuel and air to
the engine.

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The Cross Feed System is a system on a multi-engine airplane that allows an
engine on one side to use fuel from cells on the opposite side.
The Fuel Selector Valve allows the pilot to choose the source of fuel.
Sediments are solid impurities in fuel that settle to the lowest point of the
system.
Wet Wing is a term used to describe a fuel system that uses the skin of the
wing as wall to contain the fuel.
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The Collector Tank is the stub tank; it ensures continuous fuel feed to the
engine.
The fuel passes through the Feed Lines, where it goes straight to the aircraft
engine.
The Fuel Strainers are devices used for filtering solid impurities out of the fuel
before it reaches the engine.
The Shutoff Valve is an important component that cuts the engine fuel feeding.
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INGLS TCNICO
Manual de Treinamento

VENTILATION SYSTEM
The Ventilation System is an important interface of the Fuel one. It is designed to
maintain differential pressure between aircrafts tanks and atmosphere, under all
operational conditions, and either to prevent fuel sprinkle.
The Ventilation System main components are: air inlets named NACA, surge relief
valve, float vent valve, pressure relief valve and flame arrester.
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INGLS TCNICO
Manual de Treinamento

HYDRAULIC SYSTEM
PART I: VOCABULARY

Actuator

Atuador

Antiskid

Antiderrapagem

By-Pass

Derivao, Circuito de Passagem Secundrio

Check Valve

Vlvula Unidirecional, anti-retorno

Cylinder

Cilindro

Decelerate

Desacelerar

Disc

Disco (do travo)

Drum

Tambor de travo

Fairing

Carenagem

Fluid

Fluido, Lquido

Flux

Fluxo

Gasket

Junta

Jack

Macaco de levantamento

Landing Gear

Trem de Aterragem

Line

Linha

Pad

Pastilha (do travo)

Park, to

Estacionar

Parking Brake

Travo de Estacionamento

Power

Potncia, Fora, Energia

Pump

Bomba

Relief Valve

Vlvula de Alvio

Reservoir

Reservatrio

Retractable

Retrtil

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INGLS TCNICO
Manual de Treinamento

Shimmy

Trepidao, Vibrao

Shock Absorber

Amortecedor

Standard

Padro, Comum

Strut

Perna de Fora

Tire

Pneu

Tricycle

Triciclo

Valve

Vlvula

Wheel

Roda

Part II: Text Exercises

The Hydraulic System is designed to supply aircraft with hydraulic power, to


operate several units, in replacement of man power.
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Manual de Treinamento

A standard Hydraulic System has basically the same components:


The Hydraulic Fluid for strength transmission of power, the Reservoir to
storage the hydraulic fluid; several Pumps to move the fluid through the lines;
Actuators to change hydraulic flux into mechanic power; Lines to transport the
fluid; and Valves to control hydraulic pressure and flux.
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The Landing Gear Sub-system consists in providing the aircraft with ground
support, and protects the airframe from landing impacts. It is normally retractable
and in tricycle format, consisting in two main landing gears and one nose or
auxiliary landing gear.
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The Landing Gear System has leg structures, shock absorbers, brakes, retraction
mechanisms, fairings, wheels and tires. It also has an emergency extension
system that allows landing gear down movement, in case of the main system
failures.
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INGLS TCNICO
Manual de Treinamento

Hydraulic System general components and characteristics are:


The Cylinder is a device that extends or retracts, when a pressure is applied.
The By Pass Valve is used to deviation of the fluid flow.
The Gasket is usually the metal or fiber used between two parts to prevent
leaking of air or fluid.
The Jack is a device used for raising the airplane so that its weight is taken off
the wheels.
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The Pump is a device for moving fluid.
The Strut is a member of the Landing Gear that holds the wheel in place.
The Wheel is a device that allows the aircraft to run through the taxiway and the
landing way.
The Check Valve allows the hydraulic flux to flow in only one direction.
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Brakes are designed to decelerate, to stop, to park and to maintain the aircraft
stopped, even with the engines running. The brakes are installed one in each
main landing gear wheel, and are actuated independently to the other assy.
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Manual de Treinamento

The Disc is a round flat plate which turns with the wheel and against it when
braking forces are applied.
The Drum is a cylinder attached to the wheel, against which braking forces are
applied.
The Pad is the small part that is pressed against the disc to give braking action.
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The Relief Valve prevents pressures from exceeding a pre-set amount.
Shimmy is the vibration of any wheel.
The Antiskid is the electronic system that prevents the aircraft to skid after
landing, allowing a safety deceleration, even in a hard activation of the system by
the pilots.
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INGLS TCNICO
Manual de Treinamento

AIR MANAGEMENT SYSTEM


PART I: VOCABULARY
Airfoil

Aeroflio, Plano Aerodinmico, perfil aerodinmico

Alternate

Alternado

Anti-Ice

Antigelo

Bleed, to

Sangrar (ar do motor)

