AIR TRANSPORT INTERNATIONAL

DC-8 MAINTENANCE MANUAL

VOLUME 1

INTRO THRU ATA 26

This manual is the property of Air Transport International, Limited Liability Company. It is
issued for the use of Air Transport International, Limited Liability Company authorized
personnel.

Revision Number: 36

Issued: 04/06/11

All rights reserved, including the right to reproduce this publication. No part may be reproduced: stored in any retrieval
system: or transmitted in any part or form by any means electronic, photocopying, microfilm, microfiche, mechanical, or
otherwise, without prior written permission of Air Transport International, Limited Liability Company.
AIR TRANSPORT INTERNATIONAL

RECORD OF REVISIONS
TYPE MANUAL: ATI DC-8 Maintenance Manual

REVISION DATE INSERTED BY REVISION DATE INSERTED BY

NO. INSERTED NO. INSERTED
Complete
04/06/11 Publications
thru Rev. 36
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CONTROL PAGES

LOG OF REVISIONS
REV DATE REV DATE REV DATE REV DATE REV DATE
Orig 10-01-94 1 02-28-95 2 04-01-96 3 10-01-97 4 12-01-97
5 01-15-98 6 07-01-98 7 01-01-99 8 08-01-99 9 02-02-00
10 08-01-00 11 11-01-00 12 06-01-01 13 10-22-01 14 12-03-01
15 06-03-02 16 12-02-02 17 03-06-03 18 06-16-03 19 12-05-03
20 02-16-04 21 05-20-04 22 05-20-05 23 12-07-05 24 04-07-06
25 09-05-06 26 11-08-06 27 03-05-07 28 05-11-07 29 10-29-07
30 10-07-08 31 11-20-08 32 01-14-09 33 07-29-09 34 04-27-10
35 06-07-10 36 04-06-11

LIST OF EFFECTIVE PAGES

PAGE CONTROL PAGE CONTROL

NUMBER CHAPTER DATE NUMBER CHAPTER DATE
CONTROL PAGES 00 - Introduction
i 04-06-11 00-1 11-20-08
ii 06-07-10 00-2 07-29-09
iii 04-06-11 00-3 10-29-07
iv 04-06-11 00-4 07-29-09
v 04-06-11 00-5 04-27-10
vi 04-06-11 00-6 04-27-10
vii 04-06-11 00-7 04-27-10
viii 04-06-11 00-8 04-06-11
ix 04-06-11 00-9 04-27-10
x 04-06-11 00-10 04-27-10
xi 04-06-11 00-11 04-27-10
xii 04-06-11 00-12 04-27-10
xiii 04-06-11
xiv 04-06-11
xv 04-06-11
xvi 04-06-11
xvii 04-06-11
xviii 04-06-11
xix 04-06-11
xx 04-06-11
xxi 04-06-11
xxii 04-06-11
xxiii 04-06-11
xxiv 04-06-11
xxv 04-06-11
xxvi 04-06-11
xxvii 04-06-11
xxviii 04-06-11
xxix 04-06-11
xxx 04-06-11

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8 – Weighing
08-i 12-03-01
08-ii 12-03-01

08.01-i 10-29-07
08.01-ii 10-29-07

08.01.1 06-07-10
08.01.2 12-07-05
08.01.3 10-01-97
08.01.4 12-02-02
08.01.5 12-07-05
08.01.6 10-01-97
08.01.7 10-07-08
08.01.8 12-03-01
08.01.9 12-03-01
08.01.10 05-20-05
08.01.11 12-03-01
08.01.12 12-03-01
08.01.13 10-29-07
08.01.14 12-03-01
08.01.15 12-03-01
08.01.16 12-03-01
08.01.17 12-03-01
08.01.18 12-03-01
08.01.19 10-29-07
08.01.20 10-29-07
08.01.21 12-03-01
08.01.22 12-03-01
08.01.23 12-03-01
08.01.24 12-03-01

FAA APPROVED

Date

Curtis L. Weedman, Jr.

Principal Maintenance Inspector
FSDO, LIT

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9 – Ground Handling 11 – Placards (cont’d)

09-i 10-07-08 11.01.8 12-07-05
09-ii 10-07-08 11.01.9 12-07-05
11.01.10 12-07-05
09.01-i 12-03-01 11.01.11 12-07-05
09.01-ii 12-03-01 11.01.12 12-07-05
11.01.13 12-07-05
09.01.1 12-03-01 11.01.14 12-07-05
09.01.2 12-03-01 11.01.15 12-07-05
11.01.16 12-07-05
09.02-i 12-03-01 11.01.17 03-05-07
09.02-ii 12-03-01 11.01.18 12-07-05
11.01.19 12-07-05
09.02.1 12-03-01 11.01.20 12-07-05
09.02.2 12-03-01 11.01.21 12-07-05
09.02.3 12-03-01 11.01.22 10-07-08
09.02.4 12-03-01
11.02-i 10-07-08
09.03-i 12-03-01 11.02-ii 10-07-08
09.03-ii 12-03-01
11.02.1 10-29-07
09.03.1 12-03-01 11.02.2 10-29-07
09.03.2 12-03-01 11.02.3 10-07-08
11.02.4 10-07-08
09.04-i 12-03-01 11.02.5 10-07-08
09.04-ii 12-03-01 11.02.6 10-07-08

09.04.1 12-03-01 13 – Special Inspections

09.04.2 12-03-01 13-i 02-16-04
13-ii 02-16-04
09.05-i 10-07-08
09.05-ii 10-07-08 13.01-i 12-07-05
13.01-ii 12-07-05
09.05.1 10-07-08
09.05.2 10-07-08 13.01.1 12-05-03
13.01.2 12-05-03
11 – Placards 13.01.3 12-05-03
11-i 10-29-07 13.01.4 12-05-03
11-ii 10-29-07 13.01.5 12-05-03
13.01.6 12-05-03
11.01-i 10-07-08 13.01.7 12-07-05
11.01-ii 10-07-08 13.01.8 12-07-05
13.01.9 12-07-05
11.01.1 12-07-05
11.01.2 12-07-05
11.01.3 12-07-05
11.01.4 12-07-05
11.01.5 12-07-05
11.01.6 12-07-05
11.01.7 12-07-05

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13 – Special Inspections (cont’d) 15 – Limits (cont’d)

13.01.10 12-07-05 15.01.2 10-01-97
13.01.11 12-07-05 15.01.3 10-01-97
13.01.12 12-07-05 15.01.4 10-01-97
13.01.13 12-07-05
13.01.14 12-07-05 15.02-i 12-03-01
13.01.15 12-07-05 15.02-ii 12-03-01
13.01.16 12-07-05
13.01.17 12-05-03 15.02.1 10-01-97
13.01.18 12-05-03 15.02.2 04-06-11
13.01.19 12-05-03
13.01.20 12-05-03 15.03-i 12-03-01
15.03-ii 12-03-01
13.02-i 02-16-04
13.02-ii 02-16-04 15.03.1 10-01-97
15.03.2 10-01-97
13.02.1 02-16-04 15.03.3 10-01-97
13.02.2 02-16-04 15.03.4 07-01-98
13.02.3 02-16-04 15.03.5 10-01-97
13.02.4 02-16-04 15.03.6 10-01-97
13.02.5 04-27-10
13.02.6 04-27-10 15.04-i 12-07-05
13.02.7 04-27-10 15.04-ii 12-07-05
13.02.8 04-27-10
15.04.1 10-01-97
13.03.1 12-05-03 15.04.2 12-07-05
13.03.2 12-05-03 15.04.3 12-07-05
15.04.4 12-07-05
13.04-i 12-03-01
13.04-ii 12-03-01 16 – Periodic Checks
16-i 12-07-05
13.04.1 10-01-97 16-ii 12-07-05
13.04.2 10-01-97
13.04.3 10-01-97 16.01-i 12-03-01
13.04.4 10-01-97 16.01-ii 12-03-01
13.04.5 10-01-97
13.04.6 10-01-97 16.01.1 01-01-99
13.04.7 10-01-97 16.01.2 01-01-99
13.04.8 10-01-97 16.01.3 01-01-99
13.04.9 04-27-10 16.01.4 01-01-99
13.04.10 04-27-10

15 – Limits
15-i 12-03-01
15-ii 12-03-01

15.01-i 12-03-01
15.01-ii 12-03-01

15.01.1 10-01-97

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16 – Periodic Checks (cont’d) 16 – Periodic Checks (cont’d)

16.02-i 06-16-03 16.03.19 10-07-08
16.02-ii 06-16-03 16.03.20 10-07-08
16.03.21 06-16-03
16.02.1 10-07-08 16.03.22 06-16-03
16.02.2 10-07-08
16.02.3 04-06-11 16.04-i 12-03-01
16.02.4 04-06-11 16.04-ii 12-03-01
16.02.5 04-06-11
16.02.6 10-07-08 16.04.1 10-01-97
16.02.7 05-20-05 16.04.2 10-01-97
16.02.8 04-06-11
16.02.9 12-07-05 16.05-i 12-03-01
16.02.10 03-05-07 16.05-ii 12-03-01
16.02.11 10-07-08
16.02.12 06-07-10 16.05.1 12-02-02
16.02.13 12-07-05 16.05.2 12-02-02
16.02.14 05-20-05
16.02.15 04-06-11 16.06-i 12-03-01
16.02.16 04-27-10 16.06-ii 12-03-01
16.02.17 04-27-10
16.02.18 03-05-07 16.06.1 10-01-97
16.02.19 06-16-03 16.06.2 10-01-97
16.02.20 06-16-03
16.02.21 06-16-03 16.07-i 12-07-05
16.02.22 06-16-03 16.07-ii 12-07-05
16.02.23 06-16-03
16.02.24 06-16-03 16.07.1 12-07-05
16.07.2 12-07-05
16.03-i 06-16-03 16.07.3 12-07-05
16.03-ii 06-16-03 16.07.4 12-07-05
16.07.5 12-07-05
16.03.1 10-01-97 16.07.6 12-07-05
16.03.2 10-01-97 16.07.7 12-07-05
16.03.3 04-06-11 16.07.8 12-07-05
16.03.4 04-06-11 16.07.9 12-07-05
16.03.5 04-06-11 16.07.10 12-07-05
16.03.6 04-06-11
16.03.7 04-06-11
16.03.8 04-06-11
16.03.9 04-06-11
16.03.10 04-06-11
16.03.11 04-06-11
16.03.12 04-06-11
16.03.13 04-06-11
16.03.14 05-20-05
16.03.15 04-06-11
16.03.16 06-16-03
16.03.17 06-16-03
16.03.18 10-07-08

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16 – Periodic Checks (cont’d) 16 – Periodic Checks (cont’d)

16.07.11 12-07-05 16.07.60 12-07-05
16.07.12 12-07-05 16.07.61 12-07-05
16.07.13 12-07-05 16.07.62 12-07-05
16.07.14 12-07-05 16.07.63 12-07-05
16.07.15 12-07-05 16.07.64 12-07-05
16.07.16 12-07-05 16.07.65 12-07-05
16.07.17 12-07-05 16.07.66 12-07-05
16.07.18 12-07-05 16.07.67 12-07-05
16.07.19 12-07-05 16.07.68 12-07-05
16.07.20 12-07-05 16.07.69 12-07-05
16.07.21 12-07-05 16.07.70 12-07-05
16.07.22 12-07-05 16.07.71 12-07-05
16.07.23 12-07-05 16.07.72 12-07-05
16.07.24 12-07-05 16.07.73 12-07-05
16.07.25 12-07-05 16.07.74 12-07-05
16.07.26 12-07-05
16.07.27 12-07-05 16.08-i 12-07-05
16.07.28 12-07-05 16.08-ii 12-07-05
16.07.29 12-07-05
16.07.30 12-07-05 16.08.1 12-07-05
16.07.31 12-07-05 16.08.2 12-07-05
16.07.32 12-07-05 16.08.3 12-07-05
16.07.33 12-07-05 16.08.4 12-07-05
16.07.34 12-07-05
16.07.35 12-07-05 16.09-i 04-07-06
16.07.36 12-07-05 16.09-ii 04-07-06
16.07.37 12-07-05
16.07.38 12-07-05 16.09.1 04-07-06
16.07.39 12-07-05 16.09.2 10-07-08
16.07.40 12-07-05 16.09.3 09-05-06
16.07.41 12-07-05 16.09.4 09-05-06
16.07.42 12-07-05 16.09.5 04-27-10
16.07.43 12-07-05 16.09.6 04-27-10
16.07.44 12-07-05 16.09.7 04-27-10
16.07.45 12-07-05 16.09.8 04-27-10
16.07.46 12-07-05 16.09.9 04-27-10
16.07.47 12-07-05 16.09.10 04-27-10
16.07.48 12-07-05
16.07.49 12-07-05
16.07.50 12-07-05
16.07.51 12-07-05
16.07.52 12-07-05
16.07.53 12-07-05
16.07.54 12-07-05
16.07.55 12-07-05
16.07.56 12-07-05
16.07.57 12-07-05
16.07.58 12-07-05
16.07.59 12-07-05

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21 – Air Conditioning 21 – Air Conditioning (cont’d)

21-i 10-07-08 21.02.36 06-01-01
21-ii 10-07-08 21.02.37 06-01-01
21.02.38 06-01-01
21.01-i 11-20-08 21.02.39 06-01-01
21.01-ii 11-20-08 21.02.40 06-01-01
21.02.41 06-01-01
21.01.1 10-07-08 21.02.42 06-01-01
21.01.2 10-07-08 21.02.43 06-01-01
21.01.3 10-07-08 21.02.44 06-01-01
21.01.4 10-07-08 21.02.45 06-01-01
21.02.46 06-01-01
21.02-i 12-03-01 21.02.47 06-01-01
21.02-ii 12-03-01 21.02.48 06-01-01
21.02.49 06-01-01
21.02.1 02-02-00 21.02.50 06-01-01
21.02.2 02-02-00 21.02.51 06-16-03
21.02.3 06-01-01 21.02.52 06-01-01
21.02.4 02-02-00 21.02.53 06-16-03
21.02.5 02-02-00 21.02.54 06-01-01
21.02.6 06-01-01
21.02.7 06-01-01
21.02.8 06-01-01
21.02.9 06-01-01
21.02.10 06-01-01
21.02.11 06-01-01
21.02.12 06-01-01
21.02.13 06-01-01
21.02.14 02-02-00
21.02.15 02-02-00
21.02.16 02-02-00
21.02.17 06-01-01
21.02.18 06-01-01
21.02.19 02-02-00
21.02.20 02-02-00
21.02.21 02-02-00
21.02.22 02-02-00
21.02.23 06-01-01
21.02.24 02-02-00
21.02.25 02-02-00
21.02.26 12-03-01
21.02.27 06-01-01
21.02.28 06-01-01
21.02.29 02-02-00
21.02.30 02-02-00
21.02.31 02-02-00
21.02.32 02-02-00
21.02.33 02-02-00
21.02.34 02-02-00
21.02.35 06-01-01

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21 – Air Conditioning (cont’d) 21 – Air Conditioning (cont’d)

21.03-i 04-07-06 21.04.41 06-01-01
21.03-ii 04-07-06 21.04.42 06-01-01
21.04.43 06-01-01
21.03.1 04-07-06 21.04.44 06-01-01
21.03.2 04-07-06 21.04.45 06-01-01
21.04.46 06-01-01
21.04-i 12-03-01 21.04.47 06-01-01
21.04-ii 12-03-01 21.04.48 06-01-01
21.04.49 06-01-01
21.04.1 06-01-01 21.04.50 06-01-01
21.04.2 06-01-01 21.04.51 06-01-01
21.04.3 06-01-01 21.04.52 06-01-01
21.04.4 06-01-01 21.04.53 06-01-01
21.04.5 06-01-01 21.04.54 06-01-01
21.04.6 06-01-01 21.04.55 06-01-01
21.04.7 06-01-01 21.04.56 06-01-01
21.04.8 06-01-01 21.04.57 06-01-01
21.04.9 06-01-01 21.04.58 06-01-01
21.04.10 06-01-01 21.04.59 10-22-01
21.04.11 06-01-01 21.04.60 10-22-01
21.04.12 06-01-01
21.04.13 06-01-01 21.05-i 06-03-02
21.04.14 06-01-01 21.05-ii 06-03-02
21.04.15 06-01-01
21.04.16 06-01-01 21.05.1 06-03-02
21.04.17 06-01-01 21.05.2 06-03-02
21.04.18 10-22-01 21.05.3 06-03-02
21.04.19 06-01-01 21.05.4 06-03-02
21.04.20 06-01-01 21.05.5 06-03-02
21.04.21 10-22-01 21.05.6 06-03-02
21.04.22 06-01-01
21.04.23 06-01-01 24 – Electrical Power
21.04.24 06-01-01 24.i 12-03-01
21.04.25 06-01-01 24.ii 12-03-01
21.04.26 06-01-01
21.04.27 06-01-01 24.01-i 12-03-01
21.04.28 06-01-01 24.01-ii 12-03-01
21.04.29 06-01-01
21.04.30 12-03-01 24.01.1 09-05-06
21.04.31 12-03-01 24.01.2 09-05-06
21.04.32 12-03-01 24.01.3 02-02-00
21.04.33 06-01-01 24.01.4 02-02-00
21.04.34 06-01-01
21.04.35 06-01-01
21.04.36 06-01-01
21.04.37 06-01-01
21.04.38 06-01-01
21.04.39 06-01-01
21.04.40 06-01-01

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25 – Equipment & Furnishings 25 – Equipment & Furnishings (cont’d)

25-i 06-07-10 25.04.28 11-08-06
25-ii 06-07-10 25.04.29 11-08-06
25.04.30 11-08-06
25.01-i 10-29-07 25.04.31 11-08-06
25.01-ii 10-29-07 25.04.32 11-08-06
25.04.33 11-08-06
25.01.1 10-29-07 25.04.34 11-08-06
25.01.2 10-29-07 25.04.35 11-08-06
25.01.3 05-20-05 25.04.36 11-08-06
25.01.4 04-06-11 25.04.37 11-08-06
21.01.5 10-29-07 25.04.38 11-08-06
21.01.6 12-02-02 25.04.39 07-29-09
25.04.40 11-08-06
25.02.1 10-29-07 25.04.41 11-08-06
25.02.2 10-29-07 25.04.42 11-08-06
25.04.43 11-08-06
25.03.1 10-29-07 25.04.44 11-08-06
25.03.2 10-29-07 25.04.45 11-08-06
25.04.46 11-08-06
25.04-i 11-08-06 25.04.47 11-08-06
25.04-ii 11-08-06 25.04.48 11-08-06
25.04.49 11-08-06
25.04.1 11-08-06 25.04.50 11-08-06
25.04.2 11-08-06 25.04.51 11-08-06
25.04.3 11-08-06 25.04.52 11-08-06
25.04.4 11-08-06 25.04.53 11-08-06
25.04.5 11-08-06 25.04.54 11-08-06
25.04.6 11-08-06 25.04.55 11-08-06
25.04.7 11-08-06 25.04.56 11-08-06
25.04.8 11-08-06 25.04.57 11-08-06
25.04.9 11-08-06 25.04.58 11-08-06
25.04.10 11-08-06 25.04.59 11-08-06
25.04.11 11-08-06 25.04.60 11-08-06
25.04.12 11-08-06 25.04.61 11-08-06
25.04.13 11-08-06 25.04.62 11-08-06
25.04.14 11-08-06 25.04.63 11-08-06
25.04.15 11-08-06 25.04.64 11-08-06
25.04.16 11-08-06 25.04.65 11-08-06
25.04.17 11-08-06 25.04.66 11-08-06
25.04.18 11-08-06
25.04.19 11-08-06
25.04.20 11-08-06
25.04.21 11-08-06
25.04.22 11-08-06
25.04.23 11-08-06
25.04.24 11-08-06
25.04.25 11-08-06
25.04.26 11-08-06
25.04.27 11-08-06

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25 – Equipment & Furnishings (cont’d) 25 – Equipment & Furnishings (cont’d)

25.04.67 11-08-06 25.07.4 09-05-06
25.04.68 11-08-06 25.07.5 01-01-99
25.04.69 11-08-06 25.07.6 01-01-99
25.04.70 11-08-06
25.04.71 11-08-06 25.08-i 12-03-01
25.04.72 11-08-06 25.08-ii 12-03-01
25.04.73 11-08-06
25.04.74 11-08-06 25.08.1 04-07-06
25.04.75 11-08-06 25.08.2 04-07-06
25.04.76 11-08-06
25.09-i 05-20-04
25.05-i 12-07-05 25.09-ii 05-20-04
25.05-ii 12-07-05
25.09.1 05-20-04
25.05.1 10-29-07 25.09.2 05-20-04
25.05.2 10-29-07
25.05.3 10-29-07 25.10-i 12-03-01
25.05.4 10-29-07 25.10-ii 12-03-01
25.05.5 10-29-07
25.05.6 10-29-07 25.10.1 11-01-00
25.05.7 09-05-06 25.10.2 11-01-00
25.05.8 09-05-06
25.05.9 12-07-05 25.11-i 12-03-01
25.05.10 12-07-05 25.11-ii 12-03-01
25.05.11 12-07-05
25.05.12 12-07-05 25.11.1 06-01-01
25.11.2 11-01-00
25.06-i 10-07-08
25.06-ii 10-07-08 25.12-i 06-16-03
25.12-ii 06-16-03
25.06.1 10-07-08
25.06.2 10-07-08 25.12.1 05-20-05
25.06.3 10-07-08 25.12.2 06-16-03
25.06.4 10-07-08 25.12.3 06-16-03
25.06.5 10-07-08 25.12.4 06-16-03
25.06.6 10-07-08 25.12.5 06-16-03
25.06.7 10-07-08 25.12.6 06-16-03
25.06.8 10-07-08
25.06.9 10-07-08
25.06.10 10-07-08
25.06.11 10-07-08
25.06.12 10-07-08

25.07-i 12-03-01
25.07-ii 12-03-01

25.07.1 01-01-99
25.07.2 05-20-05
25.07.3 01-01-99

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25 – Equipment & Furnishings (cont’d) 26 – Fire Protection (cont’d)

25.12.7 06-16-03 26.02.1 12-07-05
25.12.8 06-16-03 26.02.2 12-07-05
25.12.9 06-16-03
25.12.10 06-16-03 26.03-i 12-03-01
25.12.11 06-16-03 26.03-ii 12-03-01
25.12.12 06-16-03
25.12.13 06-16-03 26.03.1 12-01-97
25.12.14 06-16-03 26.03.2 12-01-97
26.03.3 12-01-97
25.13-i 12-05-03 26.03.4 12-01-97
25.13-ii 12-05-03 26.03.5 12-01-97
26.03.6 12-01-97
25.13.1 12-05-03 26.03.7 12-01-97
25.13.2 12-05-03 26.03.8 12-01-97
25.13.3 12-05-03 26.03.9 12-01-97
25.13.4 12-05-03 26.03.10 12-01-97
25.13.5 12-05-03
25.13.6 12-05-03 26.04-i 06-16-03
25.13.7 12-05-03 26.04-ii 06-16-03
25.13.8 12-05-03
25.13.9 12-05-03 26.04.1 06-16-03
25.13.10 12-05-03 26.04.2 06-16-03
25.13.11 12-05-03
25.13.12 12-05-03
25.13.13 12-05-03
25.13.14 12-05-03

25.14.1 06-07-10
25.14.2 06-07-10

25.15-i 12-07-05
25.15-ii 12-07-05

25.15.1 12-07-05
25.15.2 12-07-05

25.16-i 09-05-06
25.16-ii 09-05-06

25.16.1 09-05-06
25.16.2 09-05-06

26 – Fire Protection
26-i 12-07-05
26-ii 12-07-05

26.01.1 12-07-05
26.01.2 12-07-05

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26 – Fire Protection (cont’d) 26 – Fire Protection (cont’d)

26.05-i 12-02-02 26.05.45 12-02-02
26.05-ii 12-02-02 26.05.46 12-02-02
26.05-iii 12-07-05
26.05-iv 12-07-05 26.05.47 12-02-02
26.05.48 12-02-02
26.05.1 12-07-05 26.05.49 12-02-02
26.05.2 12-07-05 26.05.50 12-02-02
26.05.3 12-02-02 26.05.51 12-02-02
26.05.4 12-02-02 26.05.52 12-02-02
26.05.5 12-07-05 26.05.53 12-02-02
26.05.6 10-22-01 26.05.54 12-02-02
26.05.7 12-02-02 26.05.55 12-02-02
26.05.8 12-02-02 26.05.56 12-02-02
26.05.9 12-02-02 26.05.57 12-02-02
26.05.10 12-02-02 26.05.58 12-02-02
26.05.11 12-02-02 26.05.59 12-02-02
26.05.12 12-07-05 26.05.60 12-02-02
26.05.13 12-02-02 26.05.61 12-02-02
26.05.14 12-02-02 26.05.62 12-02-02
26.05.15 12-07-05 26.05.63 12-02-02
26.05.16 12-07-05 26.05.64 12-02-02
26.05.17 12-02-02 26.05.65 12-02-02
26.05.18 12-02-02 26.05.66 12-02-02
26.05.19 12-02-02 26.05.67 12-02-02
26.05.20 12-02-02 26.05.68 12-02-02
26.05.21 12-02-02 26.05.69 12-02-02
26.05.22 12-02-02 26.05.70 12-02-02
26.05.23 12-02-02 26.05.71 12-02-02
26.05.24 12-02-02 26.05.72 12-02-02
26.05.25 12-02-02 26.05.73 12-02-02
26.05.26 12-02-02 26.05.74 12-02-02
26.05.27 12-02-02 26.05.75 12-02-02
26.05.28 12-07-05 26.05.76 12-02-02
26.05.29 12-07-05 26.05.77 12-02-02
26.05.30 12-02-02 26.05.78 12-02-02
26.05.31 12-02-02 26.05.79 12-02-02
26.05.32 12-02-02 26.05.80 12-02-02
26.05.33 12-02-02 26.05.81 10-29-07
26.05.34 12-02-02 26.05.82 12-02-02
26.05.35 12-02-02 26.05.83 12-02-02
26.05.36 12-07-05 26.05.84 12-02-02
26.05.37 12-02-02
26.05.38 12-02-02
26.05.39 12-02-02
26.05.40 12-02-02
26.05.41 12-02-02
26.05.42 12-02-02
26.05.43 12-02-02
26.05.44 12-02-02

xii 04-06-11 Revision 36

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26 – Fire Protection (cont’d) 27 – Flight Controls (cont’d)

26.05.85 12-07-05 27.03.2 12-03-01
26.05.86 12-07-05 27.03.3 08-01-00
26.05.87 12-02-02 27.03.4 12-03-01
26.05.88 12-02-02 27.03.5 08-01-00
26.05.89 12-07-05 27.03.6 12-03-01
26.05.90 12-07-05 27.03.7 08-01-00
26.05.91 12-02-02 27.03.8 12-03-01
26.05.92 12-07-05
27.04-i 04-27-10
26.06-i 12-02-02 27.04-ii 04-27-10
26.06-ii 12-02-02
27.04.1 04-27-10
26.06.1 07-29-09 27.04.2 04-27-10
26.06.2 07-29-09 27.04.3 04-27-10
26.06.3 07-29-09 27.04.4 04-27-10
26.06.4 07-29-09 27.04.5 04-27-10
26.06.5 07-29-09 27.04.6 04-27-10
26.06.6 07-29-09 27.04.7 04-27-10
26.06.7 07-29-09 27.04.8 04-27-10
26.06.8 07-29-09 27.04.9 04-27-10
26.06.9 07-29-09 27.04.10 04-27-10
26.06.10 07-29-09 27.04.11 04-27-10
27.04.12 04-27-10
27 – Flight Controls 27.04.13 04-27-10
27-i 04-27-10 27.04.14 04-27-10
27-ii 04-27-10 27.04.15 04-27-10
27.04.16 04-27-10
27.01-i 12-05-03 27.04.17 04-27-10
27.01-ii 12-05-03 27.04.18 04-27-10

27.01.1 12-05-03 28 – Fuel

27.01.2 12-05-03 28-i 04-27-10
27.01.3 12-05-03 28-ii 04-27-10
27.01.4 12-05-03
28.01-i 04-06-11
27.02-i 12-03-01 28.01-ii 04-06-11
27.02-ii 12-03-01
28.01.1 11-20-08
27.02.1 12-01-97 28.01.2 04-27-10
27.02.2 12-01-97 28.01.3 04-06-11
27.02.3 12-01-97 28.01.4 04-06-11
27.02.4 12-01-97 28.01.5 11-20-08
27.02.5 12-01-97 28.01.6 11-20-08
27.02.6 12-01-97 28.01.7 04-06-11
28.01.8 04-06-11
27.03-i 12-03-01 28.01.9 11-20-08
27.03-ii 12-03-01 28.01.10 11-20-08
28.01.11 04-27-10
27.03.1 08-01-00 28.01.12 04-27-10

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28 – Fuel (cont’d) 29 – Hydraulics (cont’d)

28.01.13 11-20-08 29.04-i 05-20-05
28.01.14 11-20-08 29.04-ii 05-20-05
28.01.15 04-27-10
28.01.16 04-27-10 29.04.1 05-20-05
28.01.17 04-27-10 29.04.2 05-20-05
28.01.18 04-27-10
28.01.19 11-20-08 31 – Instruments
28.01.20 04-06-11 31-i 03-05-07
31-ii 03-05-07
28.02-i 04-27-10
28.02-ii 04-27-10 31.01-i 12-03-01
31.01-ii 12-03-01
28.02.1 04-06-11
28.02.2 04-06-11 31.01.1 12-01-97
28.02.3 04-06-11 31.01.2 12-01-97
28.02.4 04-06-11
28.02.5 04-06-11 31.02-i 05-20-04
28.02.6 04-06-11 31.02-ii 05-20-04

29 – Hydraulics 31.02.1 02-16-04

29-i 05-20-05 31.02.2 07-29-09
29-ii 05-20-05 31.02.3 07-29-09
31.02.4 02-16-04
29.01-i 12-03-01 31.02.5 02-16-04
29.01-ii 12-03-01 31.02.6 02-16-04
31.02.7 02-16-04
29.01.1 12-03-01 31.02.8 02-16-04
29.01.2 12-01-97 31.02.9 02-16-04
29.01.3 01-15-98 31.02.10 02-16-04
29.01.4 12-03-01 31.02.11 05-20-04
29.01.5 12-01-97 31.02.12 05-20-04
29.01.6 12-01-97 31.02.13 02-16-04
29.01.7 01-15-98 31.02.14 02-16-04
29.01.8 12-03-01 31.02.15 02-16-04
31.02.16 02-16-04
29.02-i 12-03-01 31.02.17 02-16-04
29.02-ii 12-03-01 31.02.18 02-16-04
31.02.19 02-16-04
29.02.1 12-01-97 31.02.20 02-16-04
29.02.2 12-01-97 31.02.21 02-16-04
31.02.22 02-16-04
29.03-i 12-03-01 31.02.23 02-16-04
29.03-ii 12-03-01 31.02.24 02-16-04
31.02.25 02-16-04
29.03.1 12-01-97 31.02.26 02-16-04
29.03.2 12-01-97 31.02.27 02-16-04
29.03.3 12-01-97 31.02.28 02-16-04
29.03.4 12-01-97 31.02.29 02-16-04
31.02.30 02-16-04

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31 – Instruments (cont’d) 31 – Instruments (cont’d)

31.02.31 02-16-04 31.05.4 11-01-00
31.02.32 02-16-04 31.05.5 11-01-00
31.02.33 02-16-04 31.05.6 11-01-00
31.02.34 02-16-04
31.02.35 02-16-04 31.06-i 03-05-07
31.02.36 02-16-04 31.06-ii 03-05-07
31.02.37 02-16-04
31.02.38 02-16-04 31.06.1 07-29-09
31.02.39 02-16-04 31.06.2 03-05-07
31.02.40 02-16-04 31.06.3 03-05-07
31.02.41 02-16-04 31.06.4 03-05-07
31.02.42 02-16-04 31.06.5 03-05-07
31.02.43 05-20-05 31.06.6 03-05-07
31.02.44 05-20-05 31.06.7 03-05-07
31.02.45 05-20-05 31.06.8 03-05-07
31.02.46 05-20-05 31.06.9 03-05-07
31.02.47 05-20-05 31.06.10 03-05-07
31.02.48 05-20-05 31.06.11 03-05-07
31.02.49 05-20-05 31.06.12 03-05-07
31.02.50 05-20-05
31.02.51 05-20-05 32 – Landing Gear
31.02.52 05-20-05 32-i 04-27-10
31.02.53 05-20-05 32-ii 04-27-10
31.02.54 05-20-05
32.01-I 12-03-01
31.03-i 12-03-01 32.01-ii 12-03-01
31.03-ii 12-03-01
32.01.1 12-01-97
31.03.1 06-01-01 32.01.2 12-01-97
31.03.2 05-20-04
32.02-i 04-27-10
31.04-i 06-03-02 32.02-ii 04-27-10
31.04-ii 12-03-01
32.02.1 04-27-10
31.04.1 06-03-02 32.02.2 04-27-10
31.04.2 06-01-01 32.02.3 04-27-10
31.04.3 06-01-01 32.02.4 04-27-10
31.04.4 05-20-04
31.04.5 05-20-04 33 – Lightning
31.04.6 10-22-01 33-i 06-03-02
31.04.7 06-01-01 33-ii 06-03-02
31.04.8 06-01-01
33.01-i 06-03-02
31.05-i 12-03-01 33.01-ii 06-03-02
31.05-ii 12-03-01
33.01.1 06-16-03
31.05.1 11-01-00 33.01.2 06-03-02
31.05.2 11-01-00 33.01.3 06-03-02
31.05.3 11-01-00 33.01.4 06-03-02

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33 – Lightning (cont’d) 34 – Navigation (cont’d)

33.01.5 06-03-02 34.01.14 06-03-02
33.01.6 05-20-04 34.01.15 06-03-02
34.01.16 06-03-02
33.02-i 12-03-01 34.01.17 06-03-02
33.02-ii 12-03-01 34.01.18 12-02-02
34.01.19 06-03-02
33.02.1 12-07-05 34.01.20 12-02-02
33.02.2 02-02-00 34.01.21 12-02-02
33.02.3 12-07-05 34.01.22 12-02-02
33.02.4 11-01-00 34.01.23 12-02-02
33.02.5 11-01-00 34.01.24 12-02-02
33.02.6 11-01-00 34.01.25 12-02-02
33.02.7 02-02-00 34.01.26 06-03-02
33.02.8 02-02-00 34.01.27 12-02-02
33.02.9 11-01-00 34.01.28 06-03-02
33.02.10 02-02-00 34.01.29 12-02-02
34.01.30 12-02-02
33.03-i 12-03-01 34.01.31 12-02-02
33.03-ii 12-03-01 34.01.32 12-02-02
34.01.33 12-02-02
33.03.1 10-22-01 34.01.34 12-02-02
33.03.2 11-01-00 34.01.35 12-02-02
34.01.36 12-02-02
33.04-i 06-03-02 34.01.37 12-02-02
33.04-ii 06-03-02 34.01.38 12-02-02
34.01.39 12-02-02
33.04.1 06-03-02 34.01.40 12-02-02
33.04.2 06-03-02 34.01.41 12-02-02
34.01.42 12-02-02
34 – Navigation 34.01.43 12-02-02
34-i 09-05-06 34.01.44 12-02-02
34-ii 09-05-06 34.01.45 12-02-02
34.01.46 12-02-02
34.01-i 12-02-02 34.01.47 12-02-02
34.01-ii 12-02-02 34.01.48 12-02-02
34.01.49 12-02-02
34.01.1 06-16-03 34.01.50 12-02-02
34.01.2 06-16-03 34.01.51 12-02-02
34.01.3 06-16-03 34.01.52 12-02-02
34.01.4 06-16-03 34.01.53 12-02-02
34.01.5 06-16-03 34.01.54 11-20-08
34.01.6 12-02-02 34.01.55 12-02-02
34.01.7 12-02-02 34.01.56 06-16-03
34.01.8 12-02-02 34.01.57 12-02-02
34.01.9 06-03-02 34.01.58 12-02-02
34.01.10 06-03-02
34.01.11 06-03-02 34.02-i 05-11-07
34.01.12 06-03-02 34.02-ii 05-11-07
34.01.13 06-03-02

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34 – Navigation (cont’d) 34 – Navigation (cont’d)

34.02.1 10-29-07 34.06.3 01-15-98
34.02.2 10-29-07 34.06.4 06-01-01
34.02.3 10-29-07 34.06.5 06-01-01
34.02.4 05-11-07 34.06.6 01-15-98
34.02.5 10-29-07 34.06.7 01-15-98
34.02.6 10-29-07 34.06.8 01-15-98
34.06.9 01-15-98
34.03-i 12-03-01 34.06.10 06-01-01
34.03-ii 12-03-01 34.06.11 01-15-98
34.06.12 01-15-98
34.03.1 01-15-98 34.06.13 01-15-98
34.03.2 01-15-98 34.06.14 01-15-98
34.03.3 01-15-98
34.03.4 01-15-98 34.07-i 12-03-01
34.03.5 01-15-98 34.07-ii 12-03-01
34.03.6 01-15-98
34.07.1 06-16-03
34.04.1 09-05-06 34.07.2 06-16-03
34.04.2 09-05-06 34.07.3 08-01-99
34.07.4 06-16-03
34.05-i 12-02-02 34.07.5 08-01-99
34.05-ii 12-02-02 34.07.6 06-16-03
34.07.7 08-01-99
34.05.1 01-15-98 34.07.8 01-15-98
34.05.2 01-15-98
34.05.3 09-05-06 34.08-i 12-07-05
34.05.4 05-11-07 34.08-ii 12-07-05
34.05.5 01-15-98
34.05.6 01-15-98 34.08.1 12-05-03
34.05.7 01-15-98 34.08.2 06-16-03
34.05.8 01-15-98 34.08.3 06-16-03
34.05.9 01-15-98 34.08.4 06-16-03
34.05.10 01-15-98 34.08.5 12-05-03
34.05.11 01-15-98 34.08.6 06-16-03
34.05.12 01-15-98 34.08.7 06-16-03
34.05.13 01-15-98 34.08.8 06-16-03
34.05.14 01-15-98 34.08.9 06-16-03
34.05.15 01-15-98 34.08.10 06-16-03
34.05.16 01-15-98 34.08.11 06-16-03
34.05.17 01-15-98 34.08.12 06-16-03
34.05.18 01-15-98 34.08.13 12-05-03
34.05.19 12-02-02 34.08.14 06-16-03
34.05.20 12-02-02

34.06-i 12-03-01
34.06-ii 12-03-01

34.06.1 01-15-98
34.06.2 01-15-98

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34 – Navigation (cont’d) 34 – Navigation (cont’d)

34.08.15 06-16-03 34.08.64 04-06-11
34.08.16 06-16-03 34.08.65 04-06-11
34.08.17 03-05-07 34.08.66 04-06-11
34.08.18 03-05-07 34.08.67 10-07-08
34.08.19 06-16-03 34.08.68 12-05-03
34.08.20 06-16-03 34.08.69 12-05-03
34.08.21 06-16-03 34.08.70 12-05-03
34.08.22 06-16-03
34.08.23 06-16-03 34.09.1 09-05-06
34.08.24 06-16-03 34.09.2 09-05-06
34.08.25 06-16-03
34.08.26 06-16-03 34.10-i 12-03-01
34.08.27 06-16-03 34.10-ii 12-03-01
34.08.28 06-16-03
34.08.29 06-16-03 34.10.1 11-01-00
34.08.30 06-16-03 34.10.2 11-01-00
34.08.31 02-16-04 34.10.3 11-01-00
34.08.32 06-16-03 34.10.4 11-01-00
34.08.33 12-05-03
34.08.34 06-16-03 34.11-i 05-11-07
34.08.35 06-16-03 34.11-ii 05-11-07
34.08.36 06-16-03 34.11-iii 05-11-07
34.08.37 06-16-03 34.11-iv 05-11-07
34.08.38 06-16-03
34.08.39 06-16-03 34.11.1 09-05-06
34.08.40 06-16-03 34.11.2 11-01-00
34.08.41 06-16-03 34.11.3 09-05-06
34.08.42 06-16-03 34.11.4 11-01-00
34.08.43 06-16-03 34.11.5 11-01-00
34.08.44 06-16-03 34.11.6 11-01-00
34.08.45 06-16-03 34.11.7 11-01-00
34.08.46 06-16-03 34.11.8 11-01-00
34.08.47 06-16-03 34.11.9 11-01-00
34.08.48 06-16-03 34.11.10 11-01-00
34.08.49 06-16-03 34.11.11 11-01-00
34.08.50 06-16-03 34.11.12 11-01-00
34.08.51 06-16-03 34.11.13 11-01-00
34.08.52 06-16-03 34.11.14 03-05-07
34.08.53 06-16-03 34.11.15 11-01-00
34.08.54 06-16-03 34.11.16 11-01-00
34.08.55 06-16-03
34.08.56 06-16-03
34.08.57 06-16-03
34.08.58 06-16-03
34.08.59 06-16-03
34.08.60 06-16-03
34.08.61 06-16-03
34.08.62 05-11-07
34.08.63 04-06-11

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34 – Navigation (cont’d) 34 – Navigation (cont’d)

34.11.17 11-01-00 34.12.8 03-05-07
34.11.18 11-01-00 34.12.9 03-05-07
34.11.19 11-01-00 34.12.10 03-05-07
34.11.20 11-01-00 34.12.11 03-05-07
34.11.21 11-01-00 34.12.12 03-05-07
34.11.22 11-01-00 34.12.13 03-05-07
34.11.23 11-01-00 34.12.14 03-05-07
34.11.24 11-01-00 34.12.15 03-05-07
34.11.25 11-01-00 34.12.16 03-05-07
34.11.26 11-01-00 34.12.17 03-05-07
34.11.27 11-01-00 34.12.18 03-05-07
34.11.28 03-05-07 34.12.19 03-05-07
34.11.29 03-05-07 34.12.20 03-05-07
34.11.30 03-05-07 34.12.21 03-05-07
34.11.31 11-01-00 34.12.22 03-05-07
34.11.32 11-01-00 34.12.23 03-05-07
34.11.33 11-01-00 34.12.24 03-05-07
34.11.34 11-01-00 34.12.25 03-05-07
34.11.35 11-01-00 34.12.26 03-05-07
34.11.36 11-01-00 34.12.27 03-05-07
34.11.37 11-01-00 34.12.28 03-05-07
34.11.38 11-01-00 34.12.29 03-05-07
34.11.39 11-01-00 34.12.30 03-05-07
34.11.40 11-01-00 34.12.31 03-05-07
34.11.41 05-11-07 34.12.32 03-05-07
34.11.42 05-11-07 34.12.33 03-05-07
34.11.43 05-11-07 34.12.34 03-05-07
34.11.44 05-11-07 34.12.35 03-05-07
34.11.45 05-11-07 34.12.36 03-05-07
34.11.46 05-11-07 34.12.37 03-05-07
34.11.47 05-11-07 34.12.38 03-05-07
34.11.48 05-11-07 34.12.39 03-05-07
34.11.49 10-29-07 34.12.40 03-05-07
34.11.50 10-29-07 34.12.41 03-05-07
34.11.51 04-07-06 34.12.42 03-05-07
34.11.52 04-07-06 34.12.43 03-05-07
34.11.53 03-05-07 34.12.44 03-05-07
34.11.54 03-05-07 34.12.45 03-05-07
34.12.46 03-05-07
34.12-i 03-05-07 34.12.47 03-05-07
34.12-ii 03-05-07 34.12.48 03-05-07

34.12.1 03-05-07
34.12.2 03-05-07
34.12.3 03-05-07
34.12.4 03-05-07
34.12.5 03-05-07
34.12.6 03-05-07
34.12.7 03-05-07

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34 – Navigation (cont’d) 34 – Navigation (cont’d)

34.12.49 03-05-07 34.13.20 06-03-02
34.12.50 03-05-07 34.13.21 06-03-02
34.12.51 03-05-07 34.13.22 06-03-02
34.12.52 03-05-07 34.13.23 06-03-02
34.12.53 03-05-07 34.13.24 06-03-02
34.12.54 03-05-07 34.13.25 06-03-02
34.12.55 03-05-07 34.13.26 06-03-02
34.12.56 03-05-07 34.13.27 06-03-02
34.12.57 03-05-07 34.13.28 06-03-02
34.12.58 03-05-07 34.13.29 06-03-02
34.12.59 03-05-07 34.13.30 06-03-02
34.12.60 03-05-07 34.13.31 06-03-02
34.12.61 03-05-07 34.13.32 06-03-02
34.12.62 03-05-07 34.13.33 06-03-02
34.12.63 03-05-07 34.13.34 06-03-02
34.12.64 03-05-07 34.13.35 06-03-02
34.12.65 03-05-07 34.13.36 06-03-02
34.12.66 03-05-07 34.13.37 06-03-02
34.12.67 03-05-07 34.13.38 10-29-07
34.12.68 07-29-09 34.13.39 04-27-10
34.12.69 10-29-07 34.13.40 04-27-10
34.12.70 10-29-07
34.12.71 10-29-07 34.14-i 12-07-05
34.12.72 10-29-07 34.14-ii 10-29-07
34.12.73 07-29-09
34.12.74 07-29-09 34.14.1 12-02-02
34.14.2 12-02-02
34.13-i 06-03-02 34.14.3 12-02-02
34.13-ii 06-03-02 34.14.4 12-02-02
34.14.5 12-02-02
34.13.1 06-03-02 34.14.6 12-02-02
34.13.2 06-03-02 34.14.7 12-02-02
34.13.3 05-20-05 34.14.8 12-02-02
34.13.4 06-03-02 34.14.9 12-02-02
34.13.5 06-03-02 34.14.10 12-02-02
34.13.6 06-03-02 34.14.11 12-02-02
34.13.7 06-03-02 34.14.12 12-02-02
34.13.8 06-03-02 34.14.13 12-02-02
34.13.9 06-03-02 34.14.14 12-02-02
34.13.10 06-03-02 34.14.15 12-02-02
34.13.11 04-27-10 34.14.16 12-02-02
34.13.12 06-03-02
34.13.13 06-03-02
34.13.14 06-03-02
34.13.15 06-03-02
34.13.16 06-03-02
34.13.17 06-03-02
34.13.18 06-03-02
34.13.19 06-03-02

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34 – Navigation (cont’d) 34 – Navigation (cont’d)

34.14.17 12-02-02 34.16.8 05-20-05
34.14.18 12-02-02 34.16.9 05-20-05
34.14.19 12-02-02 34.16.10 05-20-05
34.14.20 12-02-02 34.16.11 05-20-05
34.14.21 12-02-02 34.16.12 05-20-05
34.14.22 12-02-02 34.16.13 05-20-05
34.14.23 12-02-02 34.16.14 05-20-05
34.14.24 12-02-02 34.16.15 05-20-05
34.14.25 12-02-02 34.16.16 05-20-05
34.14.26 12-02-02 34.16.17 11-08-06
34.14.27 12-02-02 34.16.18 11-08-06
34.14.28 12-02-02
34.14.29 12-02-02 34.17-i 09-05-06
34.14.30 12-02-02 34.17-ii 09-05-06
34.14.31 12-02-02
34.14.32 12-02-02 34.17.1 09-05-06
34.14.33 12-02-02 34.17.2 09-05-06
34.14.34 12-02-02 34.17.3 09-05-06
34.14.35 12-02-02 34.17.4 09-05-06
34.14.36 12-02-02 34.17.5 09-05-06
34.14.37 12-02-02 34.17.6 09-05-06
34.14.38 12-02-02 34.17.7 09-05-06
34.14.39 12-02-02 34.17.8 09-05-06
34.14.40 12-02-02 34.17.9 09-05-06
34.14.41 12-02-02 34.17.10 09-05-06
34.14.42 12-02-02 34.17.11 09-05-06
34.14.43 12-02-02 34.17.12 09-05-06
34.14.44 12-02-02 34.17.13 09-05-06
34.14.45 12-02-02 34.17.14 09-05-06
34.14.46 12-02-02 34.17.15 09-05-06
34.17.16 09-05-06
34.15-i 04-07-06 34.17.17 09-05-06
34.15-ii 04-07-06 34.17.18 09-05-06
34.17.19 09-05-06
34.15.1 04-06-11 34.17.20 09-05-06
34.15.2 06-16-03
34.15.3 06-16-03 36 – Pneumatic
34.15.4 06-16-03
36.01-i 04-27-10
34.16-i 05-20-05 36.01-ii 04-27-10
34.16-ii 05-20-05
36.01.1 04-27-10
34.16.1 05-20-05 36.01.2 04-06-11
34.16.2 05-20-05 36.01.3 04-06-11
34.16.3 05-20-05 36.01.4 04-06-11
34.16.4 05-20-05 36.01.5 04-06-11
34.16.5 05-20-05 36.01.6 04-06-11
34.16.6 05-20-05
34.16.7 05-20-05

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52 – Doors 52 – Doors (cont’d)

52-i 12-07-05 52.05.23 11-01-00
52-ii 12-07-05 52.05.24 11-01-00
52.05.25 11-01-00
52.01-i 12-03-01 52.05.26 11-01-00
52.01-ii 12-03-01 52.05.27 11-01-00
52.05.28 11-01-00
52.01.1 07-01-98
52.01.2 07-01-98 52.06.1 12-07-05
52.01.3 07-01-98 52.06.2 12-07-05
52.01.4 07-01-98
52.07.1 12-07-05
52.02.1 12-07-05 52.07.2 12-07-05
52.02.2 12-07-05
52.08.1 12-07-05
52.03-i 12-03-01 52.08.2 12-07-05
52.03-ii 12-03-01
52.09.1 12-07-05
52.03.1 07-01-98 52.09.2 12-07-05
52.03.2 07-01-98
52.10-i 06-16-03
52.04.1 12-07-05 52.10-ii 06-16-03
52.04.2 12-07-05
52.10.1 06-16-03
52.05-i 12-03-01 52.10.2 06-16-03
52.05-ii 12-03-01 52.10.3 06-16-03
52.10.4 06-16-03
52.05.1 10-01-08 52.10.5 06-16-03
52.05.2 07-01-98 52.10.6 06-16-03
52.05.3 07-01-98 52.10.7 05-20-05
52.05.4 07-01-98 52.10.8 05-20-05
52.05.5 07-01-98 52.10.9 06-16-03
52.05.6 07-01-98 52.10.10 06-16-03
52.05.7 07-01-98 52.10.11 06-16-03
52.05.8 07-01-98 52.10.12 06-16-03
52.05.9 07-01-98 52.10.13 12-07-05
52.05.10 07-01-98 52.10.14 12-07-05
52.05.11 11-01-00 52.10.15 12-07-05
52.05.12 11-01-00 52.10.16 12-07-05
52.05.13 11-01-00
52.05.14 11-01-00
52.05.15 11-01-00
52.05.16 11-01-00
52.05.17 11-01-00
52.05.18 11-01-00
52.05.19 11-01-00
52.05.20 11-01-00
52.05.21 11-01-00
52.05.22 11-01-00

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53 – Fuselage 57 –Wings (cont’d)

53-i 12-03-01 57.03.2 11-08-06
53-ii 12-03-01 57.03.3 11-08-06
57.03.4 11-08-06
53.01-i 12-03-01 57.03.5 11-08-06
53.01-ii 12-03-01 57.03.6 11-08-06
57.03.7 11-08-06
53.01.1 07-01-98 57.03.8 11-08-06
53.01.2 07-01-98
53.01.3 07-01-98 70 – Engine Job Cards
53.01.4 07-01-98 70-i 08-01-00
70-ii 08-01-00
53.02-i 12-03-01
53.02-ii 12-03-01 70.00-i 12-03-01
70.00-ii 12-03-01
53.02.1 07-01-98
53.02.2 07-01-98 70.00.1 08-01-00
53.02.3 07-01-98 70.00.2 05-11-07
53.02.4 07-01-98
53.02.5 07-01-98 70.01-i 12-07-05
53.02.6 07-01-98 70.01-ii 12-07-05

53.03-i 12-03-01 70.01.1 08-01-00

53.03-ii 12-03-01 70.01.2 08-01-00
70.01.3 08-01-00
53.03.1 07-01-98 70.01.4 08-01-00
53.03.2 07-01-98 70.01.5 11-01-00
70.01.6 11-01-00
57 –Wings 70.01.7 11-01-00
57-i 11-08-06 70.01.8 11-01-00
57-ii 11-08-06 70.01.9 11-01-00
70.01.10 11-01-00
57.01-i 12-03-01 70.01.11 11-01-00
57.01-ii 12-03-01 70.01.12 11-01-00
70.01.13 11-01-00
57.01.1 07-01-98 70.01.14 11-01-00
57.01.2 07-01-98 70.01.15 08-01-00
57.01.3 07-01-98 70.01.16 06-01-01
57.01.4 07-01-98 70.01.17 06-01-01
70.01.18 06-01-01
57.02-i 12-03-01 70.01.19 06-01-01
57.02-ii 12-03-01 70.01.20 06-01-01
70.01.21 06-01-01
57.02.1 07-01-98
57.02.2 08-01-00

57.03-i 11-08-06
57.03-ii 11-08-06

57.03.1 11-08-06

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70 – Engine Job Cards (cont’d) 70 – Engine Job Cards (cont’d)

70.01.22 04-06-11 70.02.36 04-06-11
70.01.23 04-06-11 70.02.37 04-06-11
70.01.24 04-06-11 70.02.38 04-06-11
70.01.25 04-06-11 70.02.39 04-06-11
70.01.26 04-06-11 70.02.40 04-06-11
70.01.27 04-06-11 70.02.41 04-06-11
70.01.28 04-06-11 70.02.42 04-06-11
70.01.29 04-06-11 70.02.43 04-06-11
70.01.30 04-06-11 70.02.44 04-06-11
70.01.31 04-06-11 70.02.45 04-06-11
70.01.32 04-06-11 70.02.46 04-06-11
70.02.47 04-06-11
70.02-i 12-05-03 70.02.48 04-06-11
70.02-ii 12-05-03 70.02.49 04-06-11
70.02.50 04-06-11
70.02.1 12-07-05 70.02.51 10-22-01
70.02.2 12-07-05 70.02.52 08-01-00
70.02.3 12-07-05 70.02.53 12-05-03
70.02.4 12-07-05 70.02.54 12-05-03
70.02.5 12-07-05 70.02.55 12-05-03
70.02.6 12-07-05 70.02.56 12-05-03
70.02.7 12-07-05 70.02.57 12-05-03
70.02.8 12-07-05 70.02.58 12-05-03
70.02.9 12-07-05 70.02.59 12-05-03
70.02.10 12-07-05 70.02.60 12-05-03
70.02.11 12-07-05 70.02.61 12-05-03
70.02.12 12-07-05 70.02.62 12-05-03
70.02.13 12-07-05 70.02.63 12-05-03
70.02.14 12-07-05 70.02.64 12-05-03
70.02.15 12-07-05 70.02.65 12-05-03
70.02.16 12-07-05 70.02.66 12-05-03
70.02.17 12-07-05
70.02.18 12-07-05 70.03-i 05-11-07
70.02.19 12-07-05 70.03-ii 05-11-07
70.02.20 12-07-05
70.02.21 12-07-05 70.03.1 06-01-01
70.02.22 12-07-05 70.03.2 06-01-01
70.02.23 12-07-05 70.03.3 06-01-01
70.02.24 12-07-05 70.03.4 08-01-00
70.02.25 12-07-05 70.03.5 06-01-01
70.02.26 12-07-05 70.03.6 06-01-01
70.02.27 04-06-11 70.03.7 08-01-00
70.02.28 04-06-11
70.02.29 04-06-11
70.02.30 04-06-11
70.02.31 04-06-11
70.02.32 04-06-11
70.02.33 04-06-11
70.02.34 04-06-11
70.02.35 04-06-11

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70 – Engine Job Cards (cont’d) 70 – Engine Job Cards (cont’d)

70.03.8 08-01-00 70.06-i 12-03-01
70.03.9 08-01-00 70.06-ii 12-03-01
70.03.10 08-01-00
70.03.11 08-01-00 70.06.1 03-05-07
70.03.12 08-01-00 70.06.2 03-05-07
70.03.13 08-01-00
70.03.14 08-01-00 71 - Powerplant
70.03.15 08-01-00 71-i 12-03-01
70.03.16 08-01-00 71-ii 12-03-01
70.03.17 08-01-00
70.03.18 08-01-00 71.01-i 12-03-01
70.03.19 08-01-00 71.01-ii 12-03-01
70.03.20 08-01-00
70.03.21 04-06-11 71.01.1 08-01-00
70.03.22 04-06-11 71.01.2 08-01-00
70.03.23 04-06-11
70.03.24 04-06-11 71.02-i 12-03-01
70.03.25 04-06-11 71.02-ii 12-03-01
70.03.26 04-06-11 71.02.1 08-01-00
70.03.27 04-06-11 71.02.2 08-01-00
70.03.28 04-06-11 71.02.3 08-01-00
70.03.29 05-11-07 71.02.4 08-01-00
70.03.30 05-11-07 71.02.5 08-01-00
70.03.31 05-11-07 71.02.6 08-01-00
70.03.32 05-11-07 71.02.7 08-01-00
70.03.33 05-11-07 71.02.8 08-01-00
70.03.34 05-11-07 71.02.9 08-01-00
70.03.35 05-11-07 71.02.10 08-01-00
70.03.36 05-11-07 71.02.11 08-01-00
70.03.37 05-11-07 71.02.12 08-01-00
70.03.38 05-11-07 71.02.13 04-07-06
70.03.39 05-11-07 71.02.14 04-07-06
70.03.40 05-11-07 71.02.15 04-07-06
70.03.41 05-11-07 71.02.16 04-07-06
70.03.42 05-11-07 71.02.17 04-07-06
70.03.43 05-11-07 71.02.18 04-07-06
70.03.44 05-11-07 71.02.19 04-07-06
71.02.20 04-07-06
70.04-i 12-03-01 71.02.21 04-07-06
70.04-ii 12-03-01 71.02.22 04-07-06
71.02.23 04-07-06
70.04.1 08-01-00 71.02.24 04-07-06
70.04.2 08-01-00

70.05-i 12-03-01
70.05-ii 12-03-01

70.05.1 10-22-01
70.05.2 08-01-00

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71 – Powerplant (cont’d) 71 – Powerplant (cont’d)

71.02.25 04-07-06 71.03.33 08-01-00
71.02.26 04-07-06 71.03.34 08-01-00
71.02.27 08-01-00 71.03.35 08-01-00
71.02.28 08-01-00 71.03.36 08-01-00
71.02.29 08-01-00 71.03.37 08-01-00
71.02.30 08-01-00 71.03.38 08-01-00
71.02.31 08-01-00 71.03.39 08-01-00
71.02.32 08-01-00 71.03.40 08-01-00
71.02.33 08-01-00 71.03.41 08-01-00
71.02.34 08-01-00 71.03.42 08-01-00
71.02.35 08-01-00 71.03.43 08-01-00
71.02.36 08-01-00 71.03.44 08-01-00
71.02.37 08-01-00 71.03.45 08-01-00
71.02.38 08-01-00 71.03.46 08-01-00
71.03.47 08-01-00
71.03-i 12-03-01 71.03.48 08-01-00
71.03-ii 12-03-01 71.03.49 08-01-00
71.03.50 08-01-00
71.03.1 08-01-00 71.03.51 08-01-00
71.03.2 08-01-00 71.03.52 08-01-00
71.03.3 08-01-00 71.03.53 08-01-00
71.03.4 08-01-00 71.03.54 08-01-00
71.03.5 08-01-00 71.03.55 08-01-00
71.03.6 08-01-00 71.03.56 08-01-00
71.03.7 08-01-00 71.03.57 08-01-00
71.03.8 08-01-00 71.03.58 08-01-00
71.03.9 08-01-00 71.03.59 08-01-00
71.03.10 08-01-00 71.03.60 08-01-00
71.03.11 08-01-00 71.03.61 08-01-00
71.03.12 08-01-00 71.03.62 08-01-00
71.03.13 08-01-00 71.03.63 08-01-00
71.03.14 08-01-00 71.03.64 08-01-00
71.03.15 08-01-00 71.03.65 08-01-00
71.03.16 08-01-00 71.03.66 08-01-00
71.03.17 08-01-00 71.03.67 08-01-00
71.03.18 08-01-00 71.03.68 08-01-00
71.03.19 08-01-00 71.03.69 08-01-00
71.03.20 08-01-00 71.03.70 08-01-00
71.03.21 08-01-00
71.03.22 08-01-00 71.04-i 12-03-01
71.03.23 08-01-00 71.04-ii 12-03-01
71.03.24 08-01-00
71.03.25 08-01-00
71.03.26 08-01-00
71.03.27 03-05-07
71.03.28 08-01-00
71.03.29 08-01-00
71.03.30 08-01-00
71.03.31 08-01-00
71.03.32 08-01-00

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NUMBER CHAPTER DATE NUMBER CHAPTER DATE

71 – Powerplant (cont’d) 71 – Powerplant (cont’d)

71.04.1 08-01-00 71.04.51 08-01-00
71.04.2 08-01-00 71.04.52 08-01-00
71.04.3 08-01-00 71.04.53 08-01-00
71.04.4 08-01-00 71.04.54 08-01-00
71.04.5 08-01-00 71.04.55 08-01-00
71.04.6 08-01-00 71.04.56 08-01-00
71.04.7 08-01-00 71.04.57 08-01-00
71.04.8 08-01-00 71.04.58 08-01-00
71.04.9 08-01-00 71.04.59 08-01-00
71.04.10 08-01-00 71.04.60 08-01-00
71.04.11 08-01-00 71.04.61 08-01-00
71.04.12 08-01-00 71.04.62 08-01-00
71.04.13 08-01-00 71.04.63 08-01-00
71.04.14 08-01-00 71.04.64 08-01-00
71.04.15 08-01-00 71.04.65 08-01-00
71.04.16 08-01-00 71.04.66 08-01-00
71.04.17 08-01-00 71.04.67 08-01-00
71.04.18 08-01-00 71.04.68 08-01-00
71.04.19 08-01-00 71.04.69 08-01-00
71.04.20 08-01-00 71.04.70 08-01-00
71.04.21 08-01-00 71.04.71 08-01-00
71.04.22 08-01-00 71.04.72 08-01-00
71.04.23 08-01-00 71.04.73 08-01-00
71.04.24 08-01-00 71.04.74 08-01-00
71.04.25 08-01-00 71.04.75 08-01-00
71.04.26 08-01-00 71.04.76 08-01-00
71.04.27 08-01-00 71.04.77 08-01-00
71.04.28 08-01-00 71.04.78 08-01-00
71.04.29 08-01-00 71.04.79 08-01-00
71.04.30 08-01-00 71.04.80 08-01-00
71.04.31 08-01-00 71.04.81 08-01-00
71.04.32 08-01-00 71.04.82 08-01-00
71.04.33 08-01-00
71.04.34 08-01-00 71.05-i 12-03-01
71.04.35 08-01-00 71.05-ii 12-03-01
71.04.36 08-01-00
71.04.37 08-01-00 71.05.1 08-01-00
71.04.38 08-01-00 71.05.2 08-01-00
71.04.39 08-01-00 71.05.3 08-01-00
71.04.40 08-01-00 71.05.4 08-01-00
71.04.41 08-01-00
71.04.42 08-01-00
71.04.43 08-01-00
71.04.44 08-01-00
71.04.45 08-01-00
71.04.46 08-01-00
71.04.47 08-01-00
71.04.48 08-01-00
71.04.49 08-01-00
71.04.50 08-01-00

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PAGE CONTROL PAGE CONTROL
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71.05.5 08-01-00 71.05.55 08-01-00
71.05.6 08-01-00 71.05.56 08-01-00
71.05.7 08-01-00 71.05.57 08-01-00
71.05.8 08-01-00 71.05.58 08-01-00
71.05.9 08-01-00 71.05.59 08-01-00
71.05.10 08-01-00 71.05.60 08-01-00
71.05.11 08-01-00 71.05.61 08-01-00
71.05.12 08-01-00 71.05.62 08-01-00
71.05.13 08-01-00 71.05.63 08-01-00
71.05.14 08-01-00 71.05.64 08-01-00
71.05.15 08-01-00 71.05.65 08-01-00
71.05.16 08-01-00 71.05.66 08-01-00
71.05.17 08-01-00 71.05.67 08-01-00
71.05.18 08-01-00 71.05.68 08-01-00
71.05.19 08-01-00 71.05.69 08-01-00
71.05.20 08-01-00 71.05.70 08-01-00
71.05.21 08-01-00 71.05.71 08-01-00
71.05.22 08-01-00 71.05.72 08-01-00
71.05.23 08-01-00 71.05.73 08-01-00
71.05.24 08-01-00 71.05.74 08-01-00
71.05.25 08-01-00 71.05.75 08-01-00
71.05.26 08-01-00 71.05.76 08-01-00
71.05.27 08-01-00 71.05.77 08-01-00
71.05.28 08-01-00 71.05.78 08-01-00
71.05.29 08-01-00 71.05.79 08-01-00
71.05.30 08-01-00 71.05.80 08-01-00
71.05.31 08-01-00 71.05.81 08-01-00
71.05.32 08-01-00 71.05.82 08-01-00
71.05.33 08-01-00 71.05.83 08-01-00
71.05.34 08-01-00 71.05.84 08-01-00
71.05.35 08-01-00 71.05.85 08-01-00
71.05.36 08-01-00 71.05.86 08-01-00
71.05.37 08-01-00 71.05.87 08-01-00
71.05.38 08-01-00 71.05.88 08-01-00
71.05.39 08-01-00 71.05.89 08-01-00
71.05.40 08-01-00 71.05.90 08-01-00
71.05.41 08-01-00 71.05.91 08-01-00
71.05.42 08-01-00 71.05.92 08-01-00
71.05.43 08-01-00
71.05.44 08-01-00
71.05.45 08-01-00
71.05.46 08-01-00
71.05.47 08-01-00
71.05.48 08-01-00
71.05.49 08-01-00
71.05.50 08-01-00
71.05.51 08-01-00
71.05.52 08-01-00
71.05.53 08-01-00
71.05.54 08-01-00

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71.05.93 08-01-00
71.05.94 08-01-00
71.05.95 08-01-00
71.05.96 08-01-00
71.05.97 08-01-00
71.05.98 08-01-00
71.05.99 08-01-00
71.05.100 08-01-00
71.05.101 08-01-00
71.05.102 08-01-00
71.05.103 08-01-00
71.05.104 08-01-00
71.05.105 08-01-00
71.05.106 08-01-00
71.05.107 08-01-00
71.05.108 08-01-00
71.05.109 08-01-00
71.05.110 08-01-00
71.05.111 08-01-00
71.05.112 08-01-00
71.05.113 08-01-00
71.05.114 08-01-00
71.05.115 08-01-00
71.05.116 08-01-00

71.06-i 12-03-01
71.06-ii 12-03-01

71.06.1 08-01-00
71.06.2 06-01-01

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INTENTIONAL
BLANK

xxx 04-06-11 Revision 36

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INTRODUCTION
TABLE OF CONTENTS
PAGE
LIST OF EFFECTIVE PAGES ---------------------------------------------------------------------------- i

TABLE OF CONTENTS ------------------------------------------------------------------------------- 00-1

EFFECTIVITY------------------------------------------------------------------------------------------- 00-2

MANUAL/JOB CARD CORRECTION FORM ---------------------------------------------------- 00-9

CHAPTER
WEIGHT & BALANCE ------------------------------------------------------------------------------------ 8
GROUND HANDLING ------------------------------------------------------------------------------------ 9
PLACARDS ------------------------------------------------------------------------------------------------- 11
SPECIAL INSPECTIONS--------------------------------------------------------------------------------- 13
LIMITS ------------------------------------------------------------------------------------------------------ 15
PERIODIC INSPECTIONS ------------------------------------------------------------------------------ 16
AIR CONDITIONING ------------------------------------------------------------------------------------- 21
ELECTRICAL POWER ----------------------------------------------------------------------------------- 24
EQUIPMENT AND FURNISHINGS ------------------------------------------------------------------- 25
FIRE PROTECTION -------------------------------------------------------------------------------------- 26
FLIGHT CONTROLS ------------------------------------------------------------------------------------- 27
HYDRAULIC POWER ----------------------------------------------------------------------------------- 29
INSTRUMENTS-------------------------------------------------------------------------------------------- 31
LANDING GEAR ----------------------------------------------------------------------------------------- 32
LIGHTING -------------------------------------------------------------------------------------------------- 33
NAVIGATION---------------------------------------------------------------------------------------------- 34
CARGO DOORS ------------------------------------------------------------------------------------------- 52
FUSELAGE ------------------------------------------------------------------------------------------------- 53
WINGS ------------------------------------------------------------------------------------------------------ 57
ENGINE JOB CARDS------------------------------------------------------------------------------------- 70
POWER PLANT GENERAL ---------------------------------------------------------------------------- 71

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INTRODUCTION
EFFECTIVITY
A. The literature provided by Douglas for the maintenance of the DC-8 aircraft utilizes a system
of codes in order to make it possible for the mechanic to find the proper procedures and parts for
the precise aircraft being worked on. The Maintenance (MM) & Wiring Diagram (WD) Manuals
assign codes based on the original operator, and ties those codes to the aircraft serial number,
original registration number, and fleet number. The IPC assigns effectivity codes based on the
original operator. Listed below are the pertinent codes for the aircraft currently operated by Air
Transport International.
N Aircraft
DACO DACO DACO Previous
O Serial/ ATI
Model IPC MM WD Item Registration
T Fuselage Reg. No.
Code Code Effectivity /Fleet Numbers
E No.

DC-8-62F 1 46129/523 41CX SK069 3 SAS6F N798AL -SE-DBI – AF-110

DC-8-62F 1 45922/335 799AL SK063 3 SAS6F OY-KTE - AF-112
DC-8-62F 1 45961/361 71CX AZ020 8 ALI6F DIWQ - N3931A - CFHAA -
818CK

DC-8-71F 46065/460 820BX UA098 1 UAL6A 8098U - 2598

DC-8-71F 45811/262 821BX UA071 1 UAL6A 8071U - 2571
DC-8-71F 45813/284 822BX UA073 1 UAL6A 8073U - 1573
DC-8-71F 46064/459 823BX UA097 1 UAL6A 8097U - 1597
DC-8-71F 45978/381 825BX UA088 1 UAL6A 8088U - 1588
DC-8-71F 45993/382 828BX UA089 1 UAL6A 8089U - 1989
DC-8-71F 45994/387 829BX UA090 1 UAL6A 8090U - 2990
DC-8-71F 45973/358 830BX UA083 1 UAL6A 8083U - 2883; UPS - N783UP

DC-8-72F 1 46013/427 721CX AY001 24 FIN6F OH-LFR; FRAFG

DC-8-72F 1/3 46130/542 722CX AY003 24 FIN6F OH-LFY; FRAFF

DC-8-73F 45991/380 602AL FT081 17 FTL6H N781FT – D-ADUI

DC-8-73F 46003/401 603AL FT083 17 FTL6H N783FT – D-ADUA
DC-8-73F 46046/444 604BX FT092 17 FTL6H N792FT
DC-8-73F 2 46106/490 605AL SB015 22 SEA6J N8641 – F-GATO – D-ADUC
CA001 – N919CL
IA001
DC-8-73F 46044/432 606AL FT090 17 FTL6H N790FT – D-ADUE
NOTES:
(1) -May be configured as either cargo or passenger/cargo(COMBI)
(2) - SB015’s original IPC Code is as a DC-8-63. CA001/IA001 will be the applicable IPC codes in the DC-8-70
IPC.
(3) – Not RVSM Certified

AY – Finn Air – OH-LFR to French Air Force as FRAFG to ATI as 721CX;

OH-LFY to French Air Force as FRAFF to ATI as 722CX.
AZ – Alitalia – DIWQ to N3931A to C-FHAA to N818CK
FT - Flying Tiger Line, Inc. - N783FT to Lufthansa Cargo AG as D-ADUA to Emery Worldwide Inc. as N603AL;
N790FT to Lufthansa Cargo AG as D-ADUE to Aerolease as N606AL; N781FT to Lufthansa Cargo AG as D-
ADUI to Emery Worldwide Inc. as N602AL
SB - Seaboard World - N8639 to 867BX; N8641F to UTA as F-GATO to Capitol Air, Inc. as N919CL to Lufthansa
Cargo AG as D-ADUC to Aerolease as N605AL
SK - Scandinavian Airlines - SE-DBI to Aerolease as 798AL to ICX as 41CX; OY-KTE to Thailand-RTAF as
AF-112 to International Air Lease as N799AL.
UA - United Airlines

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INTRODUCTION
EFFECTIVITY (Cont’d)
B. DC-8-62/-72 COMBI. In addition to the maintenance procedures and illustrated parts
catalog contained in the approved Douglas publications, the following sections in this manual
specifically provide additional maintenance procedures/parts information for COMBI aircraft:
Section Description
08.01 Weighing
13.04 Three Engine Ferry Procedures
16.02 Preflight Inspection
16.03 “A” Check Inspection
21.04 DC-8-60 Series NASI Cabin Pneumatic Air Cycle (PAC) System
25.09 COMBI Ball Panel Assembly Configuration (PEMCO)
25.12 TEAC VE 801DC DVD Video Player
25.14 Powerheart Automated External Defibrillator (AED) G3
26.03 COMBI Main Deck Cargo Smoke Detection Description and Operation
26.05 Lower Cargo Compartment Smoke Detection & Fire Suppression System
29.01 Vickers Engine Driven Hydraulic Pump
29.02 Filter, Pump Case Drain
29.03 Vickers Engine Driven Hydraulic Pump Bypass Solenoid
31.02 ARINC 542A DFDR Expanded Parameters
31.05 Exhaust Gas Temperature Indicator Upgrade
31.06 ADT 406S Emergency Locator Transmitter (ELT)
33.01 Passenger Emergency Escape Path Lighting System
33.02 COMBI Photo Luminescent Aisle Path Marking
34.05 Traffic Alert and Collision Avoidance System – CAS-81
34.07 Safe Flight Windshear Warning System
34.08 UNS-1D Flight Management System
34.11 LTR-97 FOG Vertical Gyro/Directional Gyro System
34.12 Reduced Vertical Separation Minimums (RVSM) Compliant Digital Air Data
System
34.13 Collins TCAS II Traffic Alert & Collision Avoidance System
34.16 Terrain Awareness & Warning System (TAWS)
34.17 Electronic Flight Instrument (EFI) 600 (DC-8-72’s Only)
52.05 National Aircraft Service Vent Door (STC SA1614GL)
52.10 NASI Flight Deck Door System (STC ST01791CH)
57.03 DC-8-70 Pylon (Inboard or Outboard) Removal and Installation (DC-8-72’s Only)
70.01 Engine Job Cards
71.01 DC-8-60 Series Engine Hush Kit Description & Identification
71.02 DC-8-60 Hush Kit component Removal and Installation (STC’s SA4892NM &
SA5455NM)
71.03 DC-8-60 Husk Kit Illustrated Parts Catalog(STC’s SA4892NM & SA5455NM)
71.04 Structural Repair Manual for BAC II Stage III Hush Kits(STC SA4892NM)
71.05 Structural Repair Manual for BAC II ADC Upgrade Hush Kit(STC SA5455NM)
71.06 DC-8-70 Series Nacelle Inlet Cowl

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INTRODUCTION
EFFECTIVITY (Cont’d)
.
C. DC-8-60 Series Engine Hush Kit Installation
DC-8-62
Burbank Aeronautical Corp. SA4892NM 71CX
(BAC) II Stage III (Burbank)
SA5455NM 41CX, 799AL
(ADC Upgrade)
.
D. Cargo Door and Cargo Loading System Installation
Door/Cargo Loading System S.T.C. ATI Registration Number
1 DOUGLAS CARGO DOOR N/A
PEMCO SA1327NM All DC-8-71F/-73F
DACO IPC N/A 41CX, 71CX, 799AL, 721CX, 722CX
NASI VENT DOOR INSTL. SA1614GL 41CX, 71CX, 799AL, 604BX

E. Air Conditioning
Air Conditioning System S.T.C. ATI Registration No.
NASI Flight Deck Floor ST00792CH 602AL, 603AL, 604BX, 605AL, 606AL,
Heat 820BX, 821BX, 822BX, 825BX, 828BX,
829BX, 830BX, 721CX, 722CX (Note: To be
added to remaining DC-8-70 series at next “C”
Check.)
NASI Cabin Pac System ST01253CH* 41CX, 71CX, 799AL
*Incorporates the provisions of STC ST00792CH.

F. Traffic Alert and Collision Avoidance (TCAS) Systems

TCAS S.T.C. ATI Registration No.
Honeywell ST00094AT, or 41CX, 71CX, 721CX, 722CX, 820BX,
(Allied Signal) SA3032SO, or 821BX, 822BX, 823BX, 825BX, 828BX,
(Bendix/King) ST00375AT 829BX, 830BX
CAS-81/TPA-81
Collins SA4866NM, or 799AL, 602AL, 603AL, 605AL, 606AL
TCAS II SA5468NM, or
ST00881WI-D, or
ST00988LA-D

G. Anti-Skid Systems
Anti-Skid S.T.C. ATI Registration No.
Mark II N/A 721CX, 71CX, 722CX, All DC-8-71’s
Mark III N/A 41CX, 799AL, DC-8-73’s

H. Electronic Flight Instrument

Anti-Skid S.T.C. ATI Registration No.
Universal EFI 600 ST10503SC 721CX

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INTRODUCTION
EFFECTIVITY (Cont’d)

I. Job Card Table

JOB CARD TITLE PAGE
13.01-1 TAIL SKID INSPECTION --------------------------------------------- 13.01.3
13.01-2 LIGHTING STRIKE INSPECTION ---------------------------------- 13.01.7
13.01-3 ENGINE – FOREIGN OBJECT DAMAGE INSPECTION ------- 13.01.10
13.01-4 BIRD STRIKE INSPECTION------------------------------------------ 13.01.13
13.01-5 UNSCHEDULED MAINTENANCE INSPECTION --------------- 13.01.16
13.02-1 SHORT TERM ACTIVE STORAGE --------------------------------- 13.02.3
13.02-2 LONG TERM ACTIVE STORAGE----------------------------------- 13.02.5
16.02-1 POTABLE WATER & WASTE DISPOSAL SYSTEMS
SERVICING -------------------------------------------------------------- 16.02.20
16.08-1 COMBI PASSENGER COMPARTMENT MATERIAL
CONDITION INSPECTION ------------------------------------------- 13.01.21
16.09-1 AIRCRAFT EXTERIOR WASH -------------------------------------- 16.09.3
16.09-2 ENGINE COMPRESSOR WASH ------------------------------------- 16.09.5
21.04-1 NASI PNEUMATIC AIR CYCLE SYSTEM 3240 LANDING
EDDY CURRENT ------------------------------------------------------- 21.04.55
21.04-2 NASI PNEUMATIC AIR CYCLE SYSTEM MANIFOLD
PRESSURE DECAY CHECK ----------------------------------------- 21.04.59
25.05-1 LOOSE EQUIPMENT INVENTORY -------------------------------- 25.05.1
25.05-2 AFT COURIER AREA SET-UP IN ACCORDANCE WITH
FAR 121.583 -------------------------------------------------------------- 25.05.5
25.05-2A AFT COURIER AREA TEARDOWN -------------------------------- 25.05.7
25.05-3 RECONFIGURE COMBI AIRCRAFT TO FULL CARGO
FREIGHTER AIRCRAFT ONLY USING 125” PALLETS ------- 25.05.9
25.05-3A RECONFIGURE COMBI AIRCRAFT FROM FULL
FREIGHTER BACK TO COMBI AIRCRAFT
CONFIGURATION------------------------------------------------------ 25.05.10
25.05-4 HORSE CHARTER CONVERSION UP TO 36 SEATS
INSTALLATION -------------------------------------------------------- 25.05.11
25.05-4A HORSE CHARTER CONVERSION UP TO 36 SEATS
REMOVAL --------------------------------------------------------------- 25.05.13
25.14-1 POWERHEART AED SCHEDULED MAINTENANCE---------- 25.14.13
26.06-1 INSPECT/TEST ENGINE FIRE EXTINGUISHING SYSTEM -- 26.06.1
27.01-1 ELEVATOR GUST LOCK OFF WHILE PARKED CHECK ----- 27.07.1
27.04-1 DC-8 LONGITUDINAL TRIM JACKSCREW
LUBRICATION ---------------------------------------------------------- 27.04.2
27.04-2 DC-8 LONGITUDINAL TRIM JACKSCREW WEAR
CHECK -------------------------------------------------------------------- 27.04.10
28.01-1 DC-8 REPAIR WIRE GAUGE, TYPE, & INSTALLATION
INSPECTION------------------------------------------------------------- 28.01.3
28.01-2 DC-8 FQIS WIRE ISOLATION INSPECTION --------------------- 28.01.4
28.01-3 DC-8 IN-TANK WIRE SPLICE INSPECTION --------------------- 28.01.5

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JOB CARD TITLE PAGE

28.01-4 DC-8 PROHIBITION OF POWER FEEDER SPLICES IN
AREAS ABOVE FUEL TANKS INSPECTION -------------------- 28.01.6
28.01-5 DC-8 FUEL TANK ACCESS DOOR BONDING
INSPECTION------------------------------------------------------------- 28.01.7
28.01-6 DC-8 FUEL TANK STRUCTURAL DESIGN INSPECTION ---- 28.01.8
28.01-7 DC-8 WIRING NEAR FUEL TANKS & FUEL PIPES
INSPECTION------------------------------------------------------------- 28.01.9
28.01-8 DC-8 PROHIBITION OF SAFETY WIRE, LOCKWIRE,
SAFETY CABLE, OR COTTER PINS INSIDE FUEL TANKS
INSPECTION------------------------------------------------------------- 28.01.10
28.01-9 DC-8 FUEL PUMP (BOOST OR TRANSFER) AND
HOUSING ASSEMBLIES INSPECTION---------------------------- 28.01.11
28.01-10 DC-8 FUEL PUMP (BOOST OR TRANSFER) AND
HOUSING ASSEMBLIES INSPECTION (WELDON FUEL
PUMP) --------------------------------------------------------------------- 28.01.13
28.01-11 DC-8 FUEL PUMP ELECTRICAL CONNECTOR WIRE /
CONDUIT ASSEMBLY INSPECTION ------------------------------ 28.01.14
28.01-12 DC-8 OUTER WING SURFACE PREPARATION
INSPECTION------------------------------------------------------------- 28.01.15
28.01-13 DC-8 FUEL QUANTITY MASTER INDICATORS
INSPECTION------------------------------------------------------------- 28.01.17
28.01-14 DC-8 FUEL PUMP CONNECTOR INSPECTION ----------------- 28.01.18
28.01-15 DC-8 FUEL PUMP CIRCUIT BREAKER RESET
INSPECTION------------------------------------------------------------- 28.01.19
28.02-1 DC-8 ALTERNATE AND CENTER AUXILIARY TANK
FUEL PUMP CONTROL SYSTEMS CHECK ---------------------- 28.02.2
31.02-1 F800 DFDR GROUND TEST PROCEDURE – 17
PARAMETERS ---------------------------------------------------------- 31.02.15
31.02-2 F1000 DFDR GROUND TEST PROCEDURE – 17
PARAMETERS ---------------------------------------------------------- 31.02.23
31.02-3 SUNSTRAND 980-4120-RXUS – DFDR GROUND TEST
PROCEDURE (71CX) -------------------------------------------------- 31.02.33
31.02-4 ALLIED SIGNAL 980-4100-GQUS – DFDR GROUND TEST
PROCEDURE (-73 SERIES ONLY) ---------------------------------- 31.02.45
32.02-1 DC-8 LANDING GEAR BOGIE ATTACH POINT
LUBRICATION ---------------------------------------------------------- 32.02.2
32.02-2 DC-8 MAIN LANDING GEAR BOGIE INSPECTION------------ 32.02.3
34.02-1 FAR 43 ATC TRANSPONDER SYSTEM RAMP TEST
RECORD ------------------------------------------------------------------ 34.02.05
34.08-1 UNS-1D+ FMS DEACTIVATION OF GPS/RRS SYSTEM ------ 34.08.69
34.08-2 UNS-1D+ FMS REACTIVATION OF GPS/RRS SYSTEM ------ 34.08.70
34.11-1 REMOVAL OF THE DG/VG GYROS FOR INSTALLATION
OF THE LTR-97 FIBER OPTIC GYRO(S) -------------------------- 34.11.49

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EFFECTIVITY (Cont’d)

JOB CARD TITLE PAGE

34.11-2 REMOVAL OF THE LTR-97 FIBER OPTIC GYRO(S) FOR
INSTALLATION OF THE DG/VG GYROS ------------------------ 34.11.51
34.12-1 RVSM AIR DATA SYSTEMS CHECK------------------------------ 34.12.69
34.12-2 RVSM AUTOPILOT ALTITUDE HOLD CHECK----------------- 34.12.73
36.01-1 DC-8 PNEUMATIC SYSTEM DECAY CHECK ------------------- 36.01.2
57.03-1 DC-8-70 PYLON (INBOARD OR OUTBOARD) REMOVAL
AND INSTALLATION ------------------------------------------------- 57.03.1
7001 COMPONENT CONTROL – JT3D-3B/-7 REMOVAL------------ 70.01.1
7002 COMPONENT CONTROL – JT3D-3B/-7 INSTALLATION ----- 70.01.3
7003 SPARE ENGINE “C” CHECK – JT3D-3B/7 ------------------------ 70.01.5
7004 COMPONENT CONTROL – CFM56-2 REMOVAL -------------- 70.01.15
7005 COMPONENT CONTROL – CFM56-2 INSTALLATION ------- 70.01.19
7006 SPARE ENGINE “C” CHECK – CFM56-2 -------------------------- 70.01.23
7101 ENGINE REMOVAL – JT3D-3B/-7 ---------------------------------- 70.02.1
7102 ENGINE INSTALLATION – JT3D-3B/-7 --------------------------- 70.02.13
7103 ENGINE REMOVAL – CMF56-2------------------------------------- 70.02.27
7104 ENGINE INSTALLATION – CFM56-2------------------------------ 70.02.37
7105 MAX POWER ASSURANCE RUN – CFM56-2-------------------- 70.02.51
7106 OFF WING ENGINE T3/4 DISK REPLACEMENT – JT3D------ 70.02.53
7201 FIRST STAGE NOZZLE GUIDE VANE ISOTOPE
INSPECTION – JT3D --------------------------------------------------- 70.03.1
7202 FRONT COMPRESSOR REAR HUB EDDY CURRENT
INSPECTION – JT3D --------------------------------------------------- 70.03.13
7203 BORESCOPE INSPECTION RECORD – CFM56-2 --------------- 70.03.21
7204 BORESCOPE INSPECTION RECORD – JT3D-3B/-7 ------------ 70.03.29
7301 INTERMIX OF JT3D-3B & -7 ENGINES – DC-8-62-------------- 70.04.1

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INTRODUCTION
EFFECTIVITY (Cont’d)

J. ATI Accomplishment of Boeing SCIs, CDCCLs, & ALIs

Boeing CDCCL, SCI, Non-Routine Job

Description
& ALI Task Number Card Number

CDCCL 20-1 DC-8 Repair Wire Gauges DC8-28.01-1

CDCCL 20-2 DC-8 FQIS Wire Installation DC8-28.01-2

CDCCL 20-3 DC-8 In Tank Wire Splices DC8-28.01-3

CDCCL 20-4 DC-8 Repair Wire Types DC8-28.01-1

CDCCL 20-5 DC-8 Wire Installation DC8-28.01-1

CDCCL 20-6 DC-8 Prohibition of Power Feeder Splices in DC8-28.01-4

Areas Above Fuel Tanks

CDCCL 20-7 DC-8 Fuel Tank Access Door Bonding DC8-28.01-5

CDCCL 20-8 DC-8 Fuel Tank Structural Design DC8-28.01-6

CDCCL 20-9 DC-8 Wiring Near Fuel Tanks and Fuel Pipes DC8-28.01-7

CDCCL 20-10 DC-8 Float Switch Circuit (Boeing SB DC8- DC8-28.01-16

28-090)

CDCCL 28-1 DC-8 Prohibit Safety Wire, Lockwire, Safety DC8-28.01-8

Cable, or Cotter Pins Inside Fuel Tanks

CDCCL 28-2 DC-8 Fuel Pump (Boost or Transfer) and DC8-28.01-9

Housing Assemblies

CDCCL 28-3 DC-8 Fuel Pump (Boost or Transfer) and DC8-28.01-10

Housing Assemblies

CDCCL 28-4 DC-8 Fuel Pump Electrical Connector DC8-28.01-11

Wire/Conduit Assembly

CDCCL 28-5 DC-8 Outer Wing Surface Preparation DC8-28.01-12

CDCCL 28-6 DC-8 Fuel Quantity Master Indicators DC8-28.01-13

CDCCL 28-7 DC-8 Fuel Pump Connector DC8-28.01-14

SCI 27-1 DC-8 Longitudinal Trim Jackscrew Lubrication DC8-27.01-1

SCI 27-2 DC-8 Longitudinal Trim Jackscrew Wear DC8-27.01-2

Check

SCI 32-1 DC-8 Landing Gear Bogie Attach Point DC8-32.02.-1

Lubrication (SL DC-8-SL-32-112)

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EFFECTIVITY (Cont’d)

Boeing CDCCL, SCI, Non-Routine Job

Description
& ALI Task Number Card Number

SCI 32-2 DC-8 Main Landing Gear Bogie Inspection (SL DC8-32.02-2
DC-8-SL-32-112)

ALI 20-1 DC-8 Fuel Pump Circuit Breaker Reset DC8-28.01-15

ALI 28-1 DC-8 Alternate & Center Auxiliary Tank Fuel DC8-28.02-1
Pump Control Systems Check

ALI 30-1 DC-8 Pneumatic System Decay Check DC8-36.01-1

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MANUAL/JOB CARD/FORM CORRECTION REQUEST AND REPLY

TO: PUBLICATIONS DEPT., LITTLE ROCK ____________Reply Requested

FROM: Info Only

DATE: __________________________Manual/Job Card/Form #

THE FOLLOWING “CORRECTION REQUEST AND REPLY” FORM IS PROVIDED FOR YOUR USE TO
BRING TO OUR ATTENTION ANY ERROR (TECHNICAL OR OTHERWISE) REQUIRING CORRECTION,
OR ANY TECHNICAL DATA WHICH YOU FEEL SHOULD BE INCLUDED IN THIS MANUAL.

Suggested correction and reason: (attach marked up copy, if possible)

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TABLE OF CONTENTS

SECTION PAGE

08.01 WEIGHING PROCEDURE...................................................................... 08.01.1

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08.01 – WEIGHING PROCEDURE

TABLE OF CONTENTS
Paragraph Page
1. GENERAL ................................................................................................ 08.01.1
2. ATI WEIGHING PROGRAM.................................................................. 08.01.1
3. PREPARATION FOR WEIGHING OF AIRPLANE .............................. 08.01.2
4. ACTUAL WEIGHING PROCEDURE .................................................... 08.01.3
5. FLUID DRAINING PROCEDURE – 8 TANK FUEL SYSTEM (-62/72/
73) ............................................................................................................. 08.01.5
6. FLUID DRAINING PROCEDURE – 8 TANK ARRANGEMENT (-71) 08.01.7
7. UNUSABLE OIL...................................................................................... 08.01.8
8. CALCULATING THE EMPTY OPERATING WEIGHT....................... 08.01.9
9. LATITUDE/ALTITUDE CORRECTION FACTOR............................... 8.01.10

FIGURES
08.01-1 LEVELING DIAGRAM........................................................................... 08.01.5

FORMS
08.01-1 OPERATING WEIGHT CALCULATION.............................................. 08.01.14
08.01-2 DC-8-71 WEIGHT & BALANCE USING LOAD CELL SCALES........ 08.01.15
08.01-3 DC-8-71 WEIGHT & BALANCE USING PLATFORM SCALES ........ 08.01.16
08.01-4 DC-8-62/72 WEIGHT & BALANCE USING LOAD CELL SCALES .. 08.01.17
08.01-5 DC-8-62/72 WEIGHT & BALANCE USING PLATFORM SCALES ... 08.01.18
08.01-6 DC-8-73 WEIGHT & BALANCE USING LOAD CELL SCALES........ 08.01.19
08.01-7 DC-8-73 WEIGHT & BALANCE USING PLATFORM SCALES ........ 08.01.20
08.01-8 DC-8 WEIGHT AND CUMULATIVE CHANGE .................................. 08.01.21

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FORMS (cont’d)
08.01-9 PRE-WEIGH CHECK LIST..................................................................... 08.01.22
08.01-10 SHORTAGE/OVERAGE LIST................................................................ 08.01.23
08.01-11 EQUIPMENT LIST .................................................................................. 08.01.24

TABLES
08.01-1 LATITUDE CORRECTION FACTORS - ALTITUDES <2500 FEET .. 08.01.11
08.01-2 LATITUDE CORRECTION FACTORS - ALTITUDES >2500 FEET .. 08.01.12

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1. General

a. This section describes a procedure for obtaining the “as weighed” empty weight, total
arm, and total moment of the DC-8 airplane, needed to calculate the “Empty Operating
Weight (EOW) & Center of Gravity (CG).” This procedure is based on the usage of
electronic scales which are subject to FAA approval and yearly calibration.
b. The procedures within this section will be sued as the training syllabus for the weighing
of ATI aircraft. Documentation of training will be completed using ATI GMM
procedures 4.303 and 7.104.
c. When weighing the airplane, it is recommended that the electronic load cells be mounted
on suitable jacks at the fuselage nose jack pad and main wing jacking points. An axle
jacking procedure may also be used, although it is more complicated and prone to error.
The axle jacking method is somewhat less risky than the wing jacking procedure, because
the vertical lift requirement is much less.
d. Equipment shortages which are revealed during the weighing procedure must be included
as corrections (plus or minus) to the “as weighed” weight in the determination of Empty
Operating Weight.

2. Air Transport International Weighing Program

a. A.T.I. will use the individual weight of the aircraft in computing pertinent gross weight
and balance data. The individual weight and center of gravity of each aircraft shall be
confirmed by re-weighing at intervals of three years (36 months). In addition, it will be
re-established by re-weighing whenever the cumulative change to the operating weight
exceeds plus or minus one-half of one percent of the maximum landing weight or the
cumulative change in the center of gravity position exceeds one-half of one percent of
mean aerodynamic chord (MAC). (This does not include configuration changes. See
paragraph 2c.)
b. A Weight and Balance Data Log will be kept as a part of each individual aircraft’s
records. This Log will contain the following;
(1) The current weigh job documentation.
(2) An Operating Weight Form for each desired configuration.
(3) The cumulative weight change record.
(4) A historical section of superseded weigh jobs for comparison purposes.
In addition, this information will be entered in a parallel records program in the computer
for better publication in summary form to the airline. The computer summary of the
weight and balance information will also list the MTOW, MLW, MZFW, SelCal code,
type of international navigation, number of seats on the aircraft, and the configuration of
the aircraft for each respective EOW. Each EOW on this list is inclusive of cumulative
weight and moment changes.

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c. Due to the variety of Spare Parts Kit content and loading equipment configurations, it is
permissible to prepare in advance the desired number of Operating Weight Forms for a
given aircraft establishing all pertinent data for operating in different configurations.
These Operating Weight Form Configuration Designations are published and updated as
required as the “Weight and Balance Datasheet”. Such Operating Weight Forms
prepared in advance will be inserted into their respective Weight and Balance Data Logs,
and be summarized in computer format.
d. An ATI Representative shall be present and observe the preparation and weighting of
Company Aircraft. Additionally, this person shall be responsible for ensuring all
procedures are followed and all weight forms are properly completed and sent to LIT
Q/C immediately.
3. Preparation for Weighing of Airplane(Refer to Pre-Weigh Check List, Form 08.01-9)
a. The fuel system, prior to airplane weighing, shall be completely dry, or drained in
accordance with the procedure for obtaining the “Tare Fuel” condition as contained in
this chapter.
b. The engines and CSD lubricating oil system, prior to airplane weighing, shall be
completely dry, or filled to “Full Level” immediately after engines have been run. The
“Unusable Oil” weight shall be established in accordance with the procedure outlined in
this chapter.
c. Position airplane in hangar or protected area with no wind, and shut down blowers,
compressors, welding equipment, etc. Close doors and windows in the area.
CAUTION: MAKE CERTAIN LANDING GEAR GROUND LOCKPINS ARE
INSTALLED
d. The following miscellaneous fluid containers and systems shall be charged or filled to
operating capacity:
(1) Hydraulic systems, tanks and accumulators.
(2) Crew, passenger and first-aid oxygen cylinders.
(3) Engine and hand fire-extinguisher bottles.
e. The lavatory-galley drinking water, wash water and waste water tanks and systems shall
be completely dry.
f. The airplane structure and loose equipment shall be in exact agreement with the A.T.I.
Loose Equipment Inventory List. Any shortages will be documented on this list. All
airplane loose equipment items (emergency equipment, pallet system, flight kits, etc.)
shall be in their normal location. However all spare parts, including wheels, brakes,
components, fluids, etc., will be removed from the aircraft during weighing. This is to
facilitate the computation of several configurations from the same weigh job.