Blower

Ventilador

Boot

Bota

Bottle

Garrafa, Recipiente

Check Valve

Vlvula Unidirecional

Chemical

Qumico

Comfort

Conforto

Cooling

Arrefecimento

Cycle

Ciclo, Perodo

Deflate, to

Esvaziar

Defroster

Desembaciador

De-Ice

Degelo

Duct

Tubo, conduta

Filler

Abastecimento

Gauge

Medidor

Generate, to

Gerar, criar

Heat Exchanger

Permutador de calor

Heater

Aquecimento

Indicator

Indicador

Inflate, to

Insuflar, encher

Inlet

Entrada

Level

Nvel

Management

Gesto

Mask

Mscara

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INGLS TCNICO
Manual de Treinamento

Outflow

Fluxo de Sada

Outlet

Sada

Oxygen

Oxignio

Pack

Mquina de ciclo de ar

PACK

Pressurization Air Conditioning Kit

Pitot Tube

Tubo Pitot

Pneumatic

Pneumtico

Portable

Porttil

Precooler

Refrigerador Primrio

Principle

Princpio (de funcionamento)

Regulating

Regulando

Rubber

Borracha

Seal, to

Selar, estancar

Sensor

Sensor

Set up

Ajuste

Staff

Equipa, pessoal

Static Port

Tomada Esttica

Supply, to

Fornecer

Switch

Interruptor

Thermostat

Termostato

Vacuum

Vcuo

Ventilation

Ventilao

Vessel

Vaso, recipiente

Water separation

Separador de gua

Windshield

Vidro Pra-brisas

Wipe

Escova do pra-brisas

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INGLS TCNICO
Manual de Treinamento

PART II: EXERCISES

The Air Management System is designed to supply comfort and life support to the
passengers and the crew. It is divided into many other systems like:
Pneumatic System
Air Conditioning
Pressurization
Oxygen
De-Ice
Anti Ice.
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The Pneumatic System works exactly like the hydraulic system, but instead of
hydraulic fluid it is used air to generate power. It supplies air extracted from
engines to air conditioning and anti-ice systems.
The Regulating Valves are devices to regulate the pressure of the air extracted
from engines.
Shut Off Valve: cuts completely the air flux.
The Pressure Sensor feels the level of pressure in the air and sends information
to regulating valves.
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INGLS TCNICO
Manual de Treinamento
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Temperature Sensor: it senses air temperature and sends informations to the
system controllers.
The Precooler is a device that cools the hot air extracted from the engines.
Check Valve: forces the air flux to go in only one direction.
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The Air Conditioning System is designed to maintain a comfortable air


temperature inside aircraft cabin, heating or cooling the air as needed. And
besides, the system supplies air flux to control aircraft pressurization.
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The Heat Exchanger cools the system hot air at the same time it heats the
aircraft fuel.
The Water Separator removes condensed water from the system.
The Heater is a device that heats the air as needed.
The Thermostat is a device to regulate automatically the air temperature.
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INGLS TCNICO
Manual de Treinamento
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The Blower moves the air inside the cabin.
The Pack is the main component of the system. It adjusts air flux and pressure to
desirable levels.
Ventilation: function of the system that circulates fresh air at the cabin.
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The Pressurization System operational principle simulates a pressure vessel,
consisting in inserting pressurized air at a reinforced and sealed portion of the
aircraft. An outflow valve controls pressure regulating air flow outside the cabin.
Even though the aircraft can fly in high altitudes, the internal pressure can be set
up to a comfortable level.
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INGLS TCNICO
Manual de Treinamento

Vacuum is the total absence of air in a confined place.


Inlet and Outlet is the way the air is allowed to enter or to exit the cabin.
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The aircraft Oxygen System is divided into two parts, one that supplies oxygen
to crew and another one that supplies oxygen to passengers. The oxygen is
supplied through portable oxygen cylinders, provided with a regulator assembly,
masks, flow indicator and plastic tubes.
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Ducts: Tubes that are used to carry oxygen.
Masks: A short way of saying oxygen masks, which are worn on the face to
supply oxygen at high altitudes.
Oxygen Regulator: Controls the amount of oxygen flow into a mask.
The Filler Valve allows external operations to fill oxygen cylinders.
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INGLS TCNICO
Manual de Treinamento

The Pressure Gauge measures the input pressure inside the oxygen cylinders
and indicates the pressure level of the oxygen.
Pressure Switch: Indicates to maintenance staff the pressure level of the
oxygen.
The Chemical Generator supplies passengers with oxygen generated by
chemical reactions.
The Oxygen Portable Bottles can carry oxygen that flight attendants use when
walking by the cabin.
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The Anti-Ice System works under certain atmospheric conditions, where ice can
build rapidly on airfoils and air inlets, thus affecting the performance and
efficiency of the aircraft in many ways.
Pneumatic de-icing system use rubber de-icers called boots, attached to the
leading edge of the wing and stabilizers.
During operation the tubes are inflated with pressurized air, and deflated in an
alternating cycle, thus causing the ice to break off.
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Pg 41