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g. All tools, work equipment and trash shall be removed from the airplane prior to
weighing.

h. Inflate nose gear strut to fully extended position.

i. Close all airplane doors (entrance, access, inspection, etc.) Check the airplane exterior
for interference with work stands and other equipment. All personnel shall be clear of
the airplane while weighing.

4. Actual Weighing Procedure

a. Weighing Using Load Cell Scales. (Wing and Nose Jack Pads)

(1) The jacking and leveling sequence is as follows:

(a) Position all jacks with their respective load cells under the nose and wing jack
points. Leave main gear struts in static position.

(b) Extend wing jacks until respective load cells read cells read approximately 500
lbs. each. Jack nose jack until nose cell reads approximately 200 lbs. Allow kit
to warm up to power-on in this position for 20 to 30 minutes.

(c) This period may be used to check Equipment Lists, resolve shortages, etc.

(d) Lower jacks until all cells are clear of jack pads.

(e) Zero the weighing kit indicators for each cell. After a two minute wait, check
for zero drift.

NOTE: If compensation for drift is excessive, either the load cells have not adjusted to
ambient temperature conditions, or the kit is defective. Repeat pre-load
procedure and allow sufficient time to elapse for temperature equalization. If
excessive drift is still present, repair or replace kit.

(f) Raise all jacks simultaneously until all tires clear ground. Place level on
brackets provided in nose wheel well. Jack nose to level longitudinally; Jack
low wing to level laterally. Re-check to be sure all tires are clear of ground.

(g) Read weighing kit and record readings on A.T.I. Airplane Actual Weight and
Balance Form for the appropriate airplane model.

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(2) Lower jacks simultaneously until all cells are clear of jack pad and axles.
CAUTION: DO NOT TOUCH OR REMOVE LOAD CELLS UNTIL NEXT
STEP HAS BEEN ACCOMPLISHED.
(3) Read and record cell drift corrections. Record on the A.T.I. Airplane Actual Weight
and Balance Form. Also record any tare weight values at this point.
(4) Repeat steps (1)(d) through (3) above three times each so an average weight may be
obtained.
(5) Remove and store equipment.

b. Weighing Using Platform Scales

(1) Place eight platform scales in front of the main landing gear, aligned with the main
wheels.
(2) Place one platform scale in front of the nose landing gear.
(3) Carefully tow the aircraft onto the platform scales and remove the towbar from the
aircraft.
(4) Level the aircraft laterally and longitudinally using the leveling brackets installed in
the aircraft.
(5) Obtain the scale readings in accordance with the scales’ operating instructions.
Record on the actual Weight and Balance Form for that model aircraft.
(6) Suspend a plumb bob from the fuselage jig point drain hole at FS 926.0.
(7) Stretch a string between the main gear jig points (centerline of hollow bolts through
the rear brake compensator trunnion on the shock strut.)
(8) Measure the horizontal distance from the string to the plumb line. Record this as
dimension “D.” Using the formulas below, calculate the nose gear weighing-point
H-Arm.
MLG Weighing Arm = FS 926.0 + D - 6.0”, or FS 920 + “D.”

Measure the distance from the centerline of the nose gear to the main gear jig point
string. Record this as dimension “E.” Using the formula below, calculate the nose
gear weighing point H-ARM.

NLG Weighing Arm = FS 926 + “D” - “E.”

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APPROXIMATE ARMS
Model NLG MLG
DC-8-71/-73 -8.9 921.0
DC-8-62/-72 191.1 921.0
See Leveling Diagram (Figure 08.01-1)
(9) Enter both arms on the A.T.I. Actual Weight and Balance Form for that model
aircraft for use in calculating MLG and NLG moments.
(10) Carefully re-connect the towbar and push the aircraft off the platforms following
manufacturer’s operating instructions.
(11) Repeat steps (3) through (10) above three times each so an average weight may be
obtained.

LEVELING DIAGRAM
Figure 08.01-1

5. Fluid Draining Procedure - 8 Tank Fuel System DC-8-62/-72/-73 (Combined Inboard Tanks)

Note: TARE FUEL (for weighing wet airplanes) is the fuel remaining in the airplane after
defueling from the high pressure refueling adapters by the following prescribed
method:
a. Prior to draining the fuel, all lines, engine pumps, engines, and other components of the
fuel system must be fully primed. Also there must be sufficient head of fuel in each tank
to insure that the boost and feed pumps, when started, will properly prime and thereafter
pump fuel until the tanks are drained.

b. Level the airplane laterally and 1 degree nose down.

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c. Attach a defueling hose to the manifold adapter under the wing. Either side and either
adapter is satisfactory.

d. Turn all firewall shut-off valves to “Fuel Off’ position.

e. Turn all cross-feed controls to “Cross-Feed” position.

f. Turn all fill valves to “Off” position.

g. Turn the center wing auxiliary tank selector valve to “Auxiliary” position. Actuate
pumps by turning pump switch to “Boost” position. Wait until the fuel has started to
flow then turn the forward auxiliary tank selector valve to “Auxiliary” position. After
fuel has stopped flowing steadily through meter or into truck, continue running the
pumps for at least 5 minutes.

h. Turn all tank selector valves to “Main” position. Actuate pumps by turning switches to
“Feed and Boost” position for all main tanks. Allow to run until feed pump pressure
warning light burns steadily. Continue running pumps for at least 5 minutes.

Note: After start of de-fueling of “Main” tanks, scavenge pump may be actuated to
reduce quantity of sump fuel in C.W. Aux. Turn off scavenge pump before
main tank is below 2000 pounds.

i. Turn outboard tank selector valves to “Alternate” position. Actuate pumps by turning
switches to “Boost” position for alternate tanks. After fuel has stopped flowing steadily
through the meter or into truck, continue running the boost pumps for at least 5 minutes.

j. Wait 30 minutes -repeat steps g., h. and i. continuing until fuel ceases to flow from hoses.

k. Drain the sumps of the center wing auxiliary tank. NOTE: Apply suction to sump drains
to insure complete drain out. Do not drain tank sumps.

l. Drain the fuel tank vent sumps.

Note: When fuel pumps have been started and fuel flow has been established, it is
necessary that the operation continue without interruption until the fuel no
longer continues to flow from the tanks.

m. The following weight of Fuel must be subtracted from “As-Weighed (Wet) weight of the
airplane to determine Manufacturer’s Empty Weight (used in the derivation of
Delivery/Basic Empty Weight):

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Weight H-Arm Moment

(LB) (Fus. Sta.) (about Sta. 0)

TARE FUEL +1019 837.2 853,106.8

6. Fluid Draining Procedure - 8 Tank Arrangement (DC-8-71F)

Note: Tare Fuel (for wet-weighing airplanes) is the fuel remaining in the airplane after
defueling from the high pressure refueling adapters by the following method:

(a) Prior to draining the fuel, all lines, engine pumps, engines, and other components of the
fuel system must be fully primed. Also, there must be a sufficient head of fuel in each
tank to insure that the boost and feed pumps, when started, will properly prime and
therefore pump fuel until the tanks are drained. The inboard alternate tanks should
contain at least 3,500 lb. each.

(b) Level the airplane laterally and 1.0 degree nose down.

(c) Attach a defueling hose to the manifold adapter under the wing. Either side and either
adapter is satisfactory.

(d) Turn all firewall shut-off valves to “Fuel Off” position.

(e) Turn all cross-feed controls to “Cross Feed” position.

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(f) Turn all fill valves to “Off” position.

(g) Turn all tank selector valves to “Main” position. Actuate pumps by turning switches to
“Feed and Boost” position for all main tanks. Allow to run until feed pump pressure
warning light burns steadily. Continue running pumps for at least five minutes.

(h) Turn all Tank Selector valves to “Alternate” position. Actuate pumps by turning
switches to “Boost” position for all alternate tanks. After fuel has stopped flowing
steadily through the meter or into truck, continue running the boost pumps for at least
five minutes.

(i) Wait 30 minutes - repeat steps g. and h., continuing until fuel ceases to flow from hoses.

(j) Drain the fuel tank vent sumps.

NOTE: When fuel pumps have been started and fuel flow has been established, it is
necessary that the operation continue without interruption until the fuel no
longer continues to flow from the tanks.

(k) The following weight of Tare fuel must be subtracted from the “As-Weighted (Wet)”
weight of the airplane to determine Manufacturer’s Empty Weight (used in the derivation
of Delivery/Basic Empty Weight):

Weight H-Arm Moment

(LB) (Fus. Sta.) (about Sta. 0)

TARE FUEL 794 853.5 677,676

7. Unusable Oil. (System Oil)

(a) Unusable for engines and Constant Speed Drives is the weight of oil remaining in the
airplane after subtracting the oil in the tanks above the engine feed stand pipes, or gage
zero levels.

(b) To obtain airplane weight with the correct value of unusable oil, the engines and
Constant Speed Drive tanks must be “topped off” immediately after engine run, while the
oil is still hot.

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(c) Oil should not be added after the engines and Constant Speed Drives have cooled, as this
will overfill the systems and result in erroneous weight, The weights and moments of
usable oil in both systems are the subtracted from the “As-Weighed” weight to obtain
airplane weight with “unusable oil.”

8. Calculating the Empty Operating Weight

a. Subsequent to weighing the airplane, the Actual Airplane Weight and Balance Form
should be filled out, and the weights added, making allowance for instrument corrections
and tare weight. When weighing with platform scales, note that a latitude/altitude
correction factor is generally also a part of the instrument correction procedure (See
Tables 08.01-1 & -2). The corrected display weight is multiplied by this latitude/altitude
correction factor to obtain the true weight of the correction tables are found in each
platform scales operator’s manual.

b. If any equipment required to be onboard during weighing is left off, or if extra weight
was inadvertently left onboard, adjustments may be made at the bottom of the Actual
Airplane Weight and Balance Form as either “plus” or “minus” items. Use the ATI
Shortage/ Overage Form to record and calculate total values for all “plus” and “minus”
items. The empty center of gravity is also calculated in terms of the total H-Arm for the
basic empty weight, and also in percent of MAC. This information is used to initiate the
calculations on the Operating Weight Form for each model aircraft.

c. The information on the Actual Airplane Weight and Balance Form is transferred to the
computer generated Operating Weight Form. The desired configuration of the aircraft is
also selected. All personnel and items required to operate the aircraft not included in the
basic empty weight are added at this time in the body of the Operating Weight Form.
These include;

(1) Flight Crew

(2) Flight Crew Manual Purses
(3) Flight Crew Baggage
(4) Specific parts and equipment per the Configuration Legend
(4) International Nav Kits
(5) Miscellaneous Items
d. All items are added algebraically, and a total weight, arm, and moment are derived for
the airplane with all additional items added over and above the basic empty weight. This
yields the Empty Operating Weight.

e. The center of gravity in percent MAC is calculated, as well as the index units for the
Empty Operating Weight.

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f. All cumulative weight changes will be listed on the ATI cumulative weight change
record. The first entry will be the EOW. Subsequent entries will be accomplished for
weight changes of plus or minus 10 pounds. Therefore, any weight change less than 10
pounds is negligible. The EOW will be re-calculated in the cumulative “totals” column.
When the cumulative changes exceed those limits as stated in paragraph 2.a. of this
chapter, re-weighing of the aircraft must be accomplished.

g. This information is entered into the parallel Q.C. computer program, from which the fleet
weight and balance summary is produced.

9. Latitude / Altitude Correction Factor. The true weight of an object is dependent upon
gravity, G, or more precisely, the accleration due to gravity. Since it varies with latitude
north or south of the equator it is necessary to make a latitude correction to the corrected
displayed weight to obtain the actual weight. Perform the latitude correction as follows:

a. Determine latitude / altitude of weighing site. (Flight operation, engineering, or weather

office can usually provide latitude).

b. Refer to Table 08.01-1 or Table 08.01-2 for the proper correction factor for the latitude /
altitude. Inter-polate if necessary.

c. Multiply corrected displayed weight by latitude / altitude correction factor to obtain true
weight.

Example: Latitude of site is 50 degrees 12 minutes north, altitude is 3,000 ft. Displayed
weight is 36,120 from Table 2, correction factor is 0.9999.

36,120 pounds X 0.9999 = 36,116 pounds.

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LATITUDE CORRECTION LATITUDE CORRECTION

(DEGREES) FACTOR (DEGREES) FACTOR
0 1.0027 50 .9996
5 1.0026 55 .9991
10 1.0025 60 .9987
15 1.0023 65 .9983
20 1.0021 70 .9980
25 1.0017 75 .9978
30 1.0014 80 .9976
35 1.0009 85 .9974
44 1.0005 90 .9974
45 1.0000
1. Platform is calibrated to standard gravity G. 930.665 cm / sec / sec
(32.174 ft / sec) at sea level.

2. To obtain actual weight, multiply the weight indicated on the display by correction factor
for latitude at which the scale is being used.

LATITUDE CORRECTION FACTORS

FOR ALTITUDES < 2500 FEET
Table 08.01-1

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ELEVATION ABOVE SEA LEVEL (FT)

LATITUDE
(DEGREES) +3000 +4000 +5000 +6000 +7000
0 1.0030 1.0031 1.0032 1.0033 1.0034
5 1.0029 1.0030 1.0031 1.0032 1.0033
10 1.0028 1.0029 1.0030 1.0031 1.0032
15 1.0026 1.0027 1.0028 1.0029 1.0030
20 1.0024 1.0025 1.0025 1.0026 1.0027
25 1.0020 1.0021 1.0022 1.0023 1.0024
30 1.0017 1.0017 1.0018 1.0019 1.0020
35 1.0012 1.0013 1.0014 1.0015 1.0016
44 1.0008 1.0009 1.0010 1.0011 1.0012
45 1.0003 1.0004 1.0005 1.0006 1.0007
50 .9999 1.0000 1.0001 1.0002 1.0003
55 .9994 .9995 .9996 .9997 .9998
60 .9990 .9991 .9992 .9993 .9994
65 .9986 .9987 .9988 .9989 .9990
70 .9983 .9984 .9985 .9986 .9987
75 .9980 .9981 .9982 .9983 .9984
80 .9979 .9979 .9980 .9981 .9982
85 .9977 .9978 .9979 .9980 .9981
90 .9977 .9978 .9979 .9980 .9981
1. Platform weighing system is calibrated to standard gravity G. 980.665 cm / sec / sec
(32.174 ft / sec) at sea level.

2. To obtain actual weight, multiply the weight indicated on the display by correction factor
for latitude / altitude at which the scale is being used.

LATITUDE CORRECTION FACTORS

FOR ALTITUDES > 2500 FEET
Table 08.01-2

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CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)

OPERATING WEIGHT FORMULA - DC-8-71

OP WEIGHT CG = ARM - LEMAC X 100 ( ) - 789.7 X 100 = %MAC

MAC 275.9

EOW I.U. = EOW (ARM - 858.7) ( ) X ( - 858.7) = I.U.

10,000 10,000

PREPARED BY CHECKED BY

OPERATING WEIGHT FORMULA - DC-8-62/72

OP WEIGHT CG = ARM - LEMAC X 100 ( ) - 795.8 X 100 = %MAC

MAC 272.8

EOW I.U. = EOW (ARM - 858.7) ( ) X ( - 858.7) = I.U.

10,000 10,000

PREPARED BY CHECKED BY

OPERATING WEIGHT FORMULA - DC-8-73

OP WEIGHT CG = ARM - LEMAC X 100 ( ) - 795.8 X 100 = %MAC

MAC 272.8”

EOW I.U. = EOW (ARM - 858.7) ( ) X ( - 858.7) = I.U.

10,000 10,000
PREPARED BY CHECKED BY

Operating Weight Worksheet

Revision 29 10-29-07 08.01.13

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DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)

AIRCRAFT: DATE:
ITEM (s) WEIGHT ARM MOMENT INDEX UNIT
Aircraft Empty Weight
Pilots with Kits
F/E with Kit
Crew Baggage
Full Navigation Kits
Aircraft Library
Catering Equipment
Potable Water
Lav Chemicals
Pillows/Blankets
Spare Parts Kit
2 Main Wheels & Tires
2 Nose Wheels & Tires
2 Brake
1 Tow Bar
Oil & Hydraulic Fluid

TOTALS (CF)

CG (CF)

INDEX UNIT (CF)

Catering
1 Flight Attendant
F/A's Baggage

TOTALS (C1)

CG (C1)

INDEX UNIT (C1)

2nd Flight Attendant

F/A's Baggage

TOTALS (C2)

CG (C2)

INDEX UNIT (C2)

THE OPERATING EMPTY WEIGHT (EOW) INCLUDES THE EMPTY WEIGHT PLUS
CREW AND MISCELLANIOUS EQUIPMENT NOT INCLUDED IN THE EMPTY WEIGHT.
Prepared by: ______________________ Checked by: __________________________

OPERATING WEIGHT CALCULATION

Form 08.01-1

08.01.14 12-03-01 Revision 14

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)

A/C SCALE TYPE WEIGHED BY

DATE S/N INSPECTOR

STA CAL DATE

<───LEMAC
<───────────────────789.7───────────────────> <─── 275.9 ───>
(MAC)

71.6 842.7
(NOSE)
<───────────────────914.3───────────────────>
(DATUM) (WING)

SCALE POSITION SCALE READING INST. CORR. TARE NET WEIGHT

NOSE
RIGHT WING
LEFT WING
TOTAL WEIGHT
(NOSE) (ARM)

CG FROM DATUM (AS WEIGHED) = 914.3 - ( x 842.7) = INCHES

(TOTAL WEIGHT)

ITEM WEIGHT ARM MOMENT

AS WEIGHED WEIGHT
PLUS ITEMS
MINUS ITEMS
BASIC EMPTY WEIGHT

EMPTY WT. BALANCE = ( - 789.7) x 100 = % MAC

275.9

DC-8-71 Aircraft Actual Weight & Balance Using Load Cell Scales
Form 08.01-2

Revision 14 12-03-01 08.01.15

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DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)
A/C S/N WEIGHED BY

DATE STA INSPECTOR

SCALE TYPE CAL DATE

SCALE S/N’S

NLG R/H INBD FWD R/H OTBD FWD

R/H INBD AFT R/H OTBD AFT L/H INBD FWD

L/H INBD AFT L/H OTBD FWD L/H OTBD AFT

SCALE POSITION SCALE READING SCALE TARE NET WEIGHT
CORRECTION
NOSE GEAR
RH FWD INBD MLG
RH FWD OTBD MLG
RH AFT INBD MLG
RH AFT OTBD MLG
LH FWD INBD MLG
LH WD OTBD MLG
LH AFT INBD MLG
LH AFT OTBD MLG
TOTAL WEIGHT
RECORD THE FOLLOWING:
LATITUDE/ALTITUDE CORRECTION FACTOR

ARMS (AS MEASURED WITH REFERENCE TO THE FS 926.0 DRAIN HOLE)

MLG ARM NLG ARM
AVERAGE
WEIGHT:
POSITION AVERAGE WT. LAT. CORR. TOTAL WEIGHT ARM MOMENT
NOSE GEAR X = X =
R/H FWD MLG X = X =
R/H AFT MLG X = X =
L/H FWD MLG X = X =
L/H AFT MLG X = X =
TOTAL “AS WEIGHED” WEIGHT/ARM/MOMENT

ITEM WEIGHT ARM MOMENT

AS WEIGHED WEIGHT
PLUS ITEMS
MINUS ITEMS
BASIC EMPTY WEIGHT

EMPTY WT. BALANCE = ( - 789.7) x 100 = % MAC

275.9
DC-8-71 Aircraft Actual Weight & Balance Using Platform Scales
Form 08.01-3

08.01.16 12-03-01 Revision 14

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE

08.01 WEIGHING PROCEDURE(cont’d)

A/C SCALE TYPE WEIGHED BY

DATE S/N INSPECTOR

STA CAL DATE

LEMAC
795.8 272.8
(MAC)

271.6 642.7
(NOSE)
914.3
(DATUM) (WING)

SCALE POSITION SCALE READING INST. CORR. TARE NET WEIGHT

NOSE
RIGHT WING
LEFT WING
TOTAL WEIGHT
(NOSE) (ARM)

CG FROM DATUM (AS WEIGHED) = 914.3 - ( x 642.7) = INCHES

(TOTAL WEIGHT)

ITEM WEIGHT ARM MOMENT

AS WEIGHED WEIGHT
PLUS ITEMS
MINUS ITEMS
BASIC EMPTY WEIGHT

EMPTY WT. BALANCE = ( - 795.8) x 100 = % MAC

272.8

DC-8-62/72 Aircraft Actual Weight & Balance Using Load Cell Scales
Form 08.01-4

Revision 14 12-03-01 08.01.17

AIR TRANSPORT INTERNATIONAL, L.L.C.
DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)
A/C S/N WEIGHED BY

DATE STA INSPECTOR

SCALE TYPE CAL DATE

SCALE S/N’S

NLG R/H INBD FWD R/H OTBD FWD

R/H INBD AFT R/H OTBD AFT L/H INBD FWD

L/H INBD AFT L/H OTBD FWD L/H OTBD AFT

SCALE POSITION SCALE READING SCALE TARE NET WEIGHT
CORRECTION
NOSE GEAR
RH FWD INBD MLG
RH FWD OTBD MLG
RH AFT INBD MLG
RH AFT OTBD MLG
LH FWD INBD MLG
LH WD OTBD MLG
LH AFT INBD MLG
LH AFT OTBD MLG
TOTAL WEIGHT
RECORD THE FOLLOWING:

LATITUDE/ALTITUDE CORRECTION FACTOR

ARMS (AS MEASURED WITH REFERENCE TO THE FS 926.0 DRAIN HOLE)

MLG ARM NLG ARM

AVERAGE WEIGHT:
POSITION AVERAGE WT. LAT. CORR. TOTAL WEIGHT ARM MOMENT
NOSE GEAR X = X =
R/H FWD MLG X = X =
R/H AFT MLG X = X =
L/H FWD MLG X = X =
L/H AFT MLG X = X =
TOTAL “AS WEIGHED” WEIGHT/ARM/MOMENT

ITEM WEIGHT ARM MOMENT

AS WEIGHED WEIGHT
PLUS ITEMS
MINUS ITEMS
BASIC EMPTY WEIGHT

EMPTY WT. BALANCE = ( - 795.8) x 100 = % MAC

272.8
DC-8-62/72 Aircraft Actual Weight & Balance Form Using Platform Scales
Form 08.01-5

08.01.18 12-03-01 Revision 14

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)
A/C SCALE TYPE WEIGHED BY

DATE S/N INSPECTOR

STA CAL DATE

<───LEMAC
<───────────────────795.8───────────────────> <─── 272.8 ───>
(MAC)

71.6 842.7
(NOSE)
<───────────────────914.3───────────────────>
(DATUM) (WING)

SCALE POSITION SCALE READING INST. CORR. TARE NET WEIGHT

NOSE
RIGHT WING
LEFT WING
TOTAL WEIGHT
(NOSE) (ARM)

CG FROM DATUM (AS WEIGHED) = 914.3 - ( x 842.7) = INCHES

(TOTAL WEIGHT)

ITEM WEIGHT ARM MOMENT

AS WEIGHED WEIGHT
PLUS ITEMS
MINUS ITEMS
EMPTY OPERATING
WEIGHT

EMPTY WT. BALANCE = ( - 795.8) x 100 = % MAC

272.8

DC-8-73 Aircraft Actual Weight & Balance Using Load Cell Scales
Form 08.01-6

Revision 29 10-29-07 08.01.19

AIR TRANSPORT INTERNATIONAL, L.L.C.
DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)
A/C S/N WEIGHED BY

DATE STA INSPECTOR

SCALE TYPE CAL DATE

SCALE S/N’S

NLG R/H INBD FWD R/H OTBD FWD

R/H INBD AFT R/H OTBD AFT L/H INBD FWD
L/H INBD AFT L/H OTBD FWD L/H OTBD AFT
SCALE POSITION SCALE READING SCALE TARE NET WEIGHT
CORRECTION
NOSE GEAR
RH FWD INBD MLG
RH FWD OTBD MLG
RH AFT INBD MLG
RH AFT OTBD MLG
LH FWD INBD MLG
LH WD OTBD MLG
LH AFT INBD MLG
LH AFT OTBD MLG
TOTAL WEIGHT
RECORD THE FOLLOWING:
LATITUDE/ALTITUDE CORRECTION FACTOR
ARMS (AS MEASURED WITH REFERENCE TO THE FS 926.0 DRAIN HOLE)
MLG ARM NLG ARM
AVERAGE WEIGHT
POSITION AVERAGE WT. LAT. CORR. TOTAL WEIGHT ARM MOMENT
NOSE GEAR X = X =
R/H FWD MLG X = X =
R/H AFT MLG X = X =
L/H FWD MLG X = X =
L/H AFT MLG X = X =
TOTAL “AS WEIGHED” WEIGHT/ARM/MOMENT

ITEM WEIGHT ARM MOMENT

AS WEIGHED WEIGHT
PLUS ITEMS
MINUS ITEMS
EMPTY OPERATING
WEIGHT
EMPTY WT. BALANCE = ( - 795.8) x 100 = % MAC
272.8
DC-8-73 Aircraft Actual Weight & Balance Form Using Platform Scales
Form 08.01-7

08.01.20 10-29-07 Revision 29

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)

Aircraft Series Serial No.

CHECKED BY:

ITEM WEIGHT ARM MOMENT DATE NAME SIGNATURE

Aircraft Weighed

TOTALS

DC-8 Weight and Cumulative Change

Form 08.01-8

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AIR TRANSPORT INTERNATIONAL, L.L.C.
DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)

Aircraft: __________________ Station :___________________ Date : _____________

Mech. Insp.
A. Drain fuel system. Prior to airplane weighing, the fuel system shall be
completely dry, or drained in accordance with the procedure for obtaining
the “Tare Fuel” condition as contained in DC-8 MM Chapter 8.

B. The engines and CSD lubricating oil system, prior to airplane weighing,
shall be completely dry, or filed to “Full Level” immediately after engines
have been run. The “Unusable Oil” weight shall be established in
accordance with the procedure outlined in W / B Manual Chapter 5

C. Position airplane in hangar or protected area with no wind, and shut

down blowers, compressors, welding equipment, etc. Close doors and
windows in the area.

D. Ensure the Landing gear ground lockpins are installed (3 ea.)

E. The following miscellaneous fluid containers and systems shall be

charged or filled to operating capacity.

1.) Hydraulic systems, tanks and accumulators.

2.) Crew, passenger and first-aid oxygen cylinders.

3.) Engine and hand fire-extinguisher bottles

F. The lavatory-galley drinking water, wash water and waste water tanks
and systems shall be completely dry.

G. The airplane structure and loose equipment shall be in exact agreement

with the A. T. I. Loose Equipment Inventory List. Any shortages will be
documented on this list. All airplane loose equipment items (emergency
equipment, pallet system, flight kits,etc. ) shall be in their normal location.
However, all spare parts, including wheels, brakes, components, fluids,
etc., will be removed from the aircraft during weighing. This is to facilitate
the computation of several configurations from the same weigh job.

H. All tools, work equipment and trash shall be removed from the airplane
prior to weighing.

I. Inflate nose gear strut to fully extended position.

J. Close all airplane doors (entrance, access, inspection, etc.) Check the
airplane exterior for interference with work stands and other equipment.
All personnel shall be clear of the airplane while weighing.

Pre-Weigh Check List

Form 08.01-9

08.01.22 12-03-01 Revision 14

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DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)
AIRCRAFT STATION DATE

ITEMS NOT ON AIRCRAFT WHEN WEIGHED BUT PART OF EMPTY WEIGHT

ITEMS DESCRIPTION WEIGHT ARM MOMENT
( ) ( ) ( )

TOTAL “ PLUS “ ITEMS

ITEMS ON AIRCRAFT WHEN WEIGHED BUT NOT PART OF EMPTY WEIGHT

ITEMS DESCRIPTION WEIGHT ARM MOMENT
( ) ( ) ( )

TOTAL “MINUS” ITEMS

Shortage/Overage List
Form 08.01-11

Revision 14 12-03-01 08.01.23

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DC-8 MAINTENANCE MANUAL
CHAPTER 8 - WEIGHT AND BALANCE
08.01 WEIGHING PROCEDURE(cont’d)

EQUIPMENT LIST
PAGE ___ OF ___
COMPT ITEMS BEW REQ WEIGHT H
& ( Items checked (€) are included in BEW ) € APL EACH ARM
ITEM # (POUNDS)

AIRLINE__________________________

REGISTRATION NO.________________

DOUGLAS SERIAL NO. _____________

DATE ____________________________

Equipment List
Form 08.01-11

08.01.24 12-03-01 Revision 14

AIR TRANSPORT INTERNATIONAL L. L. C.
DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING

TABLE OF CONTENTS
Page
09.01 TAXI ---------------------------------------------------------------------------------- 09.01.1
09.02 NOSE GEAR TOWING PROCEDURES --------------------------------------- 09.02.1
09.03 FLAT TIRE TOWING PROCEDURES ----------------------------------------- 09.03.1
09.04 AIRCRAFT GROUND OPERATIONS ----------------------------------------- 09.04.1
09.05 PARKING, TIE DOWN, AND GROUND HANDLING---------------------- 09.05.1

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CHAPTER 09-GROUND HANDLING

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING

09.01 - TAXI
TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 09.01.1

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CHAPTER 09-GROUND HANDLING

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING
09.01 TAXI

1. General

a. All ground maintenance operations (taxi, run-up, etc.) will require a 3-person cockpit
crew.

(1) One person occupying the left seat who will be run and taxi qualified per the
Company’s General Maintenance Manual.

(2) One person occupying the right seat who will operate ships communications.

(3) One person at the F/E Station who is familiar with that function, as determined by
the person in the left seat.

b. Each occasion for aircraft taxi will be authorized separately by telephone communication
with Maintenance Control.

c. Refer to DACO Maintenance Manual Microfilm Chapter 9-20-0 for other specific
procedures.

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CHAPTER 09-GROUND HANDLING

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING

09.02 – NOSE GEAR TOWING PROCEDURES

TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 09.02.1
2. LIMITATIONS ------------------------------------------------------------------------ 09.02.1
3. PROCEDURES ------------------------------------------------------------------------ 09.02.2

FIGURES

09.02-1 TOW BAR AND TOW CABLE ATTACHMENT-------------------------------- 09.02.4

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING
09.02 NOSE GEAR TOWING PROCEDURES

1. General

a. The information published below is specific to DC-8 type aircraft.

CAUTION: MAKE CERTAIN BOGIE IS LOCKED BEFORE PUSHING

AIRPLANE BACKWARD. (IF APPLICABLE)

b. Prior to start of the towing operation, the airplane hydraulic system pressure must be
more than 1500 psi.

c. During the towing operation, the vehicle operator must make certain that turning limits of
the nose gear are not exceeded. Tow bar turn limits are indicated by strips painted on the
fuselage just above the nose gear doors. During nose wheel towing all turning is
accomplished through the towbar. The nose wheel steering control is made inoperative
by placing nose wheel steering bypass valve in bypass (OPEN) position and installing
nose wheel steering bypass valve lockpin. On airplanes without bypass valve, nose
wheel steering control is made inoperative by disconnecting nose gear torque links.

2. Limitations

a. Do not tow with a flat or over extended nose or main strut (nose strut not to exceed a
maximum of 7 inches).

b. Do not tow with main gear doors in DOWN position.

c. Do not tow with any of the passenger or service doors open. This includes the main
cargo door.

d. Aircraft with non-swivel bogies:

(1) Do not exceed 500 towing or pushing with torque links connected, or 600 with
torque links disconnected.
CAUTION: EXCEEDING 500 WITH TORQUE LINKS CONNECTED MAY
DAMAGE STEERING CYLINDERS. EXCEEDING 600 AT
ANY TIME MAY DAMAGE MAIN GEAR TRUNNION
FITTINGS.
e. Aircraft with swivel bogies:
(1) If bogie is unlocked:

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING
09.02 NOSE GEAR TOWING PROCEDURES (cont'd)

(a) Do not push backwards or bogie will jack-knife.

(b) Do not exceed 700 towing angle.
(2) If bogie is locked:
(a) Pushing - do not exceed 400.
(b) Towing - do not exceed 500.
Note: Maximum angle of turn of 400 during pushout can be determined by
lining up tow bar leg (not the center) with the 500 marking on the
fuselage.
f. If the brakes seize, do not try to break them loose by pushing or pulling on the nose gear.
This practice could lead to a failed nose gear.
g. Ensure main and nose gear downlock pins are installed.
h. Where maneuvering room is limited, guides will be stationed where they can observe
wing tips, wheels, tail, etc. which might contact other objects. Guides will keep in view
of signal man who will relay their signals to the cockpit. Under these conditions speed
must not exceed normal walking rate.
3. Procedures
a. Pull bypass handle and install bypass pin or disconnect torque links, if required.
b. If required, disconnect the nose strut torque links and manually push the lower link down
against the stop so it will clear the upper link while turning. Severe damage to the nose
gear might result if lower link contacts upper link while turning. Position upper torque
link in uppermost position to ensure airplane systems affected are in ground mode. It
may be necessary to connect the tow bar and move the nose wheel to one side or the
other to disconnect torque links. If bypass valve is installed, place in bypass mode
instead of disconnecting torque links.

c. Attach approved tow bar securely to the nose wheel axle. Under extraordinary
circumstances it will be permissible to push the airplane to facilitate docking, provided
the airplane is to be moved over level ground and no excessive force required to move it.
This practice will be limited only to instances where it is absolutely necessary.

d. Disconnect GPU. Position cable on tow bar in facility provided (Ref. Figure 9.02-1). Be
sure to position cable in tow bar correctly for the airplane involved.

e. Check nose strut extension. The nose strut extension shall not exceed 7 inches to provide
clearance for the nose strut centering cams.

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING
09.02 NOSE GEAR TOWING PROCEDURES(cont'd)

f. The cockpit operator will accomplish the following before releasing the brakes:

(1) Check landing gear handle DOWN.

(2) Check gust lock ON.
(3) Check aileron and rudder power OFF.
(4) Position auxiliary pump selector in the #2 (NORMAL) position.
(5) Position auxiliary pump switch to ON.
(6) Pressurize hydraulic system to 1500 psi minimum.

Note: Ground power must be available and External Power Control Switch
(EPCSW) in the EXT PWR position to have indication on both the
hydraulic brake and hydraulic system pressure gauges.

(7) Check emergency air brake pressure - 3000 psi at 700F.

(8) If towing is to be accomplished during hours of darkness, check that navigation

lights are ON. Switch located on Captain’s overhead panel.

(9) Turn anti-collision lights ON.

g. Remove wheel chocks.

h. Prior to moving the airplane, the tractor operator will signal verbally to the cockpit
operator “Nose Scissors Disconnected - Brakes OFF” or “Nose Steering Bypassed -
Brakes OFF.”

i. The cockpit operator will release the brakes only after receipt of the preceding signal and
will then affirm verbally “Brakes OFF.”

j. If airplane is to be pushed from a nose-in passenger gate position disconnect torque

links or bypass nose steering before moving airplane if equipped with several bogies,
determine that bogies are both straight aft and locked.

k. Reconnect torque links or return bypass valve to normal mode.

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AIR TRANSPORT INTERNATIONAL L. L. C.
DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING
09.02 NOSE GEAR TOWING PROCEDURES(cont'd)

TOW BAR AND TOW CABLE ATTACHMENT

Figure 09.02-1

09.02.4 12-03-01 Revision 14

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING

09.03 – FLAT TIRE TOWING PROCEDURES

TABLE OF CONTENTS
Paragraph Page
1. ONE FLAT TIRE ---------------------------------------------------------------------- 09.03.1
2. TWO FLAT TIRES-------------------------------------------------------------------- 09.03.1

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CHAPTER 09-GROUND HANDLING

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING
09.03 FLAT TIRE TOWING PROCEDURES

1. One Flat Tire. At times it may be necessary to move an airplane having one flat tire off an
active runway or taxiway. If there is only one flat tire on a dual tire axle, the airplane may be
towed or taxied normally while avoiding sharp turns and sudden starts or stops.

2. Two Flat Tires

a.. Airplane NOT on Active Runway or Taxiway

(1) Two flat tires on one axle will allow the wheel flange to contact the ground.
Towing on smooth, hard surface for a very short distance will probably result in
little additional damage. Turn of more than 100 or towing over rough or soft
surfaces will probably damage the wheels and brakes beyond repair.

(2) When there are two or more main gear tires flat, towing must be by the main gear to
avoid excessive loads on the nose gear.

(3) If it is necessary to tow the airplane more than the short distance every attempt
should be made to have at least one inflated tire on each axle. Where only two
inflated tires are available for a main gear, they must be installed in staggered
position.

b. Airplane ON Active Runway or Taxiway. Every effort will be made to move the
airplane clear of the runway or taxiway immediately, even if it means additional damage
to wheels, tires, or axle.

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DC-8 MAINTENANCE MANUAL
CHAPTER 09-GROUND HANDLING

09.04 – AIRCRAFT GROUND OPERATIONS

TABLE OF CONTENTS
Paragraph Page
1. TOWING AIRCRAFT ---------------------------------------------------------------- 09.04.1
2. GROUND OPERATIONS – TOWER CONTROL ------------------------------- 09.04.1

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CHAPTER 09-GROUND HANDLING

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CHAPTER 09-GROUND HANDLING
09.04 AIRCRAFT GROUND OPERATIONS
WARNING: COMMUNICATIONS BETWEEN THE CONTROL TOWER AND
THE AIRCRAFT, TOWING VEHICLE AND/OR ESCORT MUST
BE AVAILABLE AND MAINTAINED DURING TAXING OR
TOWING OPERATION.
1. Towing Aircraft
a. The operator of the towing vehicle will be in complete charge of the towing operation,
and the responsibility for the aircraft in tow shall rest on the operator.
b. The towing vehicle shall be operated in its lowest gear ratio and the aircraft towed at a
speed not greater than a person normally walks. The tow vehicle operator shall
determine the number of personnel necessary to move the aircraft safely, dependent of
the conditions under which the tow is made.
c. Before towing any aircraft, the tow vehicle operator in charge shall ensure assisting
personnel are properly instructed at their stations and the aircraft is towed in accordance
with procedures set forth in section 9.02 of this manual.
2. Ground Operations - Tower Control
a. Ground vehicles operating on, or crossing active runways or taxiways must have prior
authorization from the Airport Control Tower Operator. All control tower instructions,
both oral and visual, shall be strictly adhered to.
b. Before operating on, or driving across an active runway or taxiway with a ground vehicle,
or before taxiing on, or across an active runway or taxiway with an aircraft, the operator
shall establish either oral or visual communications with the control tower. If unable to
establish communications with the control tower, DO NOT PROCEED.
(1) If possible, radio or mobile telephone contact should be established and maintained
with the control tower prior to and throughout the taxi or tow operation.
(2) If relying on visual signals from the control tower, the operator(taxi or tow) shall
stop clear of the runway and wait for clearance from the tower. Visual signals will
be given by the tower through the use of light guns. All visual signals received by
the operator shall be acknowledged by rolling the ailerons, or if ground vehicle, by
blinking the running or head lights on and off.
c. Tower Light Signals are interpreted as follows:
Steady Red STOP
Flashing Red: Clear the Runway Area
Flashing Green: Clear to Taxi or Tow
Alt. Red & Green Warning - Exercise Extreme Caution
Flashing White Return to starting point on airport.

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CHAPTER 09-GROUND HANDLING

09.05 – PARKING, TIE DOWN, AND GROUND HANDLING

TABLE OF CONTENTS
Paragraph Page
1. PARKING ------------------------------------------------------------------------------ 09.05.1
2. ENGINE INLET COVER & PITOT COVER INSTALLATION --------------- 09.05.1

3. JACKING, LIFTING, HOISTING 09.05.1

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CHAPTER 09-GROUND HANDLING
09.05 PARKING, TIE DOWN, AND GROUND HANDLING

1. Parking

a. Aircraft shall be parked only in approved parking areas. Parked aircraft will be spotted
so that there will be no damage to the aircraft or other equipment in the event of landing
gear, tire or strut failure. Whenever aircraft are parked during darkness they shall be
flood lighted if possible.

b. In addition, the following precautions should also be taken:

(1) All electrical switches “OFF”.

(2) Landing gear safety locks/pins will be used on all overnight or extended parking.
(3) Parking brakes off except in extremely high wind.
(4) Main landing gear wheels blocked (chocked) both fore and aft.
(5) Cargo compartment doors and cabin doors and windows closed.
(6) Cabin outflow valves should be closed and engine plugs installed if aircraft is to be
parked for an extended period.
(7) Place orange wing and tail cones around aircraft to alert ground vehicles not to
drive under aircraft wings or fuselage.
(8) During freezing weather, water jugs, lavatory water or any other container or
system containing liquids which might freeze should be drained.
(9) Gust locks “ON”.
(10) Aircraft should not be parked near buildings or under wires from which snow or ice
might slide or fall and damage the aircraft.
(11) All ground equipment must be removed from aircraft and lowered to full down
position once loading/unloading, maintenance, servicing of any kind, or any other
activity is not anticipated for that aircraft for an extended period of four hours or
more.

NOTE: Additional instructions for the handling of specific aircraft are located in
the applicable chapter of the appropriate manufacturer's manual.

c. If tie down of an aircraft is necessary, refer to the appropriate manufacturer's manual for
recommended procedures.

2. Engine Inlet Cover and Pitot Cover Installation – DC-8 engine inlet cover and pitot cover
installation is only required when the aircraft will layover for more than 24 hours.

3. Jacking, Lifting and Hoisting -Manufacturers Maintenance Manual procedures will be used
for jacking, lifting and hoisting.

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CHAPTER 11 - PLACARDS

TABLE OF CONTENTS

SECTION PAGE

11.01 EXTERIOR PLACARDS ......................................................................... 11.01.1

11.02 INTERIOR PLACARDS .......................................................................... 11.02.1

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CHAPTER 11 - PLACARDS

11.01 – EXTERIOR PLACARDS

TABLE OF CONTENTS
Paragraph Page
A. FUSELAGE ---------------------------------------------------------------------------- 11.01.1

B. WINGS ---------------------------------------------------------------------------------- 11.01.9

C. ENGINES/PYLONS------------------------------------------------------------------- 11.01.17

FIGURES

11.01-1 FWD FUSELAGE & NOSE SECTION EXTERIOR MARKINGS ------------ 11.01.1

11.01-2 AFT FUSELAGE EXTERIOR MARKINGS ---------------------------------- 11.01.6

11.01-3 NOSE LANDING GEAR MARKINGS ---------------------------------------- 11.01.7

11.01-4 DC-8-71 WING EXTERNAL MARKINGS (UPPER SURFACE) --------- 11.01.9

11.01-5 DC-8-71 WING EXTERNAL MARKINGS (LOWER SURFACE)-------- 11.01.11

11.01-6 DC-8-62/-72/-73 WING EXTERNAL MARKINGS (UPPER SURFACE) 11.01.13

11.01-7 DC-8-62/-72/-73 WING EXTERNAL MARKINGS (LOWER SURFACE) -- 11.01.15

11.01-8 DC-8-62 ENGINE COWLING EXTERNAL MARKINGS ----------------- 11.01.17

11.01-9 DC-8-70 ENGINE COWLING #1 & 2 PYLON & NACELLE

EXTERNAL MARKINGS (OUTBOARD SIDE)----------------------------- 11.01.18

11.01-10 DC-8-70 ENGINE COWLING #1 & 2 PYLON & NACELLE

EXTERNAL MARKINGS (INBOARD SIDE)-------------------------------- 11.01.19

11.01-11 DC-8-70 ENGINE COWLING #3 & 4 PYLON & NACELLE

EXTERNAL MARKINGS (OUTBOARD SIDE)----------------------------- 11.01.20

11.01-12 DC-8-70 ENGINE COWLING #3 & 4 PYLON & NACELLE

EXTERNAL MARKINGS (INBOARD SIDE)-------------------------------- 11.01.21

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11.01 Exterior Placards

A. Fuselage

FWD FUSELAGE & NOSE SECTION (LEFT) EXTERIOR MARKINGS

Figure 11.01-1 (1 of 5)

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CHAPTER 11 - PLACARDS
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FWD FUSELAGE & NOSE SECTION (RIGHT) EXTERIOR MARKINGS

Figure 11.01-1 (2 of 5)

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11.01 Exterior Placards (cont’d)

FWD FUSELAGE & NOSE SECTION EXTERIOR MARKINGS

Figure 11.01-1 (3 of 5)

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FWD FUSELAGE & NOSE SECTION EXTERIOR MARKINGS

Figure 11.01-1 (4 of 5)

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

FWD FUSELAGE & NOSE SECTION EXTERIOR MARKINGS

Figure 11.01-1 (5 of 5)

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

AFT FUSELAGE EXTERIOR MARKINGS

Figure 11.01-2

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

NOSE LANDING GEAR MARKINGS

Figure 11.01-3 (1 of 2)

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11.01 Exterior Placards (cont’d)

NOSE LANDING GEAR MARKINGS

Figure 11.01-3 (2 of 2)

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

B. Wings

NOTE: The letter size of all wing stencils is ¼”.