INGLS TCNICO
Manual de Treinamento

The Air Management System general components and characteristics are:

The Defroster is a device for removing frost or mist from the windshield.
The De-icer is a system for removing ice after it has formed.
The Windshield Wiper is a device used for removing rain from the windshield.
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ELECTRICAL SYSTEM
PART I: VOCABULARY

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INGLS TCNICO
Manual de Treinamento

AC Alternate Current

AC Corrente Alternada

Alarm

Alarme

Alternator

Alternador

Anti-collision Light

Luz Anti-coliso

Battery

Bateria

Beacon

Farol, sinalizador

Bus Bar

Barramento
Distribuio

Cabin Light

Luz da Cabine de Passageiros

Circuit

Circuito

Circuit Breaker

Disjuntor

Cockpit

Cabine de Pilotos

Cockpit Light

Luz da Cabine de Pilotos

DC Direct Current

DC Corrente Contnua

Distribution

Distribuio

Emergency Light

Luz de Emergncia

Engine driven

Comandado pelo motor, accionado pelo motor

Equipments

Equipamentos

Flood light

Luz fluorescente, projetor

Fuse

Fusvel

Generate (to)

Gerar

Harness

Cablagem

Illumination

Iluminao

Inspection Light

Luz de Inspeco

Inverter

Inversor

Landing Light

Farol de aterragem

Logo Light

Luz de Logotipo

Master Switch

Disjuntor Geral

Navigation Light

Luz de Navegao

Relay

Rel

de

Alimentao

ou

barra

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de

Pg 43

INGLS TCNICO
Manual de Treinamento

Several

Vrios, Diversos

Short-circuit

Curto Circuito

Starter

Motor de Arranque

Switch

Interruptor

Take off

Descolagem

Taxi Light

Farol de Txi

Voltmeter

Voltmetro

Wire

Fio

PART II: EXERCISES

The aircraft Electrical System consists in the generation and distribution of


electrical energy used to allow the functioning of several systems, including
equipments, illumination circuits, and failure alarms.
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INGLS TCNICO
Manual de Treinamento

The Generation & Distribution System is responsible to feed all aircraft


systems with electrical power.
It is usually composed by batteries, generators, fuses, switches, relays,
connectors, cables and wires, converters and circuit breakers.
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The Electrical System general components and characteristics are:
AC / DC are the abbreviations for Alternating Current and Direct Current.
The Alternator is an engine-driven device for producing AC Power.

APU: Auxiliary power unit.


The Battery is a device that stores and supplies the aircraft with DC Power.
The Master Switch is the main switch for controlling the entire system.
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The Bus Bar is a heavy wire that distributes power from the battery to each
major circuit.
The Circuit is the path over which electricity flows.
Circuit Breakers are devices to disconnect an electrical circuit in case of
overload.
The Wires are electrical conductors for distributing energy through all electrical
system.
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INGLS TCNICO
Manual de Treinamento

The Fuse is a device that melts when excessive current flows through it.
The Generator is an engine-driven device for producing DC.
The Inverter is a device for changing DC into AC.
A Short Circuit is the failure of an electrical current to flow through the entire
circuit.
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The Starter is a device for turning the engine to prepare it to run under its own
power.
The Voltmeter is an instrument for showing the difference of potential in
electrical force between two points of a circuit.
The Ground Power Unit (GPU) is the unit that generates electrical current to
energize the aircraft on ground.
The Harness is an assembly of wires and/or cables arranged in a way it may be
installed or removed as unique unit.
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The Aircraft lighting systems provide illumination for both exterior and interior
use. Lights on the exterior provide illumination for such operations as landing at
night, inspection of icing conditions and safety from midair collision. Interior
lighting provides illumination for instruments, cockpit, cabin and other sections
occupied by crew members and passengers.
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INGLS TCNICO
Manual de Treinamento

The Landing Lights are installed at wings leading edges. They provide lighting
for obstacles, and ground references during approaches, landing and take-off.
The Taxi Light is installed at Nose Landing Gear and lights an adequate area in
front of the aircraft.
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The Navigation Lights provide position reference from one aircraft to another.
The red light is installed at the forward part of left wing tip, the green light is
installed at the forward part of right wing tip, and white lights are installed at rear
part of both wing tips.
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The Anti-collision Lights provide proximity reference from one aircraft to
another. The white stroboscopic lights are installed at both wing tips. One red
beacon is installed at upper fuselage and the other is at the lower fuselage. Both
must be on when engines are running or when the aircraft is on movement.