DC-8-71 WING EXTERNAL MARKINGS (UPPER SURFACE)

Figure 11.01-4 (1 of 2)

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

Item No. Stencil Marking

1 NO. 2 & 3 MAIN TANK
AUXILIARY FILL
STRUCTURAL LIMIT 17,605 LBS.
FUEL – PWA SPEC. 522 REVISED
1A NO. 2 & 3 MAIN TANK ACCESS
2 NO. 2 & 3 ALT. TANK
AUXILIARY FILL
STRUCTURAL LIMIT 12,550 LBS.
FUEL – PWA SPEC. 522 REVISED
2A NO. 2 & 3 ALT TANK ACCESS
3 NO. 1 & 4 EXT. ALT. TANK
AUXILIARY FILL
STRUCTURAL LIMIT 10,475 LBS.
FUEL – PWA SPEC. 522 REVISED
3A NO. 1 & 4 ALT TANK ACCESS
4 NO. 1 & 4 MAIN TANK
AUXILIARY TANK
STRUCTURAL LIMIT 20,240 LBS.
FUEL – PWA SPEC. 522 REVISED
4A NO. 1 & 4 MAIN TANK ACCESS

DC-8-71 WING EXTERNAL MARKINGS (UPPER SURFACE)

Figure 11.01-4 (2 of 2)

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

DC-8-71 WING EXTERNAL MARKINGS (LOWER SURFACE)

Figure 11.01-5 (1 of 2)

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

Item No. Stencil Marking

1 FUEL SUMP DRAIN
NO. 1 & 4 MAIN TANK
2 FUEL SUMP DRAIN
NO. 2 & 3 MAIN TANK
3 FUEL SUMP DRAIN
NO. 1 & 3 ALT. TANK
4 FUEL SUMP DRAIN
NO. 2 & 3 ALT. TANK
5 VENT MANIFOLD
DRAIN VALVE
6 FUEL PRESSURE FILL
MAX. SERV. PRESS. 50 PSI
FUEL: PWA SPEC.
522 REVISED

DC-8-71 WING EXTERNAL MARKINGS (LOWER SURFACE)

Figure 11.01-5 (2 of 2)

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11.01 Exterior Placards (cont’d)

DC-8-62/-72/-73 WING EXTERNAL MARKINGS (UPPER SURFACE)

Figure 11.01-6 (1 of 2)

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

Item No. Stencil Marking

1 NO. 2 & 3 MAIN TANK
AUXILIARY FILL
STRUCTURAL LIMIT 31,691 LBS.
FUEL – PWA SPEC. 522 REVISED
1A NO. 2 & 3 MAIN TANK ACCESS
2 NO. 1 & 4 ALT. TANK
STRUCTURAL LIMIT 11,682 LBS.
FUEL – PWA SPEC. 522 REVISED
2A NO. 1 & 4 ALT. TANK ACCESS
3 NO. 1 & 4 MAIN TANK
AUXILIARY FILL
STRUCTURAL LIMIT 20,904 LBS.
FUEL – PWG SPEC. 522 REVISED
3A NO. 1 & 4 MAIN TANK ACCESS

DC-8-62/-72/-73 WING EXTERNAL MARKINGS (UPPER SURFACE)

Figure 11.01-6 (2 of 2)

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11.01 Exterior Placards (cont’d)

DC-8-62/-72/-73 WING EXTERNAL MARKINGS (LOWER SURFACE)

Figure 11.01-7 (1 of 2)

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DC-8 MAINTENANCE MANUAL
CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

Item No. Stencil Marking

1 FUEL SUMP DRAIN
NO. 1 MAIN TANK
2 FUEL SUMP DRAIN
NO. 2 MAIN TANK
3 FUEL SUMP DRAIN
NO. 1 ALT. TANK
4 FUEL SUMP DRAIN
FWD. AUX. TANK
5 VENT MANIFOLD
DRAIN VALVE
6 FUEL PRESSURE FILL
MAX. SERV. PRESS. 50 PSI
FUEL: PWA SPEC.
522 REVISED
7 FUEL SUMP DRAIN
C. W. AUX. TANK

DC-8-62/-72/-73 WING EXTERNAL MARKINGS (LOWER SURFACE)

Figure 11.01-7 (2 of 2)

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)
C. Engines/Pylons

Item No. Stencil Marking

1* CONSTANT SPEED DRIVE, INPUT PAD AND GENERATOR
OIL FILL
FOR CAPACITY SEE CSD SERVICE PLATE
SEE MAINTENANCE MANUAL
FOR APPROVED SYNTHETIC LUBRICATING OIL
2* ENGINE OIL FILL
TOTAL CAPACITY: 5.5 GAL. (JT3D-3B)
SEE MAINTENANCE MANUAL FOR APPROVED
SYNTHETIC LUBRICATING OIL
3** ACCESS TO ACCESSORY COMPT.
IN CASE OF FIRE PUSH
AND DISCHARGE AGENT
DC-8-62 ENGINE COWLING EXTERNAL MARKINGS
Figure 11.01-8

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

DC-8-70 ENGINE COWLING #1 & 2 PYLON & NACELLE

EXTERNAL MARKINGS (OUTBOARD SIDE)
Figure 11.01-9

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

DC-8-70 ENGINE COWLING #1 & 2 PYLON & NACELLE

EXTERNAL MARKINGS (INBOARD SIDE)
Figure 11.01-10

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

DC-8-70 ENGINE COWLING #3 & 4 PYLON & NACELLE

EXTERNAL MARKINGS (OUTBOARD SIDE)
Figure 11.01-11

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CHAPTER 11 - PLACARDS
11.01 Exterior Placards (cont’d)

DC-8-70 ENGINE COWLING #3 & 4 PYLON & NACELLE

EXTERNAL MARKINGS (INBOARD SIDE)
Figure 11.01-12

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CHAPTER 11 - PLACARDS

11.02 – INTERIOR PLACARDS

TABLE OF CONTENTS
Paragraph Page
A. COCKPIT ------------------------------------------------------------------------------- 11.02.1

B. COMBI CABIN PLACARDING ---------------------------------------------------- 11.02.3

FIGURES

11.02-1 CAPTAIN & FO’S EMERGENCY EVACUATION PLACARD -------------- 11.02.1

11.02-2 COMBI CABIN PLACARDING ------------------------------------------------ 11.02.3

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11.02 Interior Placards

A. Cockpit

NOTES:
(1) Placard Background Color: White; Lettering: Black
(2) All text to be bold print and contrast with background.
(3) Placard printed on self-adhesive vinyl.

CAPTAIN & FIRST OFFICER’S EMERGENCY EVACUATION PLACARD

Figure 11.02-1 (1 of 2)

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CHAPTER 11 - PLACARDS
11.02 Interior Placards

CAPTAIN & FIRST OFFICER’S EMERGENCY EVACUATION PLACARD

Figure 11.02-1 (2 of 2)

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CHAPTER 11 - PLACARDS
11.02 Interior Placards (cont’d)

B. COMBI Cabin Placarding

NOTES:
(1) “S” indicates FAA required placard.
(2) Placarding may vary depending upon COMBI configuration. Contact the Chief Flight
Attendant for additional information.
(3) Text of placarding is in “bold” characters in table below.

AREA NAME PLACARDS

1 Weight Placards a. Close and Latch for Takeoff and Landing
(on inside of bin door) b. MAX Capacity _____S (Max Weight from below)
799AL half bins = “20 lbs”; full bins = “40 lbs”
71CX: half bins = “45 lbs”; full bins = “75 lbs”
41CX:
721CX:
722CX:
2 Row & Seat Placards a. 1 DEF; 2 DEF; 3 DEF; 4 DEF; 5 DEF
(A/F-window; B/E- b.. 1 ABC; 2 ABC; 3 ABC; 4 ABC; 5 ABC; 6 AB
center; C/D-aisle)
3 Emergency a. PO2B; Bio Hazard Kit; 02 Masks; Life Vests; Seat Belt Ext. S
Equipment Placards (overhead bin 5DEF)
(or symbols) b. PO2B; Halon Ext; 1st Aid Kit; Fire Suit & Gloves; 2 Way
Communicator; FA Demo Kit; PBES (overhead bin 1ABC)
4 Exit Signs EXIT S
5 2L & 2R Doors and a. {Directional Arrow} (for door handle travel) S; OPEN
Slide Boxes(placards b. DO NOT SIT (on top of slide box)
b, c, & d) c. SLIDE WILL NOT INFLATE AUTOMATICALLYS
d. ESCAPE SLIDES
TO OPERATE
1. Open Airplane Entry Door
2. Pull Inflation Handle
6 Shelves & Storage SHELF CAPACITY _____ LBS S(TO BE DETERMINED)
Area Weight Placards
7 Galleys a. Forward & Aft Upper Cabinets
(1) INSERTS TO BE SECURED, TABLES TO BE STORED &
SECURED, DRAWERS, DOORS & SHELVES TO BE
CLOSED & SECURED FOR TAKEOFF, LANDING &
TURBULENT WEATHER.
(2) NOTICE: ALL FOOD HANDLING EMPLOYEES MUST
WASH THEIR HANDS AFTER EACH USE OF TOILET
FACILITIES & BEFORE PREPARING OR SERVING
FOOD.
b. Forward Lower Cabinet
(1) NO BURNING OBJECTS (S-on all trash bins & trash bin
doors)
c. First Aid Oxygen (overhead of 2R door)

COMBI CABIN PLACARDING

Figure 11.02-2 (1 of 3)

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CHAPTER 11 - PLACARDS
11.02 Interior Placards (cont’d)

AREA NAME PLACARDS

8 Closet a. CLOSET (on outside of door)
b. SHELF CAPACITY _____ LBSS (inside on shelf)
9 Inside of each LAV a. FEDERAL LAW PROVIDES FOR A PENALTY OF UP TO $2,000
DOLLARS FOR TAMPERING WITH THE SMOKE DETECTOR
INSTALLED IN THIS LAVATORY. S
b. 115 VAC SHAVER OUTLET
c. ATTENDANT CALLS
d. RETURN TO SEATS
d. TOWEL DISPOSAL
PUSH
e. NO CIGARETTES
DISPOSAL
f. NO BURNING OBJECT (S-adjacent to towel disposal bin)
g. NO SMOKING IN LAVATORY(with no smoking symbol)
h. LAVATORY DOOR MUST BE CLOSED. LAVATORY NOT TO
BE OCCUPIED DURING TAKEOFF & LANDING.
i. PLEASE LOCK DOOR (ensure directional arrows/text indicated
Locked/Unlocked positions)
j. NO TRASH IN TOILET (under toilet seat cover)
10 Outside of LAV a. NO SMOKING IN LAVATORYS (with no smoking symbol)
door b. LAVATORY DOOR MUST BE CLOSED.
LAVATORY NOT TO BE OCCUPIED
DURING TAXI, TAKEOFF OR LANDING.
11 Emergency Equip. a. FIRST AID KITS
Closet Door b. OXYGEN BOTTLES
(text &/or symbols)
c. MEGAPHONES
d. FIRE EXTINGUISHERS
e. PBES
f. DOOR MUST BE LATCHED CLOSED DURING TAKEOFF,
LANDING AND TURBULENCE.
12 Jump Seat Area a. EMERGENCY FLASHLIGHTS
b. FLIGHT ATTENDANT ONLY S (above jump seat)
c. COCKPIT EMERGENCY LIGHT SWITCH MUST BE ARMED
(adjacent to light switch)
d. LIGHT SWITCH; ON; NORMAL (adjacent to switch)
13 Sliding Door CREW ONLY
14 Forward Bulkhead a. FASTEN SEAT BELT WHILE SEATEDS
& on back of each b. LIFE VEST UNDER SEATS
seat
15 Walkway Overhead a. OXYGEN INSIDE
b. LIFE RAFT INSIDE S (2 places)
c. SILENCE SWITCH (for cargo smoke warning)
d. 02 BOTTLE (2 places)

COMBI CABIN PLACARDING

Figure 11.02-2 (2 of 3)

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CHAPTER 11 - PLACARDS
11.02 Interior Placards (cont’d)
13-SLIDING DOOR
1-WEIGHT 1-WEIGHT
PLACARDS PLACARDS

14-FWD
BULKHEAD &
3B-EMER.
BACK OF
EQUIP.
EACH SEAT

2B-ROW 2A-ROW
& SEAT & SEAT
PLACARD PLACARD

3A-EMER.
EQUIP.
15-WALKWAY
OVERHEAD

4-EXIT
SIGNS
4-EXIT
SIGNS
5-DOOR 12-JUMPSEAT

6-SHELVES & 7-GALLEYS

STORAGE AREAS

5-DOOR

11- EMERG. 8-CLOSET

EQUIPMENT 10-LAV DOORS

9-LAV 9-LAV

COMBI CABIN PLACARDING

Figure 11.02-2 (3 of 3)

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TABLE OF CONTENTS
Page
13.01 GENERAL ----------------------------------------------------------------------------- 13.01.1
13.02 AIRCRAFT STORAGE -------------------------------------------------------------- 13.02.1
13.03 RESERVED FOR FUTURE USE -------------------------------------------------- 13.03.1
13.04 THREE ENGINE FERRY PROCEDURES --------------------------------------- 13.04.1

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13.01 - GENERAL
TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 13.01.1

2. TAIL SKID INSPECTION ----------------------------------------------------------- 13.01.2

3. LIGHTNING STRIKE INSPECTION ---------------------------------------------- 13.01.6

4. ENGINE – FOREIGN OBJECT DAMAGE --------------------------------------- 13.01.9

5. UNSCHEDULED MAINTENANCE CHECKS/INSPECTIONS--------------- 13.01.17

TABLES

13.01-1 SPECIAL INSPECTIONS ------------------------------------------------------------ 13.01.1

JOB CARDS

13.01-1 TAIL SKID INSPECTION ----------------------------------------------------------- 13.01.3

13.01-2 LIGHTNING STRIKE INSPECTION ---------------------------------------------- 13.01.7

13.01-3 ENGINE – FOREIGN OBJECT DAMAGE INSPECTION --------------------- 13.01.10

13.01-4 BIRD STRIKE INSPECTION ------------------------------------------------------- 13.01.15

13.01-5 UNSCHEDULED MAINTENANCE INSPECTION ----------------------------- 13.01.18

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13.01 GENERAL

1. General - During normal operation, the aircraft may be subject to the events listed in Table
13.01-1. When such an event occurs, the applicable referenced inspection must be
performed prior to the next flight.

2. Each of the events listed in Table 13.01-1 require a Type 1 Aircraft Airworthiness Release in
accordance with GMM 3.101 prior to the next flight.

INSPECTION DACO-60 MM DC-8 MM

Tail Skid Strike 5-55-0 13.01-1
Lightning Strike 5-53-0 13.01-2
ENGINE -FOD 5-54-0 13.01-3
Bird Strike Inspection 13.01-4
Excessive Ground Maneuver (High Speed - Turn, Rejected T/O, 5-50-0 13.01-5
etc.)
Rough Air/Excessive Maneuver (Over-rotation, Hard/Overweight 5-50-0 13.01-5
Landing, Aircraft Overspeed, etc.)

Three Engine Ferry Procedures 13.04.1

Gust Lock OFF While Parked Check 27.01.1

SPECIAL INSPECTIONS
Table 13.01-1

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13.01 GENERAL

2. Tail Skid Inspection – The tail skid inspection is a visual inspection made to determine if the
skid contacted the ground and the energy absorber was utilized due to an over-rotation
maneuver during takeoff. If evidence indicates the tail skid contacted the ground, Job Card
13.01-1 must be completed prior to the next flight. (Reference Douglas DC-8 Maintenance
Manual Chapter 32.)

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-1
JOB TITLE
TAIL SKID INSPECTION
J/C Reviewed By: Date: Page 1 of 3
Mechanic Inspector
General Information
The tail skid inspection is accomplished by making a visual check of the tail skid
plate to determine if contact was made with the ground during the previous
takeoff. If the skid contacted the ground, an additional inspection is made of
other components of the tail skid assembly for possible damage.
References
Douglas DC-8 Maintenance Manual, 5-55-0
Procedure
1. Inspect lower surface of tail skid steel plate (Figure 1) for removal of paint. If
no paint was removed, the tail skid inspection is complete. If paint has been
removed, proceed with step 2.
2. Determine stroke energy absorber cylinder traveled:
a. Open rear half of tail skid fairing. This will expose energy absorber and
remove fairing spring load against tail skid.
b. Push up on tail skid. Energy absorber cylinder will travel due to internal
cartridge having been crushed.
c. Measure length of stroke of cylinder [Figure 1, (2)].

Length of Stroke: ____________________ inches

3. If stroke as determined in step 2 is ½ inch or less, the energy absorber is
acceptable for additional use.
4. If stroke as determined in step 2 is greater than ½ inch, a complete new
internal cartridge for the absorber must be installed. (See Douglas DC-8
Maintenance Manual Chapter 32.)
5. Inspect tail skid plate for excessive wear:
a. If minimum thickness is greater than 3/16 inch, plate is acceptable for
further service after repainting.
b. If minimum thickness is less than 3/16 inch, replace with new plate and
make certain it is painted.
6. If stroke as determined in step 2 is greater than 4 ½ inches, proceed with
inspection.
NOTE: A stroke greater than 4 ½ inches indicates some components of the tail
skid assembly bottomed-out against others or contacted the runway
causing damage.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-1
JOB TITLE
TAIL SKID INSPECTION
J/C Reviewed By: Date: Page 2 of 3
Mechanic Inspector
7. Inspect the following Figure 1 parts for evidence of any twisted or bent bolts,
loose rivets, cracks, warping, buckling, or other structural damage:
a. Bracket (3)
b. Tube (4)
c. Aft fairing assembly (5)
d. Both parts of frame assemblies (6 & 7)
e. Forward fairing assembly (8)
f. Pressure bulkhead (9)
8. Make aircraft logbook entry stating compliance with this job card and any
corrective action taken. Comply with Type 1 Airworthiness Release
Procedures per GMM 3.101. Attach this completed job card to the log page
and forward to the Aircraft Records Section.
NOTES:

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-1
JOB TITLE
TAIL SKID INSPECTION
J/C Reviewed By: Date: Page 3 of 3
Mechanic Inspector

TAIL SKID AND ENERGY ABSORBER

Figure 1

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13.01 GENERAL (cont’d)

3. Lightning Strike Inspection

a. An airplane flying through, or in the vicinity of, an electrical storm may have become
part of the discharge path. Flight crews may not be aware of lightning activity as they
pass through an area and therefore may not report this fact. However, when electrical
storms are prevalent or reports indicate the airplane may have passed through a region
during an electrical storm, an inspection should be made for damage.

b. During a lightning strike, the current enters the airplane at one point and exits at another,
usually at the airplane extremities. It is in these areas (wing tips, nose, and tail sections)
where damage is most likely to occur. Burning and/or eroding of small surface areas of
the airplane skin, trailing edge, or structure may be detected during inspection. The
lightning strike may cause a series of small pinholes in a tree-like pattern or similar to the
veins of a leaf. The edges of the holes will be burned and coated with oxides or soot. In
most cases, the damage is obvious; in other cases, however, hidden damage may result.
The purpose of the lightning strike inspection is to locate any damage that may have
occurred before returning the airplane to service.

c. Complete Job Card 13.01-2 when inspecting the aircraft for lightning strike.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-2
JOB TITLE
LIGHTNING STRIKE INSPECTION
J/C Reviewed By: Date: Page 1 of 2
Mechanic Inspector
General Information
When lightning strikes have been reported by the flight crew, or if reports indicate
the airplane has passed through a region during an electrical storm, it is essential
the airplane be inspected for damage before release for flight.
References
Douglas DC-8 Maintenance Manual, 5-53-0
Procedure
1. Inspection Procedures – Nose Section
a. Inspect exterior and interior of radome for damage.
b. Inspect radar reflector, feed horn, motor box assembly, and all mounting
structure for damage.
(1) If damage is noted, a bench check of radar system is required.
(2) If superficial pitting or burning of the mounting structure only is
noted, perform a functional check of radar system. (See Douglas
DC-8 MM Chapter 34.)
c. Inspect glide slope antenna for burning or pitting.
(1) Replace antenna if damage is noted.
(2) Perform functional check of glide slope system. (See Douglas DC-
8 MM Chapter 34.)
d. Inspect pitot tubes for burning or pitting.
(1) Replace pitot tubes if damage is noted.
(2) Perform functional check of pitot system. (See Douglas DC-8 MM
Chapter 34.)
2. Inspection Procedures – Fuselage
a. Inspect complete fuselage for burning and/or eroding.
b. Inspect all antennas on lower fuselage for damage.
(1) If damage is noted, perform functional check on affected system.
c. Inspect tail cone and associated lightning for damage.
3. Inspection Procedures – Tail Section
a. Inspect vertical stabilizer for burning, eroding, and loose or missing
rivets.
b. Inspect rudder surfaces for burning and/or eroding.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-2
JOB TITLE
LIGHTNING STRIKE INSPECTION
J/C Reviewed By: Date: Page 2 of 2
Mechanic Inspector
c. If damage has occurred on vertical stabilizer or rudder above HF isolation
band, perform a checkout of the HF system and the VHF system. (See
Douglas DC-8 MM Chapter 23.)
(1) If malfunction is reported in the HF system, remove HF antenna
coupler, inspect coupler, lightning arrestor, and antenna connector.
Check to be sure portion of connector remaining in airplane is not
damaged.
(2) If malfunction is reported in the VHF system, inspect VHF isolation
unit through HF access door. Inspect outside surface of VHF tip
cap antenna and fiberglass housing located at top of vertical
stabilizer. If damage has occurred in VHF antenna region, remove
antenna and inspect for damage.
d. Inspect horizontal stabilizer for damage.
e. Inspect all control surfaces for damage to surfaces and hinging
mechanisms.
f. Inspect static dischargers on tip and trailing edges of horizontal and
vertical stabilizers for damage and replace, if damaged.
4. Inspection Procedures – Wing Area
a. Inspect wing tips for burning and/or eroding.
(1) If damage is noted, perform functional check of wing tip lighting
system.
b. Inspect fuel vent outlets (external and internal) for burning and/or
eroding.
c. Check all control surfaces and hinging mechanisms for damage.
d. Inspect static dischargers on wing tips and trailing edges and replace if
damaged.
5. Inspection Procedures – Pylon and Engine Pods
a. Inspect pylons and engine nacelle areas for burning, eroding, and loose or
missing rivets.
b. Inspect access doors for obvious damage and security of fastenings.
6. Make aircraft logbook entry stating compliance with this job card and any
corrective action taken. Comply with Type 1 Airworthiness Release
Procedures per GMM 3.101. Attach this completed job card to the log page
and forward to the Aircraft Records Section.
NOTES:

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13.01 GENERAL (cont’d)

4. Engine – Foreign Object Damage

a. Damage to the engine may be caused by bird strike or by ingestion of slush or any type of
foreign object while operating the airplane on the ground or in flight. Dents, nicks, or
scratches within the confines of the engine inlet should be regarded as evidence of
foreign object ingestion.

b. Safety precautions should be taken to prevent foreign objects from coming in contact
with the engine during aircraft towing and at all times when not in service. The purpose
of the foreign object inspection is to locate any damage that may have occurred.

c. Complete Job Card 13.01-3 when inspecting the engine for foreign object damage.
Complete Job Card 13.01-4 when inspecting the aircraft for a bird strike. Complete Job
Card 7203 when CFM56 engine borescope inspection is required.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-3
JOB TITLE
ENGINE – FOREIGN OBJECT DAMAGE (FOD) INSPECTION
J/C Reviewed By: Date: Page 1 of 5
Mechanic Inspector

Engine Serial Number: ___________________

(Complete a job card for each affected engine.)
General Information
If foreign object damage (FOD) to the engine is suspected, the following
inspection should be accomplished.
References
Douglas DC-8 Maintenance Manual, 5-54-0
P&W JT3D/JT3D-7 MM, Section 600
CFM56 Maintenance Manual, 72-00-00
Job Card 7203, Borescope Inspection Record – CFM56-2
Procedure
Check the box for the type of engine being inspected and proceed to the
appropriate section of this job card.
JT3D Engine
CFM56 Engine
Inspection – JT3D Engine
1. Inspect the following:
a. Inlet Cowling – Inspect for nicks dents, or other evidence of passage of
foreign material.
b. Inlet Bullet – Inspect for nicks, dents, or other evidence of passage of
foreign material.
c. Inlet Guide Vanes – Inspect for nicks, dents, or other evidence of passage
of foreign material.
d. Fan Blades – Rotate compressor and inspect all visible fan blades for
foreign object damage. Damaged blades within limits (see Figures 1 and
2) may be continued in service without repair.
NOTE: Compressor blade limits as specified in this section (see Figures 1 and
2) are evaluated from the standpoint of structural integrity only. Use of
a substantial number of blades reworked at or near maximum limits or
use of blades having many reworked areas may adversely affect
compressor efficiency and engine performance.
e. Compressor (fan) vanes – Inspect for nicks, dents, or other evidence of
passage of foreign material.
2. Make aircraft logbook entry stating compliance with this job card and any
corrective action taken. Comply with Type 1 Airworthiness Release
Procedures per GMM 3.101. Attach this completed job card to the log page
and forward to the Aircraft Records Section.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-3
JOB TITLE
ENGINE – FOREIGN OBJECT DAMAGE INSPECTION
J/C Reviewed By: Date: Page 2 of 5
Mechanic Inspector

JT3D COMPRESSOR FAN BLADES INSPECTION AND REPAIR LIMITS

Figure 1

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-3
JOB TITLE
ENGINE – FOREIGN OBJECT DAMAGE INSPECTION
J/C Reviewed By: Date: Page 3 of 5
Mechanic Inspector

JT3D FIRST STAGE VANE INSPECTION AND REPAIR LIMITS

Figure 2

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-3
JOB TITLE
ENGINE – FOREIGN OBJECT DAMAGE INSPECTION
J/C Reviewed By: Date: Page 4 of 5
Mechanic Inspector
Inspection – CFM56 Engine
1. Inspect for the following:
a. Possible damage to the spinner front and rear cones. Reference CFM56
MM 72-21-00.
b. General condition of the fan rotor blades (blade leading edge distortions,
shingling of blade tip shrouds, bending, cracking). Reference CFM56
MM 72-21-00.
c. Wear of abradable material in fan inlet case. Reference CFM56 MM 72-
23-00.
d. Condition of acoustical panels that may have been damaged as a result of
interference with blade tip shrouds. Reference CFM56 MM 72-23-00.
e. Condition of splitter fairing and booster inlet guide vanes (IGV).
Reference CFM56 MM 72-23-00 and 72-21-00.
f. Condition of fan outlet guide vanes (OGV) and seals of fan OGV inner
shroud. Reference CFM56 MM 72-23-00.
g. Damage to T12 sensor probe. Reference CFM56 MM 73-21-40.
h. Condition of exhaust and stage 4 LP turbine blades. Reference CFM56
MM 72-54-00.
2. Gaspath Inspection
a. FOD Event associated with Normal Engine Parameters – Complete the
following steps if one or more of these conditions apply:
(1) FOD event has resulted in fan blades missing material/fan blade
damage beyond serviceable limits.
NOTE: If a birdstrike has occurred, refer to Job Card 13.01-4 and CFM56 MM
72-42-00 M/P.
(2) Evidence of Debris Entering the Booster Inlet
NOTE: The borescope inspection may be delayed 25 hours or 10 cycles
(whichever occurs first), providing that FOD event did not result in
missing fan blade material, blade tearing, or surge/stall or flame out.
Service extension is only allowed on one engine in the event of a multi-
engine FOD event.
(a) Complete Job Card 7203 – Borescope Inspection Record.
Borescope the following:
1) HPC Stages 1, 3, 5, & 9
2) Combustion Chamber
NOTE: If a birdstrike has occurred, refer to Job Card 13.01-4 and CFM56 MM
72-42-00 M/P.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-3
JOB TITLE
ENGINE – FOREIGN OBJECT DAMAGE INSPECTION
J/C Reviewed By: Date: Page 5 of 5
Mechanic Inspector
b. FOD Event Associated with Abnormal Engine Parameters or Flame Out –
Complete the following steps if the FOD event was associated with surge,
stall, or flame out.
(1) Complete Job Card 7203 – Borescope Inspection Record.
Borescope the following:
(a) Booster
(b) HPC Stages 1, 3, 5, & 9
(c) Combustion Chamber
NOTE: If a birdstrike has occurred, refer to Job Card 13.01-4.
(2) Do a max power assurance run. Reference IAW ERH 70.01.
(3) If the MPA run failed, do a check of the CIT sensor for
impact/damage. Reference CFM56 MM 73-21-20 M/P.
3. Make aircraft logbook entry stating compliance with this job card and any
corrective action taken. Comply with Type 1 Airworthiness Release
Procedures per GMM 3.101. Attach this and other completed job card to the
log page and forward to the Aircraft Records Section.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-4
JOB TITLE
BIRD STRIKE INSPECTION - AIRCRAFT
J/C Reviewed By: Date: Page 1 of 2
Mechanic Inspector
General Information
Where a station is advised of, or has reported, any bird strike, it will (upon
arrival of the airplane) complete this job card and accomplish a very
comprehensive check of the area involved. Where there has been no
serious damage to the airplane or when required repairs have been
completed, the Non-Routine Maintenance Form and Aircraft Flight Log
will be completed showing the accomplishment of the inspection or the
repairs made.
Tools and Materials
Applicable Engine Maintenance Manual
Procedure
1. Perform the following inspection whenever an airplane is known to
have had a bird strike:
a. At Non-Maintenance Stations:
(1) A Flight Crew Member will contact LIT Maintenance Control
for further instructions.
(2) With the concurrence of LIT Maintenance Control, a Flight
Engineer may accomplish a check of the suspect area and
report results to LIT Maintenance Control.
(a) If no evidence of damage is reported, the airplane may
be returned to flight status.
(b) If evidence of damage is found, LIT Maintenance
Control will determine course of action to be taken.
b. At Maintenance Stations:
(1) An A&P mechanic will check the suspect area to determine
the extent of damage and if repairs will be necessary.
NOTE: Refer to Recurring Non-Routine Job Card 13.01-3 for information
which applies when a bird strike affects an engine.
2. Minor Damage – Where minor damage not affecting the airworthiness
of the aircraft is found, the area will be painted with contrasting paint
and a subsequent entry made in the logbook that the damage is
“allowable” and the aircraft shall be returned to flight status.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-4
JOB TITLE
BIRD STRIKE INSPECTION - AIRCRAFT
J/C Reviewed By: Date: Page 2 of 2
Mechanic Inspector
3. Notify MX Control – If any damage is incurred where the
airworthiness of the airplane is in question or where the extent of the
damage will necessitate a major repair, LIT Maintenance Control will
be immediately notified of the circumstances and will determine the
disposition of the airplane.
4. Make aircraft logbook entry stating compliance with this job card and
any corrective action taken. Comply with Type 1 Airworthiness
Release Procedures per GMM 3.101. Attach this completed job card to
the log page and forward to the Aircraft Records Section.
NOTES:

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13.01 GENERAL (cont’d)

5. Unscheduled Maintenance Checks/Inspections

a. During normal operations, the airplane may be subjected to an over-rotation maneuver,

hard landing, exceeding placarded speed (VMO/MMO), excessive turbulent (rough) air,
towing with a large fuel unbalance, an excessive ground maneuver involving a high
speed turn, rejected take-off pivots in excess of recommended procedures, a skid from a
prepared surface, landing short of prepared surface, or landing involving the blowing of
two or more tires.

b. When any of these conditions are reported by the flight crew, an external visual
inspection of the airframe and specific inspection of components and/or areas involved
must be accomplished. The inspections are performed to determine and evaluate the
extent of damage, in the areas of visible damage, and to the structure and components
adjacent to the area of damage. Complete Job Card 13.1-5 when inspecting the aircraft.

c. If damage is detected at any step during the inspection, certain portions of the “B”
inspection must be accomplished. Contact ATI Maintenance Control for further
instructions at this point.

d. Portions of the airplane must be inspected when subjected to towing with a high
unbalance of fuel between the left and right main tanks.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-5
JOB TITLE
UNSCHEDULED MAINTENANCE INSPECTION
J/C Reviewed By: Date: Page 1 of 3
Mechanic Inspector
General Information
If unscheduled maintenance inspections are needed, the following inspection
should be accomplished.
References
Douglas DC-8 Maintenance Manual, 5-50-0 ATI DC-8 MM, 13.01.5
Procedure
Check the applicable box(s) below for the task(s) being complied with on this job
card:

Over-rotation Maneuver Rough Air/Excessive Maneuver

Hard/Overweight Landing Excessive Ground Maneuver (High
Aircraft Overspeed Speed-Turn, Rejected T/O, Skid
from Prepared Surface, Landing
Short of Prepared Surface, Blowing
2 or More Tires, Etc.)
NOTE: Check for condition or discrepancy as noted from ground level unless
otherwise noted.
NOSE TO WING ROOT
1. Radome
a. Inspect for visible damage and general condition.
b. Inspect condition of seals, hinges, and latches.
2. Pitot Tubes – Inspect for visible damage.
3. Nose Wheel Well
a. Inspect doors for damage and general condition.
b. Inspect for visible hydraulic leaks.
c. Inspect condition of cables.
d. Inspect tires’ condition & inflation.
e. Ensure normal oleo extension.
f. Inspect torque links and static ground wire condition and security.
g. Inspect wheel well light operation.
4. Cabin Compressor Scoops – Inspect condition of impellers.
5. Fuselage Exterior and Interior
a. Inspect condition of exterior surfaces.
b. Access doors closed.
c. Inspect condition of ground air conditioning inlet flapper.
d. Inspect condition of heat exchanger and ACM doors.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-5
JOB TITLE
UNSCHEDULED MAINTENANCE INSPECTION
J/C Reviewed By: Date: Page 2 of 3
Mechanic Inspector
e. Inspect condition of R.A.T. bulb.
f. Inspect air conditioning, baggage compartment, and hydraulic
compartment for general condition.
g. Oxygen blowout disc present.
h. Condition of service panels.
WING ROOT TO WING TIP
6. Bottom of Fuselage and Wing Center Section
a. Inspect condition of radio antennas.
b. Inspect fuel leaks and general condition.
c. Inspect vents, scoops, and exhaust for condition.
d. Access doors closed.
e. Inspect wing slots for general condition, hyd. leaks.
f. Inspect condition of anti-collision and navigation lights.
WING TRAILING EDGE & WHEEL WELLS
7. Ailerons, Tabs, & Wing Flaps – Inspect general condition.
8. Lower Surface of Wing
a. Ensure there is no obvious damage.
b. Check for evidence of fuel leaks.
c. Inspect landing and navigation lights for damage/operation.
d. Access doors closed.
9. Power Plants & Pylons
a. Check for visible fuel leaks.
b. Ensure there is no visible damage to cowling, nacelle doors, engine
reverser, tail pipe, and pylon skin/planks.
c. Inspect condition of Pt2 probes.
10. Static Dischargers – Present and secure.
11. Flight & Ground Spoilers – Ensure no visible damage, hyd. leaks.
12. Fuel Sumps & Vent Line Drain – Inspect for condition.
13. Main Gear & Wheel Wells
a. Ensure normal oleo extension.
b. Inspect tires & wheels for inflation and damage.
c. Check for visible hydraulic leaks.
d. Inspect lockout cyl. pin extension.
e. Inspect general condition of all attached components.
f. Inspection condition of landing gear doors, hinges, and actuators.
g. Inspect condition of system components in wheel wells.
h. Inspect condition of gear down indicators.
i. Inspect operation of wheel well lights.

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A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.01-5
JOB TITLE
UNSCHEDULED MAINTENANCE INSPECTION
J/C Reviewed By: Date: Page 3 of 3
Mechanic Inspector
AFT FUSELAGE & EMPENNAGE
14. Fuselage Exterior & Interior
a. Ensure no visible damage, drains open.
b. Access doors closed.
c. Inspect baggage bins for general condition.
d. Inspect condition of cabin doors, windows, and window shades.
e. Ensure operation of navigation lights.
f. Inspect condition of service panels.
15. Empennage
a. Inspect stabilizer leading & trailing edges, tips, & surfaces for general
conditions.
b. Inspect elevator control surface & tabs for condition.
c. Inspect rudder surface & tabs for condition.
d. Inspect static dischargers for condition & security.
e. Inspect condition of tail strut energy absorber, skid show, and fairing.
(Series 60/70)
16. Cabin Outflow Nozzle – Ensure clear
17. Cabin Outflow Butterfly – Ensure clear.
18. Fuselage Static Pressure Ports – Ensure clear.
19. Cockpit Windows – Inspect for damage and clean.
20. If damage is detected during the inspection, contact ATI Maintenance Control
for further instructions.
21. Make aircraft logbook entry stating compliance with this job card and any
corrective action taken. Comply with Type 1 Airworthiness Release
Procedures per GMM 3.101. Attach this completed job card to the log page
and forward to the Aircraft Records Section.
NOTES:

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13.02 – AIRCRAFT STORAGE

TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 13.02.1

2. SHORT TERM ACTIVE STORAGE----------------------------------------------- 13.02.3

3. LONG TERM ACTIVE STORAGE ------------------------------------------------ 13.02.5

JOB CARDS

13.02-1 SHORT TERM ACTIVE STORAGE----------------------------------------------- 13.02.3

13.02-2 LONG TERM ACTIVE STORAGE ------------------------------------------------ 13.02.5

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INTENTIONAL
BLANK

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13.02 AIRCRAFT STORAGE

1. When placing an aircraft into short/long term active storage, the appropriate Recurring Non-
routine Jobcard must be completed. For Short Term Active Storage, complete job card
13.02.1. For Long Term Active Storage, complete Job Card 13.02-2. For Long Term
Inactive Storage, refer to the aircraft/equipment manufacturers’ procedures.

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13.02 AIRCRAFT STORAGE (cont’d)

2. Short Term Active Storage

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.02-1
JOB TITLE
SHORT TERM ACTIVE STORAGE
J/C Reviewed By: Date: Page 1 of 2
Mechanic
Procedure
INITIAL SHORT TERM STORAGE
A. Move the aircraft to its parking spot and comply with the following:
1. Accomplish general parking procedures.
2. Inflate all landing gear struts to operational levels.
3. Treat aircraft windows with Spray-Lat.
4. Disconnect aircraft, SAI, and emergency exit light batteries and store under charge.
5. Install engine, pitot covers, blanks, panels, etc.
6. Cover pitot static ports and PT2 probes.
7. Drain and flush toilets and waste water systems. (Reference JC 16.02-1.)
8. Drain a minimum of one gallon of fuel from all tank sumps.
9. Treat fuel tanks with Biobor. Accomplish appropriate Biobor form and attach to
storage package.
10. Close oxygen supply system cylinder shut-off valve.
11. Check for any hydraulic, fuel, or other leaks.
12. Remove all trash from interior of aircraft.
13. Check grounding cable for security.
14. Record fuel totalizer reading: ________________ pounds/kilograms
15. Initiate logbook entry as follows:

“Placed in short term storage as of ____________ (date) and __________ (time).”

RECURRING SHORT TERM STORAGE
A. Every 7 Days:
1. Check for any hydraulic, fuel, oil, or other fluid leaks.
2. Drain a minimum of one gallon of fuel from all tanks.
3. Open all doors to allow for ventilation.
4. Check aircraft exterior for obvious discrepancies.
5. Check tires for proper inflation.
6. Check aircraft for evidence of bird nests.
7. Check shock strut for proper inflation. Clean piston with hydraulic fluid and
service to operational levels.

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ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.02-1
JOB TITLE
SHORT TERM ACTIVE STORAGE
J/C Reviewed By: Date: Page 2 of 2
Mechanic
B. Every 14 Days:
1. Check Fire Extinguishers. For servicing, generate logbook entry and contact ATI
Maintenance Control.
2. Prepare Aircraft for Engine Run:
a. Remove all engine, PT2, pitot, blanks, or panel covers.
b. Ensure current fuel load is sufficient for run.
c. Check for chocks and grounding straps.
d. Check all accumulators for proper servicing.
3. Perform engine idle runs per ATI ERH.
4. When performing run, exercise all controls and hydraulic systems that are free to
operate.
5. Rotate tires approximately 120°. If possible, rotate wheels three turns to distribute
grease in the bearings.
6. Upon completion of run and engine cool down:
a. Check engine oil and CSD for servicing. (Service as required.)
b. Reinstall all covers.
c. Record fuel totalizer reading _________________ pounds/kilograms.
d. Close all doors and check security of plates, plugs, etc.
C. Initate logbook entry as follows:

“Completed recurring short-term (7 or 14 day) storage on __________ (date)

________ (time).”
NOTES:

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3. Long Term Active Storage

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.02-2
JOB TITLE
LONG TERM ACTIVE STORAGE Page 1 of 3
J/C Reviewed By: Date: Frequency Signature
Initial Monthly As Req. Mechanic
Procedure
A. Aircraft Parking (Tarmac or Concrete Pad)
1. Position the aircraft into the prevailing wind where
X
possible.
2. Check outboard main landing gear wheels, fore and
X X
aft.
3. Statically ground the aircraft from the landing gear to
X X
the earth grounding points.
B. Fuselage Exterior
1. Cover passenger windows with metalized mylar or
Spray-Lat over windows. (Combi aircraft) Check X X
window protection.
2. Close and latch cabin doors. X
3. Check that all drain holes are clear. Cover with
cheesecloth; tape in place with aluminum tape. X
DON’T BLOCK DRAIN HOLES!
4. Cover all openings, pitot tubes, static ports, and TAT
probes. Ensure that no tape adhesive enters static X
port.
5. Bleed off all hydraulic system pressure to nominal
X X
accumulator pressure.
6. Check for hydraulic system pressure to nominal
X X
accumulator pressure.
7. Cover cockpit window with metalized mylar or
X X
Spray-Lat over windows. Check window protection.
8. Close and cover the outflow valves, ram air doors,
X
and intake scoops.
9. Vent aircraft by opening doors when temperature is
X
over 90°.

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ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.02-2
JOB TITLE
LONG TERM ACTIVE STORAGE Page 2 of 3
J/C Reviewed By: Date: Frequency Signature
Initial Monthly As Req. Mechanic
C. Wings
1. Ensure fuel tanks filled to 45,000 lbs. minimum.
(1 & 4 Alt = 3,000#) (1 & 4 Main = 7,000#) X
(2 & 3 Main = 10,000#) (Ctr = 5,000#)
2. Cover fuel vents, cavity vents, and fuel dump
openings with cheesecloth. Secure with tape and red
X X
streamers.
Remove for engine runs.
3. Treat fuel tanks with Biobar JF or PFA 55MB fuel
X Annually
additive.
4. Drain fuel sumps for water. X X
5. Check for fuel and hydraulic leaks. X X
D. Landing Gear
1. Install landing gear down locks. X
2. Wipe exposed portion of inner cylinders with BMS
X X
3-23/BMS 3-26 corrosion inhibitor.
3. Check tire pressure. Inflate as required. X
4. Rotate tires 1/3 turn. X X
5. Service struts with nitrogen. X X
6. Wipe and then coat nose steering cylinders with
X X
MSC0352 or equivalent.
7. Check gear and wheel well for fluid leaks, corrosion,
X X
and general condition.
8. Close wheel well doors and cover strut openings and
X
gears with paper and tape.
9. Cover tires with fabric tire covers. X
10. Lube landing gear. X Annually
E. Nacelles/Engines
1. Run engines. N/A if preserved IAW applicable
X X
engine manuals.
2. Install desiccant (10 lbs. inlet – 10 lbs. exhaust) X
3. Remove and reinstall desiccant during engine runs. X
4. Check desiccant for color changes. X
F. Aft Fuselage
1. Cover all openings with cloth or mylar. X X

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13.02 AIRCRAFT STORAGE (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
13.02-2
JOB TITLE
LONG TERM ACTIVE STORAGE Page 3 of 3
J/C Reviewed By: Date: Frequency Signature
Initial Monthly As Req. Mechanic
G. Control Surfaces
1. Lube flap tracks, cables, and actuators as required. X Annually
2. Check fluid levels in control surface snubbers. X Annually
3. Set horizontal stab at nose down. X
4. Check for hydraulic leaks. X X
5. Cycle all control surfaces. X X
6. Ensure all surface drains are clear. X X
7. Spray jackscrews and actuating rods with oil. X
H. Systems/Cockpit
1. Ensure all switches are off. X
2. Disconnect all Ni-Cad batteries.
X X
Reconnect at engine runs.
3. Release parking brake. X
4. Depressurize brake hydraulic system. X
5. Shut off all oxygen valves at the bottle. X
6. Store O2 masks in a sealed plastic bag. X
7. Close outflow valves, ram air scoops, and doors. X
I. Fuselage Interior
1. Clean and drain all galleys and lavatories. X
2. Drain potable water system. Purge with air. Remove
X
filters and leave valves open. (JC 16.02-1.)
3. Check seats and carpet for mildew. X
4. Apply a wet spray, dry granules, or suitable
X
powdered substitute to the interior with insecticide.
5. Distribute desiccant bags throughout cabin. X X
6. Check the desiccant for color change. X Annually
7. In the forward and aft cargo compartment, remove
one floor panel each. Check for wet insulation Annually
blankets.
J. Initiate logbook entry as follows:

“Placed in log term active storage on _______ (date) X X Annually

________ (time).”
NOTES:

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13.03 RESERVED FOR FUTURE USE

1. This section is reserved for future use.

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13.04 – DC-8 THREE ENGINE FERRY PROCEDURES

TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 13.04.1
2. WINDMILL FERRY: PROCEDURE FOR DEFECTIVE ENGINE----------- 13.04.1
3. NON-WINDMILL FERRY: DEACTIVATION METHODS FOR
DEFECTIVE ENGINE---------------------------------------------------------------- 13.04.3
4. CFM-56 ENGINES -------------------------------------------------------------------- 13.04.5

FIGURES

13.04-1 BLOCKER PLUG (METHOD ONE) ----------------------------------------------- 13.04.6

13.04-2 LOCKING STRAPS (METHOD TWO)-------------------------------------------- 13.04.7

FORMS

13.04-1 FERRY FLIGHTS WITH ONE ENGINE INOPERATIVE --------------------- 13.04.9

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1. General

a. A three-engine Ferry Flight may be performed when an engine change at a given location
is undesirable.

b. Two types of ferries can be accomplished.

(1) WINDMILL FERRY

(2) NON-WINDMILL FERRY

c. Contact LIT Maintenance Control

(1) Prior to a three engine ferry, the senior maintenance employee on duty must contact
LIT Maintenance Control to ensure no additional checks/inspections are required.

(2) Maintenance Control will establish the method to be used to prevent the inoperative
engine from wind milling in flight.

d. Proceed as follows:

(1) Upon completion of troubleshooting, determine if the affected engine is capable of

being wind milled per the limits stated in the PWA JT3D Maintenance Manual
Chapter 72-0, or CFM-56 Maintenance Manual Chapter 72. Inform Maintenance
Control, who will obtain further check requirements and/or concurrence from the
Director of Quality Control, Director of Maintenance, and Director of Operations
prior to departure.

(2) In all other respects, the ferry checks are to be consistent with those for a three
engine ferry with an inoperative engine.

2. Windmill Ferry: Procedure for Defective Engine

a. In cases where the engine is mechanically sound and rotates freely, and has a fully
serviceable lubrications system, the engine may be wind milled.

b. Perform a detailed engine inspection:

(1) External case for cracks or penetration.
(2) Free rotation of rotors. Ref. P&W or CFM M/M 72.
(3) Verify serviceable inlet and turbine blades as viewed from both intake and exhaust.
(4) Check main oil screen or lube unit for excessive metal for contamination (as
applicable P&W or CFM)

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(cont’d)

c. Motor engine per JRH and check for the following:

(1) Leaks
(2) Rotor to case rubbing
(3) Unusual noise or vibration
(4) Oil pressure

d. Service engine oil and CSD

e. Close oil cooler and heat exchanger doors.(-61 only)

f. Confirm thrust reverser position meets the minimum requirements of the DC-8 MEL.

g. Position cockpit controls of inoperative engine.

(1) Generator disconnect switch DISENGAGE

(2) Generator control switch OFF
(3) Oil cooler door switch(-61 only) OFF
(4) Heat exchanger door circuit breaker(-61 only) OPEN
(5) Engine ignition circuit breakers OPEN
(6) Continuous ignition circuit breaker(-61 only) OPEN
(7) Hydraulic pump (inboard engine) BYPASS***

***DO NOT BYPASS THE HYD. PUMP UNTIL DEPARTURE.

(8) Fuel lever shut off OFF

(9) Firewall shutoff lever (E handle) FUEL, AIR, HYD OFF

Note: Consideration must be given for adequate lubrication of the fuel control, fuel
pump, and hydraulic pump. The flight crew will position the fire wall shut off
and the fuel on levers to the on position at regular intervals as per the DC-8
OPS Manual.

WARNING: OPERATION IN FLIGHT OF AN ENGINE THAT IS BEING WINDMILL

FERRIED IS PROHIBITED. DO NO ATTEMPT A START.

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(cont’d)

3. Non-Windmill Ferry: Deactivation Methods for Defective Engine. Two methods are
available for flexibility. LIT Maintenance Control will decide which method will be
incorporated based on availability and location.

a. METHOD ONE (60 SERIES ONLY)

(1) Deactivate by installing blocker plug. Ref. Figure 13.04-1. This plug can be
manufactured on location.

(a) Position blocker plug segments inside the engine inlet against the inlet guide
vane.

(b) Install splice plate bolts.

(2) Confirm thrust reverser position meets the minimum requirement of the DC-8
MEL.

(3) Service engine and CSD oil.

(4) Close oil cooler and heat exchanger doors.(-61 only)

(5) Position cockpit controls as follows:

(a) Generator disconnect switch DISENGAGE

(b) Generator control switch OFF
(c) Oil cooler door switch OFF
(d) Heat exchanger door circuit breaker OPEN
(e) Engine ignition circuit breakers OPEN
(f) Continuous ignition circuit breaker(-61 only) OPEN
(g) Hydraulic pump (inboard engine) ON
(h) Fuel lever shut off OFF
(i) Firewall shutoff lever (E handle) FUEL, AIR, HYD OFF

b. METHOD TWO (PRATT & WHITNEY ENGINES)

(1) Secure front compressor rotor using three PWA-30233 locking straps. Ref. Figure
13.04-2.

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(cont’d)

(a) Feed one end of the strap into the engine rotor inboard of the mid span shroud,
around the trailing edge of the first stage fan blade and back forward through the
first stage.

(b) Position strap so one end extends past the leading edge of the inlet guide vane
approximately one inch.

(c) Pass the other (long) end of the strap over the next inlet guide vane in the
direction of engine rotation (counter clockwise facing the engine) and around the
trailing edge of the closest first stage blade, causing the strap to pull the blade in
the direction of engine rotation.

(d) Continue weaving the strap alternately between blades and vanes. Every blade
will not be strapped because the number of vanes does not equal the number of
blades. Keep strap tight and always pull compressor rotor in the direction of
rotation.

(e) When the end of the strap is reached, bring the end out of the engine, pull tight
and overlap the Velcro at each end of the strap.