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INGLS TCNICO
Manual de Treinamento

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The Inspection lights provide wings leading edges and engine air intakes
illumination, to allow crew inspection for ice formation.
The Logo Lights provide illumination for operator logo painted at vertical
empennage.
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The Cockpit Lights provide general and local illumination for all instruments,
control panels, flood lights and reading lights. Instruments and panels lights are
electronically dimmed by potentiometers located at front panel.
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The Cabin Lights are composed by several flood lights, distributed proportionally
by passengers cabin, and controlled by flight attendant controls. Lavatory, Galley
and Main Door areas are provided by individual lights. The PSU - Passengers
Service Units have reading light and call switch for each seat.
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The Emergency Lights system is provided by individual power units,
independent from aircrafts electrical system. They allow crew and passengers to
leave the aircraft safely, in case of night emergencies.
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INGLS TCNICO
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AVIONIC SYSTEM
PART I: VOCABULARY
Aid, to

Ajudar, auxiliar

Airspeed

Velocidade Aerodinmica

Altimeter

Altmetro

Antenna

Antena

Artificial Horizon

Horizonte Artificial

Avoid, to

Evitar

Bearing

Direco, Afastamento Relativo

Bus Coupler

Acoplador de Barramento

Clock

Relgio

Collision

Coliso

Communication

Comunicao

Course

Curso

Data Bus

Barramento de Dados

Diagnosis

Diagnstico

Display

Mostrador

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Manual de Treinamento

Frequency

Frequncia

Glide

Planar

Gyro

Giroscpio

Inner

Interno

Localizer

Localizador

Locator

Localizador

Magnetic Compass

Bssola Magntica

Maintenance

Manuteno

Marker

Marcador, Sinalizador

Measure, to

Medir

Meteorological

Meteorolgico

Middle

Mediano, Intermedirio

Multifunction

Multi-funes

Navigation

Navegao

Omni-Directional

Em todas as direes

Outbound

Afastamento

Outer

Externo

Path

Trajetria, Trajeto, Caminho

Radial

Radial, Raios (circunferncia)

Receiver

Receptor

Recorder

Gravador

Regulations

Regulamentos, Regras, Normas

Static

Esttico

Traffic

Trfego

Transceiver

Transceptor

Transmitter

Transmissor

Transponder

Transponder

Turn and Bank

Curva e Inclinao

Vertical Speed

Velocidade Vertical

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INGLS TCNICO
Manual de Treinamento

PART II: TEXT EXERCISES


The Avionic System of an aircraft provides the resources needed to internal and
external communications, navigation aids, landing instruments, aerial traffic,
meteorological information, computer data processing, and automatic flight
controls.
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The aircraft Avionic System is composed basically by Flight Instruments,
Navigation System, Computing System and Communication System.
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INGLS TCNICO
Manual de Treinamento

The basic aircraft instruments are:


The Artificial Horizon is used to show the attitude of an airplane, what is the
position of its wings and fuselage in relation to the earth, frequently called
attitude indicator.
The Magnetic Compass is an instrument that points to the magnetic north of the
earth.
The Turn-and-Bank Indicator measures the rate of turn. It is also called as
turn and slip.
Glide Path: The descending path flown by an airplane on an ILS approach.
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The Vertical Speed Indicator (VSI) shows the rate of altitude change, when the
aircraft is climbing.
The Airspeed Indicator measures the speed of the aircraft through the air.
The Altimeter is an instrument for measuring the aircraft altitude.
The Digital Clock is a digital display that shows time, chronometer and calendar.
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Multi-Function Display (MFD): Shows navigation graphic part, such as flight
plans and maps, and pictorial parts of some systems, like flight controls, electrical
and hydraulic systems.
Engine Indication And Crew Alerting System (EICAS): Shows warning
messages and indications like engine status, fuel, landing gear, etc.
Primary Flight Display: Digital display that shows pilot and copilot tactical flight
indications, such as navigation and radio backup.

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Manual de Treinamento
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Some Navigation Devices are:
Directional Gyro: A flight instrument stabilized by a gyroscope that shows the
direction of flight.
IFR: Instrument Flight Rules.
The Localizer is a part of the ILS that transmits a signal to indicate alignment
with the runway.
Middle Marker: The marker beacon placed about half mile from the end of
runway, along the glide path.
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Outer Marker: The marker beacon placed at the point of glide slope interception.
The ADF (Automatic Direction Finder) indicates a local commercial radio station,
nearby the runway.
Back Course: An approach to a runway in an opposite direction to that from
which a normal approach is made.
Course Selector: The control on a VOR receiver that selects the desired radial
from VOR.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

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The DME measures the distance between the aircraft and the next runway.
ILS: (Instrument landing system) An instrument approach system.
Outbound: To fly away from the radio facility.
A Radial is a magnetic bearing extending from a VOR.
The VOR is the VHF (Very High Frequency) Omni-directional Radio range.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
The Global Positioning System (GPS) is a satellite navigation system that
receives signals to compute aircraft global positioning, speed and time.
The Radar Altimeter provides crew with aircraft ground altitude when
approaching and landing.
The Meteorological Radar main function is the detection of flight meteorological
conditions in front of the aircraft.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
The Emergency Locator Transmitter (ELT) is the equipment that provides
automatic transmissions, by satellite, in case of aircraft collision.
The Digital Voice & Data Recorder (DVDR) records and preserves all
stipulated flight data parameters, and records the voice inside the aircraft.
The Traffic Collision Avoidance System (TCAS) is an Independent system
that monitors transponder equipped aircrafts course, which has high potential
risks of collision, and allows crew with the better escape maneuver.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