(f) Secure Velcro by rolling it up tightly and secure it to the nearest inlet guide vane
with speed tape.

(g) Continue to secure the remaining portions of the rotor with the rest of the straps
repeating the above procedure.

(2) Secure the rear compressor using PWA-30251 lock.

(a) Remove starter from engine. Ref. DACO M/M Chap. 80.

(b) Place PWA-30251 lock over studs and engage the starter driver splines. Secure
the lock to the starter drive using the nuts removed with the starter.

(3) Verify start valve closed, remove cannon plug and stow.

(4) Place starter and ferry kit box aboard the aircraft. The locks will be put back into
the ferry kit box when the aircraft reaches the destination. The starter will be
reinstalled when the aircraft reaches destination.

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4. CFM-56 ENGINES

a. Secure engine IAW CFM maintenance manual Chapter 71-00-00.

b. Complete the three engine ferry checklist, Form 13.04-1, for serviceable engines.

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(cont’d)

BLOCKER PLUG (METHOD ONE)

Figure 13.04-1

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(cont’d)

1. NYLON CORD WRAP (TWO PLACED)

2. SPEED TAPE
3. PULL CORD TIGHT
4. STRAP COVER
5. INLET GUIDE VANE, REF.
6. FIRST STAGE COMPRESSOR BLADE REF.

LOCKING STRAPS (METHOD TWO)

Figure 13.04-2

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(cont’d)

FERRY FLIGHTS WITH ONE ENGINE INOPERATIVE

(FORM DC-8-13.04-1)

Note: Make two copies - insert one in the flight log.

A/C Sta Date Log Page

TAT TAC

Windmill Ferry

Ferry with Engine Blocked

Note: If an enroute stop is required for fueling, items 1A, B, C, G, H, 2A. 2 for a blocked
engine and 2B.1 and 2B.2 for a wind milled engine must be repeated and
documented on an additional form at that time.

1. Preparation of Aircraft and Good Engines Mechanic’s

Signature
A. Accomplish a Preflight Check or higher check as directed by
Maintenance Control.
B. Check and service hydraulic fluid quantities, accumulators and
air bottles as required.
C. Visually check inlets and exhausts of serviceable engines for
irregularities or damage.
D. 1. DC-8-60 SERIES Check the main oil screens on all
serviceable engines per the PWA JT3D Maint. Manual and
confirm they are free of contamination, especially metal
particles and coke.
2. DC-8-70 SERIES Check lube unit chip detectors for metal
or contamination per the CFM maintenance manual.
Confirm lube unit bypass indicators are not popped.
E. Operate the serviceable engines at idle and check for fluid leaks
after all work has been accomplished.
F. Operate serviceable engines at take-off power per the DC-8
ERH and verify ability to reach max power.
G. Check tires and brakes; cool and serviceable.
H. Verify the fuel load by using the magna sticks.
I. Initiate a deferred item per this procedure reference against the
inoperative engine.

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(cont’d)

Mechanic’s
Signature

J. Make a general safety inspection of the aircraft and enter a

statement into the flight log, signed off by a qualified A&P
mechanic, certifying the aircraft safe for the ferry flight per the
GMM 3.117.
Statement: I have inspected the aircraft and found it SAFE
for a one-time ferry flight per the GMM 3.117.
K. Obtain a copy of the Special Flight Authorization issued by LIT
and install it in the flight log per the GMM 3.117.
2. Preparation of the Inoperative Engine for Ferry
A. If the inoperative engine is to be blocked or secured:
1. Install either the inlet plug or the N1 and N2 rotor locks.
2. Verify that the thrust reverser is stowed in the forward thrust
position.
3. If an inboard engine is inoperative, ensure the remaining
engine driven hydraulic system is operating properly.
B. If the engine is to be wind milled:
1. Service the engine and CSD oils as required.
2. Check the main oil screen or lube unit chip detectors to
confirm there is no indication or abnormal wear or pending
bearing failure.
3. Motor the engine in accordance with the DC-8 ERH to
check for oil leaks. Confirm oil pressure is steady at more
than 5 PSI.
4. Verify that the thrust reverser is stowed in the forward thrust
position.
5. Obtain final approval from the VP of Quality Control/VP of
Maintenance for the windmill ferry.

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CHAPTER 15 - LIMITS

TABLE OF CONTENTS
Page
15.01 INTEGRAL WING FUEL TANK LEAKAGE
CLASSIFICATION AND LIMITS-------------------------------------------------- 15.01.1
15.02 HYDRAULIC SYSTEM EXTERNAL LEAKAGE LIMITS-------------------- 15.02.1
15.03 TIRES ----------------------------------------------------------------------------------- 15.03.1
15.04 ALTIMETER IN-SERVICE TOLERANCES ------------------------------------- 15.04.1

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LIMITS
TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 15.01.1
2. CLASSIFICATION-------------------------------------------------------------------- 15.01.1
3. REPAIR REQUIREMENTS --------------------------------------------------------- 15.01.2

FIGURES

15.01-1 FUEL LEAK EXAMPLES ----------------------------------------------------------- 15.01.1

15.01-2 INTERGAL WING FUEL TANKS ------------------------------------------------- 15.01.4

TABLES

15.01-1 FUEL LEAK LOCATION AND ACTION REQUIRED PRIOR TO 15.01.3

FLIGHT ---------------------------------------------------------------------------------

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1. General: The text contained herein are excerpts from the Douglas Aircraft DC-8 Structure
Repair Manual. If any conflict arises the SRM will prevail. Reference Douglas DC-8 SRM
51-1-12 for limits and SRM 51-1-11 for general instructions if any questions arise.

2. Classification

a. It is important that the fuel leak be carefully evaluated to facilitate an effective repair
now or when the aircraft can be scheduled for a repair visit. Classification of fuel leaks is
necessary to differentiate between those leaks that constitute a flight safety hazard and
those that can be repaired at a scheduled maintenance opportunity.

b. Fuel leak evaluation should be begin by washing the suspect area with solvent and
wiping the area dry. This will remove existing traces of fuel from the area to allow for a
better evaluation.

WARNING: OBSERVE ALL SAFETY REGULATIONS WHEN USING

SOLVENTS.

c. Apply leak detector (blue chalk line powder) or equivalent, to the suspect leak area to
assist in location and size of the leak. Let the area soak 15 minutes to determine the size
of the wetted area. Compare to Figure 15.01-1 for leak examples and to the definitions
following for classification of leaks.

FUEL LEAK EXAMPLES

Figure 15.01-1

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(cont’d)

d. Fuel leaks are classified into four groups:

(1) SLOW SEEP: Fuel wets the area NOT over 1-1/2 inches in diameter.

(2) SEEP: Fuel wets the area NOT over 4 inches in diameter.

(3) HEAVY SEEP: Fuel wets the area NOT over 6 inches in diameter. In any
case the fuel shall not run, flow, or drip.

(4) RUNNING LEAK: Fuel is running, flowing, or dripping from the exterior
structure OR wets the area over 6 inches in diameter. A
RUNNING LEAK MUST BE REPAIRED PRIOR TO
FLIGHT.

3. Repair Requirements

a. Leak location and repair requirements are listed in Table 15.01-1.

b. ACTION REQUIRED: Reference Table 15.01-1 and Figure 15.01-2.

(1) No repair required. Frequent inspection for leak progression. SEE NOTE (A)
BELOW.

(2) No immediate repair required. Frequent inspection for leak progression. SEE
NOTE (A) BELOW.

(3) Immediate repair required.

(4) Immediate repair required to a no-leak category prior to further flight.

(5) Initiate a CARRY OVER ITEM stating the location and classification of the leak.
Include this reference in the carry over.

NOTES A. Frequent inspection requirements are complied with during the normal Pre-Flight
or higher routine inspection and will require no additional documentation.

B. Leaks developing at piping, pipe fittings, and other equipment will be repaired
prior to flight.

C. Leaks caused by structural or installation failure which are not sealant failures are
subject to the appropriate repair prior to flight.

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D. Thoroughly investigate any type of fuel leak occurring at spar webs, tank
bulkheads, and other areas for possible structural cracks. LEAKS
OCCURRING AS A RESULT OF CRACKS MUST BE REPAIRED PRIOR
TO FLIGHT.

E. All fuel leaks, regardless of classification, will be repaired when extensive

maintenance or heavy check is completed.

SLOW HEAVY
LEAK LOCATION SEEP SEEP SEEP

Exposed skin of upper and lower surfaces from wing Station XRS 172.0 1&5 1&5 2&5
outboard.

Upper and lower skin surfaces from wing Station XRS 172.0 inboard to 1&5 2&5 3
edge of wing fillet.

Enclosed area of upper skin from edge of wing fillet inboard to centerline. 4 4 4

Enclosed area of lower skin from edge of fairing panels inboard to 2&5 3 3
centerline.

Enclosed areas of the engine pylons and pylon fairings. 2&5 3 3

Area of aft spar web from wing Station XRS 172.0 inboard to centerline. 2&5 3 3

Area of aft spar web form wing Station XRS 172.0 outboard. 1&5 2&5 3

Area of front spar web wing Station Xcw 69.5 inboard to centerline. 4 4 4

Area of front spar web wing Station Xcw 69.5 outboard. 2&5 3 3

Exposed areas of nose cap fuel tanks. 1&5 2&5 3

Structural cracks and piping installations. 4 4 4

Tank closing bulkhead and wing tip. 2&5 3 3

FUEL LEAK LOCATION AND ACTION REQUIRED PRIOR TO FLIGHT

BY CLASSIFICATION
Table 15.01-1

NOTE: RUNNING LEAKS ARE NOT INCLUDED IN THE CHART.

RUNNING LEAKS MUST BE REPAIRED PRIOR TO THE NEXT FLIGHT.

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15.01 INTEGRAL WING FUEL TANK LEAKAGE CLASSIFICATION & LIMITS
(cont’d)

Note: * Not applicable on some aircraft.

INTERGAL WING FUEL TANKS

Figure 15.01-2

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15.02 – HYDRAULIC SYSTEM EXTERNAL LEAKAGE LIMITS

TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 15.02.1
2. SPECIAL TOOLS AND MATERIALS -------------------------------------------- 15.02.1
3. EXTERNAL LEAKAGE LIMITS -------------------------------------------------- 15.02.1

TABLES

15.02-1 HYDRAULIC EXTERNAL LEAKAGE LIMITS -------------------------------- 15.02.2

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15.02 HYDRAULIC SYSTEM EXTERNAL LEAKAGE LIMITS

1. General

a. Before checking dynamic seal leakage, operate the component through several cycles to
exercise the seals. The seals may have taken a set after sitting several hours, particularly
in the cold weather.

b. This document outlines general external leakage limits in areas where no other
specifications exist.

c. There are three levels of limits:

(1) Maximum leakage to permit dispatch of an airplane to next layover to avoid a delay
or cancellation, upon Little Rock Maintenance and QC approval.

(2) Maximum leakage that should be allowed during layover, extended downtime, or
“A” check.

(3) Maximum leakage that should be allowed during B, C or D checks.

CAUTION: SPILLED HYDRAULIC FLUID MUST BE THOROUGHLY CLEANED

UP AT THE FIRST OPPORTUNITY. RESIDUAL FLUID CAN BE
SPREAD OVER LARGE AREAS OF EXTERNAL PAINT BY THE
AIRSTREAM, CAUSING UNACCEPTABLE PAINT
DETERIORATION.

d. These limits do not pertain to leakages caused by obvious failures such as cracks, pin
holes or wear holes.

e. Leakage on or near to hot air ducts is not acceptable as it may damage ducts or cause
fumes in the airplane. Leakage is not acceptable within the pressurized area of the
fuselage.

f. All checks will be accomplished both with system pressurized to normal operation
pressure and with it depressurized (see note for pump shaft seals).

2. Special Tools and Materials: None required.

3. External Leakage Limits: See Table 15.02-1.

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15.02 HYDRAULIC SYSTEM EXTERNAL LEAKAGE LIMITS (cont’d)

LAYOVER OR “A”
TYPE OF LEAK DISPATCH CHECK ALL HIGHER
CHECK

Pump or motor shaft

seal leak while 60 drops/min 30 drops/min 3 drops/min
pressurized

Tubing or hose “B” 5 drops/min 1 drop/min None allowed.

nut connections

Other leaks (Swivel

glands, Actuator rod 30 drops/min or 10 drops/min or 1 drop/min or
seals, Component vent 5 drops/cycle 1 drop/cycle 1 drop/5 cycles
holes, etc.)

HYDRAULIC EXTERNAL LEAKAGE LIMITS

Table 15.02-1

NOTE: Shaft seal leakage with pump or motor not operating is not cause for pump
replacement, unless it generally affects airplane maintenance or hydraulic system
fluid level.

4. Hydraulic External Leakage Repair Requirements

a. Hydraulic external leakage limits are listed in Table 15.02-1. Also reference paragraph
1.c.

b. ACTION REQUIRED: Reference Table 15.02-1. Initiate a CARRY OVER ITEM

stating the location and classification of the leak. Include this reference in the carry over.

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15.03 - TIRES
TABLE OF CONTENTS
Paragraph Page
1. DIAMETERS, LIMITS AND ALTERATIONS----------------------------------- 15.03.1
2. PRESSURES AND UNDER INFLATION PROCEDURES -------------------- 15.03.1
3. WEAR AND DAMAGE INSPECTION-------------------------------------------- 15.03.3

FIGURES

15.03-1 TIRE WEAR POINTS ---------------------------------------------------------------- 15.03.3

TABLES

15.03-1 TEMPERATURE COMPENSATED PRESSURE READINGS ---------------- 15.03.2

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15.03 TIRES

1. Diameters, Limits and Alterations

a. -62 350,000 lb. Gross Weight Tire Diameter Limits

-63 358,000 lb. Gross Weight Tire Diameter Limits

(1) Nose Gear tire 34” X 11” 22 ply rated 225 MPH
Max. 33.4” in diameter
Min. 32.5” in diameter
(2) Main gear tire 44.5” X 16.5” 30 ply rated 225 MPH
Max. 44.5” in diameter
Min. 43.5” in diameter
b. -62 335,000 lb. Gross Weight Tire Diameter Limits
-61 325,000 lb. Gross Weight Tire Diameter Limits

(1) Nose gear tire 34” x 11” 22-ply rated 225 MPH
Max. 33.4” in diameter
Min. 32.5” in diameter

(2) Main gear tire 44” x 16” 32-ply rated 225 MPH
Max. 44” in diameter
Min. 43” in diameter

CAUTION Wheel and Tire Assy. P/N 154251-1, tire size 44” x 16” (DC-8-62
335,00 G.W. and DC-8-61 325,000 G.W.) ARE NOT interchangeable
with Wheel and Tire Assy. P/N 2601411-2, tire size 44.5” x 16.5” (DC-
8-62 350,000 G.W. and DC-8-63 358,000 G.W.)

2. Pressures and Under Inflation Procedures

a. Tire pressures are checked using a calibrated dial type gauge and inflated as required on
all daily services and above in accordance with temperature corrected charts.

b. Any tire found to be under inflated by less than approximately 25 psi of the temperature
corrected pressure (refer to both charts) will be inflated to normal chart pressure and a
Carry-Over Item written to check it at next two subsequent stations. If under inflation
persists, tire will be replaced.
c. Tubeless tires lose approximately 5% of inflation pressure in a 24-hour period by
sidewall seepage, etc.

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15.03 TIRES (cont’d)
d. Landing and taxi maneuvers cause an increase of temperature in the tires, wheels and
brakes. It normally requires a minimum of two hours ground time for the tire pressure
and temperature to stabilize to ambient air temperature.
e. Tire inflation pressure will increase/decrease 1 psi for each 3 degree change from 70
degrees Fahrenheit (use data in Chapter 16, Figure 16.04-3).
EXAMPLE A properly inflated nose landing gear tire at a stabilized temperature of +
10 degrees Fahrenheit would indicate 130 - 0 + 5 psig and a pressure of
155 psig at a temperature of 85 degrees Fahrenheit.
f. Paired tires are both tires on one axle.
g. If both tires on the same axle require replacement (due to one tire’s pressure loss) at a
station where insufficient tires are available, the tire within limits need not be replaced
under the following conditions:
(1) It is inspected and found serviceable.
(2) A Carry-Over item is written to replace it at the first station where equipment and
manpower is available.
h. Replace any tire where tire pressure loss occurs while aircraft is parked.

350,000 and 358,000 G.W. AIRCRAFT MAIN LANDING GEAR (44.5 X 16.5) @ 70° F
INFLATED & REMOVE
CARRY-OVER BOTH TIRES
NORMAL INFLATED (SEE ITEM 2.b.) REMOVE (PAIRED)

MLG 205-200 PSI 199-190 PSI 189-175 PSI UNDER 175 PSI UNDER 135 PSI
NLG 155-150 PSI 149-140 PSI 139-125 PSI UNDER 135 PSI UNDER 100 PSI
(SEE ITEM 2.f, g, h).

325,000 and 335,000 G.W. AIRCRAFT MAIN LANDING GEAR (44 X 16) @ 70° F
INFLATED & REMOVE
CARRY-OVER BOTH TIRES
NORMAL INFLATED (SEE ITEM 2.b.) REMOVE (PAIRED)

MLG 185-180 PSI 179-170 PSI 169-155 PSI UNDER 155 PSI UNDER 120 PSI
NLG 155-150 PSI 149-140 PSI 149-125 PSI UNDER 125 PSI UNDER 100 PSI
(SEE ITEM 2.f, g, h.)

TEMPERATURE COMPENSATED PRESSURE READINGS

Table 15.03-1

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15.03 TIRES (cont’d)

3. Wear and Damage Inspection

a. Tires are “On Condition” Items. This section establishes limits of common tire
conditions which are cause for tire removal from service. Since it is impossible to cover
all conditions or combinations of conditions that may affect the reliability of a tire, it is
expected that good judgment will be exercised when tires exhibit damage not specifically
covered in the publication.

b. Tire Wear Limits

(1) MAJOR CHECK LIMITS: Remove Main and Nose wheel tires when center rib or
ribs measure less than 1/32 inch above wear points (grooves).

(2) LINE STATION LIMITS: Remove Main and Nose wheel tires when center rib or
ribs are worn to the depth of the grooves (bald).

TIRE WEAR POINTS

Figure 15.03-1

c. Tire Damage Inspection Limits

(1) General: During the visual inspection of a tire, remove all foreign pieces of
material from the tread. An awl or a screwdriver should be used to remove foreign
particles. Care should be exercised so that cuts are not enlarged or increased in
depth.

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(2) Inspection Limits

Note: Tread cuts of 1-1/2” or less in length that do not penetrate through more
than two cord piles (breaker strips and fabric tread excluded) may be
considered serviceable.
(a) Tires are to be removed from service if any of the following conditions are
found: (Return all removed tires to Little Rock Stores)

1) Any tire having a cut in excess of the above dimensions as to either length
or depth will be removed.

2) Any tire having more than six cuts into the cord plies of 1” or over in
length will be removed.

3) Any tire having three or more cuts into the cord piles of 1” or over in
length grouped in an area of 25% of the tire surface will be removed.

Note: The above dimensions apply both to cuts with the tread and cuts
across the tread.

4) Sidewall cuts extending to cord will be cause for removal.

(b) Bulges - Signs of bulge at the tread or on the sidewalls is cause for removal.
This condition is often the result of injury to the cord body. Mark the bulge
area with crayon and print in capital letters “BULGE”, since after deflation the
bulge cannot be seen.

(c) Open Tread Splice or Sidewall Splices - Any tire should be removed from
service when tread splice separation is found down to the cord body.

(d) Bruises - Blister or scuffed hole in the tread shoulder or crown is cause for
removal. A bruised tire may appear as a bulge. Before it is dismounted,
indicate damage area.

(e) Unsatisfactory Retread or Recap - Any evidence of a recap tread separating

from the casing is cause for removal.

(f) Cracks and Weather Checking

1) Cracks in the base of the groove of the tread more than 3” long exposing
cord are cause for removal.

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2) Any tire exhibiting weather checking that extends to the cord may remain
in service for one tread life. When removed, tire will be suitable tagged to
alert recapper to the sidewall condition.

(g) Bead Failure - Exposed bead wires and torn chafer piles are cause for removal.
Excessive chafing wear in the rim flange area or signs of cracking or blistering
is cause for removal.

(h) Radial Cracks - Any tire exhibiting radial cracks in the sidewall extending to the
cord will be removed from service.

(i) Heat Damage - Any sidewall blistering or charring of rubber adjacent to the
bead area is cause for removal.

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15.04 – ALTIMETER IN-SERVICE TOLERANCES

TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 15.04.1

TABLES

15.04-1 DOUGLAS ALTIMETER TOLERANCES IN-SERVICE ---------------------- 15.04.2

15.04-2 RVSM ALTIMETER TOLERANCES IN-SERVICE ---------------------------- 15.04.3

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15.04 ALTIMETER IN-SERVICE TOLERANCES

Note: All altimeter adjustments must be done in a certified repair shop. This includes
barometric/field elevation adjustments.

1. General: Each pilot discrepancy concerning altimeter tolerance must be thoroughly analyzed
while taking aircraft maintenance manual tolerances into consideration.

a. To determine if an altimeter is within tolerance while aircraft is on the ground:

(1) Set altimeter barometric scale to local altimeter setting as furnished by airport
control tower or weather station.

(2) Compare the indicated altitude with the know airport elevation.

(3) If observed error is less than specified tolerance (Table 15-4) the altimeter is within
limits at field elevation.

(4) If error exceeds tolerance, altimeter must be replaced with serviceable unit.

b. Altimeter discrepancies written up during flight usually are errors as compared with
another altimeter. The allowable error would be equal to the total of the plus and minus
factor of that error shown in Table 15.04-1 opposite the altitude at which observation was
made.

EXAMPLE: At 20,000 feet the allowance error is +/- 130 ft. on the table; this
combined tolerance would equal 260 ft.

If combined tolerance exceeds this figure, both altimeters must be removed for test in a
Certified Repair Station or, if available, the altimeters may be checked in the aircraft by
means of a static system tester which includes an altimeter with a current correction card
and is designated for this purpose.

WARNING: THE GMM SPECIFIES THAT THE REPLACEMENT OF PITOT

OR STATIC SYSTEM INSTRUMENTS REQUIRES AN RII
SYSTEM LEAKAGE CHECK. REFER TO THE DOUGLAS MM
CHAPTER 34 FOR TESTING REQUIREMENTS.

NOTES: A. If an altimeter has been compared in flight with two other altimeters, it
may be possible to determine which is out of tolerance. In this case the one
altimeter may be replaced.

B. Altimeter readings should be taken after gently tapping instrument panel

near the instrument. Do not tap on the instrument glass.

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15.04 ALTIMETER IN-SERVICE TOLERANCES (cont’d)

Altimeters should be analyzed as individual units because the tolerance involved when
comparing two instruments may be two times the allowable error (one unit with minus
error and one unit with a plus error).

c. Allowable Errors: Following (Tables 15.04-1 & -2) are the allowable errors at the
indicated altitude area which give an allowance for temperature and normal deterioration
due to aging. The basis for these errors is FAR 43, Appendix E at room temperature of
25°C. The errors are the difference from standard pressure altitude for a single
instrument. When two instruments are compared, the difference could be 2 times these
allowable errors above 10,000 feet.

Non-RVSM Barometric Type

Standard Altitude Capt. Standby Mode Allowable
(Feet) +/- Feet Difference
At Ground Level *+/-20 40
1,000 *+/-20 40
2,000 *+/-30 60
4,000 *+/-35 70
6,000 *+/-40 80
10,000 +/-80
14,000 +/-100
16,000 +/-110
18,000 +/-120
20,000 +/-130
22,000 +/-140
25,000 +/-155
30,000 +/-180
35,000 +/-205
40,000 +/-230
45,000 +/-255
50,000 +/-280
* Difference from aircraft elevation with barometric scale set to “Altimeter Setting” as furnished
by control tower or local weather bureau.

DOUGLAS ALTIMETER TOLERANCES IN-SERVICE

Table 15.04-1

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DC-8-71/-73
RVSM Altitude Allowable Altitude Allowable Difference
(Feet) Tolerance (feet)
29000 +/- 68 136
30000 +/- 68 136
31000 +/- 68 136
32000 +/- 68 136
33000 +/- 67 134
34000 +/- 67 134
35000 +/- 67 134
36000 +/- 68 136
37000 +/- 68 136
38000 +/- 68 136
39000 +/- 68 136

DC-8-62/-72
RVSM Altitude Allowable Altitude Allowable Difference
(Feet) Tolerance (feet)
29000 +/- 84 168
30000 +/- 85 170
31000 +/- 86 172
32000 +/- 88 176
33000 +/- 90 180
34000 +/- 91 182
35000 +/- 92 184
36000 +/- 94 188
37000 +/- 95 190
38000 +/- 96 192
39000 +/- 98 196

NOTE: If one of the 3 sources of Altimetry is lost, the remaining 2 sources must remain within
+/- 200 feet of one another.

RVSM ALTIMETER TOLERANCES IN-SERVICE

Table 15.04-2

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TABLE OF CONTENTS
Page
16.01 INTRODUCTION ------------------------------------------------------------------ 16.01.1

16.02 PRE-FLIGHT CHECK------------------------------------------------------------- 16.02.1

16.03 “A” CHECK ------------------------------------------------------------------------- 16.03.1

16.04 “B” CHECK ------------------------------------------------------------------------- 16.04.1

16.05 “C” CHECK ------------------------------------------------------------------------- 16.05.1

16.06 “D” CHECK ------------------------------------------------------------------------- 16.06.1

16.07 LUBRICATION--------------------------------------------------------------------- 16.07.1

16.08 COMBI PASSENGER COMPARTMENT MATERIAL CONDITION

INSPECTION ----------------------------------------------------------------------- 16.08.1

16.09 AIRCRAFT EXTERIOR WASH ------------------------------------------------- 16.09.1

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16.01 - INTRODUCTION
TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 16.01.1
2. INSPECTION METHODS DEFINITIONS ---------------------------------------- 16.01.3

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16.01 INTRODUCTION
1. General
a. Air Transport International’s DC-8 Maintenance Program consists of “Pre-Flight”, “A”,
“B”, “C” and “D” Checks. CHECK INTERVALS AS PER OPS SPEC. DOC. NO. ATI-
DC8-001.

(1) A Pre-Flight Inspection shall be accomplished prior to aircraft dispatch if:

(a) the aircraft has not had a Maintenance Pre-Flight within the preceding 72
elapsed hours, or

(b) ground time exceeds 12 continuous hours.

(2) The Company’s Aircraft Maintenance Pre-Flight Inspection is satisfied by two
methods: The Maintenance Pre-Flight (MX P/F) or the Flight Engineer’s Pre-Flight
Inspection (FE P/F). The MX P/F shall be accomplished by authorized company
maintenance personnel. The FE P/F shall be accomplished by a FAA Certificated
Company Flight Engineer.
(a) Maintenance Pre-Flight - A MX P/F shall be accomplished prior to aircraft
dispatch in accordance with the procedures outlined in the ATI DC-8
Maintenance Manual whenever:
1) the aircraft has not had a MX P/F within the preceding 72 elapsed hours,
or

2) ground time exceeds 12 hours and ATI maintenance personnel are

available.
(b) Flight Engineers Pre-Flight Inspection - A FE P/F shall be accomplished prior
to aircraft dispatch as specified in the Operations Department’s DC-8 Cockpit
Operating Manual(Section 2). When the FE P/F is used to satisfy the 12 hour
requirement noted above, it must be documented in the Aircraft Log Book in the
Check/Inspection block as “FE P/F”, along with the signature/certificate
number of the Flight Engineer performing the inspection. The FE P/F
inspection shall be accomplished whenever:

1) the aircraft has had a MX P/F within the preceding 72 elapsed hours, ATI
maintenance personnel are not available, and ground time exceeds 12
hours.

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Example 1: The MX P/F is accomplished at 0001Z on 1 Jan. The aircraft flies numerous trips
with no ground times exceeding 12 hours. The MX P/F expires at 0001Z on 4 Jan.
Example 2: The MX P/F is accomplished at 0001Z on 1 Jan. The aircraft flies several short
trips then lands at TOL at 1200Z on 2 Jan. The aircraft’s next scheduled departure
is 0001Z on 3 Jan. A new MX P/F is required since the aircraft ground time
exceeded 12 hours and maintenance personnel are available.
Example 3: Same as Example 2 except the aircraft lands at an airport where no ATI
maintenance personnel are available and ground time exceeds 12 hours. The
aircraft is scheduled for departure at 0001Z on 3 Jan. When the Flight Engineer
accomplishes the FE P/F the 12 hour rule is satisfied and the MX P/F continues to
be valid until 0001Z on 4 Jan or until ground time exceeds 12 hours again.
(3) “A” Check - “A” Check to be performed not to exceed 125 hours aircraft time in
service. Details of inspection and work are outlined in the ATI DC-8 Maintenance
Manual.
(4) “B” Check - “B” Check to be performed not to exceed 700 hours time in service for
all DC-8 series aircraft. Details of inspection and work to be performed will be
detailed on job cards generated by computer from the Work Card Index Master List.
(5) “C” Check - “C” Check to be performed not to exceed 3000 hours time in service.
(6) “D” Check - “D” Check to be performed not to exceed 25,000 hours time in
service.
b. Correction of non-routine and deferred items may be accomplished in conjunction with
any check.
c. All Checks are to be accomplished at the time intervals specified in the Maintenance
Operations Specifications.
d. The time interval for any check starts again at zero on accomplishment of a higher
lettered periodic check.
e.g. Accomplishing a “B” Check
“B” Check TSO = 0
“A” Check TSO = 0
Pre-Flight Check TSO = 0
e. The accomplishment of higher lettered periodic Check does not interrupt the number
sequence of the lower periodic Checks.
e.g. If the last “C” Check was “C4,”
Accomplishment “D” Check, TSO = 0
“C5” Check, TSO = 0

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16.01 INTRODUCTION (cont'd)

2. Inspection Methods Definitions

Inspection Method Description Interpretation and Use

A visual check conducted from ground
Walk Around Check Observations from the ground to detect
level to detect obvious discrepancies.
obvious discrepancies, such as leaks.
A collective term which includes the
General Visual A visual check of Exposed Areas of wing
External Surveillance Inspection, the
lower surface; lower fuselage; doors and
Internal Surveillance Inspection, and
cutouts; and landing gear bays.
the Walk Around Check.
Surveillance External: Visual check to detect A visual examination of defined internal or
obvious unsatisfactory conditions or external structural areas from a distance
discrepancies in externally visible considered necessary to carry out an
structure. May also include internal adequate check. External includes
structure which is visible through quick structure which is visible through quick
opening access panels/doors, work opening access panels/doors. Internal
stand, ladders, etc. May be required to applies to obscured structure requiring
gain proximity. removal of fillets, fairings, access
panels/doors, etc. For visibility.
Internal: Visual check to detect obvious
(SEE NOTE 1 BELOW)
unsatisfactory conditions or
discrepancies in internal structure. This
type of inspection applies to obscured
structure and installations which require
removal of fillets, fairings, access
panels/doors, etc.
An intensive visual check of a specified
Detailed Close intensive visual inspections of highly
detail, assembly or installation. It
defined structural details or locations
searches for evidence of structural
searching for evidence of structural
irregularity using adequate lighting and,
irregularity.
where necessary, inspection aids such
as mirrors, hand lens, etc. Surface (SEE NOTE 1 BELOW)
cleaning and elaborate access
procedures may be required.
Special Detailed An intensive check of a specific Inspections of specific locations or hidden
location similar to the Detailed details using specified non-destructive
Inspection except for the following inspections (NDI) procedures. Also used
differences. The check requires some for intensive inspection of details with a
special technique such as non- known history of service discrepancies.
destructive test techniques, dye
(SEE NOTE 2 BELOW)
penetrate, high-powered magnification,
etc., and may require disassembly
procedures.
NOTE 1: Using adequate lighting and, where necessary, inspection aids such as mirrors, etc., surface cleaning
and access procedures may be required to gain proximity.

NOTE 2: Details where internal or external visual inspections do not provide adequate opportunity for timely
detection of damage.

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16.02 – “PRE-FLIGHT” CHECK

TABLE OF CONTENTS
Paragraph Page
1. ACCOMPLISHMENT SPECIFICATIONS------------------------------------- 16.02.1
2. PRE-FLIGHT INSPECTION------------------------------------------------------ 16.02.3
3. PRE-FLIGHT INSTRUCTIONS ------------------------------------------------- 16.02.5

FIGURES

16.02-1 EMERGENCY EQUIPMENT DIAGRAM ---------------------------------- 16.02.14

16.02-2 EMERGENCY EQUIPMENT SYMBOLS ---------------------------------- 16.02.15
16.02-3 TIRE PRESSURE LIMIT/TEMPERATURE CHART --------------------- 16.02.18
16.02-4 NITROGEN SERVICING PLACARD INSTALLATION----------------- 16.02.19

TABLES

16.02-1 EMERGENCY EQUIPMENT MATRIX------------------------------------- 16.02.12

FORMS

16.02-1 PRE-FLIGHT INSPECTION--------------------------------------------------- 16.02.3

JOB CARDS

16.02-1 POTABLE WATER & WASTE DISPOSAL SYSTEMS SERVICING - 16.02.20

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16.02 “PRE-FLIGHT” CHECK

1. Accomplishment Specifications

a. A “Pre-Flight” Check is a brief visual check of significant items of the Aircraft, Systems,
and Appliances to ensure a safe and airworthy continuation of operation.

b. The “Pre-Flight” Check is to be accomplished at the frequency specified in Section 16.01

in accordance with the Form DC 8-16.02-1 with specific instruction in paragraph 3
(following).

c. “Pre-Flight” Check accomplishment will be confirmed by the mechanic's signature on the

Pre-Flight form. All non-routine items are to be recorded on the log page.

d. Refer to the General Maintenance Manual for Airworthiness Release Procedures.

e. All non-routine items must be cleared by appropriate corrective action prior to aircraft
release for flight.

f. “Pre-Flight” check accomplishes all areas of the Aircraft Search requirements stated by
TSA issued Security Directives.

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2. PRE-FLIGHT INSPECTION (FORM DC-8-16.02-1) (See Paragraph 3. PRE-FLIGHT
INSTRUCTIONS for detailed procedures)
LOG PAGE __________ TAT __________ STA __________ DATE __________ A/C ___________
NOTE: Items 1 thru 25 must be checked within 1 hour of aircraft arrival unless otherwise noted:
SIGNATURE
1. REVIEW AIRCRAFT FLIGHT LOG. DMI’S and CARRY OVERS. Correct, declare
serviceable, carry over or defer all discrepancies. Identify any repetitive discrepancies -----
2. CHECK COCKPIT emergency equipment, windows, 02 masks, equipment, flight crew
deferral kit; clean as necessary------------------------------------------------------------------------
3. CHECK CABIN emergency equipment, side walls, ceiling, floor; clean as necessary -------
4. CHECK CARGO DOOR AND CONTROLS ------------------------------------------------------
5. CLEAN GALLEYS: Check for security, condition, and supplies -------------------------------
6. FLUSH & CLEAN TOILET. Service waste disposal system if necessary---------------------
7. CLEAN SINKS and perform operational check of potable water system-----------------------
8. CHECK WHEELS AND TIRES for condition and wear -----------------------------------------
9. CHECK MAIN LANDING GEAR AND WHEEL WELL AREAS ----------------------------
10. CHECK NOSE LANDING GEAR AND WHEEL WELL AREAS ----------------------------
11. SERVICE #1 ENG OIL, record the amount of oil used qt. _____[check all engines within
12. SERVICE #2 ENG OIL, record the amount of oil used qt. _____ 15 minutes of arrival. ---
13. SERVICE #3 ENG OIL, record the amount of oil used qt. _____Fill tank to within 1” of --
14. SERVICE #4 ENG OIL, record the amount of oil used qt. _____top of fill neck]-------------
15. SERVICE #1 CONSTANT SPEED DRIVE OIL [check all CSD’s within 30 ----------------
16. SERVICE #2 CONSTANT SPEED DRIVE OIL minutes of aircraft arrival]---------------
17. SERVICE #3 CONSTANT SPEED DRIVE OIL --------------------------------------------------
18. SERVICE #4 CONSTANT SPEED DRIVE OIL --------------------------------------------------
19. PERFORM INTERNAL & EXTERNAL VISUAL CHECK OF #1 ENGINE ----------------
20. PERFORM INTERNAL & EXTERNAL VISUAL CHECK OF #2 ENGINE ----------------
21. PERFORM INTERNAL & EXTERNAL VISUAL CHECK OF #3 ENGINE ----------------
22. PERFORM INTERNAL & EXTERNAL VISUAL CHECK OF #4 ENGINE ----------------
23. CHECK FUSELAGE, EMPENNAGE, WINGS for obvious irregularities---------------------
24. CHECK EXTERIOR LIGHTS -----------------------------------------------------------------------
25. RESERVED--------------------------------------------------------------------------------------------- N/A
26. CHECK BRAKES. A.D. 94-06-10 reduces brake wear limit to 1/2”, ALL AIRCRAFT.
Refer to DACO DC-8 MM 32-42-1 for inspection procedures. ---------------------------------
27. PERFORM BRAKE DECAY CHECK--------------------------------------------------------------
28. CHECK FLOW LIMITERS or BRAKE LOCKOUTS--------------------------------------------

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2. PRE-FLIGHT INSPECTION (FORM DC-8-16.02-1) (cont’d) (See Paragraph 3. PRE-
FLIGHT INSTRUCTIONS for detailed procedures)
SIGNATURE

29. CHECK AND CLEAN LOWER CARGO COMPARTMENTS: fore and aft ----------------
30. INSPECT CARGO LOADING SYSTEM ---------------------------------------------------------
31. INSPECT AND LUBE LH & RH UPLATCHES. (Lube references listed below)
UPLATCHES (RH & LH): Section 16.07 for Lubrication. --------------------------------------
32. SERVICE HYDRAULIC RESERVOIRS: main and spoiler ------------------------------------
33. CHECK HYDRAULIC ACCUMULATORS FOR PRE-CHARGE
Main ____ Aux_____ Rudder Standby ____ Nose Steering (3) ____
Brakes (3) ____ Thrust Reverser ____ (2) Spoiler ____ ----------------------------------------
34. CLEAN EXPOSED PORTION OF GEAR OLEO STRUTS with rag dampened with MIL-
H-5606 (after cargo/pax download is complete & before fueling) -------------------------------
35. CHECK 02 BOTTLES for supply, condition and security CREW ----
PASSENGER ----
36. CHECK INTERIOR LIGHTS (-62/-72: leave PAX on full bright for last 45 min prior to
dep.) ------------------------------------------------------------------------------------------------------
37. SERVICE TIRES with dry nitrogen only, (AD 87-08-09). See Chapter 15, Section 3, for
wear limits and under inflation, Figure 16.02-3 for temp conversion chart.
Pressures given at 70 degrees. Tolerance +5/-0 PSI Tolerance.
DC-8-62/-71/-72 Series.....................................................................MAINS 185 PSI
DC-8-73 AIRCRAFT........................................................................MAINS 200 PSI
ALL AIRCRAFT ..............................................................................NOSE 150 PSI----------
38. DRAIN FUEL SUMPS (Not applicable if fuel temperature is below 32º F) ------------------
39. COMPLETE EXTENDED OVER WATER EQUIPMENT CHECK (If applicable) ---------
40. COMPLETE AIR MOBILITY COMMAND PRE-DEPARTURE EQUIPMENT CHECK
(If applicable) -------------------------------------------------------------------------------------------
41. MAINTENANCE RELEASE:
A. Routine check items completed and signed off.
B. Aircraft Flight Log items completed and signed off.
C. Review flight time on current log page and compute “Flight Hours Remaining” to
Next “A” Check. Verify time with Records/Maintenance Control.
D. Make entry in logbook for “Type Check/Inspection Performed”, “Date”, “Time”,
“Station” , followed by full signature and FAA Certificate Number.
E. Ensure extra aircraft logbook, Engine Performance Report book, a ladder, and 2 cases
each of oil & applicable hydraulic fluid is on aircraft.
F. Ensure aircraft documents are onboard. To include Aircraft Registration, Standard
Airworthiness Certificate, and ship’s radio license.
G. Forward paperwork to Records by most expeditious means immediately after
departure.
H. Deferred Maintenance Items MEL requirements recorded in the aircraft flight logbook
as necessary
Date & G.M. Time
I. Signature ______________________________________________
FAA Certificate Number __________________________________

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CHAPTER 16 – PERIODIC CHECKS
16.02 “PRE-FLIGHT” CHECK(cont’d)

3. PRE-FLIGHT INSTRUCTIONS (NOTE: UNLESS OTHERWISE SPECIFIED, ALL

REFERENCES PERTAIN TO OTHER PORTIONS OF THIS MANUAL.)(PARAGRAPH
NUMBERS BELOW CORRESPOND WITH ITEM NUMBERS ON FORM DC-8 16.02-1)
SECURITY NOTE: If during the inspection of the aircraft a suspicious, dangerous or deadly item
or unauthorized person is discovered, immediately notify airport security or appropriate law
enforcement officials and, in the U.S., the local airport Federal Security Director or designee.
Also notify ATI Maintenance Control or Flight Operations. All inspection items specifically
directed by the TSA Security Directive are annotated by the following symbol: “*”.
1. REVIEW Aircraft Flight Log - Review aircraft logbook for possible repeat problems within the last
seven (7) flight releases. If a problem has repeated twice within this period of time it warrants
investigation as a possible chronic problem. Contact Maintenance Control for previous trouble-
shooting areas and parts already utilized. Review DMI’s, troubleshoot, correct and clear as time
permits. Also make required entries into the aircraft logbook any DMI required notes. Review Carry
Over items, troubleshoot, correct and clear as time permits. Pass on to Maintenance Control any
troubleshooting information or parts requirements.
2. CHECK COCKPIT
a. CHECK WINDOWS for serviceability (DACO M/M Chapter 56).
b. CHECK O2 MASKS for serviceability and cleanliness.
c. CHECK SEATS AND SEAT BELTS for serviceability. *For Security reasons, special attention
must be given to areas under the seat cushions, seat pockets and under seats.
d. CHECK EQUIPMENT: FIRST AID KIT, LIFE RAFT, LIFE VESTS, FIRE EXTINGUISHERS,
PBE’S, MEGAPHONE, EMERGENCY MEDICAL KITS, CRASH AXE, ELT,
UNDERWATER LOCATOR BEACONS (voice & flight data recorders), SMOKE GOGGLES,
AND FURNISHINGS for condition, security, and placarding. Inspect FLIGHT CREW
DEFERRAL KIT in FE’s desk. 10 CB collars required, replenish as necessary. Refer to Figure
16.02-1 for applicable type aircraft and emergency equipment location and to GMM 3.206 for
Emergency Equipment Tag Requirements. * For Security reasons, special attention must be
given to accessible compartments on the flight deck that do not require special tools to open.
e. CLEAN AND VACUUM as necessary.
3. CHECK CABIN - Check equipment, first aid kits, life rafts, life vests, fire extinguishers, PBE’s,
megaphone, flight attendants' flashlights, and furnishings for condition and security. Refer to GMM
3.206 for Emergency Equipment Tag requirements. Check side walls, ceiling and floor for damage;
all holes or tears in protective lining must be repaired prior to aircraft departure. Refer to Chapter 53
for repair procedure. Clean compartment as necessary. *For Security reasons, special attention must
be given to overhead bins, closets, lavatories, to include compartments within the lavatories, galleys,
trash receptacles, storage bins and other accessible compartments in the cabin that do not require
special tools to open.

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CHAPTER 16 – PERIODIC CHECKS
16.02 “PRE-FLIGHT” CHECK(cont’d)
4. CHECK CARGO DOOR AND CONTROLS -
a. DOUGLAS DOORS - Check door control valve and actuating shaft for freedom of movement,
Tee handle and stowage clip, Tee handle universal and roll pin for wear, access door and spacer,
isolation valve switch and guard for security.
b. CARGO DOOR INTERIOR ALL SERIES: Check door interior and components for general
condition, security, leaks, chafing, and wear. Check door jambs, seal depressor and door seal for
general condition and serviceability. Check cargo door wiring and hydraulic components
between upper door jamb and door for condition and leaks. Repair as required.
5. CLEAN GALLEYS - Self-explanatory. On COMBIs, check & replenish supplies. *For Security
reasons, special attention must be given to trash receptacles, storage bins and other accessible
compartments.
6. FLUSH, and CLEAN TOILETS. Service waste disposal system if necessary.
a. PORTA-POTTI cleaning procedures::
(1) Remove bungee cord from around porta-potti.
(2) Remove potty from aircraft.
(3) Separate top and bottom halves of potty by releasing side latches and removing top half.
(4) Dump bottom half of potty in appropriate facility.
(5) Clean porta-potti.
(6) Reassemble porta-potti and secure side latches.
(7) Remove servicing cap from top half of potti.
(8) Service to half-full with blue deodorizing toilet water.
(9) Reinstall servicing cap.
(10) Reinstall porta-potti in aircraft.
(11) Reinstall bungee cord around potti.
NOTE: Ensure bungee is secure; if it slips, it could break the seal and spillage may occur.
b. FLUSH TOILET cleaning procedures: Flush and clean toilets. Service Waste Disposal Systems
IAW DACO MM Chapter 12-41-1.
7. CLEAN SINK: Wash sink, rinse and dry. Perform operational check of potable water system.
8. CHECK WHEELS AND TIRES - Check wheels for cracks and loose tie bolts. Refer to Chapter 15
for tire conditions.
9. CHECK MAIN LANDING GEAR AND WHEEL WELL AREAS - Visually check MLG assembly
and wheel well components including actuating components, emergency air bottle, and up-latch for
security and general condition. Check bogie truck for dents, scratches and gouges, shock strut for
proper extension, and landing gear attach points for integrity. *For Security reasons, special attention
must be given to the MLG Wheel Well areas.
10. CHECK NOSE LANDING GEAR AND WHEEL WELL AREA - Visually check NLG assembly
and wheel well for general condition and leaks. Check shock strut for leakage at top and for proper
extension. Check condition and installation of actuating components, gear doors, linkages and gear
up and down lock mechanisms. Check nose steering cables. Check gear attach points for integrity.
Pay particular attention to taper pins; minimum of one thread showing light. *For Security reasons,
special attention must be given to NLG Wheel Well areas.

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16.02 “PRE-FLIGHT” CHECK(cont’d)
11-14. SERVICE (4ea.) ENGINE OIL - The engine oil level must be checked within 15 minutes of
engine shutdown. If engine has been shut down for more than 15 minutes, operate it for a
minimum of one minute to empty scavenge system and then service. Service to within one inch
of top of fill neck full mark on dipstick with EXXON/BP 2380.
15-18. SERVICE (4ea.) CONSTANT SPEED DRIVE OIL - Check oil level of CSD by means of the
sight gauge. Oil level is to be within the green band in the center of the sight gauge.
a. Remove dust cap from CSD transmission pressure fill fitting located on the right side of the
scavenge filter.
b. Connect pressure fill hose.
c. SLOWLY fill CSD transmission oil system with EXXON/BP 2380 until oil reaches the bottom of
the sight gauge. Allow 5 minutes for the oil level to stabilize, then continue to add oil until the oil
level stabilizes within the green band as directed below:
DC-8-62 with A.D.C. and Burbank hush kit - below middle of green band.
All other aircraft - upper half of green band.
WARNING: USE EXXON/BP OIL 2380 ONLY.
WARNING: DO NOT OVER SERVICE CSD. OVER SERVICING FILLS THE
AIR/OIL SEPARATOR WITHIN THE CSD WITH OIL, MAKING IT
UNABLE TO RID THE OIL OF AIR WHICH IS NOT A VERY
EFFECTIVE LUBRICANT. OVERHEATING AND OIL SLUDGING
WILL RESULT AND WILL DESTROY THE CSD. CONFIRMING A
CSD FAILURE BY RECONNECTING THE UNIT AND BRINGING
IT UP TO SPEED WILL PROBABLY DOUBLE THE COST OF
OVERHAUL AND IS LIKELY TO RENDER THE UNIT BER.
19-22. PERFORM INTERNAL/EXTERNAL VISUAL CHECK OF EACH ENGINE.
a. Visually inspect the fan rotor, bypass ducts, tailpipe, & turbine for damage & cracking.
b. Pay particular attention to the #6 bearing for leakage.
c. Inspect cowling, nacelle and access ports for evidence of fluid leakage.
23. CHECK for obvious irregularities.

a. CHECK FUSELAGE including: radome, cabin windows access doors, pitot heads, and static
vents - condition, security and fluid leaks; radio rank venturi - clear and no air flow; heat
exchanger outlet doors - condition; external power protection access door - secure; 02 blow-out
disc(s) - in place; LH and RH pressure relief valve/static port closed/clear; outflow valves -
open/condition; fore and aft toilet/water service doors - secure; main cargo door exterior plating
and periphery - condition, security, pressurization leaks, nicks, dents, loose fasteners. *For
Security reasons, special attention must be given to the exterior areas of the aircraft.