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Some of the Computing equipments that are used nowadays are:


The Auto-Pilot is a system designed for automatically maintaining a pre-set
course.
Computer: A device used by pilots to solve navigational problems quickly.
The Pitot-Static System operates the flight instruments that sense the
movement and pressure of outside air.
The Pitot Tube admits air to the instrument for measuring speed.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Static Port: A lateral opening to obtain static air pressure.
The Data Bus is a digital way that allows communication between several
computers.
The Bus Coupler connects the data bus to all computers.
The Central Maintenance Computer (CMC) is the computer that storages,
manages and allows systems failure diagnosis.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Some Communication Devices are:

The Transponder is an electronic device carried in an airplane that causes a


distinctive pattern to appear on observing radar.
The Antenna is a device for sending and receiving electromagnetic waves.
The Receiver is a device for receiving radio signals.
The Transceiver is a radio that is capable of sending and receiving
electromagnetic messages.
Static is an undesired noise on a radio.
Transmitter: A device for sending radio waves.
_________________________________________________________________
_________________________________________________________________

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_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
CABIN
PART I: VOCABULARY
Announcements

Anncios, Avisos, Comunicados

Arm Rest

Descanso de Brao

Aural Warning

Alarme Sonoro

Baggage

Bagagem

Belt

Cinto

Cabin

Cabine

Clean

Limpo

Cold Drink

Refresco, Refrigerante

Console

Consola, Painel Lateral

Discharge, to

Descarregar

Dispenser

Alojamento

Entertainment

Entretenimento

Environment

Ambiente

Extinguish, to

Extinguir, Eliminar

Fasten Seat Belt

Aperte o Cinto de Segurana

Fasten, to

Apertar

Feet

Ps (unidade de medida de distncia)

Fire Extinguisher

Extintor de Incndio

Flight Attendant

Assistente de Vo

Food Table

Mesa de Refeies

Furniture

Mveis, Moblia

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Galley

Copa, Cozinha

Gather, to

Recolher, Juntar

Grant, to

Garantir, Assegurar

Hygiene

Higiene

Lavatory

Lavatrio, bacia

Lifejacket

Colete Salva-Vidas

Load

Carga

Loudspeaker

Alti-falante, coluna (de som)

Luggage

Bagagem

Meal

Refeio

Non smoking

No Fumador

Oven

Forno

Overheat

Sobreaquecimento

Panel

Painel

Pax

Passageiro

Pocket

Bolso, Bolsa

Pushbutton

Boto

Recline, to

Reclinar

Rest, to

Descansar

Seat Belt

Cinto de Segurana

Side-by-side

Lado-a-lado

Signal

Sinal, Aviso

Sink

Pia (lavatrio)

Smell

Cheiro

Smoke

Fumo

Smoke Detector

Detector de Fumo

Toilet

Casa-de-banho

Typical

Bsica, Tpica

Visual Warning

Alarme Visual

Wardrobe

Armrio, Roupeiro

Waste

Detrito, Desperdcio

Waste, to

Desperdiar, Deitar Fora

Water

gua

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PART II: TEXT EXERCISES


Aircraft Cabins: are designed to provide comfort to passengers and crew.
Nowadays, pilots can seat in an aircraft, with high comfort levels, flying at 35,000
feet, breathing pressurized air, at the temperature of 21 C, and provide this
same comfort to passengers.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
One typical cabin configuration is composed by flight compartment or cockpit,
passengers compartment, galleys and wardrobes, toilets and baggage
compartment.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

The cockpit furniture is composed basically by two pilots seats with arm rest
and seat belt, one observer seat, panels and consoles for flight operations,
portable oxygen equipments, and a portable fire extinguisher.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
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The basic passengers compartment internal configuration has Pax seats sideby-side, flight attendant seats, and passenger service units (PSU). The PSU is
configured with loudspeakers, crew call pushbuttons, reading lights, oxygen
masks dispenser, gasper air outlet, and the visual signals of non smoking and
fasten seat belts.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
The Pax cabin, depending on aircraft configuration, has reclining Pax seats with
abdominal seat belts, food table for meals, a literature pocket and a lifejacket
under the seat.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