-60 SERIES AIRCRAFT - Check Turbo and Freon Compressor exhaust, clear and no oil.

-70 SERIES AIRCRAFT - Check chin scoops and ground cooling doors for condition.

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16.02 “PRE-FLIGHT” CHECK(cont’d)
b. CHECK EMPENNAGE including: control surfaces and leading edges for condition, security of
access plates and fluid leakage. Check condition of tail energy absorber, tail skid and static
dischargers.

c. CHECK WINGS including: control surfaces and leading edges condition, security, and fluid
leaks; pylon stress screws security; fuel vent and surge box overflow - clear; aileron curtains -
wear and tear; static dischargers - proper security; fuel magna sticks - serviceable condition.
WITH HYDRAULIC AND FUEL SYSTEMS PRESSURIZED, check wings for fuel and
hydraulic leaks. (If walk around becomes excessive, turn off pumps and continue later.)

24. CHECK EXTERIOR LIGHTS - Ensure all exterior lights are in operational order.

25. RESERVED
26. CHECK BRAKES - Check brake assemblies and lines for leakage, security, and wear indicators
(brake must be parked). Check brake compensating links for condition.
WEAR LIMITS - A.D. 94-06-10 reduced brake wear limits to 1/2” for all aircraft. Refer to DACO
DC-8 MM 32-42-1 for inspection procedures.
27. PERFORM BRAKE DECAY CHECK - Auxiliary hydraulic pump off, check brake pressure and
decay time. Maximum decay is 100 psi in 15 min.
28. CHECK FLOW LIMITERS ON BRAKE LOCKOUTS - The fluid quantity limiter is self-resetting,
requiring only a pressure equalization of approximately 5 psi to reset. Check limiter by fully
depressing brake pedals with hydraulic system pressurized. Pressure indicator should pop out, and
retract when brakes are released. The brake lockouts are checked with the brakes set. Check piston
extension by dust cover service mark indicator.
29. CHECK AND CLEAN LOWER COMPARTMENTS - Check condition of floors, walls and ceilings
in pits 1, 2, 3, and 4. All holes or tears in baggage compartments must be repaired before departure.
Refer to Chapter 53 for repair procedure. *For Security reasons, special attention must be given to all
lower cargo compartments.
30. INSPECT CARGO LOADING SYSTEM: (See EFFECTIVITY in INTRODUCTION SECTION for
applicability and CHAPTER 25 for CARGO SYSTEM MAINTENANCE)
a. Check all assembled parts for cleanliness and security of mechanical attachment.
b. Inspect all parts for indications of damage, wear, corrosion, or stress. Pay particular attention to
system attachment fittings, and latching and rotating mechanism components.

c. Check 9G net and smoke curtain for serviceability. If net is damaged, refer to DACO DC-8 SRM
53-2-3 for tolerances. If damage is close to maximum wear limits, notify Maintenance Control so
that a serviceable net can be routed to the aircraft. Ensure all net and curtain attachment pins and
hardware are installed.
31. INSPECT AND LUBRICATE LH & RH MAIN GEAR DOOR UPLATCHES (RH & LH):
Inspect and lubricate, as necessary, Main Gear Door Uplatches (RH & LH) – Section 16.07 for
Lubrication.

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16.02 “PRE-FLIGHT” CHECK(cont’d)
32. SERVICE HYDRAULIC RESERVOIRS - The main reservoir may be filled by gravity, or by
pressure pot through ground test connection. The spoiler reservoir may be filled by pressure pot or
the alternate spoiler power solenoid may be opened and the tank filled from the left manifold pressure
system return from its own lateral control spoiler drive cylinder. The left and right cylinders plus the
inboard spoiler drive cylinder are used to maintain the reservoir during normal operation. (HYJET
IV)

NOTE: If alternate spoiler power solenoid procedure is used to service spoiler reservoir, it is
required to recheck main reservoir for proper service level.

33. CHECK HYDRAULIC ACCUMULATOR FOR PRECHARGE - De-pressurize each system with the
pumps off. Service accumulators to the following pressures with dry nitrogen:
Main: 1000 psi - LH keel beam fwd of flap lockouts.
Aux: 1000 psi - Aft inbd corner of LH wing root.
Rudder Standby: 1000 psi - Aft inbd corner of LH wheel well. Open bleed valve to relieve
trapped pressure.
Nose Steering: 500 psi - (2) RH side of nose wheel well.
50 psi - (1) LH side of nose wheel well, will hold at 150 psi and there is
no requirement to check pre-charge. If a steering complaint exists,
depressurize with bleed screw on relief valve and reservice.
Brake: 700 psi - Numbered 1 through 3 from fwd to aft on RH keel beam.
Thrust Reverser: 1000 psi - Numbered 4 and 5 from fwd to aft on RH keel beam.
Spoiler: 2000 psi - Number 6 from fwd to aft on RH keel beam.
34. CLEAN EXPOSED PORTION OF LANDING GEAR OLEO STRUTS - Self-explanatory. (MIL-H-
5606)
35. CHECK 02 BOTTLES - Change bottles that are within 2 months of hydrostatic test date. When
pressure drops to refill, remove bottle from aircraft for recharging to maximum value or replacement.
REFILL MAXIMUM
Portable 1600 psi 1800 psi
Crew (Main) 1650 psi 1850 psi
Courier 1650 psi 1850 psi
Passenger 1650 psi 1850 psi

Pressure given is for 70° F. For each 10-degree increase or decrease, add or subtract 35 psi to given
pressure respectively.
Verify that oxygen master and bottle valves are in open position.

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CHAPTER 16 – PERIODIC CHECKS
16.02 “PRE-FLIGHT” CHECK(cont’d)
36. CHECK INTERIOR LIGHTS - Ensure all passenger, cargo, and cabin lights are in operational order.
(Passenger aircraft only: Perform Photo Luminescent Aisle Path Marking check in accordance with
Section 33.02.
37. SERVICE TIRES - Self-explanatory. (DRY NITROGEN ONLY) Ref. AD 87-08-09. Tires should
be allowed to cool prior to tire pressure checks. Pressures given are at 70 degrees F. Refer to Figure
16.02-3 for temperature conversion chart. TOLERANCE +5 -0 PSI. See Chapter 15 for under
inflation requirements and procedures if more than 25 PSI under pressures given below.
DC-8-62/-71/-72 ACFT MAINS 185 PSI
DC-8-73 AIRCRAFT MAINS 200 PSI
ALL AIRCRAFT NOSE 150 PSI

38. DRAIN FUEL SUMPS - Drain one quart of fuel from each tank to check for presence of water and
contamination. Fuel tanks should be stabilized (no transferring or adding fuel to tanks) for a
minimum of 4 hours prior to sumping tanks. If sump draining contains a small amount of solid
particles, slime or sludge, followed by clear fuel, no further action is required. If sump drainings
contain more than one ounce of dark colored water, or so much foreign material that the draining of
four or five gallons does not produce clear fuel, or if even small amounts of contaminates appear
chronically, contact Maintenance Control providing all details possible. Maintenance Control will
decide course of action.
39. EXTENDED OVER WATER FLIGHT EQUIPMENT CHECK.
a. Life Rafts and Life Vests (Check each item for installation and security.
(1) Two life rafts with E.L.T. Beacon installed (in cockpit/companionway). Verify life raft
expiration date is within 24 months since last overhaul. (Note: Two additional life rafts
with E.L.T. Beacons are required to be installed in rear of aircraft on horse charter flights.
(2) One life vest with light installed per occupied seat. Verify life vest expiration date is
within 36 months since last overhaul. *For Security reasons, special attention must be
given to life vest packages. Inspection of life vest package must include physically
removing each life vest package from holder and inspect for signs of tampering. Once life
vest package is removed, the holder area should be visually inspected. Any life vest
package or holder which appears to have been tampered with must be removed from the
aircraft.
b. Radio/Navigation Equipment. The following systems must be functionally checked and fully
functional:
(1) HF System (#1 and #2)
(2) SelCal System (#1 and #2)
(3) GPS System (#1 and #2)
(4) 8.33 Spaced VHF Comm System (#1 and #2)
c. Lavatory and Galley. Check for function, security, and proper servicing of all equipment.

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CHAPTER 16 – PERIODIC CHECKS
16.02 “PRE-FLIGHT” CHECK(cont’d)
40. AIR MOBILITY COMMAND PREDEPARTURE EQUIPMENT CHECK.
a. CARGO AND COMBI AIRCRAFT IAW A.D. 93-07-15 and A.C.25-18
(1) Cargo loading system operable and compartment clean. (Note: Set up in 88” X 108” unless
specified otherwise.)
(2) Each upper and lower cargo compartment properly placarded for weight.
(3) Interior upper and lower cargo compartment lighting operable and adequate.
(4) Courier seat serviceable (if installed).
(5) FWD and Main cargo door safety straps are available and serviceable.
(6) Ground headsets and ground cords available for concurrent fueling.
Cargo-2 Headsets & 2 ground cords - one will be 100’ long and the other 50’ long.
Combi-3 Headsets & 3 Ground Cords - one will be 100’ long and the other 50’ long.
(7) Interior and exterior appearance acceptable.
(8) Lower cargo compartment door nets installed.
b. COMBI AIRCRAFT ONLY
(1) FWD and AFT galley operable and appearance acceptable.
(2) Carpet appearance acceptable.
(3) Left and Right Lavatory operable and appearance acceptable.
(4) Movie operable.
(5) Boarding music operable.
(6) AFT entrance doors safety straps available and serviceable.
(7) Safety equipment accounted for.
(8) Potable water serviced and operable.
(9) Check seat covers, armrests and food trays for condition and serviceability.
*For Security reasons, special attention must be given to overhead bins, closets, lavatories,
to include compartments within the lavatories, galleys, trash receptacles, storage bins and
other accessible compartments in the cabin that do not require special tools to open.
(10) Ensure ten serviceable Fire Containment covers (FCC) are available in the COMBI cargo
compartment, along with five serviceable spares in A pit. Refer to ATI DC-8 MM 26.04
for damage limiations.
41. MAINTENANCE RELEASE - Refer to General Maintenance Manual.

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CHAPTER 16 – PERIODIC CHECKS
16.02 “PRE-FLIGHT” CHECK(cont’d) (Ref. AOM 6.03)

COCKPIT AREA
QUANTITY
ITEM -62/-72 -70
COMBI Freighter
Escape Ropes-Emergency Window Exits 2 2
Life Raft 2 1(a)
Portable Breathing Equipment (PBE) 1 1
Oxygen Masks-Quick Don 5 5
Smoke Goggles 5 5
Life Vests 5 5
Crash Axe 1 1
Halon Fire Extinguisher 1 1
Water Fire Extinguisher 1
First Aid Kit 1
Medical Kit 1
Communicator(Hand Held Radio) 1
Hazardous Waste Spill Kit 1 1
(a) Installed for over water operations only.

COURIER AREA
Escape Rope-Main Cabin Door 1 1
Life Raft 1(a)
PBE 7 1
Portable O2 Bottle(Note-In Lavatory) 1
Full Face Mask(Note-In Lavatory) 1
Oxygen Masks-Quick Don 2/1(b)
Life Vests 2/1(b)
Halon Fire Extinguisher 3 1
Crew Oxygen Bottle (or in ‘C’ Pit-location/quantity may vary) 2 2
Water Fire Extinguishers 2
Communicator 1
Protective Garment-Fire Resistant Nomex Suit 1
Applicator Wand 1
Megaphone 1
Emergency Locator Transmitter 1(c) 1
(a) Installed for over water operations only
(b) 2 installed on –71’s and 604BX and 1 on other –73’s
(c) 1 required; may be more installed

EMERGENCY EQUIPMENT MATRIX

Table 16.02-1 (1 of 2)

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16.02 “PRE-FLIGHT” CHECK(cont’d) (Ref. AOM 6.03)

COMBI PASSENGER COMPARTMENT

ITEM QUANTITY
Escape Slides-Aft Right and Left Doors 2
Life Rafts 2
PBE 2
Portable Oxygen Bottle 3
Life Vests (Overhead Bin) 3(c)
Life Vests (Jumpseat) 2
Halon Fire Extinguishers 2
Water Fire Extinguisher 1
First Aid Kits 2
Communicator 1
Protective Garment 1
Passenger Oxygen Bottles 3(d)
Spare O2 Masks 3
Door Barrier Straps 2
Emergency Flashlights 2
Megaphone 1
FA Demo Kit 1
Bio-Hazard Cleanup Kit 1
Automatic External Defibrillator (AED) 1
Seat Belt Extenders 3
Slide “Armed” Strap 2
Door “Opened” Safety Strap 2
(c) Plus 1 for each passenger seat
(d) 1 bottle is for emergency medical use

EMERGENCY EQUIPMENT MATRIX

Table 16.02-1 (2 of 2)

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16.02 “PRE-FLIGHT” CHECK (cont’d) (Ref. AOM 6.03 & FAM 6.01)

DC-8-62/72 COMBI
EMERGENCY EQUIPMENT DIAGRAM
Figure 16.02-1 (1 of 2)

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16.02 “PRE-FLIGHT” CHECK (cont’d) (Ref. AOM 6.03)

DC-8 70 SERIES FREIGHTER

EMERGENCY EQUIPMENT DIAGRAM
Figure 16.02-1 (2 of 2)

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16.02 “PRE-FLIGHT” CHECK(cont’d) (Ref. AOM 6.03 & FAM 5.02)

EMERGENCY EQUIPMENT SYMBOLS

Figure 16.02-2

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16.02 “PRE-FLIGHT” CHECK(cont’d)

NOTE: TIRES TO BE SERVICED WITH DRY NITROGEN ONLY (Ref. A.D. 87-08-09.)

DC-8-62/-71/-72 DC-8-73

TIRE PRESSURE LIMIT/TEMPERATURE CHART

Figure 16.02-3

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CHAPTER 16 – PERIODIC CHECKS
16.02 “PRE-FLIGHT” CHECK(cont’d)

“A” “B” CHECK REFERENCE Figure

FOR USE WITH JOB CARD 350

NITROGEN SERVICING PLACARD INSTALLATION

Figure 16.02-4

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CHAPTER 16 – PERIODIC CHECKS
16.02 RECURRING NON-ROUTINE JOB CARD
ATI RECURRING NONROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

16.02-1
JOB TITLE
Potable Water and Waste Disposal Systems Servicing
Job Card Reviewed By Date Page _1_ of _5
Mechanic Inspector
I. General:
(1) The applicable portions of this Job Card are to be complied with
whenever the outside air temperature(OAT) is, or is expected to fall
below, 32°F, and aircraft is expected to be on the ground in excess of
2 hours and no heater is available:
(a) draining, (b) flushing, (c) sterilizing, or (d) filling the potable
water system after it has been flushed/sterilized; or (e) cold weather
servicing of the waste disposal system.
(2) This Job Card is not required for routine filling of the potable
water system, which is accomplished in accordance with the Douglas
DC-8-60 Maintenance Manual.
(3) Check the applicable box(s) below for the task(s) being complied
with on this Job Card:
1. Pressure Drain Water 4. Sterilize Water Supply
Supply System System
2. Gravity Drain Water 5. Fill Water Supply System
Supply System
3. Flush Water Supply System 6. Waste Disposal Cold
Weather Servicing
CAUTION: DO NOT FILL WATER SUPPLY SYSTEM FROM
SOURCE CAPABLE OF DELIVERING WATER AT
MORE THAN 90 PSIG.
II. NOTES
(1) When the OAT is, or expected to fall below, 32°F, and the
aircraft is expected to be on the ground in excess of 2 hours and no
heater is available, completely drain water supply and waste
disposal systems before airplane cools to freezing temperature.
(2) When access doors and coupling caps are difficult to open due to
freezing, apply hot air to doors and caps. Do not attempt to pry
doors open.
(3) Upon completion of servicing, dry all water from access doors,
couplings, caps, and service panel areas before closing access doors.
III. Tools and Equipment (Equivalent substitutes may be used instead
of the following listed items.
Item Name Number Use
1 Sodium 5% solution Sterilizing water system
Hyprochlorite
2 Aerowash A (or equiv) Cleaning Water System

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CHAPTER 16 – PERIODIC CHECKS
16.02 RECURRING NON-ROUTINE JOB CARD
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

16.02-1
JOB TITLE
Potable Water and Waste Disposal Systems Servicing
Job Card Reviewed By Date Page _2_ of _5
Mechanic Inspector
IV. Tasks:
1. Pressure Drain Water Supply System:
a. Open all lavatory heater and coffee maker circuit breakers.
b. Ensure faucet and coffee maker valves are closed, lavatory shutoff and
galley supply valves are open, and fill-and-overflow and drain valves are
closed.
c. Pressurize water system to 45 psig through air valve on water supply
service panel, and maintain pressure during draining period.
d. Attach drain hoses to water supply tank drain coupling and aft and
mid-system drain couplings.
e. Open water supply tank drain valve on water supply tank drain panel,
and allow water to drain from tank.
f. When water tank is drained, remove air pressure supply and allow tank
to depressurize.
g. Open aft and mid-system drain valves.
h. Open galley and lavatory water faucets. Hold faucets open until water
drains from lines.
i. Close aft, mid-system, and water tank drain valves.
j. Remove drain hoses and install caps on drain couplings.

2. Gravity Drain Water Supply System:

a. Depress or remove valve core from tank pressure valve on service
panel to relieve water supply system pressure.
b. Open fill and overflow valve and remove caps from fill and overflow
couplings.
(1) Actuate test lamp switch on service panel to check fill-and-
overflow couplings.
(2) Actuate and hold the fill and overflow valve switch on the service
panel in the up or down position for approximately 3 seconds. The fill
and overflow valve indicator light should come on. If the indicator
light does not come on, hold the switch in the opposite direction; the
indicator light will come on. If the airplane ground electrical power is
not on, the fill and overflow valve can be actuated manually by
moving the override control handle counterclockwise until the handle
stops to engage the ratchet and then clockwise for 90°. The handle
will snap up into proper position and matching red dots on the valve
will indicate the vale is open(Ref. DACO MM 38-10-4).
c. Open all lavatory heater and coffee maker breakers.
(continued on next page)

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16.02 RECURRING NON-ROUTINE JOB CARD
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

16.02-1
JOB TITLE
Potable Water and Waste Disposal Systems Servicing
Job Card Reviewed By Date Page _3_ of _5
Mechanic Inspector
d. Attach drain hoses to water supply tank drain coupling, aft drain
coupling, and mid-system drain coupling.
e. Ensure lavatory shutoff drain valve and galley supply valves are open.
f. Open water supply tank drain valve on water supply tank drain panel,
and allow water to drain from tank.
g. Open aft and mid-system drain valves to allow water to drain from
supply.
h. Open all faucets and coffee maker valves. Hold open until water
drains from lines.
i. Close aft, mid-system, and water tank drain valves.
j. Remove drain hoses and install caps on drain couplings.
k. Replace valve core in service panel tank pressure valve.
l. Close fill and overflow valve and replace caps on fill and overflow
couplings.
(1) Actuate and hold the fill and overflow valve switch on the service
panel in the up or down position for approximately 3 seconds. The fill
and overflow valve indicator light should go off. If the light does not
go off, hold the switch in the opposite direction; the indicator light will
go off. If the airplane ground electrical power is not on, the fill and
overflow valve can be actuated manually by moving the override
control handle counterclockwise until the handle stops to engage the
ratchet and then clockwise for 90°. The handle will snap up into
proper position and matching red dots on the valve will indicate the
vale is closed.
(2) Actuate test lamp switch on service panel to check fill-and-
overflow couplings.

3. Flush Water Supply System:

a. Remove element from lavatory water filter and reassemble filter.
b. Prepare a cleaning solution composed of 6 ounces of detergent
(Aerowash A) to 1 gallon of potable water.
c. Fill water supply tank with cleaning solution using procedures
described in Task 5.
d. Pressurize water tank to 38 psig through air valve on water supply
service panel.
e. Open all faucets and coffee maker valves until cleaning solution begins
to flow through each valve.
f. Retain cleaning solution in water supply system for 30 minutes.
(continued on next page)

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16.02 RECURRING NON-ROUTINE JOB CARD
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

16.02-1
JOB TITLE
Potable Water and Waste Disposal Systems Servicing
Job Card Reviewed By Date Page _4_ of _5
Mechanic Inspector
g. Drain cleaning solution from water supply system using procedures
described in Task 1.
h. Fill and drain water supply system with potable water until water
supply system is thoroughly flushed, using procedures described in Tasks
1 and 5.

4. Sterilize Water Supply System:

a. Ensure water supply system is completely drained and coffee maker
selector valves are in the OFF position.
b. Fill water supply system with a chlorinated water solution of 15 fluid
ounces of 5 percent sodium hypochlorite solution and 100 gallons of
potable water.
c. Open all faucets and coffee maker valves until sterilizing solution
begins to flow through each valve.
d. Retain sterilizing fluid in the water supply system for 4 hours.
e. Drain sterilizing fluid from water supply system using procedures
described in Task 1.
f. Fill and drain system with potable water until system is thoroughly
flushed and no chlorine odor is evident.
g. Install new filter element in lavatory water filter.
h. Fill water supply system with potable water, using procedures
described in Task 5.

5. Fill Water Supply System:

a. Ensure aft, mid-system and water tank drain valves are closed; all
faucet and coffee maker valves are closed; and all lavatory shutoff valves
and galley water supply valves are open.
b. Open fill and overflow valve, using procedures described in Task 2.a.
c. Install fill hose from field service equipment on fill coupling, and
install drain hose on overflow coupling.
d. Fill water supply system with potable water until water runs from the
overflow coupling and water level gage on service panel indicates full.
e. Remove fill and drain hoses from the fill and overflow couplings.
f. Close fill and overflow valve, using procedures described in Task 2.l.
g. Dry all water from service panel area, and install caps on fill-and-
overflow couplings.
h. Pressurize water supply system to 38 psig through air valve on service
panel.
i. Close panel access doors.
h. Close coffee maker and lavatory water heater circuit breaker switches.

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16.02 RECURRING NON-ROUTINE JOB CARD
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

16.02-1
JOB TITLE
Potable Water and Waste Disposal Systems Servicing
Job Card Reviewed By Date Page _5_ of _5
Mechanic Inspector
6. Waste Disposal Cold Weather Servicing:
a. When the OAT is below, or expected to fall below, 32°F, completely
drain the waste disposal system before airplane cools to freezing
temperature.
b. If access doors and coupling caps are difficult to open due to freezing,
apply hot air to doors and caps. Do not attempt to pry open.
c. On completion of servicing dry all water from access doors, couplings,
caps, and service panel areas before closing access doors.
d. If tanks are not to be drained, add a non-flammable, automotive-type
antifreeze to the water, and add a chemical mixture in the tank and flush
the toilet assembly at least twice to ensure antifreeze is mixed thoroughly
with water chemical solution. Use a ratio of water to anti-freeze
comparable to that for an automobile, based upon the lowest expected
temperature anticipated for the cold-soak period.

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16.03 – “A” CHECK

TABLE OF CONTENTS
Paragraph Page
1. ACCOMPLISHMENT SPECIFICATIONS---------------------------------------- 16.03.1
2. “A” CHECK INSPECTION ---------------------------------------------------------- 16.03.3
3. “A” CHECK INSTRUCTIONS------------------------------------------------------ 16.03.7

FIGURES

16.03-1 MAGNETIC DRAIN PLUG INSPECTION --------------------------------- 16.03.21

FORMS

16.03-1 “A” CHECK INSPECTION ---------------------------------------------------- 16.03.3

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16.03 “A” CHECK

1. Accomplishment Specifications

a. An “A” Check is a visual check of the Aircraft, Systems, and Appliances at specified
intervals. An augmented check of significant items ensures airworthiness and reliability
until the next scheduled check.

b. The “A” Check is to be accomplished at the frequency specified in Section 16.01 in

accordance with the Form DC 8-16.03-1 (following).

c. “A” Check accomplishment will be confirmed by mechanic’s signature, on the “A”

Check form. All non-routine items are to be recorded in the Aircraft Flight Log.

d. All items must be cleared by appropriate corrective action prior to aircraft release for
flight.

e. Refer to the General Maintenance Manual for Airworthiness Release Procedures.

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16.03 “A” CHECK(cont’d)
2. “A” CHECK INSPECTION (FORM DC-8-16.03-1)(See Paragraph 3, “A” CHECK
INSTRUCTIONS for detailed procedures)
LOG PAGE __________ TAT __________ STA __________ DATE __________ A/C ___________
NOTE: Items 1 thru 24 must be checked within 1 hour of aircraft arrival unless otherwise noted:
SIGNATURE
1. REVIEW AIRCRAFT FLIGHT LOG. DMI’S and CARRY OVERS. Correct, declare
serviceable, carry over or defer all discrepancies. Identify any repetitive discrepancies -----
2. CHECK COCKPIT emergency equipment, windows, 02 masks, equipment, cockpit air
conditioning drain, flight crew deferral kit; lube/check cockpit seats; clean as necessary ----
3. CHECK CABIN emergency equipment, side walls, ceiling, floor; clean as necessary -------
4. CHECK CARGO DOOR AND CONTROLS ------------------------------------------------------
5. CLEAN GALLEYS: Check for security, condition, and supplies -------------------------------
6. SERVICE LAVATORIES:
a. FLUSH, and CLEAN TOILETS. Service waste disposal system if necessary.
b. CONDUCT LEAK TESTS OF TOILET TANK DUMP VALVE, and SERVICE
PANEL DRAIN VALVE.
c. INSPECT OUTER DOOR/CAP AND SEAL MATING SURFACE.
d. INSPECT “DONUT” VALVES. ------------------------------------------------------------------
7. CLEAN SINKS and perform operational check of potable water system-----------------------
8. CHECK WHEELS AND TIRES for condition and wear -----------------------------------------
9. CHECK MAIN LANDING GEAR AND WHEEL WELL AREAS ----------------------------
10. CHECK NOSE LANDING GEAR AND WHEEL WELL AREAS ----------------------------
11. SERVICE #1 ENG OIL, record the amount of oil used qt. _____[check all engines within
12. SERVICE #2 ENG OIL, record the amount of oil used qt. _____ 15 minutes of arrival. ---
13. SERVICE #3 ENG OIL, record the amount of oil used qt. _____Fill tank to within 1” of --
14. SERVICE #4 ENG OIL, record the amount of oil used qt. _____top of fill neck]-------------
15. SERVICE #1 CONSTANT SPEED DRIVE OIL [check all CSD’s within 30 ----------------
16. SERVICE #2 CONSTANT SPEED DRIVE OIL minutes of aircraft arrival]---------------
17. SERVICE #3 CONSTANT SPEED DRIVE OIL --------------------------------------------------
18. SERVICE #4 CONSTANT SPEED DRIVE OIL --------------------------------------------------
19. PERFORM INTERNAL & EXTERNAL VISUAL CHECK OF #1 ENGINE ----------------
20. PERFORM INTERNAL & EXTERNAL VISUAL CHECK OF #2 ENGINE ----------------
21. PERFORM INTERNAL & EXTERNAL VISUAL CHECK OF #3 ENGINE ----------------
22. PERFORM INTERNAL & EXTERNAL VISUAL CHECK OF #4 ENGINE ----------------
23. CHECK FUSELAGE, EMPENNAGE, WINGS for obvious irregularities---------------------
24. CHECK EXTERIOR LIGHTS -----------------------------------------------------------------------

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16.03 “A” CHECK(cont’d)
SIGNATURE
25. LUBE CABIN OUTFLOW VALVE ROD ENDS (COMBI only) ------------------------------
26. CHECK BRAKES. A.D. 94-06-10 reduces brake wear limit to 1/2”, ALL AIRCRAFT.
Refer to DACO DC-8 MM 32-42-1 for inspection procedures. ---------------------------------
27. PERFORM BRAKE DECAY CHECK--------------------------------------------------------------
28. CHECK FLOW LIMITERS or BRAKE LOCKOUTS--------------------------------------------
29. CHECK AND CLEAN LOWER CARGO COMPARTMENTS: fore and aft ----------------
30. INSPECT AND REPAIR CARGO LOADING SYSTEM I.A.W with the ATI DC-8
Maintenance Manual Chapter 25 ---------------------------------------------------------------------
31. CHECK MAIN CARGO DOORS.-------------------------------------------------------------------
32. RESERVED--------------------------------------------------------------------------------------------- N/A
33. SERVICE HYDRAULIC RESERVOIRS: main and spoiler ------------------------------------
34. CHECK HYDRAULIC ACCUMULATORS FOR PRE-CHARGE
Main ____ Aux_____ Rudder Standby ____ Nose Steering (3) ____
Brakes (3) ____ Thrust Reverser ____ (2) Spoiler ____ ----------------------------------------
35. VISUALLY CHECK OIL LEVEL IN LH AND RH AIR CYCLE MACHINE SIGHT
GLASS.
36. OPEN AND SECURE MLG DOORS
37. CLEAN EXPOSED PORTION OF GEAR OLEO STRUTS with rag dampened with MIL-
H-5606 (after cargo/pax download is complete & before fueling) -------------------------------
38. SERVICE FLAP LOCKOUTS
39. CLEAN EXPOSED PORTION OF RAM OF BOGIE TRIM CYLINDER with rag
dampened with Chevron IV or equivalent
40. LUBE, RH & LH BOGIE BEAM PIVOT POINT AND LH & RH UPLATCHES. (Lube
references listed below)
UPLATCHES (RH & LH): Section 16.07 for Lubrication.
41. CLOSE MLG DOORS
42. CHECK 02 BOTTLES for supply, condition and security CREW ----
PASSENGER ----
43. CHECK INTERIOR LIGHTS (-62/-72: leave PAX on full bright for last 45 min prior to
dep.) ------------------------------------------------------------------------------------------------------
44. CHECK OPERATION OF EMERGENCY EXIT LIGHTS

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16.03 “A” CHECK(cont’d)
SIGNATURE
45. SERVICE TIRES with dry nitrogen only, (AD 87-08-09). See Chapter 15, Section 3, for
wear limits and under inflation, Figure 16.02-3 for temp conversion chart.
Pressures given at 70 degrees. Tolerance +5-0.
DC-8-62/-71/-72 Series MAINS 185 PSI
DC-8-73 AIRCRAFT MAINS 200 PSI
ALL AIRCRAFT NOSE 150 PSI----------
46. DRAIN FUEL SUMPS (Not applicable if fuel temperature is below 32º F) ------------------
47. TEST FIRE WARNING SYSTEM
48. CHECK GEAR ANTI-RETRACTION LATCH
49. CHECK EMERGENCY AIR BRAKE PRESSURE by gauge on FE panel
50. CHECK OPERATION OF COCKPIT VOICE RECORDER
51. CHECK FLIGHT DATA RECORDER
52. CHECK VOR’S I/A/W FAR 91.171 Bearing Error Record:
#1 VOR _____ DEG #2 VOR ____ DEG
Variance ____ DEG (max 4 degrees)
53. REPLENISH SPARE BULBS AND FUSES
54. CHECK LIFE VESTS for integrity of container, emergency equipment tag
CAPT ____ FO ____ FE ____ 1 Obs ____ 2 Obs ____
Flt Attd ____ Courier Seats ____ Cabin ____
55. CHECK LIFE RAFTS for integrity of container, emergency equipment tag:
Cockpit ____ Passenger _____ (As Applic.) Aft Courier ____ (As Applicable)
56. CHECK SEAL on first aid kit (emergency equipment tag) and emergency medical kit (As
Applicable)
57. CHECK CRASH AXE for serviceable condition and emergency equipment tag..
58. CHECK EXTINGUISHERS for supply, condition, security, emergency equipment tag:
Cockpit ____ Courier Area ____ Aft Courier ____
Passenger ____ Galley ____ Bulkhead ____ (As Applicable)
59. CHECK PROTECTIVE BREATHING EQUIPMENT (PBE) for integrity of container, and
for blue humidity indicator
60. CHECK ESCAPE SLIDE(S), girt bar latches, seals, bottle pressure and emergency
equipment tags, door restraining straps as applicable
61. AUTOMATED EXTERNAL DEFIBRILLATOR. Perform inspection IAW expanded
instructions, item 61.
62. CHECK EMERGENCY AIR BRAKE BOTTLE for pressure by gauge on bottle and for
emergency equipment tag
63. INSPECT FWD SUMP CHIP DETECTOR #1 ENG. (AD 89-23-06) -70 SERIES
64. INSPECT FWD SUMP CHIP DETECTOR #2 ENG. (AD 89-23-06) -70 SERIES
65. INSPECT FWD SUMP CHIP DETECTOR #3 ENG. (AD 89-23-06) -70 SERIES
66. INSPECT FWD SUMP CHIP DETECTOR #4 ENG. (AD 89-23-06) -70 SERIES

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16.03 “A” CHECK(cont’d)
SIGNATURE
67. INSPECT #1 STARTER MAGNETIC DRAIN PLUG
68. INSPECT #2 STARTER MAGNETIC DRAIN PLUG
69. INSPECT #3 STARTER MAGNETIC DRAIN PLUG
70. INSPECT #4 STARTER MAGNETIC DRAIN PLUG
71. COMPLETE EXTENDED OVER WATER EQUIPMENT CHECK (If applicable) ---------
72. COMPLETE AIR MOBILITY COMMAND PRE-DEPARTURE EQUIPMENT CHECK
(If applicable) -------------------------------------------------------------------------------------------
73. FLIGHT DECK DOOR INSPECTION. Perform inspection in accordance with expanded
instructions, item 73. -----------------------------------------------------------------------------------
74. MAINTENANCE RELEASE:
A. Routine check items completed and signed off.
B. Aircraft Flight Log items completed and signed off.
C. Review flight time on current log page and compute “Flight Hours Remaining” to
Next “A” Check. Verify time with Records/Maintenance Control.
D. Make entry in logbook for “Type Check/Inspection Performed”, “Date”, “Time”,
“Station” , followed by full signature and FAA Certificate Number.
E. Ensure extra aircraft logbook, Engine Performance Report book, a ladder, and 2 cases
each of oil & applicable hydraulic fluid is on aircraft.
F. Ensure aircraft documents are onboard. To include Aircraft Registration, Standard
Airworthiness Certificate, and ship’s radio license.
G. Forward paperwork to Records by most expeditious means immediately after
departure.
H. Deferred Maintenance Items MEL requirements recorded in the aircraft flight logbook
as necessary
Date & G.M. Time
I. Signature ______________________________________________
FAA Certificate Number __________________________________

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16.03 “A” CHECK(cont’d)
3. “A” CHECK INSTRUCTIONS (NOTE: Unless otherwise specified, all references pertain
to other portions of this Manual.)(Paragraph Numbers below correspond with Item Numbers
of FORM DC-8-16.03-1)
1. REVIEW Aircraft Flight Log - Review aircraft logbook for possible repeat problems within the last
seven flight releases. If a problem has repeated twice within this period of time it warrants
investigation as a possible chronic problem. Contact Maintenance Control for previous trouble-
shooting areas and components already utilized. Review DMI’s, troubleshoot, correct and clear as
time permits. Also make required entries into the aircraft logbook any DMI required notes. Review
Carry Over’s, troubleshoot, correct and clear as time permits. Pass on, to Maintenance Control, any
troubleshooting information or components requirements.
2. CHECK COCKPIT –
a. Check windows for serviceability (DACO M/M Chapter 56).
b. Check 02 masks and regulators for serviceability and operation. ALL MASKS MUST MEET
TSO-C99, MEANING THAT THEY MUST BE VENTED MASKS WITH MATCHING
GOGGLES.
c. Check seats and seat belts for serviceability.
d. Check smoke masks for condition.
e. Equipment and furnishings for condition and security.
f. Clean and vacuum as necessary.
g. Ensure cockpit air conditioning supplemental drain is clear of obstructions and drains freely.
h. Inspect FLIGHT CREW DEFERRAL KIT in FE’s desk. 10 CB collars required, replenish as
necessary.
i. Lube/check cockpit seats. As necessary, lubricate the following items of the Pilot and FO’s seat
with EAL 146 oil or equivalent and wipe off excess:
(1) Seat tracks.
(2) Seat track rollers, pins, and linkages (eight places).
(3) Seat movement control handles and flexible linkage push-pull shafts (four places).
(4) Seat back adjustment mechanism (four places).
(5) Seat up and down movement rollers, pins, and linkage (six places).
Ensure seats operate smoothly, without binding.
j. Lube/check cockpit seats. As necessary, lubricate the following items of the FE’s seat with EAL
146 oil or equivalent and wipe off excess:
(1) Seat tracks.
(2) Tube.
(3) Seat movement control handles, flexible linkage push-pull shafts, and turning points (four
places).
(4) Linkage turning points.
(5) Seat track rollers, pins and linkage (eight places).
Ensure seats operate smoothly, without binding.
k. Lube/check cockpit seats. As necessary, lubricate the following items of the Observer’s seat with
EAL 146 oil or equivalent and wipe off excess:

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(1) Seat tracks.
(2) Tube.
(3) Footrest turning points (six places).
(4) Rollers and pins (eight places).
(5) Set control linkage turning points.

Ensure seats operate smoothly, without binding.

l. Lube/check cockpit seats. As necessary, lubricate the following items of the Courier
(Navigator)’s seat with EAL 146 oil or equivalent and wipe off excess:
(1) Seat tracks.
(2) Tube.
(3) Seat control linkage turning points
(4) Linkage turning points (three places).
(5) Roller and pins (four places).
Ensure seats operate smoothly, without binding.
NOTE: REFER TO FIGURE 16.02-1 FOR APPLICABLE TYPE AIRCRAFT AND
EQUIPMENT LOCATIONS. REFER TO THE ATI GENERAL MAINTENANCE
MANUAL, CHAPTER 3.206, FOR EMERGENCY EQUIPMENT TAG (FORM 3-11)
REQUIREMENTS AND TIME LIMITS ON ITEMS 15 THRU 22 AND 37.
3. CHECK CABIN - Check equipment, first aid kits, life rafts, life vests, fire extinguishers, PBE’s,
megaphone, flight attendants’ flashlights, and furnishings for condition and security. Refer to GMM
3.206 for Emergency Equipment Tag requirements. Check side walls, ceiling and floor for damage;
all holes or tears in protective lining must be repaired prior to aircraft departure. Refer to Chapter 53
for repair procedure. Clean compartment as necessary.
CAUTION: FOR SECURITY REASONS, SPECIAL ATTENTION MUST BE GIVEN TO
OVERHEAD BINS, CLOSETS, LAVATORIES, TO INCLUDE COMPARTMENTS
WITHIN THE LAVATORIES, GALLEYS, TRASH RECEPTACLES, STORAGE
BINS AND OTHER ACCESSIBLE COMPARTMENTS IN THE CABIN THAT DO
NOT REQUIRE SPECIAL TOOLS TO OPEN.
4. CHECK CARGO DOOR CONTROLS - -60 SERIES - Check door control switches and circuit
breakers for security. Check hydraulic components for leaks and security. Check hand pump and
lines for leakage and security.
5. CLEAN GALLEYS - Self-explanatory. On COMBIs, check & replenish supplies. *For Security
reasons, special attention must be given to trash receptacles, storage bins and other accessible
compartments.
6. SERVICE LAVATORIES.
a. FLUSH, and CLEAN TOILETS. Service waste disposal system if necessary.
(1) PORTA-POTTI cleaning procedures:
(a) Remove bungee cord from around porta-potti.
(b) Remove potti from aircraft.

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(c) Separate top & bottom halves of potti by releasing side latches & removing top half.
(d) Dump bottom half of potti in appropriate facility.
(e) Clean porta-potti.
(f) Reassemble porta-potti and secure side latches.
(g) Remove servicing cap from top half of potti.
(h) Service to half-full with blue deodorizing toilet water.
(i) Reinstall servicing cap.
(j) Reinstall porta-potti in aircraft.
(k) Reinstall bungee cord around potti.
NOTE: Ensure bungee is secure; if it slips, it could break the seal and spillage may occur.
(2) FLUSH TOILET cleaning procedures: Flush and clean toilet. Service Waste Disposal
System IAW DACO MM Chapter 12-41-1.
b. CONDUCT LEAK TESTS OF TOILET TANK DUMP VALVE, and SERVICE PANEL
DRAIN VALVE. The leak test of the toilet tank dump valve must be performed by servicing the
toilet tank with water/rinsing fluid and testing for leakage after a period of 5 minutes. Take
precautions to avoid overfilling the tank and spilling fluid into the airplane. The service panel
drain valve leak test must be performed with a minimum of 3 PSID applied across the valve.
c. INSPECT OUTER DOOR/CAP AND SEAL MATING SURFACE for wear or damage that may
cause leakage. This inspection shall be accomplished in conjuction with the leak tests of
paragraph 27.b.
d. INSPECT “DONUT” VALVE (PLUG) for proper mating/sealing.
NOTE: Paragraphs b, c, and d must be accomplished per AD 2002-03-05.
7. CLEAN SINKS: Wash sink, rinse and dry. Perform operational check of potable water system.
8. CHECK WHEELS AND TIRES - Check wheels for cracks and loose tie bolts. Refer to Chapter 15
for tire conditions.
9. CHECK MAIN LANDING GEAR AND WHEEL WELL AREAS - Visually check MLG assembly
and wheel well components including actuating components, emergency air bottle, and up-latch for
security and general condition. Check bogie beam for dents, scratches and gouges, shock strut for
proper extension, and landing gear attach points for integrity.
10. CHECK NOSE LANDING GEAR AND WHEEL WELL AREA - Visually check NLG assembly
and wheel well for general condition and leaks. Check shock strut for leakage at top and for proper
extension. Check condition and installation of actuating components, gear doors, linkages and gear
up and down lock mechanisms. Check nose steering cables. Check gear attach points for integrity.
Pay particular attention to taper pins; minimum of one thread showing through nut. Check operation
and alignment of nose gear down latch light.
11-14. SERVICE (4) ENGINE OIL - The engine oil level must be checked within 15 minutes of engine
shutdown. If engine has been shut down for more than 15 minutes, operate it for a minimum of one
minute to empty scavenge system and then service.
a. Service to within one inch of top of fill neck full mark on dipstick with EXXON/BP 2380.
b. Check “O” ring on cap.

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c. Secure oil cap.
d. Record number of quarts added to each engine.
15-18. SERVICE (4) CONSTANT SPEED DRIVE OIL - Check oil level of CSD by means of the sight
gauge. Oil level is to be within the green band in the center of the sight gauge.
a. Remove dust cap from CSD transmission pressure fill fitting located on the right side of the
scavenge filter.
b. Connect pressure fill hose.
c. SLOWLY fill CSD transmission oil system with EXXON/BP 2380 until oil reaches the bottom of
the sight gauge. Allow 5 minutes for the oil level to stabilize, then continue to add oil until the oil
level stabilizes within the green band, near the middle limit.

WARNING: USE EXXON/BP OIL 2380 ONLY.

WARNING: DO NOT OVER SERVICE CSD. OVER SERVICING FILLS
THE AIR/OIL SEPARATOR WITHIN THE CSD WITH OIL,
MAKING IT UNABLE TO RID THE OIL OF AIR WHICH IS
NOT A VERY EFFECTIVE LUBRICANT. OVERHEATING
AND OIL SLUDGING WILL RESULT AND WILL DESTROY
THE CSD. CONFIRMING A CSD FAILURE BY
RECONNECTING THE UNIT AND BRINGING IT UP TO
SPEED WILL PROBABLY DOUBLE THE COST OF
OVERHAUL AND IS LIKELY TO RENDER THE UNIT BER.
NOTE: DC-8-62 WITH A.D.C. AND BURBANK HUSH KIT SERVICE CSD OIL TO NOT MORE
THAN THE MIDDLE OF THE GREEN BAND.
19-22. PERFORM EXTERNAL VISUAL CHECK OF (##) ENGINE -
a. -60 SERIES AIRCRAFT: Nacelles doors are not required to be open.
(1) Visually inspect all areas for general condition and installation, including all inlet vents for
condition and engine drain lines for excessive leakage.
(2) Visually inspect the fan rotor, bypass ducts, tailpipe, and turbine for damage and cracking.
(3) Pay particular attention to the #6 bearing area for leakage.
(4) Inspect cowling, nacelle access ports, and blowout panels for evidence of fluid leakage.
b. -70 SERIES AIRCRAFT:
(1) Visually check inlet area.
(2) Cowling, pylon and thrust reverser.
NOTE: Open cowl doors if required to check the following areas: Check nose cowl, inlet
area, T12 probe, acoustic panels, fan blades, spinner and fan shroud for
unsatisfactory conditions. Refer to DC-8-70 M/M, Chapter 72-21-00 for
serviceable limits.
(a) Check cowling and pylon for irregularities.

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(b) Check engine and thrust reverser exterior condition and ground beneath for evidence of
fluid leaks.
(c) Visually check turbine frame strut for cracking. Serviceable limits: Refer to DC-8-70
MM 72-56-00.
(d) Check low pressure turbine blades for obvious damage. Serviceable limits: Refer to
DC-8-70 MM 72-54-00.
(e) Check flame arrestor screen inside center vent tube extension for plugging and cracks.
(f) Visually check installation and condition of the exhaust nozzle.
23. CHECK FUSELAGE, EMPENNAGE, AND WINGS - for obvious irregularities.
a. Check fuselage including: radome, cabin windows access doors, pitot heads, and static vents -
condition, security and fluid leaks; radio rank venturi - clear and no air flow; heat exchanger
outlet doors - condition; external power protection access door - secure; 02 blow-out disc(s) - in
place; LH and RH pressure relief valve/static port closed/clear; outflow valves - open/condition;
fore and aft toilet/water service doors - secure; main cargo door exterior plating and periphery -
condition, security, pressurization leaks, nicks, dents, and loose fasteners. Check chin scoops and
ground cooling doors for condition.
b. CHECK EMPENNAGE including: control surfaces and leading edges for condition, security of
access plates and fluid leakage. Check condition of tail energy absorber tail skid and static
dischargers.
c. CHECK WINGS including: control surfaces and leading edges - condition, security, and fluid
leaks; pylon stress screws - security; fuel vent and surge box overflow - clear; static dischargers -
proper installation; aileron bus cable - taut; aileron curtains - wear and tear; refuel ports -
condition and security; fuel magna sticks - serviceable condition.
d. WITH HYDRAULIC AND FUEL SYSTEM PRESSURIZED, check wings for fuel and
hydraulic leaks. (If walk around becomes excessive, turn off pumps and continue later.)
e. CHECK TRAILING EDGE FLAPS: Detailed inspection for security, condition, cracks,
corrosion, deformation, evidence of binding, wear, leakage, and adequate lubrication.
(1) Skin and visible structure
(2) Hinges, hinge brackets, and hinge doors.
(3) Flap actuating cylinders and hoses.
(4) Links, tracks, and rollers.
24. CHECK EXTERIOR LIGHTS - Ensure all exterior lights are in operational order.
25. LUBE CABIN OUTFLOW VALVE ROD ENDS – COMBI only. Lube rod ends IAW DACO 12-
83-1.
26. CHECK BRAKES - Check brake assemblies and lines for leakage, security, and wear indicators,
(brake must be parked). Check brake compensating links for condition.
WEAR LIMITS: ALL AIRCRAFT ULTIMATE WEAR 1/2” (Ref. Ad 94-06-10). Refer to DACO
DC-8 MM 32-42-1 for inspection procedures.
27. BRAKE DECAY CHECK - Auxiliary hydraulic pump off, check brake pressure and decay time.
Maximum decay is 100 psi in 15 min.