At Embraer Aircrafts the Baggage Compartment can be located at the rear part
of the aircraft, or under the Pax Cabin. It offers space for passengers luggage
and other types of loads.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
In the galleys flight attendants can storage food. They have oven to prepare hot
meals and a refrigerator that allows serving cold drinks. In the galley is localized
entertainment and announcements center to passengers.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
The Lavatory is a reserved place in the aircraft, which provides passengers with
some privacy. Usually it is located at aircraft rear section, and it is divided into
sink section and toilet section. The Lavatory has the same visual and aural
warnings that there are in Pax Cabin, and it still has smoke detectors.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
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The Fire Protection System provides fire and overheating indications to cockpit,
allowing crew to extinguish the fire. The system can detect fire or overheating
conditions at engines and APU, and it can detect smoke in lavatory and baggage
compartments.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
The Fire Extinguish System function is to discharge the fire extinguishing
agent, in Engines, APU and Baggage compartments, using extinguishing bottles.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
The Water and Waste System consists in providing portable water, and includes
components to storage and provide clean water. Although this water is not
adequated to drink, it can be used to passengers and crew personal hygiene.
The system allows the gathering and storage of human waste, to grant a clean
environment with no smell.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
In this chapter we are going to see some general materials, used during aircraft
manufacturing.
_________________________________________________________________
_________________________________________________________________
MATERIAL HANDBOOK
Bolt, Machine Double Hexagon Head,
Corrosion and Heat Resistant Steel

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Bolt, Machine Hexagon Head

Screw, Flat Head 130 Deg Countersunk

Screw, Machine Flat 100 Deg Head,


Short Thread, Offset Cruciform

Screw, Wood, Round Head, Steel and


Brass

Screw, Pan Head, Slotted, Cylindrical

Stud Nut

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Nut, Castellated, Hexagon

Nut, Castellated, Hexagon, Self Locking

Nut, Plain, Hexagon, Steel, Passivated

Nut, Plain, Hexagon, Drilled

Nut, Self Locking, Floating, Steel

Nut, Self Locking, Plate, Corner

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Rivet,
Blind,
Countersunk
Aluminum, Oversize

Head,

Rivet, Solid, Interference, Countersunk


Head 120 Deg, Briles

Rivet, Solid, Universal Head, Aluminum


and Titanium Alloy

Fastener, Blind, Internal Thread, 100


Deg Countersunk Head

Fastener, Blind, Shear Head, 130 Deg,


Titanium

Washer, Flat, Brass and Steel

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Washer, Internal Tooth, Bronze and


Brass

Washer, Lock, Spring, Steel and Nickel

Washer, Spring, Steel

Washer, Locking Lug

Ring, Retainer

Cotter Pin, Split

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Pin, Quick Release, Self-Retaining

Receptacle

EXERCISES
Part I: Translate and give a complete answer for the questions below.
01) You need to measure gap and steps in the doors installation. What
instruments would you use for that?
_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________

02) There are some solid rivets to be replaced in the fuselage. You will install
rivets with the same shape size but they are made with different material. What
tools will you use to perform this task?
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
_________________________________________________________________
03) You need to measure the skin thickness of a fuselage panel close to the edge.
What tool would you use for this?
_________________________________________________________________
_________________________________________________________________
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R:_______________________________________________________________
_________________________________________________________________
04) You have to drill a hole to install an interference fit fastener. What tools would
you use for this?
_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
05) You have to install screw in the floor panels. What tool would you use for
that?
_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
06) You need to measure a washer to verify if its dimension is correct. What tool
would you use to perform this task?
_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
07) There is a small region in the horizontal stabilizer that you need to check to
verify if its clean. What tool can you use to inspect this area?
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
_________________________________________________________________
08) In the windshield installation you have to install a lot of bolts. After installing
them you have to check if the torque is in the specified range. What tools would
you use to perform this task?
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
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_________________________________________________________________
09) Do you use pliers to perform what tasks?
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
10) You must to lift an airplane to perform main landing gear tests. How would
you lift the airplane to perform your task?
_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________

Part II: Translate and explain the meaning of the following Drawing
Notes

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01) Chemical conversion with alodine on aluminum.


_________________________________________________________________
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
02) Magnetic Particle Inspection Class < >.
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
03) Aerodynamic smoothness.
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
04) Cut, drill, and countersink Composite Material by CNC process.
_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________

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5) Laser mark and identify wires/ cables


_________________________________________________________________
R:_______________________________________________________________
_________________________________________________________________
6) General tolerances for sheet or extruded parts.
_________________________________________________________________
R:_______________________________________________________________
________________________________________________________________
7) Chamfer and deburr according documents.
_________________________________________________________________
R:______________________________________________________________
8) Install sleeve and nut.
_________________________________________________________________
R:_______________________________________________________________

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9) Handle and protect polished aluminum sheet.


_________________________________________________________________
R:_______________________________________________________________
10) Chemical conversion on aluminum.
_________________________________________________________________
R:_______________________________________________________________
11) Install solid rivets.
_________________________________________________________________
R:_______________________________________________________________
12) Install hi-lok rivets.
_________________________________________________________________
R:_______________________________________________________________
13) Install briles rivets.
_________________________________________________________________
R:_______________________________________________________________
14) Install fasteners.
_________________________________________________________________
R:_______________________________________________________________
15) Install nut.
_________________________________________________________________
R:_______________________________________________________________

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16) Chemical conversion with alodine on aluminum.