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28. CHECK FLOW LIMITERS OR SERVICE BRAKE LOCKOUTS - The flow limiters are self-
resetting, requiring only a pressure equalization of approximately 5 psi to reset. Check limiter by
fully depressing brake pedals with hydraulic system pressurized. Pressure indicator should pop out,
and retract when brakes are released. Service brake lockouts:
a. Pressurize brake system using Aux pump and set brakes. Turn Aux pump off.
b. Remove dust cap on brake lockout.
c. Remove safety wire between bypass valve and lockout cylinder piston rod end.
d. Open bypass valve slowly and extend cylinder piston until piston is fully extended (topped Out)
close bypass valve.
e. Resafety bypass valve and cylinder piston rod.
f. Install dust cap.
29. CHECK AND CLEAN LOWER COMPARTMENTS - Check condition of floors, walls and ceilings
in pits 1, 2, 3, and 4. All holes and tears in baggage compartments must be repaired before departure.
Refer to Chapter 53 for repair procedure. Apply ICEX to door seals. (ICEX application from
September to April only.)
30. INSPECT AND REPAIR CARGO LOADING SYSTEM:(See EFFECTIVITY in INTRODUCTION
SECTION for applicability and CHAPTER 25 for CARGO SYSTEM MAINTENANCE)
a. Check all assembled parts for cleanliness and security of mechanical attachment.
b. Inspect all parts for indications of damage, wear, corrosion, or stress. Pay particular attention to
system attachment fittings, and latching and rotating mechanism components.
c. Check 9G bulkhead for holes. Check operation and seal on the bulkhead smoke door. Locate
manual door open wrench and check serviceability. Check 9G net and smoke curtain for
serviceability. If net is damaged, refer to DACO DC-8 SRM 53-2-3 for tolerances. If damage is
close to maximum wear limits, notify Maintenance Control so that a serviceable net can be
routed to the aircraft. Ensure all net and curtain pins and attaching hardware is attached. Locate
and check serviceability of the manual door open wrench.
31. CHECK MAIN CARGO DOOR:
WARNING: CLEAR AREA OF PERSONNEL AND EQUIPMENT.
CAUTION: IN ORDER TO MINIMIZE STRESSES ON THE DOOR ACTUATING
SYSTEM, ONCE CARGO DOOR HAS STARTED DOWN, ITS TRAVEL
SHOULD NOT BE INTERRUPTED.
a. DOUGLAS CARGO DOOR - (A.D. 89-17-01) (continuing maintenance of terminated AD’s)
(1) Check main cargo door control valve tee handle access door to verify that the plate/ spacer
is located directly above the control handle actuating shaft. If plate/spacer is missing, bent,
or mislocated repair or replace before further flight.
(2) Check control valve and actuating shaft to verify that the shaft moves freely into
down/neutral lock position.
(3) Check tee handle stowage clip (P/N 1205247) for condition.
(4) Check tee handle access door closure studs and door condition. Flush when stowed.
(5) Check the integrity of the valve, universal joint, tee handle attachments. Check roll pins for
looseness and/or wear.
(6) Check the condition of the isolation switch and guard.
(7) Clean the cargo door lock mechanism view window.

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(8) Check cargo door vent door assembly for condition and security, including its indication
system.
(9) Open the cargo door, and check for correct operation of the indication system.
(10) Check door operating components for operation, leaks, security. Repair or replace as
required.
(11) Check latch spools rotate freely. Adjust or repair spools as required to obtain free rotation.
Grease spool bolts (Zerk in head) with Mobil 28. Apply only enough grease to provide for
free rotation and prevent dirt accumulation.
(12) Check door and door jambs for structural defects, dents, nicks and general serviceability.
(13) Check cargo door and vent door seals for serviceability, repair as required. Apply ICEX
(SEPTEMBER through APRIL).
(14) Lube cargo door components with Mobil 28.
(15) Restore alignment marks on the door latches.
(16) Close and lock doors and check indication system.

CAUTION: IF THE DOOR WAS RESTING ON THE LOCKING MECHANISM

FOR THE ACTUATOR, CYCLE THE DOOR TO THE OPEN
POSITION TO DISENGAGE, THEN MOVE THE CONTROL TO THE
DOWNWARD POSITION.

32. RESERVED

33. SERVICE HYDRAULIC RESERVOIRS - The main reservoir may be filled by gravity, or by
pressure pot through ground test connection. The spoiler reservoir may be filled by pressure pot or
the alternate spoiler power solenoid may be opened and the tank filled from the left manifold pressure
system return from its own lateral control spoiler drive cylinder. The left and right cylinders plus the
inboard spoiler drive cylinder are used to maintain the reservoir during normal operation. (HYJET
IV)

NOTE: If alternate spoiler power solenoid procedure is used to service the spoiler reservoir, it is
required to recheck main reservoir for proper service level.

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16.03 “A” CHECK(cont’d)

34. CHECK HYDRAULIC ACCUMULATOR FOR PRECHARGE - Depressurize each system with the
pumps off. Service accumulators to the following pressures with dry nitrogen:

Main: 1000 psi - LH keel beam fwd of flap lockouts.

Aux: 1000 psi - Aft inbd corner of LH wing root.
Rudder Standby: 1000 psi - Aft inbd corner of LH wheel well. Open bleed valve to relieve
trapped pressure.
Nose Steering: 500 psi - (2) RH side of nose wheel well. 50 psi - (1) LH side of nose
wheel well; will hold at 150 psi and there is no requirement to check pre-
charge . If a steering complaint exists, depressurize with bleed screw on
relief valve and reservice.
Brakes: 700 psi - Numbered 1,2, and 3 from fwd on RH keel beam.
Thrust Reverser: 1000 psi - Numbered 4 and 5 from fwd on RH keel beam.
Spoiler: 2000 psi - Number 6 from fwd to aft on RH keel beam.

35. PNEUMATIC AIR CYCLE SYSTEM

a. Visually check oil level in LH and RH ACM sight glass. Always maintain oil level in Air Cycle
Machines to upper half of sight glass. Service with Exxon/BP 2380 Turbo Oil.

b. Check areas and components for condition and security.

36. OPEN AND SECURE MLG DOORS - Self explanatory.

37. CLEAN EXPOSED PORTION OF LANDING GEAR OLEO STRUTS - Self explanatory. (MIL-H-
5606)

38. SERVICE FLAP LOCKOUTS - Lockout/service/bleed valves are located in the left wheel well
below/aft of the lockouts.

a. Ensure flaps are full up.

b. Pressurize main hydraulic system using the AUX pump

WARNING: CLEAR PERSONNEL FROM ALL POSSIBLE MOVING SURFACES

AND CHECK LANDING GEAR HANDLE IS IN THE DOWN POSITION.

c. The lockout piston rod should be extended within the range markings located on the wheel well
wall. If not proceed to step “d”.
d. Open (one at a time) the service valve located on the wheel well wall.
e. Shut off AUX pump.
f. Safety all service valves with lock wire.

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39. CLEAN EXPOSED PORTION OF THE BOGIE TRIM CYLINDER PISTON - Self explanatory.
(HYJET IV)
40. LUBRICATE LH & RH BOGIE BEAM PIVOT POINT:
Lubricate Main Gear Door Uplatches (RH & LH) – Section 16.07 for Lubrication.
41. CLOSE MLG DOORS - Self-explanatory.
42. CHECK O2 BOTTLES – Check for placarding, general condition and security of stowage. Each
bottle must have an ATI Emergency Equipment Tag showing the next Recheck Due Date (hydrostatic
test). Change bottles that are within 2 months of hydrostatic test date. When pressure drops to refill,
remove bottle from aircraft for replacement or recharging to maximum value.
REFILL MAXIMUM
Portable 1600 psi 1800 psi
Crew 1650 psi 1850 psi
Passenger 1650 psi 1850 psi
Courier 1650 psi 1850 psi
Pressure given is for 70° F. For each 10° increase or decrease, add or subtract 35 psi to given
pressure respectively.
43. CHECK INTERIOR LIGHTS - Ensure all passenger, cargo, and cabin lights are in operational order.
44. CHECK OPERATION OF EMERGENCY EXIT LIGHTS -
a. Place emergency light switch to “ARM.”
b. Trip emergency exit light circuit breaker (DC bus 1).
c. Check that emergency lights operate, and all other cabin lights are off.
(1) 3 lights at fwd entrance.
(2) 2 lights in cockpit dome.
(3) Glareshield lights (if installed).
(4) Floor lighting system and emergency exit lights. (Passenger aircraft only: Perform Photo
Luminescent Aisle Path Marking check in accordance with Section 33.02.)
d. Make rapid check to avoid running down batteries.
e. Place light switch to “DISARM CHECK” and observe that disarm light glows.
f. Place switch to “DISARM.”
g. Reset emergency exit light circuit breaker.
45. SERVICE TIRES - (USE DRY NITROGEN ONLY).(A.D. 87-08-09). Pressures given are at 70° F.,
refer to Figure 16.02-3 for temperature conversion chart. If tires are under inflated by more than 25
PSI refer to Chapter 15. Tires should be allowed to cool prior to checking pressures.
DC-8-62/-71/-72 AIRCRAFT MAINS 185 PSI
DC-8-73 AIRCRAFT MAINS 200 PSI
ALL AIRCRAFT NOSE 150 PSI

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46. DRAIN FUEL SUMPS - Drain one quart of fuel from each tank to check for presence of water and
contamination. If sump draining contains a small amount of solid particles, slime or sludge, followed
by clear fuel, no further action is required. If sump drainings contain more than one ounce of dark
colored water, or so much foreign material that the draining of four or five gallons does not produce
clear fuel, or if even small amounts of contaminates appear chronically, contact MX Control
providing all details possible. MX Control will decide course of action.
47. TEST FIRE WARNING SYSTEM - Actuate engine fire warning test switch on Second Officer’s
panel and holding. Light (2 bulbs) in the fire control handle for the engine being tested will come on,
master fire warning light (2 bulbs) on the Captain’s glare shield will come on, the fire warning lights
(2 bulbs) on the Second Officer’s panel will come on and the fire warning bell will ring. Press the
master fire warning light capsule. The bell will silence and all lights will go out except the light (2
bulbs) in the fire control handle. Release the test switch and check that the short circuit lights are not
illuminated
48. CHECK GEAR ANTI-RETRACTION LATCH - Disconnect nose gear torque links. As the upper
link is moved to the extended strut position, man in cockpit can watch anti-retract latch button
operate. Reconnect nose gear torque links.
49. CHECK EMERGENCY AIR BRAKE PRESSURE - Self-explanatory.
50. CHECK OPERATION OF COCKPIT VOICE RECORDER -
NOTE: Some A/C require the anti-collision lights ON.
a. Connect headphones to phone jack.
b. Turn on NAV or COM receiver, select an active frequency and ensure that voice reception is loud
and clear through overhead speakers.
c. Turn speakers off.
d. Place all audio selector switches on all audio control panels to “OFF.”
e. Cover microphone of CVR head (could use a cap lug NAS-813-18).
f. At Captain’s audio panel, position microphone and audio selector switches for interphone
operation.
g. Speak into Captain’s microphone. Speech should be audible through test headphones with
approximately 0.5 second delay.
h. At Captain’s audio panel, place audio selector switch to the radio selected in Step B.
i. Return Captain’s audio selector switches to “OFF.”
j. Repeat steps “F” through “H” using First and Second Officer’s audio control panels and
microphones.
k. Remove covering from CVR head (Step E).
l. Speak into CVR monitor microphone. Speech should be audible with approximately 0.5 second
delay.
m. Shut off receiver selected in Step B.
n. Press bulk erase button on monitor unit for approximately 7 seconds. A 400hz tone should be
heard in headphones.
NOTE: Erase test will not work if A/C is in flight mode.
o. Check Underwater Locator Beacon battery for placarding, general condition, and security of
stowage. The battery must have an ATI Emergency Equipment Tag showing the next Recheck
Due Date. Change battery if within 2 months of Recheck Due Date. Battery may be carried over
to due date.

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51. CHECK FLIGHT DATA RECORDER - Observe the FDR inop. light is illuminated with the switch
in the off position. Turn flight recorder on and observe light extinguished for one minute. Turn FDR
switch off. Light is again illuminated. Check Underwater Locator Beacon battery for placarding,
general condition, and security of stowage. The battery must have an ATI Emergency Equipment
Tag showing the next Recheck Due Date. Change battery if within 2 months of Recheck Due Date.
Battery may be carried over to due date.\
52. CHECK VOR - Using a local FAA-operated test signal (VOT), or a local VOR station whose
reception is good at the aircraft, accomplish the following:
Select the same signal source for both the #1 and #2 VOR systems. Adjust the course deviation knob
on each VOR system by carefully centering the course deviation bar in each CDI/PDI. (Confirm that
the compass cards in the #1 and #2 compass systems are reading the same.) Read the indicated
course for each VOR system on each CDI/PDI. The permissible variation between the two systems is
4 degrees. A variation of more than 4 degrees requires maintenance action. Enter the observed
bearings for the #1 and #2 VOR systems on the “A” Check Form in the blanks provided, and record
the variation.
If neither of these options is available at the aircraft’s location, a VOR-ILS tester may be used to
confirm the accuracy of the VOR systems.
53. REPLENISH SPARE BULBS AND FUSES - Self-explanatory.
54. CHECK LIFE VESTS –Check for placarding, general condition and security of stowage. Each vest
must have an ATI Emergency Equipment Tag (applied to the outside of each vest bag) which shows
the next Recheck Due Date. Change life vests that are within 2 months of Recheck Due Date. Life
vests may be carried over to due date.
55. CHECK LIFE RAFTS – Check for placarding, general condition and security of stowage. Each raft
must have an ATI Emergency Equipment Tag showing the next Recheck Due Date. Change life rafts
that are within 2 months of Recheck Due Date. Life rafts may be carried over to due date.
56. CHECK FIRST AID KIT & EMERGENCY MEDICAL KIT – Check kits for placarding, general
condition and security of stowage. Each kit must have an ATI Emergency Equipment Tag, with the
tag on the first aid kit showing the next “Recheck Due Date” and the emergency medical kit showing
“On Condition”. If the seal on the First Aid Kit is broken, compare contents with inventory list.
If complete, reseal with an Emergency Equipment Tag. If kit is not complete, replace or replenish
and reseal. If the seal on the Emergency Medical Kit(COMBI aircraft only) is broken, notify
Quality Control immediately. Do not open kit or inspect internally. The Emergency Medical kit can
only be opened by a licensed physician, or by the captain of a flight, who has approval from a
licensed physician.
57. CHECK CRASH AXE - Check for placarding, general condition and security of stowage. The axe
must have an ATI Emergency Equipment Tag showing the next Recheck Due Date as “On
Condition”.
58. CHECK FIRE EXTINGUISHERS – Check for placarding, general condition and security of stowage.
Each extinguisher must have ATI Emergency Equipment Tags as required in GMM 3.206 (3 for
refillable Halon extinguishers and 2 for all others). Change extinguishers that are within 2 months of
Recheck Due Date. Extinguishers may be carried over to due date. If seal is broken, the extinguisher
must be weighed. Refer to GMM 3.206 for weighing information and Halon 1211 portable fire
extinguisher requirements.

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59. CHECK PROTECTIVE BREATHING EQUIPMENT (PBE’s) – Check for placarding, general
condition, security of stowage, for dents, cracks, holes, or distortion in the storage case. Each PBE
must have an ATI Emergency Equipment Tag showing the next Recheck Due Date (tags are placed
on the exterior of the PBE box next to the latch). Check the sealed bag to ensure seal. Loss of
vacuum is indicated if the bag becomes soft and no longer confirms tightly to the package or if
humidity indicator inside the bag has changed from blue to pink.
50. CHECK ESCAPE SLIDE(s) – Check for placarding, general condition and security of stowage. Each
slide must have an ATI Emergency Equipment Tag showing the next Recheck Due Date. Change
slides that are within 2 months of due date. Slides may be carried over to due date.
61. AUTOMATED EXTERNAL DEFIBRILLATOR
(a) Powerheart AED - Open the AED lid and wait for the AED to indicate status. Observe the
change of the STATUS INDICATOR to RED. After less than five seconds, verify that the
STATUS INDICATOR returns to GREEN. Listen for voice prompts. At start of voice prompts,
close the lid and confirm that STATUS INDICATOR remains GREEN. Check for placarding,
general condition, and security of stowage. Each AED must have 3 ATI Emergency Equipment
Tags showing the next recheck due date (1 for adult electrodes, 1 for pediatric electrodes, and 1
for battery). Change electrodes/battery if within two months of due date.
(b) Philips HeartStart FRx AED – Observe that Green Ready light is blinking. If not, refer to DC-8
MM 25.06 for troubleshooting tips. Check for placarding, general condition, and security of
stowage. Each AED must have at least 2 ATI Emergency Equipment Tags showing the next
recheck due date (1 for each electrode pads and 1 for each battery). Change electrodes/battery if
within two months of due date. (Battery expiration date is four years from date of manufacture.)
62. CHECK EMERGENCY AIR BRAKE BOTTLE – Check for general condition and attachment. Each
bottle must have an ATI Emergency Equipment Tag showing the next Recheck Due Date (hydrostatic
test). Change bottle if within 2 months of due date. Bottle may be carried over to due date. Bottle
pressure is to be 2900-3100 psi at 70 degrees F. Refer to DACO M/M Chapter 12.
63-66. INSPECT FORWARD SUMP MAGNETIC CHIP DETECTOR PLUG ENGINE #X
a. -70 SERIES AIRCRAFT ONLY: A.D. 89-23-06 CFM-56 M/M 79-00-00
(1) Open LEFT hand forward fan cowl to access engine tube unit.
(2) Ensure area around forward chip detector is clean.
NOTE: The forward sump chip detector is located in the most aft position toward the
gearbox of the chip detectors. Fourth from forward.
(3) Remove forward sump chip detector by rotating it counter-clockwise 1/4 turn.
CAUTION: HOT OIL CAN CAUSE DEEP BURNS. USE CAUTION TO
PREVENT CONTACTING HOT OIL.
(4) Inspect chip detector for contamination and metal. If the detector shows abnormal or
suspect deposits refer to CFM-56 maintenance manual 71-00-00, fault isolation chart 72
and contact Maintenance Control with findings.
(5) Clean filter using a clean cloth and Stoddard solvent.
(6) Flush filter with clean engine oil.
(7) Replace O-ring and inspect “SOLASELE G” seal for serviceability, replace as required.

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(8) Reinstall forward sump chip detector:
(a) Carefully insert chip detector into the lube unit housing with slot opening of scavenge
filter facing the accessory gearbox.
(b) Do not force but push inward until full insertion is obtained.
(c) Align plug keys of plug with sleeve key ways and rotate a 1/4 clockwise to complete
engagement.
(d) Ensure chip detector has snapped down and engaged locks by pulling down and lightly
rotating. Flats of handle must be perpendicular to the centerline of the lube unit.
(9) Motor engine IAW JRH and check for leaks.
(10) Close and secure forward fan cowl.
67-70. INSPECT STARTER MAGNETIC DRAIN PLUG (4) FOR MAGNETIC PARTICLES -
Replace starter if contaminated. Refer to Figure 16.03-1 for acceptable contamination.
71. EXTENDED OVER WATER FLIGHT EQUIPMENT CHECK.
a. Life Rafts and Life Vests (Check each item for installation and security.
(1) Two life rafts with E.L.T. Beacon installed(in cockpit/companionway). Verify life raft
expiration date is within 24 months since last overhaul. (Note: Two additional life rafts
with E.L.T. Beacons are required to be installed in rear of aircraft on horse charter flights.
(2) One life vest with light installed per occupied seat. Verify life vest expiration date is
within 36 months since last overhaul.
b. Radio/Navigation Equipment. The following systems must be functionally checked and fully
functional:
(1) HF System (#1 and #2)
(2) SelCal System (#1 and #2)
(3) GPS System (#1 and #2)
(4) 8.33 Spaced VHF Comm System (#1 and #2)
c. Lavatory and Galley. check for function, security, and proper servicing of all equipment.
72. AIR MOBILITY COMMAND PRE-DEPARTURE EQUIPMENT CHECK.
a. CARGO AND COMBI AIRCRAFT IAW A.D. 93-07-15 and AC25-18
(1) Cargo loading system operable and compartment clean. (Note: Set up in 88” X 108” unless
specified otherwise.)
(2) Each upper and lower cargo compartment properly placarded for weight.
(3) Interior upper and lower cargo compartment lighting operable and adequate.
(4) Courier seat serviceable (if installed).
(5) FWD and Main cargo door safety straps are available and serviceable.
(6) Ground headsets and ground cords available for concurrent fueling.
Cargo-2 Headsets & 2 ground cords - one will be 100’ long and the other 50’ long.
Combi-3 Headsets & 3 Ground Cords - one will be 100’ long and the other 50’ long.
(7) Interior and exterior appearance acceptable.
(8) Lower cargo compartment door nets installed.

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(9) Ensure ten serviceable Fire Containment covers (FCC) are available in the COMBI cargo
compartment, along with five serviceable spares in A pit. Refer to ATI DC-8 MM 26.04
for damage limitations.
(10) Ensure all Emergency Equipment is properly placarded and located per Figure 16.02-1.
b. COMBI AIRCRAFT ONLY
(1) FWD and AFT galley operable and appearance acceptable.
(2) Carpet appearance acceptable.
(3) Left and Right Lavatory operable and appearance acceptable.
(4) Movie operable.
(5) Boarding music operable.
(6) AFT entrance doors safety straps available and serviceable.
(7) Safety equipment accounted for.
(8) Potable water serviced and operable.
(9) Check seat covers, armrests and food trays for condition and serviceability.
73. FLIGHT DECK DOOR INSPECTION
a. While using a flashlight to perform general visual inspection, inspect cockpit side and cabin
side of cockpit door and doorframe for general condition as follows:
(1) Missing fasteners or any holes in ballistic material without fasteners installed.
(2) Torn or missing door seal.
(3) Dents or nicks in doorframe.
(4) Bent or missing vent cover panel (cockpit side only).
(5) Broken or missing ceiling panels (at upper doorjamb).
b. Perform functional test procedures as follows while checking for door drag, snags, drooping,
misalignment, warping, and jamb-to-door misalignment:
NOTE: A minimum of two personnel is required for door operation functional testing. One person must
occupy the cockpit when manually locking latches.
(1) From cockpit side of door, close door, release door lock lever and rotate door knob while
holding lockout safety (below upper latch) to engage latches on latch pins. Latch
engagement on pins should be 7/8” ± 1/8”.
(2) Visually verify upper and lower latches are engaged over latch pins.
(3) Visually verify lock lever has engaged slot in center cam and door handle cannot be rotated.
(4) Push lock lever back (outboard) and up to the unlock position.
(5) Rotate door handle to disengage upper and lower latches from latch pins and disengage
center dead bolt. Push door open.
(6) From cabin side of cockpit door, close cockpit door (do not rotate doorknob).
(7) Visually verify door remains closed with the center dead bolt engaged in doorjamb (visually
verified from cockpit side).
(8) With the key, verify doorknob can be locked and door knob cannot be rotated.
(9) With the key, unlock the doorknob, rotate door knob, and open the door.
c. Lubricate all hinges with a dry lubricant and lubricate latch assemblies and door knob-lock
assembly using aerosol Teflon or silicone spray.
74. MAINTENANCE RELEASE - Refer to General Maintenance Manual

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16.03 “A” CHECK(cont’d)

CLEAN-ACCEPTABLE NORMAL FUZZ-ACCEPTABLE

MINOR FUZZ-NOT ACCEPTABLE MAJOR METAL-NOT ACCEPTABLE

MAGNETIC DRAIN PLUG INSPECTION

Figure 16.03-1

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16.04 – “B” CHECK

TABLE OF CONTENTS
Paragraph Page
1. ACCOMPLISHMENT SPECIFICATIONS---------------------------------------- 16.04.1

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16.04 “B” CHECK

1. Accomplishment Specifications

a. A “B” Check is a brief external inspection of the aircraft, specified systems and
appliances. Some additional items are included at specified “B” Check intervals for
inspection/check.

b. “B” Checks are to be accomplished at the frequency specified in Section 16.01.

c. “B” Check accomplishment will consist of completing job cards, as generated by

computer from the Work Card Index Master List.

d. “B” Check accomplishment will be confirmed by proper signing of the job cards, work
records, and non-routine items.

e. All non-routine items are to be recorded on Company non-routine forms. At Repair

Stations, the repair agency’s single sheet non-routine form which contains the equivalent
information, may be used to record non-routine maintenance performed at that agency.

f. All non-routine items will be cleared by appropriate corrective actions before aircraft is
released for flight.

g. Refer to the GMM for Airworthiness Release Procedures.

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16.05 – “C” CHECK

TABLE OF CONTENTS
Paragraph Page
1. ACCOMPLISHMENT SPECIFICATIONS---------------------------------------- 16.05.1

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16.05 “C” CHECK

1. Accomplishment Specifications

a. A “C” Check is an intensified external inspection and specified internal inspections of the
Aircraft, Structures, Systems, Components, and Appliances.

b. “C” Checks vary in content of routine work, there being some tasks that are not
accomplished at every “C” Check. The “C” Check cycle consists of “C-1” to “C-12”.
The “O-C” is the accomplishment of all “C” Check job cards.

c. “C” Check accomplishment will consist of completing job cards, as generated by

computer from the ATI DC-8 Work Card Master Index List. Which accounts for model
effectivity, mod status, specific inspection frequencies. Etc., for any given aircraft. (See
GMM Section 3.701)

d. “C” Check accomplishment will be confirmed by proper signing of the job cards, work
records, and non-routine items.

e. All non-routine items will be cleared by appropriate corrective actions before aircraft is
released for flight.

f. All non-routine items are to be recorded on non-routine forms, or on a repair stations

single-sheet non-routine form which contains the equivalent information, may be used to
record non routine maintenance performed at that agency.

g. Refer to the GMM for Airworthiness Release Procedures.

h. Refer to the GMM for Inspection (Buy-Back) Procedures.

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16.06 – “D” CHECK

TABLE OF CONTENTS
Paragraph Page
1. ACCOMPLISHMENT SPECIFICATIONS---------------------------------------- 16.06.1
2. INSPECTION DEFINITION--------------------------------------------------------- 16.06.1

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16.06 “D” CHECK

1. Accomplishment Specifications

a. A “D” Check is the structural inspection program for the aircraft. These inspections are
to provide thorough knowledge of the structural condition and to detect signs of
deterioration at an early stage.

b. “D” Check will be accomplished at the frequency specified in Section 16.01.

c. “D” Checks are accomplished concurrently with the next numbered “C” Check.

d. “D” Check accomplishment will consist of completing job cards, as generated by

computer from the Work Card Index Master List.

e. “D” Check accomplishment will be confirmed by proper signing of the job cards, work
records, and non-routine items.

f. Non-routine items are to be recorded on non-routine forms, or on a repair station’s single

sheet non-routine form, which has been accepted for use by the Director of Quality
Control.

g. All non-routine items must be cleared by appropriate corrective actions before the aircraft
is released for flight.

h. Refer to the GMM for Airworthiness Release Procedures.

i. Refer to the GMM for Inspection (Buy-Back) Procedures.

2. Inspection Definition

a. Basically, two types or degrees of inspection are utilized. They can be termed “normal”
or “intensified” and these two degrees of inspection are classified into four categories.
These four categories, briefly described below, define for inspectors the degrees to which
they have to evaluate a zone.

(1) A visual inspection of all external portions of aircraft structure and internal
structure visible through quick opening access doors working at a rate that will
detect obviously unsatisfactory condition or defects. “Normal” inspection in an
open area.

(2) Like the No. 1 but applied to aircraft interior structure. Access must be provided by
removing access plates, fillets, or fairings.

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(3) An “intensified” inspection is a thorough visual inspection usually applied to a

specific point or condition. To view closely, critically and to compare to known
standards at visible elements and details of an assembly, area or components (as
specified) for evidence of malfunction, structural or mechanical irregularity or any
other unsatisfactory condition. May require limited work to obtain access.

(4) An “intensified” inspection may require certain additional work to obtain access
(upholstery, sidewall insulation, flooring, sealant removal, etc.). It may also specify
the use of special equipment, i.e., X-ray, ultrasonic, etc.

b. During inspection of a specific zone, all items such as components, ducting, cables,
wiring, plumbing, brackets, etc. in that zone are considered.

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16.07 –LUBRICATION
TABLE OF CONTENTS
Paragraph Page
A. FLIGHT CONTROLS------------------------------------------------------------ 16.07.1

B. LANDING GEAR --------------------------------------------------------------- 16.07.31

C. DOORS---------------------------------------------------------------------------- 16.07.45

D. FLIGHT COMPARTMENT---------------------------------------------------- 16.07.63

FIGURES
A-1 AILERON------------------------------------------------------------------------- 16.07.2

A-2 AILERON TORQUE TUBE & OVERRIDE SPRING --------------------- 16.07.4

A-3 SPOILER-------------------------------------------------------------------------- 16.07.7

A-4 WING FLAP & REAR SPAR PIN -------------------------------------------- 16.07.10

A-5 WING FLAP EXHAUST GATE ---------------------------------------------- 16.07.16

A-6 WING FLAP JOINT------------------------------------------------------------- 16.07.18

A-7 WING SLOTS-------------------------------------------------------------------- 16.07.20

A-8 ELEVATOR ---------------------------------------------------------------------- 16.07.22

A-9 HORIZONTAL STABILIZER------------------------------------------------- 16.07.24

A-10 RUDDER ------------------------------------------------------------------------- 16.07.28

B-1 NOSE GEAR --------------------------------------------------------------------- 16.07.32

B-2 NOSE GEAR DOORS ---------------------------------------------------------- 16.07.36

B-3 MAIN GEAR --------------------------------------------------------------------- 16.07.38

B-4 MAIN GEAR DOORS ---------------------------------------------------------- 16.07.42

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FIGURES
C-1 CARGO CONTAINER (BASKET) LOADING DOOR-------------------- 16.07.46

C-2 CARGO CONTAINER (CROSS SLIDE) LOADING DOOR ------------ 16.07.48

C-3 PASSENGER & SERVICE ENTRANCE DOOR--------------------------- 16.07.50

C-4 EMERGENCY EXIT DOORS------------------------------------------------- 16.07.56

C-5 UPPER CARGO DOOR -------------------------------------------------------- 16.07.60

D-1 CLEAR VIEW WINDOW------------------------------------------------------ 16.07.64

D-2 CAPTAIN’S OR FIRST OFFICER’S SEAT--------------------------------- 16.07.66

D-3 FLIGHT ENGINEER’S SEAT------------------------------------------------- 16.07.68

D-4 NAVIGATOR’S (FIRST OBSERVER) SEAT ------------------------------ 16.07.70

D-5 OBSERVER’S SEAT ----------------------------------------------------------- 16.07.72

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16.07 LUBRICATION

A. FLIGHT CONTROLS

1. General

a. It is recommended that the airplane be secured in an area suitable for lubrication

servicing. The area should be free of sand, dirt, dust, and other environmental
conditions that might contribute to improper servicing.

b. Observe fight controls maintenance practices safety precautions, as outlined in

Chapter 27, before and during lubrication servicing.

c. The recommended lubrication servicing equipment should include grease guns, oil
cans, brushes, clean cloths, and other facilities as required for proper lubrication.

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AILERON
Figure A-1 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION
NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Aileron Tab Hinges GMD Gun 5F
2** Aileron Hinges GMD Gun 8F
3*** Valve Links OGP Oilcan -
4 Forward Gripper Shaft GMD Gun 1
5 Gripper Link GMD Gun 2
6 Aft Gripper Shaft GMD Gun 1
7 Cylinder GMD Gun 3
8 Lockout Cylinder GMD Gun 1
9*** Links OGP Oilcan -
10 Inboard Aileron Tab Hinges GMD Gun 4F
11 Pushrod Attach Fitting GMD Gun 2F
12 Aileron Tab Screw Shaft GMD Brush -
13 Trim Mechanism Screw Shaft GMD Brush -

* Apply to one flush-type grease fitting on each hinge, accessible from bottom with aileron
tab in up position.
** Apply to one flush-type grease fitting on each hinge.
*** Oil lightly and wipe off excess.
F Flush-type grease fitting.
GMD Grease - Mobil 28 (or equivalent)
OGP Oil - General Purpose
For lubrication frequency interval recommendation, see 12-80-0, General Servicing.
NOTE: Access to the aileron control mechanism can be gained by removing the outboard
pylon fairing and opening the wing trailing edge access door.

AILERON
Figure A-1 (Sheet 2 of 2)

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AILERON TORQUE TUBE AND OVERRIDE SPRING ASSEMBLY

Figure A-2 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Spline Shaft Bearing Grooves GMD Brush 2
(3 Grooves)

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

AILERON TORQUE TUBE AND OVERRIDE SPRING ASSEMBLY

Figure A-2 (Sheet 2 of 2)

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SPOILER
Figure A-3 (Sheet 1 of 3)

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SPOILER
Figure A-3 (Sheet 2 of 3)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Spoiler Drive Mechanism(9 Units) GMD Gun 5F
2 Spoiler Idler Mechanism(10 Units) GMD Gun 2F
3 Outboard Spoiler Actuator GMD Gun 1
4 Crank GMD Gun 1
5 Inboard Spoiler Actuator(Main GMD Gun 1
Gear Wheel Well)
6 * Spoiler Actuator Crank (with SB GMD Gun 2F
27-259) (10 units)
7 * Spoiler Actuator Crank (with SB Self
27-259) (6 units) lubed

F Flush-type grease fitting.

NOTE: Spoiler lubrication fittings are accessible when wing flaps are down and spoilers up.

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

* On aircraft with Service Bulletin (SB) 27-259 incorporated, it may be necessary to remove
affected spoiler actuator crank arms to gain access to lubrication fittings and to check spoiler
actuator crank with self-lubricated bearings for wear. See Douglas DC-8-60 Maintenance
Manual, 27-61-1, Maintenance Practices. Reference Temporary Revision 12-100 and 12-101 for
detailed view of Spoiler Actuator Crank Mechanism.

SPOILER
Figure A-3 (Sheet 3 of 3)

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WING FLAP & REAR SPAR PIN

Figure A-4 (Sheet 1 of 5)

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SERVICE CHART - RECOMMENDED LUBRICATION
NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS
NO. TYPE BY
OR AREAS
1 Flap Actuating Link, Compensating GMD Gun 1 or 2 (As
Link Attach Point Applicable)
2 Forward Upper Link Bolt GMD Gun 2F
3 Forward Link Upper Attach Point GMD Gun 1
4 Carriage Drive Link GMD Gun 3
5* Flap Hinge Cover Tracks SFL Brush -
6** Flap Hanger Assembly GMD Brush -
7*** Carriage Rollers GMD Gun 1F
8 Flap Aft Linkage GMD Gun 2
9 Flap Actuating Link GMD Gun 2
10 Flap Actuating Cylinder Eyebolt GMD Gun 2
(Outboard Drive Stations Only) and
Bearing Bolt (+)
11 Actuating Cylinder Crank Joint GMD Gun 4
Bolt and Bearing Bolt (+)
12 Compensating Link Upper Attach GMD Gun 1
Bolt (+)
13*** Flap Support Link GMD Gun 1

WING FLAP & REAR SPAR PIN

Figure A-4 (Sheet 2 of 5)

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SERVICE CHART - RECOMMENDED LUBRICATION (cont’d)

* Clean track surface thoroughly; spray or brush on touchup coating. Allow coating to dry
before operating. (See Lubrication Service Notes.)
** Clean track with solvent (P-D-680) and brush on coating of grease.
*** Apply to one flush-type grease fitting on each roller.
**** Apply to one grease fitting. Remaining fittings are same as wing flap drive mechanism.
+ Bearing bolt equipped with lubrication fitting on some airplanes.
F Flush-type grease fitting.
NOTE: Wing flap lubrication fittings are accessible when flaps are in the 25-degree down
position.
GMD grease - Mobil 28 (or equivalent)
SFL lubricant - Solid film
For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

WING FLAP & REAR SPAR PIN

Figure A-4 (Sheet 3 of 5)

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WING FLAP & REAR SPAR PIN

Figure A-4 (Sheet 4 of 5)

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SERVICE CHART - RECOMMENDED LUBRICATION
NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS
NO. TYPE BY
OR AREAS
1* Floor beam rear spar pin GMD Gun 1
2* Rear spar pin GMD Gun 2

* Accessible from main gear wheel well.

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

WING FLAP & REAR SPAR PIN

Figure A-4 (Sheet 5 of 5)

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WING FLAP EXHAUST GATE

Figure A-5 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Exhaust Gate Hinges GMD Gun 2F
2 Exhaust Gate Linkage GMD Gun 2F

F Flush-type grease fitting.

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

WING FLAP EXHAUST GATE

Figure A-5 (Sheet 2 of 2)

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WING FLAP JOINT

Figure A-6 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Wing Flap Joint Links GMD Gun 12F

F Flush-type grease fitting.

NOTE: Access to wing flap joint can be gained by removing lower fairing from inboard flap
with flap in up position.

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

WING FLAP JOINT

Figure A-6 (Sheet 2 of 2)

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WING SLOTS
Figure A-7 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Actuating Rod Ends GMD Gun 2F
2** Actuating Rod Ends GMD Gun 1

* Apply to one flush-type grease fitting at each end of rod.

** Apply to one flush-type grease fitting each cylinder.

F Flush-type grease fitting.

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

WING SLOTS
Figure A-7 (Sheet 2 of 2)

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ELEVATOR
Figure A-8 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Elevator Tab Hinges GMD Gun 1F
2* Outboard Elevator Hinges GMD Gun 1F
3* Elevator Geared Tab Link Attach GMD Gun 1F
Points
4 Inboard Elevator Hinge GMD Gun 1

* Apply to one flush-type grease fitting each.

F Flush-type grease fitting.

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

ELEVATOR
Figure A-8 (Sheet 2 of 2)

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HORIZONTAL STABILIZER
Figure A-9 (Sheet 1 of 3)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Gearbox OJE Gun -
2** Valve Linkage OGP Oilcan -
3*** Jackscrew Clevises (2) GMD Gun 4
4**** Jackscrews (2) GMD Brush -
5 Drive Sprocket Housing (2) GMD Gun 2
6 Chains (2) GMD Brush -
7 Hinges GMD Gun 2
8 Elevator Gustlock Rod Ends (2) GMD Gun 2F

* Gearbox - Check oil level and fill to level of fill plug with jet engine oil (MIL-L-7808).
Drain and refill at overhaul. When gearbox is being assembled, pack approximately 10
ounces of Mobil 28 grease around bearings and gears of first stage planetary and
countershaft gears. Before installing housing cover, make sure grease is packed around
all moving parts and shaft is rotated to ensure coverage of all gear meshes. After box is
completely assembled, fill to level of fill plug with jet engine oil (MIL-L-7808). Oil
capacity is approximately 0.6 pint.

** Oil lightly and wipe off excess.

*** Apply to two grease fittings on each clevis.

**** Apply light coat of grease to threads above and below drive sprocket housing; then
operate mechanism from full up to full down to distribute lubricant over length of
jackscrew threads.
Apply to one grease fitting on each housing.
Apply light coat of grease. Do not remove chains to lubricate.
Apply to one grease fitting on each hinge.
Apply to one flush-type grease fitting on each rod end.

HORIZONTAL STABILIZER
Figure A-9 (Sheet 2 of 3)

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F - Flush-type grease fitting.

OJE oil - Jet engine

OGP oil - General purpose

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General Servicing.

HORIZONTAL STABILIZER
Figure A-9 (Sheet 3 of 3)

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RUDDER
Figure A-10 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Lower rudder hinge GMD Gun 1
2* Rudder Throw-Limiter Pushrod GMD Gun 2F
Assembly
3 Rudder Power Cylinder Throw GMD Gun 2
Limiter
4 Universal Clevis Assembly GMD Gun 2
5 Rudder Gustlock Pushrod GMD Gun 1F
Assembly
6 Connector Assembly GMD Gun 2
7 Lockout Cylinder Assembly GMD Gun 1
8 Rudder Power Cylinder Attach GMD Gun 1
Point
9** Upper Rudder Hinges GMD Gun 1F
10** Rudder Tab Hinges GMD Gun 1F (each)
11 Rudder Throw Limiter Can GMD Gun 1F

* Apply to two flush-type grease fittings, one at each end of rod.

** Apply to one flush-type grease fitting on each hinge.

F Flush-type grease fitting.

GMD grease - Mobil 28 (or equivalent)

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

RUDDER
Figure A-10 (Sheet 2 of 2)

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B. LANDING GEAR

1. General

a. It is recommended that the airplane be secured in an area suitable for lubrication

servicing. The area should be free of sand, dirt, dust, and other environmental
conditions that might contribute to improper servicing.

b. Observe nose and main gear maintenance practices safety precautions, as outlined in
Chapter 32, before and during lubrication servicing.

c. The recommended lubrication servicing equipment should include grease guns, oil
cans, brushes, clean cloths, and other facilities as required for proper lubrication.

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NOSE GEAR
Figure B-1 (Sheet 1 of 3)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Upper Drag Link Beam Fittings GMD Gun 2
2* Nose Gear Uplatch Hook Striking GMD Hand -
Surface
3 Nose Gear Actuating Cylinder GMD Gun 2
4 Drag Links, Center Joint at GMD Brush 2
Kneebolt
5** Downlock Bungee Cylinder Attach OGP Oilcan -
Points
6 Upper Downlock Link GMD Gun 1
7 Cam Roller, Reserve Pressure GMD Hand -
Shutoff Valve Arm
8 Side Brace Trunnion, Beam Fittings GMD Gun 2
9 Steering Cylinder Support Bracket GMD Gun 4F
10 Steering Piston Rod Ends GMD Gun 2
11 Drag Link, Lower Attach Point GMD Gun 1
12 Steering Collar GMD Gun 1
13 Torque Links GMD Gun 4
14*** Torque Link Quick-Disconnect OGP Oilcan 2
Pins
15*** Wheel Bearings GH Hand 4
*

NOSE GEAR
Figure B-1 (Sheet 2 of 3)

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SERVICE CHART - RECOMMENDED LUBRICATION (cont’d)

* Apply light film of grease to striking surface of uplatch hook.

** Oil lightly and wipe off excess.

*** Oil two pins and wipe off excess.

**** Lubricate wheel bearings at assembly. Work grease well into rollers and race of each
bearing.

F Flush-type grease fitting.

GMD grease - Mobil 28 (or equivalent)

OGP oil - General purpose

GH grease - High temperature

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

NOSE GEAR
Figure B-1 (Sheet 3 of 3)

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NOSE GEAR DOORS

Figure B-2 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1 Bellcrank GMD Gun 1
2 Door Upper Connecting Rod End GMD Gun 1
3 Door Torque Tube Support Fittings GMD Gun 2
4 Forward Door Links GMD Gun 2
5* Door Rub Strips SFL Brush or -
Spray

* If required, clean surface thoroughly; spray or brush on touchup coating. Allow coating
to dry before operating. (See Lubrication Service Notes, 12-80-0.)

GMD grease - Mobil 28 (or equivalent)

SFL lubricant - Solid film

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

NOSE GEAR DOORS

Figure B-2 (Sheet 2 of 2)

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MAIN GEAR
Figure B-3 (Sheet 1 of 3)

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SERVICE CHART - RECOMMENDED LUBRICATION

ITEM ITEM DESCRIPTION LUBE METHOD NUMBER OF ACCOM.

NO. TYPE FITTINGS OR BY
AREAS
1 Torque Tube, Outboard End GMD Gun 1
2 Downlock Bungee Cylinder Attach GMD Gun 2
Points
3* Uplatch Hook Striking Surface GMD Brush - -
Hand
4 Torque Tube, Inboard End GMD Gun 1
5 Downlock Links GMD Gun 6
6 Trunnion Bolts GMD Gun 2
7 Universal Joint, Swivel Link, and GMD Gun 7
Upper Side Brace
8 Actuating Cylinder Attach Points GMD Gun 2
9 Brake Compensating Links GMD Gun 16
10 Torque Links GMD Gun 7
11** Upper Torque Link Uplatch Roller OGP Oilcan -
12 Bogie Trim Cylinder GMD Gun 3
13 Bogie Beam GMD Gun 3
14*** Wheel Bearings GH Gun 8

MAIN GEAR
Figure B-3 (Sheet 2 of 3)

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SERVICE CHART - RECOMMENDED LUBRICATION (cont’d)

* Apply light film of grease to striking surface.

** Oil lightly through hole in roller and wipe off excess.

*** Lubricate wheel bearings at assembly. Work grease well into rollers and race of each
bearing.

GMD grease - Mobil 28 (or equivalent)

OGP oil - General purpose

GH grease - High temperature

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

MAIN GEAR
Figure B-3 (Sheet 3 of 3)

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MAIN GEAR DOORS

Figure B-4 (Sheet 1 of 2)

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SERVICE CHART - RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS
NO. TYPE BY
OR AREAS
1* Inboard Door Hinges OGP Oilcan -
2** Rub Strip SFL Brush or -
Spray
3 Inboard Door Mechanism Turning OGP Oilcan -
Points
GMD Gun 1
Uplatch Hook Bearing Bolt
4* Outboard Door Hinges OGP Oilcan -
5 Inboard Door Actuating Cylinder GMD Gun 3
Attach Points
6 Outboard Door Link GMD Gun 1
7*** Door Uplatch Hook GMD Brush -
8* Door Uplatch Mechanism Turning OGP Oilcan -
Points

* Oil applicable areas lightly, wipe off excess oil.

** If required, clean surface thoroughly; spray or brush on touchup coating. Allow coating
to dry before operating. (See Lubrication Service Notes, 12-80-0.)

*** Apply light film of grease to striking surface of hook.

GMD grease - Mobil 28 (or equivalent)

OGP oil - General purpose

SFL lubricant - Solid film

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

MAIN GEAR DOORS

Figure B-4 (Sheet 2 of 2)

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C. DOORS

1. General

a. It is recommended that the airplane/doors be secured in an area suitable for

lubrication servicing. The area should be free of sand, dirt, dust, and other
environmental conditions that might contribute to improper servicing.

b. The recommended lubrication servicing equipment should include grease guns, oil
cans, brushes, clean cloths, and other facilities as required for proper lubrication.

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CARGO CONTAINER (BASKET) LOADING DOOR

Figure C-1 (Sheet 1 of 2)

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SERVICE CHART – RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Chain GMD Brush -
2* Rack and link assemblies GMD Brush -
3 Rollers GMD Gun 4F
4* Rack and pinion GMD Brush -
5** Linkage turning OGP Oil Can -

* Apply light coat of grease.

** Oil lightly and wipe off excess

F Flush-type grease fitting

GMD grease - Mobil 28 (or equivalent)

OGP oil - General purpose

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

CARGO CONTAINER (BASKET) LOADING DOOR

Figure C-1 (Sheet 2 of 2)

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CARGO CONTAINER (CROSS SLIDE) LOADING DOOR

Figure C-2 (Sheet 1 of 2)

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SERVICE CHART – RECOMMENDED LUBRICATION

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Racks and pinions GMD Brush 3
2** Latch pin bushing OGP Oil can 6
3*** Lifting crank bearing OGP Oil can 2
4*** Translation link bearing SGP Oil Can 4
5**** Door Track SFL Brush or spray 2
6**** T-bolt SFL Brush or spray 12

* Apply light coat of grease to working surfaces.

** Oil lightly and wipe pins dry.

*** Oil lightly and wipe off excess.

***** Apply medium film; if using aerosol can, avoid over spray.

CAUTION: DO NOT ALLOW GENERAL PURPOSE OIL TO CONTAMINATE DRY

FILM LUBRICATED SURFACES OF TRACKS.