_________________________________________________________________
R:_______________________________________________________________

17) Joints are not all ved.


_________________________________________________________________
R:_______________________________________________________________

18) Bend tube.


_________________________________________________________________
R:_______________________________________________________________

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19) Mark and identify parts and assemblies.


_________________________________________________________________
R:_______________________________________________________________
20) Tolerances for primary parts and assembly.
_________________________________________________________________
R:_______________________________________________________________
21) All dimensions shown are real.
_________________________________________________________________
R:_______________________________________________________________
22) Clean aluminum for structural bonding.
_________________________________________________________________
R:_______________________________________________________________

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Part III: Understanding problems and solutions descriptions.


Instructions to do the exercises:
1. The following exercises are simulating Aeronautical non conformity processes;
2. Any values contained in here (measures, tolerances, gaps, etc) are not real;
3. It is totally forbidden to use any information contained in these exercises to
perform production activities, because they are simulated problems with
simulated answers;
4. You have to read and understand the problems characteristics, according to
teachers instructions;
5. The pictures in each exercise simulate a file that is attached to the document;
6. The Part Numbers and the Production Document Numbers are not real;
7. When requested to describe the problems or dispositions, the answer must be
in English.
8. When requested to explain the problems or dispositions, the answer must be in
Portuguese;
9. If you have any doubt or difficulty, ask the teacher for help.

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Exercise 01
The Seat Track PN 170-00000-001 has some problems of installation and a
chamfer out of specification. Answer the following questions:

a) Report the problems (English):


_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
b) Explain the meaning of the Engineering Disposition (Portuguese):
Remove material in excess. Perform missing chamfers on Seat Track according to
drawing and reestablish superficial part protection. All other conditions are
according to Drawing.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
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c) Explain the Manufacturing Engineering disposition (Portuguese):


It was issued OM12345678 to execute rework, according to Engineering
disposition. Quality Inspector must verify if the OM is closed, before the closing
the NP.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
d) Report that your work has already been finished (English):
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Exercise 02
The following Bin Support was manufactured with the length out of specification.
Consider the tolerance +/- 0,2mm for this exercise.

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a) Report the problem (English):


_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
b) Explain Supplier disposition (Portuguese):
Send the bin supports to Supplier for rework. Supplier will rework the support
according drawing 174-77777-400. Supplier has checked that the supports were
sent to Embraer different than requested in drawing.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
c) According to supplier disposition above, write a Process disposition to send the
support to Supplier (OM 23456789). The same support will be installed at aircraft
Serial Number 835, after the rework. (English).
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
d) Write a production disposition for removing the support. (English).
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
e) Write a production disposition for reinstalling the support. (English).
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

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Exercise 03
There is an undesired gap between Fuselage skin and Tooling, indicating that the
contour of the fuselage is out of the tolerance.

a) Report the problem. (English)


_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
b) Explain Engineering disposition: It is requested a Process evaluation regarding
the impacts on next assemblies. (Portuguese)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
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Exercise 04
The fitting bellow has a manufacturing problem, because the thickness is out of
specification.

a) Report the problem. (English)


_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
b) Request a new special part without holes, to replace the defective one.
(English)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Exercise 05
The Center Fuselage has a hole that must be perpendicular to skin surface, but
the hole angularity is out of specification.

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a) Report the problem, indicating exactly where the discrepant hole is. (English)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
b) Explain Engineering disposition:
Enlarge hole for 3/16" correcting angularity. (English)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

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Exercise 06
See the problem description bellow, and answer:
It was verified that the holes of Supports Part Number 179-88888-459 and 17988888-460 are dislocated from original assembly, not allowing the assembly of
Radio Altimeter Fairing. The Support A is dislocated about 2,5mm and the
support B is dislocated about 4,1mm from original position.

Partner disposition:
As checked on the aircraft, only the Bracket A is dislocated, the other one is
according to drawing. We request to manufacture one special Bracket PN 17988888-459 without holes, and install it according to drawing, sheet 2, view 1E4.
a) Does the partner disposition agree with the problem report? Why?
(Portuguese)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
b) Write a disposition to ask for manufacturing a special bracket without holes and
7,0mm larger than the normal part. (English):
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
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_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Exercise 07
Problem description:
It was verified that during the final positioning of Floor Panels (Baggage
Compartment), several holes did not coincide with existent holes at Fuselage
Structure.
a) Explain problem report. (Portuguese)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
b) Explain Manufacturing Engineering disposition: (Portuguese)
Suggestion: to manufacture 02 parts without all the holes called on drawing, and
install new parts through existent structure holes, drilling new holes for panels
floor fixation.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
c) After receiving the new parts, when you were installing them in the aircraft,
you made 2 holes in wrong positions. Write a production disposition for this
situation. (English)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Exercise 08
Problem description:
During Quality Gate, it was verified scratches in the hole fitting of Rear Fuselage,
and the holes are without coating protection.
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Supplier disposition:
Check if holes diameter are according to drawing. In case of holes into tolerance,
rework holes by reaming to eliminate the scratches, ensuring +/- 0.009mm
maximum of diameter increasing. Finish the holes surface according to drawing
specifications. Clean holes with MEK. // In case of holes out of specification,
report in addendum.

a) Explain the problem: (Portuguese)


_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
b) Explain supplier disposition. (Portuguese)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Exercise 09
Problem description:
During the installation of Wing to Fuselage Fairing, it was verified that the
Bracket PN 187-55555-364 is without the hole edge specified at drawing. Edge
diameter of the hole must be 5,0mm 2D+1, and obtained 8,5mm. And the hole
was not countersunk.
Engineering disposition:
Reported condition is structurally acceptable for the edge margin problem. For
the countersunk problem, manufacture washer from the head of rivets HST11,
and install it with sealant. Report the final conditions.
a) Explain the problem: (Portuguese)
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b) Explain Engineering disposition. (Portuguese)


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Exercise 10
Problem description:
The Fitting PN 149-256G9-203 is not with the proper corrosion and wear
protection. It is required Chromic Anodize, Primer and PU finishing.
a) Explain problem description. (Portuguese)
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b) Write your disposition by accepting this fitting, because it does not affects
airworthiness, and aircraft is liberated for production flights. (English)
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c) Write your disposition by rejecting this fitting, because it is important to have
coating protection, and the fitting must be reworked. (English)
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Exercise 11
Problem description:
During Quality Gate, it was verified one ferrament mark on the revestment of
Center Fuselage, between caves 84 and 85, near profile 24R. The bracket nearby
is without the chanfer specified at the drawing, and there are also two discrepant
holes: one hole with a risk inside and another hole out of circle.

a) Identify at the problem description, seven technical terms that are not correct.
(English)
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b) Rewrite the problem description using the correct technical terms. (English)
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Exercise 12
The measurements of this installation is not according to the Drawing 197-33633891.

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INGLS TCNICO
Manual de Treinamento

a) Report the problem. (English)


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b) Describe your disposition to solve the problem. (English)
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Exercise 13
Problem description:
It was verified during Waterproofing Test that occurred water leakage inside
Radome area. There are gaps and steps between Radome and Forward Fuselage.
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INGLS TCNICO
Manual de Treinamento

a) Explain the problem. (Portuguese)


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b) Manufacture Engineering disposition:
Suggestion: replace Radome from PN 1235480-102 to PN 12354080-106, repeat
leak test and if its ok, change the effectivity of the Radome, including PN
12354080-106 for aircraft 3765. For additional information this Radome has the
same features, improves its rubber seal and there is no adjustment to correct the
radome installation.
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Exercise 14
Problem description:
Detected oil leak in the Reverser Manual Actuator, right side Engine, and the
Manual Drive Assembly is not correctly installed.
a) Explain the problem. (Portuguese)
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INGLS TCNICO
Manual de Treinamento

b) Supplier disposition:
Replace the manual drive assembly. After every flight leakage, the assembly has
to be checked and hydraulic fluid reservoir has to be re-filled before every flight.
Clean the aircraft of leaked fluid to avoid potential damage prior to aircraft
delivery. If leakage increases, unit has to be replaced again and Supplier should
be notified.
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c) Explain supplier disposition. (Portuguese)
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Exercise 15
Problem description:
During Water and Waste system normal operation, it was verified that the
temperature values were out of specified limits, to energy of 115VAC 400Hz. The
final time specification is 15 minutes for target temperature is 40C to 50C, and
the values found was 23C.
a) Explain problem description. (Portuguese)
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Engineering disposition: Repeat Operational Test. The measurement must be
executed getting access to the water system service panel inside the aircraft and
using a thermocouple.
b) Explain engineering disposition. (Portuguese)
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Manual de Treinamento
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Engineering disposition: Repeat Operational Test. The measurement must be
executed getting access to the water system service panel inside the aircraft and
using a thermocouple.
b) Explain engineering disposition. (Portuguese)
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Exercise 16
The photo below shows a problem in the Center fuselage, between Frames 77 and
80, and Stringers 27 and 28.

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INGLS TCNICO
Manual de Treinamento

a) Report the problem. (English)


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b) Suggest a solution for the problem according to the following instructions:
Apply cold forming on plate edges; Sandpaper 600 grit; Polishing of the skin after
rework; Eddy-Current tests; Ultra-Sound tests; X-Ray tests.
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Exercise 17
Problem description:
Sealant is missing in the fasteners head. Forward Fuselage, Frames 09 and 10,
Stringer 26RH.

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Pg 89