GMD grease - Mobil 28 (or equivalent)

OGP oil - General purpose

SFL lubricant – Solid Film

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

CARGO CONTAINER (CROSS SLIDE) LOADING DOOR

Figure C-2 (Sheet 2 of 2)

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PASSENGER & SERVICE ENTRANCE DOOR

Figure C-3 (1 of 6)

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NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Upper & lower seal mechanism & OGP Oil can 2
hinges
2** Upper & lower seal control linkage MS Hand 2
3*** Door operating mechanism OGP Oil can -
4**** Rod ends GMD Gun, Oil 4
Can
OGP
5 Door summers (see note) GMD Gun 2F
6*** Latch rollers OGP Oil can -
7**** Roller (service door) GMD Gun, Oil 1F
can
OGP
* Oil clevis bolts & hinges thoroughly; wipe off excess.
** Apply light coat of moly silicon oil to nylon-coated cables.
*** Oil lightly and wipe off excess.
**** Apply to flush type grease fittings where applicable. Apply general-purpose oil where
grease fittings are omitted.
NOTE: Access to forward passenger entrance door snubber is through access door 669.
F – Flush Type grease fitting
GMD grease - Mobil 28 (or equivalent)
OGP oil - General purpose
MS oil – Moly silicone
For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

PASSENGER & SERVICE ENTRANCE DOOR

Figure C-3 (2 of 6)

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PASSENGER & SERVICE ENTRANCE DOOR

Figure C-3 (3 of 6)

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PASSENGER & SERVICE ENTRANCE DOOR

Figure C-3 (4 of 6)

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NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Bayonet fitting rollers OGP Oil can 3
2* Seal Mechanism roller OGP Oil can 1
3* Seal mechanism pivot bolt OGP Oil can 1
4** Upper & lower seal mechanism OGP Oil can 2
clevis bolts & hinges
5 Door opening & closing GMD Gun 1F
mechanism aft end door rotation
rod
6* Door rotation rod forward end OGP Oil can 1
fitting
7* Bayonet rod end fitting OGP Oil can 1
8*** Bayonet rod end fitting GMD Brush – 1
hand
9* Bayonet pivot bolt OGP Oil can 1
10*** Door handle shaft cam GMD Brush – 1
hand
11* Door handle shaft bushings OGP Oil can 2
12* Bayonet bellcrank pivot roller OGP Oil can 1
13* Bayonet bellcrank pivot bolt OGP Oil can 1
14* Door hinge torque tube bushings OGP Oil can 1
15* Door hold-open hook linkage end OGP Oil can 2
fittings
16* Door hold open hook pivot bolt OGP Oil can 1
17* Door hold open hook linkage OGP Oil can 2
18 Door snubbers OGP Oil can 2F
19* Latch rollers OGP Oil Can 2
20 Rollers (service door) GMD Gun, Oil 1F
can
OGP
PASSENGER & SERVICE ENTRANCE DOOR
Figure C-3 (5 of 6)

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* Oil lightly and wipe off excess.

** Oil clevis bolts & hinges thoroughly; wipe off excess.
*** Apply light coating of grease to working surfaces; wipe off excess.

F – Flush Type grease fitting

GMD grease - Mobil 28 (or equivalent)
OGP oil - General purpose
For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

PASSENGER & SERVICE ENTRANCE DOOR

Figure C-3 (6 of 6)

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EMERGENCY EXIT DOORS

Figure C-4 (1 of 3)

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EMERGENCY EXIT DOORS

Figure C-4 (2 of 3)

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NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
2
1* Emergency exit door handle latch OGP Oil can,
Each Door
mechanism – roller Brush
GMD
1
2** Emergency exit door handle latch OGP Oil Can
Each Door
mechanism – toggle lever
1
3** Overwing emergency exit door OGP Oil can
Each Door
handle & latch mechanism
5
4** Hinge mechanism OGP Oil Can
Each Door
3
5** Snubber mechanism OGP Oil can
Each Door
* Oil bearing of roller lightly and wipe off excess; paint outer surface of roller with thin
coat of grease.
** Oil lightly and wipe off excess.
*** Oil lightly and wipe off excess.
GMD grease - Mobil 28 (or equivalent)
OGP oil - General purpose
For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

EMERGENCY EXIT DOORS

Figure C-4 (3 of 3)

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UPPER CARGO DOOR

Figure C-5 (Sheet 1 of 2)

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NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Hinge OGP Oil can 1
2 Actuating cylinder attach point GMD Gun 1F
3 Linkage GMD Gun 11
4* Lock OGP Oil can 1
7
5 Door latches GMD Gun
(3 fittings
each latch)
6** Hook GMD Brush 1
7*** Latch spool lube bolts GMD Gun 7
* Oil lightly & wipe off excess.
** Apply light coat of grease to striking surface.
*** Freighter airplanes equipped with cargo door latch spool lube bolts & airplanes with
Service Bulletin incorporate.
F – Flush Type Grease Fitting
GMD grease - Mobil 28 (or equivalent)
OGP oil - General purpose
For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

UPPER CARGO DOOR

Figure C-5 (Sheet 2 of 2)

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D. FLIGHT COMPARTMENT

1. General

a. It is recommended that the airplane be secured in an area suitable for lubrication

servicing. The area should be free of sand, dirt, dust, and other environmental
conditions that might contribute to improper servicing.

b. The recommended lubrication servicing equipment should include grease guns, oil
cans, brushes, clean cloths, and other facilities as required for proper lubrication.

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CLEAR VIEW WINDOW

Figure D-1 (Sheet 1 of 2)

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NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Track hinges OGP Oil can -
2** Sun visor monorail - Hand -
3*** Upper pushrod GMD Gun 2F
4* Hinges OGP Oil can -
5*** Forward Pushrod GMD Gun 2F
6*** Lower aft pushrod GMD Gun 2F
* Oil lightly & wipe off excess.
** Apply light film of paraffin.
*** Apply to two flush-type fittings.
F – Flush Type grease fitting

NOTE: Wipe all excess lubricants from window mechanism.

GMD grease - Mobil 28 (or equivalent)
OGP oil - General purpose
For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

CLEAR VIEW WINDOW

Figure D-1 (Sheet 2 of 2)

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CHAPTER 16 - PERIODIC CHECKS
16.07 LUBRICATION (cont’d)

CAPTAIN’S OR FIRST OFFICER’S SEAT

Figure D-2 (Sheet 1 of 2)

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CHAPTER 16 – PERIODIC CHECKS
16.07 LUBRICATION (cont’d)

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Seat tracks SFL Brush or -
Spray
2** Seat track rollers, pins, and linkage OGP Oil can -
3** Seat movement control handles & OGP Oil can -
flexible linkage push-pull shafts
4** Seat back adjusting mechanism OGP Oil can -
5** Seat up & down movement rollers, OGP Oil can -
pins, & linkage
* Normally, seat tracks do not require lubrication. If lubrication is necessary, clean surface
thoroughly, and spray or brush on coating. Allow coating to dry before operating. (See
Lubrication Service Notes in DACO DC-8-60 MM.)

** Apply lightly and wipe off excess.

OGP oil - General purpose

SFL lubricant – Solid film

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

CAPTAIN’S OR FIRST OFFICER’S SEAT

Figure D-2 (Sheet 2 of 2)

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CHAPTER 16 - PERIODIC CHECKS
16.07 LUBRICATION (cont’d)

FLIGHT ENGINEER’S SEAT

Figure D-3 (Sheet 1 of 2)

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DC-8 MAINTENANCE MANUAL
CHAPTER 16 – PERIODIC CHECKS
16.07 LUBRICATION (cont’d)

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Seat tracks SFL Brush or -
Spray
2** Tube OGP Oil can -
3** Seat movement control handles & OGP Oil can -
flexible linkage push-pull shafts,
turning points
4** Linkage turning points OGP Oil can -
5** Seat track rollers, pins, and linkage OGP Oil can -
* Normally, seat tracks do not require lubrication. If lubrication is necessary, clean surface
thoroughly, and spray or brush on coating. Allow coating to dry before operating. (See
Lubrication Service Notes in DACO DC-8-60 MM.)

** Apply lightly and wipe off excess.

OGP oil - General purpose

SFL lubricant – Solid film

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

FLIGHT ENGINEER’S SEAT

Figure D-3 (Sheet 2 of 2)

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CHAPTER 16 - PERIODIC CHECKS
16.07 LUBRICATION (cont’d)

NAVIGATOR’S (FIRST OBSERVER) SEAT

Figure D-4 (Sheet 1 of 2)

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DC-8 MAINTENANCE MANUAL
CHAPTER 16 – PERIODIC CHECKS
16.07 LUBRICATION (cont’d)

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Seat tracks SFL Brush or -
Spray
2** Tube OGP Oil can -
3** Seat control linkage turning points OGP Oil can -
4** Linkage turning points OGP Oil can -
5** Rollers & pins OGP Oil can -
* Normally, seat tracks do not require lubrication. If lubrication is necessary, clean surface
thoroughly, and spray or brush on coating. Allow coating to dry before operating. (See
Lubrication Service Notes in DACO DC-8-60 MM.)

** Apply lightly and wipe off excess.

OGP oil - General purpose

SFL lubricant – Solid film

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

NAVIGATOR’S (FIRST OBSERVER) SEAT

Figure D-4 (Sheet 2 of 2)

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CHAPTER 16 - PERIODIC CHECKS
16.07 LUBRICATION (cont’d)

OBSERVER’S SEAT
Figure D-5 (Sheet 1 of 2)

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DC-8 MAINTENANCE MANUAL
CHAPTER 16 – PERIODIC CHECKS
16.07 LUBRICATION (cont’d)

NUMBER OF
ITEM LUBE ACCOM.
ITEM DESCRIPTION METHOD FITTINGS OR
NO. TYPE BY
AREAS
1* Seat tracks SFL Brush or -
Spray
2** Tube OGP Oil can -
3** Footrest turning points OGP Oil can -
4** Rollers & pins OGP Oil can -
5** Linkage turning points OGP Oil can -
6** Seat control linkage turning points OGP Oil can -
* Normally, seat tracks do not require lubrication. If lubrication is necessary, clean surface
thoroughly, and spray or brush on coating. Allow coating to dry before operating. (See
Lubrication Service Notes in DACO DC-8-60 MM.)

** Apply lightly and wipe off excess.

OGP oil - General purpose

SFL lubricant – Solid film

For lubrication frequency interval recommendation, see 12-80-0, General-Servicing.

OBSERVER’S SEAT
Figure D-5 (Sheet 2 of 2)

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16.08 – COMBI PASSENGER COMPARTMENT MATERIAL

CONDITION INSPECTION
TABLE OF CONTENTS

JOB CARDS

16.08-1 COMBI PASSENGER COMPARTMENT MATERIAL CONDITION

INSPECTION -------------------------------------------------------------------- 16.08.1

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CHAPTER 16 – PERIODIC CHECKS
16.07 COMBI PASSENGER COMPARTMENT MATERIAL CONDITION
INSPECTION
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
16.08-01
JOB TITLE
COMBI PASSENGER COMPARTMENT MATERIAL CONDITION INSPECTION
Job Card Accomplished By: Certificate Number Date
Page 1 of 3
The purpose of this JC is to perform a thorough visual inspection of the passenger
compartment with the intent of improving the material condition and visual appeal of the
entire compartment. This JC is intended to enhance, not replace, any existing inspection
requirements. All discrepancies noted are to be documented in accordance with GMM
procedures. A copy of this card and all logbook entries generated are to be forwarded to
Maintenance Control/Records when the inspection is complete.
A. LAVATORIES Mechanic Inspector
Check lavatory doors and door locks for condition and proper
operation. Confirm that the “Vacant/Occupied” sign works, the
door locks, and lavatory light illuminates.
Inspect all lavatory floor coverings for general condition and
cleanliness.
Inspect lavatory toilet shrouds and seats for condition, cleanliness
and proper installation of hardware.
Inspect lavatory side/ceiling panels for condition and cleanliness.
Inspect lavatory oxygen, paper towel, and vanity doors for condition,
lock operation, and cleanliness.
B. GALLEY/CLOSETS
Inspect all doors and drawers for proper operation and cleanliness.
Inspect galley floor coverings for tears and cleanliness.
Inspect galley ceiling/side panels for condition and cleanliness.
Lower all galley and hallway ceiling panels. Check for ease of
operation, security of hinges, condition, and presence of proper
hardware.
Inspect closet doors & door latches for condition and proper
operation.
Inspect closet shelves for condition and security.
Inspect closet restraint nets for condition and availability.
Inspect cabin attendant seats. Check for clean cushion covers that
are in good repair, proper seat operation, and for belts and shoulder
harnesses that are not frayed. Check exterior shell for cleanliness
and condition.

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CHAPTER 16 – PERIODIC CHECKS
16.07 COMBI PASSENGER COMPARTMENT MATERIAL CONDITION
INSPECTION (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
16.08-01
JOB TITLE
COMBI PASSENGER COMPARTMENT INSPECTION
Job Card Reviewed By Date
Page 2 of 3
C. PASSENGER COMPARTMENT Mechanic Inspector
Inspect escape slide covers for condition and security. Ensure
bottle pressure indicator is centered in inspection window.
Inspect carpeting for tears, cleanliness, and security.
Inspect sidewall panels for damage, cleanliness, and security.
Inspect all interior panel GAP trim for cleanliness, security &
installation.
Inspect cabin window panes for damage and cleanliness.
Inspect window shades for proper operation, damage, and
cleanliness.
Inspect window trim panels for damage and cleanliness.
Inspect cold air gasper outlets for proper operation.
Inspect overhead baggage bins for security, damage, cleanliness,
door operation; hold open rods for proper tension, and hinges for
cracks and security.
Inspect cabin speakers for general condition and proper operation.
Inspect seat row numbers for presence and legibility.
Inspect ceiling panels for condition, damage, and cleanliness.
Inspect seats for structural soundness, operation, condition, and
security/condition of safety belts.
Inspect seat cushions for wear.
Inspect cushion covers for cleanliness and tears in fabric and
presence of Velcro® strips on covers.
Inspect seat back pockets for security and elasticity.
Inspect seat trays for security, cleanliness, condition, stability, and
ease of operation.
Inspect seat tray latches for operation and security.
Inspect armrests for damage and cleanliness.
Inspect seat recline function and locks for proper operation.

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CHAPTER 16 – PERIODIC CHECKS
16.07 COMBI PASSENGER COMPARTMENT MATERIAL CONDITION
INSPECTION (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
16.08-01
JOB TITLE
COMBI PASSENGER COMPARTMENT INSPECTION
Job Card Reviewed By Date
Page 3 of 3
C. PASSENGER COMPARTMENT(cont’d) Mechanic Inspector
Inspect floor tracks and seat locks for cleanliness, operation and
security and installation of seat track filler panels.
Inspect under-seat life vest pouches for condition.
Inspect reading lights for proper operation and condition of lenses.
Inspect “No Smoking/Fasten Seat Belt” lights for condition and
operation.
Check all passenger seat audio Control Units for proper operation
and security within armrest.
Inspect passenger entertainment monitors for condition and
operation.
Inspect forward bulkhead for cleanliness, security, and installation of
accessory pouches.
Inspect cabin-to-cargo compartment access door for cleanliness,
condition, security, locking, and ease of operation.
Inspect emergency track lighting strips and arrow lenses for
condition, security, and cleanliness.
Perform operational check of passenger address and entertainment
systems.
Inspect armrest ashtrays for presence of permanent covers.
Inspect condition and operation of ceiling & sidewall lighting.

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16.09 – AIRCRAFT EXTERIOR AND ENGINE WASH

TABLE OF CONTENTS
Paragraph Page
A. AIRCRAFT EXTERIOR WASH ---------------------------------------------------- 16.09.1
1. GENERAL------------------------------------------------------------------------------ 16.09.1
2. PREPARATION ----------------------------------------------------------------------- 16.09.1
3. WASH EMPENNAGE AND UPPER FUSELAGE------------------------------- 16.09.1
4. WASH LOWER FUSELAGE BELOW CUSP LINE AND EMPENNAGE -- 16.09.1
5. INSPECT FOR PROPER WASH OF ALL AREAS ------------------------------ 16.09.2
6. LUBRICATION------------------------------------------------------------------------ 16.09.2
7. REMOVE COVERS------------------------------------------------------------------- 16.09.2
8. COMPLETE RECURRING NON-ROUTINE JOB CARD 1601 --------------- 16.09.2
B. ENGINE WASH ----------------------------------------------------------------------- 16.09.2

RECURRING NON-ROUTINE JOB CARDS

16.09-1 AIRCRAFT EXTERIOR WASH ---------------------------------------------- 16.09.3

16.09-2 ENGINE COMPRESSOR WASH--------------------------------------------- 16.09.5

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16.09 AIRCRAFT EXTERIOR AND ENGINE WASH

A. Aircraft Exterior Wash.

1. General.

a. The aircraft will be washed to the extent indicated.

b. A complete wash includes all items.

2. Preparation.

a. Cover all openings.

(1) Place 3M tape, Part Number 471 (or equivalent), over static fittings on right and left
side of fuselage. (Full wash only)
(2) Place covers over pitot tubes. (Full wash only)
(3) Close outflow valve, baggage doors, cargo doors, entrance and service doors, all
accessory compartment doors.
(4) Close cockpit windows.
(5) Install engine covers if available.

b. Make Aircraft Logbook entry. (Per sample on Job Card 16.09-1)

3. Wash Empennage and Upper Fuselage.

a. Wash complete empennage.

(1) Vertical stabilizer

(2) Rudder and top tail section
(3) Horizontal stabilizer and elevator

b. Wash complete upper fuselage.

4. Wash Lower Fuselage below Cusp Line and Empennage.

a. Wash complete lower fuselage.

b. Wash nose wheel well and nose gear. Avoid direct stream on wheel bearings.
c. Wash left wing.

(1) Wash bottom of wing, aileron and flaps.

(2) Wash landing gear and well. Avoid direct stream on wheel bearings.
(3) Wash top of wings, aileron, flaps.
(4) Wash #1 and #2 engine cowling and pylon.

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16.09 AIRCRAFT EXTERIOR AND ENGINE WASH (cont’d)

d. Wash right wing.

(1) Wash bottom of wing, aileron and flaps.

(2) Wash landing gear and well. Avoid direct stream on wheel bearings.
(3) Wash top of wing, aileron, flaps.
(4) Wash #3 and #4 engine cowling and pylon.

5. Inspect for proper wash of all areas.

6. Lubrication. Refer to ATI DC-8 Maintenance Manual, Figures 16.07-3 and 16.08-1 thru
16.08-4.

a. Lubricate nose gear actuators, fittings, uplatches, mechanism and doors.

b. Lubricate left main landing gear bogies, actuators, fittings, uplatches, doors &
mechanisms.
c. Lubricate right main landing gear bogies, actuators, fittings, uplatches, doors &
mechanisms.
d. Lubricate left and right wing spoiler drive mechanism, spoiler idler mechanism, inboard
and outboard spoiler actuators, and the outboard spoiler actuator crank.

7. Remove Covers

a. Remove installed covers.

(1) Remove tape from static fittings on right and left side of fuselage, check for
obstructions.
(2) Remove pitot tube covers.
(3) Remove engine covers.
(4) Open outflow valve.

b. Log Book Sign Off. Make aircraft logbook entry. (Per sample on Job Card 16.09-1)

8. Complete Recurring Non-Routine Job Card 16.09-1, sign it in the “Job Card Reviewed By”
block, date, and attach the job card to the signed off log page and forward to LIT per the
GMM.

B. Engine Wash – Accomplish an Engine Compressor Wash when analysis has determined the
Δ EGT is at a level for the engine to be placed on the Engine Watch List by the Engine
Analyst. Complete Recurring Non-routine Job Card 16.09-2, sign it in the “Job Card
Reviewed By” block, date it, attach the job card to the signed-off log page, and forward to
LIT per the GMM.

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CHAPTER 16 – PERIODIC CHECKS
16.09 AIRCRAFT EXTERIOR AND ENGINE WASH (cont’d)
RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

16.09-1
JOB TITLE
AIRCRAFT EXTERIOR WASH
Job Card Reviewed By Date
Page __1_ of __1_
Mechanic Inspector
1. General Type of Wash Scheduled (Check appropriate block)

FULL PARTIAL
2. Preparation:
a. Cover all openings (Pitot/Static Ports/Tubes do not need to be
covered for partial wash.)
b. Log Book Entry Required: (“Pitot/Static Ports/Tubes and other
openings covered for aircraft wash.”) LOG PAGE #
3. Wash Upper Fuselage and Empennage: (Not applicable if partial wash
is performed.
a. Empennage

b. Upper Fuselage
4. Wash Lower Fuselage and Empennage:
a. Lower fuselage and empennage.

b. Nose wheel well and nose gear..

c. Left wing, nacelles and pylons.

d. Right wing, nacelles and pylons.

5. INSPECT FOR PROPER WASH OF ALL AREAS.

6. Post Wash Lubrication:
a. Nose Gear. (16.07, Figures B-1 and B-2.)

b. Left Main Gear. (16.07, Fig. B-3 and B-4)

c. Right Main Gear. (16.07, Fig. B-3 and B-4)

d. Left Wing Spoiler Actuator Drive. (16.07, Fig. A-3)

e. Right Wing Spoiler Actuator Drive. (16.07, Fig A-3)

7. Remove Covers:
a. Remove installed covers.
b. Log Book Sign Off Required: (“All covers installed for aircraft
wash have been removed.” ) LOG PAGE #

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16.09 AIRCRAFT EXTERIOR AND ENGINE WASH (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
16.09-2
JOB TITLE
ENGINE COMPRESSOR WASH (CFM56-2-C1)
ENGINE TSN__________________ ENGINE CSN____________________
J/C Reviewed By: Date: Page 1 of 5
Mechanic Inspector

Engine Serial Number: ________________

(Complete a job card for each affected engine.)
NOTE: This Job Card will be controlled by an ATI Work Request issued
by an Engine Analyst.
References
Oil Servicing: CFM56 MM 12-00-00
ERH: DC-8 Engine Run Handbook
Open and close engine cowls: ATI GMM 3.116
Open and close thrust reversers: CFM56 MM 78-30-00
Juniper Operating Manual
Fan Blade & Gas Path Washing Procedures – Cleaning (CFM MM 72-00-
00)
Tools & Equipment
Juniper Compressor Wash Cart
2 CFM56-2 Washing Probes, Part Number JMP/CFM56/D/4435
Thrust Reverser Hand Pump
CDP, CBP Plugs
Materials
Lube System Corrosion Preventative Oil, CP2851 (or)
Corrosion Preventative Additive, CP2859
Nitrogen
Hot Water
Procedure
NOTE: The water in the wash cart must be heated to a temperature of
158° F (70° C) prior to engine compressor wash.
NOTE: Do not wash engine unless the EGT indication is below 150° F
(66° C).
1. Prepare the engine compressor wash cart by:
a. Ensuring the water temperature is correct.
b. Charging the nitrogen cylinders (if needed).
c. Check the wash cart for any obvious defects.
NOTE: Refer to the Juniper Engine Compressor Wash Rig General &
Technical Information Manual for detailed instructions.

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CHAPTER 16 – PERIODIC CHECKS
16.09 AIRCRAFT EXTERIOR AND ENGINE WASH (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
16.09-2
JOB TITLE
ENGINE COMPRESSOR WASH (CFM56-2-C1)
J/C Reviewed By: Date: Page 2 of 5
Mechanic Inspector
d. Make sure the 3-way engine selector valve is set to the CFM56
engine.
2. Prepare to clean the engine:
a. Check that the EGT is less than 150° F (66° C) and the OAT is
not at or below 40° F (5° C).
CAUTION: IF ONE OR BOTH OF THE ABOVE CRITERIA IS NOT
MET, THE COMPRESSOR WASH CANNOT BE
ACCOMPLISHED. N/A JOB CARD.
b. Open the Engine Fan Cowls.
c. Open Thrust Reversers.
d. Disconnect and plug the CDP and CBP lines at the Combustion
Case. (DO NOT CAP FITTING ON THE COMBUSTION
CASE.)
CAUTION: MAKE SURE THE FAN IS NOT ROTATING WHEN
INSTALLING THE WASHING PROBES.
e. Install the washing probes at the 4:00 and 8:00 positions on the
outside casing of the splitter in the fan duct. Make sure that the
front of the probe is placed into the booster inlet. Secure wands
with the clamping devices provided on the wands.
f. Prior to towing, after the water is heated make sure to turn off and
unplug the Pressure Vessel Heaters.
CAUTION: DO NOT CLEAN AN ENGINE EXPOSED TO DRY
CHEMICAL FIRE EXTINGUISHING AGENTS.
DAMAGE TO EQUIPMENT WILL OCCUR.
CAUTION: THE FUEL PUMP AND THE MEC ARE FUEL
LUBRICATED. DO NOT MOTOR, START, OR
OPERATE THE ENGINE UNLESS THERE IS A POSITIVE
FUEL INLET PRESSURE. DAMAGE TO THE
COMPONENTS COULD OCCUR.
CAUTION: DO NOT MOTOR THE ENGINE MORE THAN THE
STARTER DUTY CYCLE. STARTER DAMAGE COULD
OCCUR.
CAUTION: MAKE SURE THE N1 ROTOR TURNS FREELY
THROUGHOUT THE CLEANING PROCESS TO
PREVENT OIL SYSTEM CONTAMINATION.

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CHAPTER 16 – PERIODIC CHECKS
16.09 AIRCRAFT EXTERIOR AND ENGINE WASH (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
16.09-2
JOB TITLE
ENGINE COMPRESSOR WASH (CFM56-2-C1)
J/C Reviewed By: Date: Page 3 of 5
Mechanic Inspector
CAUTION: DO NOT APPLY WATER AT A RATE OF MORE THAN 6
U.S. GALLONS (23 LITERS) PER MINUTE. ENGINE
DAMAGE CAN OCCUR.
g. Position the water wash cart in a safe location adjacent to the
engine to be washed. Place the tow bar in the vertical position to
apply the parking brake. Connect the washing probes to the
delivery hose of the water wash cart and recheck the connection.
h. Open the nitrogen cylinders to turn on nitrogen supply. Confirm
the nitrogen supply is fully charged by reference to the gauges on
the main regulator valve; the right hand gauge registers cylinder
pressure and the left hand gauge registers the regulated pressure
(80 lbf/sq. in. (5.5 bar) max). Regulate system pressure not to
exceed 6 gallons per minute flow rate (approximately 15-25 psi
tank pressure). DO NOT EXCEED MAXIMUM WATER
TANK PRESSURE. {80 lbf/sq. in. (5.5 bar) max}
3. Position engine controls as follows:
a. Ignition....................................................................OFF
b. Fuel Shutoff Lever ..................................................OFF
c. Throttle....................................................................Idle
d. Engine Inlet Anti-ice...............................................OFF
e. Engine Bleed...........................................................Auto
f. Fuel Boost ...............................................................ON
4. Dry motor the engine for 2 minutes:
WARNING: STAND A MINIMUM OF 3 FEET AWAY FROM THE
ENGINE INLET WHILE MOTORING IS
ACCOMPLISHED TO AVOID PERSONAL INJURY.
a. While motoring, start injecting hot water 10 seconds after the start
of the dry motoring. The water is injected by opening the fluid
outlet valve. Inject the water for 1 minute and 50 seconds. After
this period, close the fluid outlet valve. (Starter switch and water
off at the same time.)
5. Let engine soak for 5 minutes.
6. Dry motor the engine for 2 minutes:
a. While motoring, start injecting hot water 10 seconds after the start
of the dry motoring. The water is injected by opening the fluid
outlet valve. Inject the water for 1 minute and 50 seconds. After
this period, close the fluid outlet valve.
7. Let engine soak for 5 minutes.

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CHAPTER 16 – PERIODIC CHECKS
16.09 AIRCRAFT EXTERIOR AND ENGINE WASH (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
16.09-2
JOB TITLE
ENGINE COMPRESSOR WASH (CFM56-2-C1)
J/C Reviewed By: Date: Page 4 of 5
Mechanic Inspector
8. Dry motor the engine for 3 minutes:
a. While motoring, start injecting hot water 10 seconds after the start
of the dry motoring. The water is injected by opening the fluid
outlet valve. Inject the water for 1 minute and 50 seconds. After
this period, close the fluid outlet valve. Continue motoring for 1
minute.
9. Let engine soak for 5 minutes:
a. While soaking the engine, disconnect the washing probes from
the delivery hose of the water wash cart.
b. Remove the plugs from the CDP and CBP lines.
CAUTION: DO NOT BLOW AIR INTO THE MEC. DAMAGE WILL
OCCUR.
c. Connect the CDP line and torque coupling nut to 260-300 inch
pounds and safety wire.
d. Connect the CBP lines and torque coupling nut to 135-150 inch
pounds and safety wire.
e. Service oil tank with 1 qt (1 liter) of Corrosion Preventative Oil
(CP2851) or Corrosion Preventative Additive (CP2859).
f. Remove the washing probes and stow on wash cart.
g. Ensure the CDP, CBP Weep Hole located at the 6:00 position on
the Fan Case is clean and free of obstructions.
10. Prepare the wash cart for storage by:
a. Closing of inlet and outlet valves.
b. Exhausting remaining pressure from the pressure vessels.
c. Draining water from pressure vessels.
d. Stowing all hoses and probes.
e. Recharging the nitrogen cylinders.
NOTE: One charge should be sufficient to wash two engines.
11. Return the thrust reversers to their closed/stowed condition.
12. Close and secure the engine cowling.
13. Remove all wash equipment from around the aircraft.

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16.09 AIRCRAFT EXTERIOR AND ENGINE WASH (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
16.09-2
JOB TITLE
ENGINE COMPRESSOR WASH (CFM56-2-C1)
J/C Reviewed By: Date: Page 5 of 5
Mechanic Inspector
14. Prepare the aircraft for engine run.
CAUTION: THE FUEL PUMP AND THE MEC ARE FUEL
LUBRICATED. DO NOT MOTOR, START, OR
OPERATE THE ENGINE UNLESS THERE IS A POSITIVE
FUEL INLET PRESSURE. DAMAGE TO THE
COMPONENTS COULD OCCUR.
CAUTION: DO NOT MOTOR THE ENGINE MORE THAN THE
STARTER DUTY CYCLE. STARTER DAMAGE COULD
OCCUR.
NOTE: Run engine within 30 minutes of last wash cycle to purge
lube/sump system of any water ingestion.
NOTE: Double the run time if corrosion inhibitor is not available.
15. Start and run the engine as follows:
a. 5 minutes at ground idle.
b. 5 minutes at 90% core (N2, Power Assurance 70% Setting).
c. 5 minutes at ground idle.
d. Cycle engine bleed and engine anti-ice 2-3 times.
NOTE: If odor is still present, increase engine run time.
16. Shutdown engine
17. Sign off Log Book.
18. Secure Aircraft.
Return completed job card to Engine Analyst at LITHQ

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TABLE OF CONTENTS
Page
21.01 DC-8 AIR CONDITIONER MAINTENANCE REQUIREMENTS ------------- 21.01.1

21.02 TECH AIR COCKPIT AIR CONDITIONING SYSTEM (STC ST145CH)---- 21.02.1

21.03 AIR CONDITIONING WATER SEPARATOR (70 SERIES) ------------------- 21.03.1

21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) SYSTEM

(STC ST01253CH)---------------------------------------------------------------------- 21.04.1

21.05 NASI FLIGHT DECK FLOOR HEAT SYSTEM (STC ST00792CH) ---------- 21.05.1

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21.01 – DC-8 AIR CONDITIONER MAINTENANCE

REQUIREMENTS
TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 21.01.1
2. TECHNICIAN CERTIFICATION -------------------------------------------------- 21.01.1
3. SERVICING EQUIPMENT REQUIREMENTS ---------------------------------- 21.01.1
4. VENTING PROHIBITION----------------------------------------------------------- 21.01.1
5. SERVICE PRACTICE REQUIREMENTS ---------------------------------------- 21.01.2

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21.01 DC-8 AIR CONDITIONER MAINTENANCE REQUIREMENTS

1. General

a. The purpose of this section is to list the requirements and limitations of the Clean Air Act
(Sections 608 and 609) regarding servicing, maintenance, and repair of the DC-8 air
conditioning system containing either R-12 or R-134 refrigerant.

2. Technician Certification - Technicians servicing, maintaining, or repairing DC-8 air

conditioners must comply with the following when the servicing, maintaining, or repairing
involves the refrigerant in the air conditioner:

a. The technician must be trained and certified by an EPA approved organization.

b. To be certified, the technician must pass an EPA approved test given by an EPA
approved certifying organization.

c. A copy of the certificate or wallet card issued by the certifying organization must be sent
to Maintenance Training to be filed in the certified Technician’s training file.

3. Servicing Equipment Requirements

a. Recovery/Recycling equipment must be used to evacuate the refrigerant before opening

an air conditioner system.

(1) Connecting and disconnecting hoses and gauges to and from the appliance to
measure pressures within the appliance, and to add refrigerant to or recover
refrigerant from the appliance is not considered opening.

b. Recovery/Recycling equipment must be certified by an EPA approved equipment test

organization.

c. The Recovery/Recycling equipment must not be altered in a way that would affect the
equipment’s ability to meet the certification standards.

4. Venting Prohibition

a. The Clean Air Act prohibits individuals from knowingly venting Class I (R-12) and Class
II refrigerants, or their substitutes (R-134a), into the environment while maintaining,
servicing, repairing, or disposing of air conditioning or refrigeration equipment.

b. Only four types of releases are permitted under the prohibition:

(1) “De minimis” quantities of refrigerant released in the course of making good faith
attempts to recapture and recycle or safely dispose of refrigerant.

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(2) Refrigerants emitted in the course of normal operation of air conditioning and
refrigeration equipment (as opposed to during the maintenance, servicing, repair, or
disposal of the equipment) such as from mechanical purging and leaks. However,
EPA is requiring the repair of substantial leaks.

(3) Mixtures of nitrogen and R-22 that are used as holding charges or as leak test gases
because in these cases, the ozone depleting compound is not used as a refrigerant.
However, a Technician may not avoid recovering refrigerant by adding nitrogen to a
charged system. Before nitrogen is added, the system must be evacuated to
established level; otherwise, the CFC or HCFC vented along with the nitrogen will
be considered a refrigerant. Similarly, pure CFCs or HCFCs released from
appliances will be presumed to be refrigerants, and their release will be considered a
violation of the prohibition on venting.

(4) Small releases of refrigerant which result from purging hoses, or from connecting or
disconnecting hoses to charge or service appliances, will not be considered
violations of the prohibition on venting. However, recovery and recycling
equipment manufactured after November 15, 1993, must be equipped with low-loss
fittings.

5. Service Practice Requirements

a. Evacuation Requirements - Technicians are required to evacuate air conditioning and

refrigeration equipment to established vacuum levels.

b. Exceptions to Evacuation Requirements - EPA has established limited exceptions to its

evacuation requirements for (1) repairs to leaky equipment and (2) repairs that are not
major and that are not followed by an evacuation of the equipment to the environment.
If, due to leaks, evacuation to established levels is not attainable or would substantially
contaminate the refrigerant being recovered, persons opening the appliance must:

(1) Isolate leaking from non-leaking components whenever possible. Evacuate non-
leaking components to established levels.

(2) Evacuate leaking components to the lowest level that can be attained without
substantially contaminating the refrigerant. This level cannot exceed 0 psig.

c. If evacuation of the equipment to the environment is not to be performed when repairs

are complete and if the repair is not major, then the appliance must be evacuated to at
least 0 psig before it is opened. Methods that require subsequent purging (e.g., nitrogen)
cannot be used.

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d. Major repairs to an air conditioner are those involving removal of the compressor,
condenser, evaporator, or auxiliary heat exchanger coil; or uncovering an opening of
more than 4 square inches of flow area for more than 15 minutes.

e. Evacuated refrigerant must be recycled before it can be returned to the same system or
another system.

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21.02 – TECH AIR COCKPIT AIR CONDITIONING SYSTEM

(STC ST145CH)
TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 21.02.1
2. DESCRIPTION OF AIR CONDITIONING SYSTEM--------------------------- 21.02.1
3. DESCRIPTION OF HEATING SYSTEM ----------------------------------------- 21.02.2
4. HEATING MAINTENANCE PRACTICES --------------------------------------- 21.02.8
5. BASIC VAPOR CYCLE DESCRIPTION ----------------------------------------- 21.02.13
6. CHARGING OF REFRIGERANT -------------------------------------------------- 21.02.19
7. AIR CONDITIONER PERFORMANCE TEST ----------------------------------- 21.02.30
8. TROUBLE DIAGNOSIS AND CORRECTIONS--------------------------------- 21.02.30
9. CLEANING AND SERVICING----------------------------------------------------- 21.02.35
10. ILLUSTRATED PARTS CATALOG----------------------------------------------- 21.02.47

FIGURES

21.02-1 AIR CONDITIONING / HEATING SYSTEM SCHEMATIC ------------ 21.02.2

21.02-2 AIR CONDITIONER / HEATER ELECTRICAL SCHEMATIC--------- 21.02.3
21.02-3 HEATER-EVAPORATOR-BLOWER LOCATION------------------------ 21.02.4
21.02-4 HEATER ELEMENT ----------------------------------------------------------- 21.02.12
21.02-5 EVAPORATOR / BLOWER / HEATER ASSEMBLY -------------------- 21.02.12
21.02-6 AIR CONDITIONER SYSTEM SCHEMATIC ----------------------------- 21.02.13
21.02-7 OIL DIPSTICK------------------------------------------------------------------- 21.02.16
21.02-8 SERVICE PORT CONNECTION --------------------------------------------- 21.02.17
21.02-9 VACUUM PUMP & MANIFOLD GAUGE --------------------------------- 21.02.18

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FIGURES

21.02-10 COMPRESSOR PALLET ASSEMBLY-------------------------------------- 21.02.37

21.02-11 EVAPORATOR / BLOWER / HEATER ASSEMBLY -------------------- 21.02.39
21.02-12 COMPRESSOR ASSEMBLY ------------------------------------------------- 21.02.44
21.02-13 ILLUSTRATED PARTS CATALOG - AIR CONDITIONING SYS. --- 21.02.47
21.02-14 ILLUSTRATED PARTS CATALOG – EVAPORATOR ASSEMBLY - 21.02.49
21.02-15 ILLUSTRATED PARTS CATALOG – CONDENSER ASSEMBLY --- 21.02.51

TABLES

21.02-1 REFRIGERANT LEVEL ---------------------------------------------------------- 21.02.25

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1. GENERAL. The supplemental cockpit air conditioning and heating utilizes a vapor cycle
machine, (air conditioner) defined in “Description of Air Conditioning System”, and heating
elements, (heater) defined in “Description of Heating System”. A seven position climate
control switch located on the flight engineers panel controls the temperature in the cockpit as
follows: HEAT, HI, HEAT LO, OFF, FAN HI, FAN LO, AIR CONDITIONER LO. The HI
and LOW positions for heating, air conditioning, and fan do effect the operation of the heater
or air conditioner, as they are a function of the fan (blower) speed only.

2. DESCRIPTION OF AIR CONDITIONING SYSTEM

a. Figure 21.02-1 shows a schematic of the “AC” system, which is a closed system. Each
major element of this system is described starting with the receiver/dryer.

b. The air-cooling system stores the liquid Refrigerant R134a (which is non-harmful to
humans), under pressure in a combination receiver/dryer. The pressure in the
receiver/dryer varies depending on the surrounding temperatures. The dryer portion of
the assembly, removes any traces of moisture that may have been accumulated in the
system which may cause the air conditioning unit to malfunction. Protection of the
system against abnormally high pressure is accomplished by a fusible plug screwed into
the receiver/dryer.

c. When the cooling system is in operation, the liquid Refrigerant R134a flows from the
combination receiver/dryer unit through hoses to the evaporator expansion valve where it
is allowed to spray into the evaporator hence reducing the pressure.

d. The rate of Refrigerant R134a evaporation is controlled by an expansion valve which

allows only enough refrigerant to flow into the evaporator to keep the evaporator
operating efficiently.

e. The expansion valve has a temperature sensing tube connected to a bulb which is
clamped to the outlet pipe of the evaporator.

f. The refrigerant leaves the evaporator in the form of gas. This gas is pumped by the
compressor located on a pallet assembly in the nose wheel well. The compressor always
pumps a gas, raising the gas pressure and temperature. This hot high temperature gas
then flows to the condenser. Cooling air passes over the condenser located in the nose
wheel well. The cooling air comes from a fan attached to the armature shaft of the
compressor drive motor. The outlet hot air is exhausted overboard via the open doors of
the nose wheel.

g. The cooled gas is now condensed to a cooled liquid ready to enter the receiver/dryer,
repeating the events all over again.

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h. Air is passed over the evaporator by a blower driven by a 28VDC motor. This air is
cooled since heat is removed from the air by the refrigerant that flows through a line
attached to the evaporator cover.

3. DESCRIPTION OF HEATING SYSTEM

a. Cockpit heating is produced by elements installed in the evaporator assembly. These

heater elements use three phases 400Hz electrical power. To provide for air movement a
28VDC electric motor powers the blower. This is the same motor/blower that is used to
provide air movement for the air conditioner. Thermal fuses in circuit provide protection
against heating if blower is nor operating. Thermal switches in the circuit automatically
turn the blower on high to protect against blower relay malfunction or excessive heat
buildup after heater and blower has been switch.

AIR CONDITIONING-HEATING SYSTEM

Figure 21.02-1

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AIR CONDITIONER/HEATER ELECTRICAL SCHEMATIC

Figure 21.02-2

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b. Heater, Air Conditioner, Blower; Climate Control Switch is located on the flight
engineers panel underneath the SAT-indicator. Circuit breaker “A/C HEATER- 15A” is
located on circuit breaker panel position I 38, Circuit Breaker “A/C HEAT-BLOWER
CONTROL-10A” is located on circuit breaker panel position J 45. Locations of circuit
breakers may vary. Refer to specific aircraft wiring manual for exact location.

HEATER-EVAPORATOR-BLOWER LOCATION
Figure 21.02-3

c. Cockpit heat is derived from heating elements inserted in the forward row of evaporator
coils. There are three sets of two 815 watt heating elements for 4,890 total watts of heat.
Two single elements are wired in parallel to produce one set of elements. One end of
each set of elements is connected to one leg of the three-phase 115-VAC 400Hz power
supplied through a 15-amp air conditioner/heater circuit breaker. The other end of each
set of elements has a thermal switch wired in series with the set of elements and
terminating at a single ground stud.

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HEATING SYSTEM
TROUBLESHOOTING CHART
TROUBLE PROBABLE CAUSE REMARKS

Heater runs but blower will Control switch malfunction. Replace control switch.
not run.
Poor ground at blower motor. Repair ground.
Open wire at motor. Repair wiring as required.
Blower motor malfunction. Replace blower motor.
Blower does not rotate freely. Inspect blower and housings.
Heater cycles on and off. Blower inlet or outlet plugged. Unplug inlet and outlet.
Blow weak brushes worn. Replace blower.
Thermal switch S3 too Replace thermal Switch S3.
sensitive.
Blower runs low speed only. HI blower relay inop. Replace relay.
Open wire to or from LO Repair wiring as required.
blower relay.
Open resistor R1. Replace resistor.
HI blower will not shut off. Heater is overheated. Let cool.
Thermal switch S3 is stuck Replace thermal switch S3.
closed.
HI blower relay is stucked Replace relay.
closed.
Control switch malfunction Replace control switch.
Insufficient heat (blower runs One or two thermal fuses With both 10 amp
normal). blown. AC/Heater/Blower control and
15 amp AC/Heater circuit
breakers pulled, confirm no
power at terminal block
TA07-53. Use Ohmmeter, an
open across limit switches S4
requires replacement of
unserviceable switch.

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HEATING SYSTEM
TROUBLESHOOTING CHART (cont’d)
TROUBLE PROBABLE CAUSE REMARKS

Insufficient heat (blower runs One or more heater elements With power “OFF” (pull
normal). non-serviceable. heater/air conditioner C/B),
inspect for open heater
element with OHM meter on
evaporator terminal block
TA07-1. OHM reading
should be 8.0 to 8.6 when
testing across stud 1 to 4, 2 to
5, and 3 to 6. If test results
confirm non-serviceable
heater elements, send
evaporator assembly to NASI
for repair.
One phase or more open from Reset HEAT/AC 15 AMP
circuit breaker. circuit breaker and verify 115
vac on load and bus side of
each phase of circuit breaker.
Open wire (phase) to heater After testing circuit breaker
element with power “ON” and control
switch on “HEAT LO”, check
for 115 vac at studs 1, 2, and 3
on terminal block TA07-53.
An open circuit requires repair
between circuit breaker and
evaporator. After testing for
power at terminal block
TA07-53 with power “ON”
and control switch on “HEAT
LO”, check for 115 vac at stud
1, 2, and 3 on terminal block
TA07-1.
Unserviceable heater relay. One or two open phases
identifies an unserviceable
heater relay P/N TA07-10.
All three open phases requires
testing of heater relay control
wiring.

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HEATING SYSTEM
TROUBLESHOOTING CHART (cont’d)
TROUBLE PROBABLE CAUSE REMARKS

Neither blower nor heater Control C/B popped. Reset C/B.

operates.
Poor ground at ground stud Repair ground.
(wire No. TA-H24F16N).
Control switch malfunction. Replace control switch.
Open wire from BUSS to Repair wire.
control C/B.
Heater inoperative but blower Heater/air conditioner C/B Reset C/B.
runs. popped.
Control switch malfunction. Replace control switch.
Poor ground at ground from Repair ground.
stud heater element (wire No.
TA-H17A12N).
Open wire to heater relay. Repair wire.
Malfunction at ground shift Repair relay.
relay.
Over temp. switch S2 open. Replace over temp switch .
Poor ground from heater relay, Repair ground.
(wire No. TA-H24C16N).

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4. HEATING MAINTENANCE PRACTICES.

a. Removal of Evaporator Pallet Assembly

NOTE: Discharge R134a coolant from air conditioning system before removing heater.
Refrigerant is not allowed to be discharged into the atmosphere; a recovering stand
must be used.

(1) Pull circuit breakers 15 AMP A/C HEATER and 10 AMP A/C HEAT-BLOWER
CONTROL.

(2) Ensure Climate Control Switch is in position OFF.

(3) Disconnect (TA09-7) Drain line at (TA08) Cover.

(4) Remove (TA08) Cover.

(5) Disconnect pressure and suction lines at evaporator and plug open fittings. Any
foreign material in coolant system may cause a system failure.

(6) Disconnect wires from Terminal Block (TA07-53) as follows:

(a) Disconnect wires HV-TA-H14A12 and HV-TA-H10A12 from stud #1.
(b) Disconnect wires HV-TA-H15A12 and HV-TA-H11A12 from stud #2.
(c) Disconnect wires HV-TA-H16A12 and HV-TA-H12A12 from stud #3.
(d) Disconnect wire TA-H23A16 from stud #4.
(e) Disconnect wire TA-H22A16 from stud #5.
(f) Disconnect wire TA-H30G16 from stud #6.
(g) Disconnect wire TA-H30A16 from stud #7.
(h) Disconnect wire TA-H19B16 from stud #8.
(i) Disconnect wire TA-H18A16 from stud #9.
(j) Disconnect wire TA-H20B16 from stud #10.

(7) Disconnect ground wires TA-H24F16N and TA-H17A12N from ground studs.

(8) Remove 6 each AN3-4A bolts attaching heater-evaporator-blower assembly mount

plate to airframe and remove heater-evaporator-blower assembly.

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b. Installation of Evaporator Pallet Assembly

(1) Install heater-evaporator-blower assembly to airframe, use AN3-4A bolts with

AN970-3 washers (6 places) through mount plate.

(2) Connect wires to Terminal Block as follows:

(a) Connect wires HV-TA-H14A12 and HV-TA-H10A12 to stud #1.
(b) Connect wires HV-TA-H15A12 and HV-TA-H11A12 to stud #2.
(c) Connect wires HV-TA-H16A12 and HV-TA-H12A12 to stud #3.
(d) Connect wire TA-H23A16 to stud #4.
(e) Connect wire TA-H22A16 to stud #5.
(f) Connect wire TA-H30G16 to stud #6.
(g) Connect wire TA-H30A16 to stud #7.
(h) Connect wire TA-H19B16 to stud #8.
(i) Connect wire TA-H18A16 to stud #9.
(j) Connect wire TA-H20B16 to stud #10.

(3) Connect ground wires TA-H24F16N and TA-H17A12N to ground studs.

NOTE: Use NYLOG gasket thread sealant #RT201B (or equivalent)

(4) Connect pressure and suction lines to evaporator. Be careful to keep lines and
connections clean and free of any foreign debris.

(5) Charge air conditioning system with R143a coolant, see Paragraph 6, “CHARGING
OF REFRIGERANT”.

(6) Install (TA08) cover.

(7) Connect (TA09-7) Drain line to (TA08) Cover.

(8) Reset Circuit Breakers, 15 AMP A/C HEATER and 10 AMP A/C HEATER-
BLOWER-CONTROL.

(9) Perform functional test as described below.

NOTE: When installing factory repaired/overhauled assembly, use Tube-O to flare

fitting adapters for all aircraft with Flare fitting style plumbing. For
expansion valve fitting, use TA09-N-13 and for Evaporator return line
fitting, use TA09-N-15 adapter.

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c. Functional Test

NOTE: External power must be applied for test.

(1) At control switch select FAN LO position, and forced air should be felt four to five
feet away from air outlets.

(2) Select FAN HI position, and noticeable increase in forced air should be felt.

NOTE: Forced air should not be hot or cold in the FAN LO or FAN HI positions.

(3) Select A/C LO position, and forced air should become cold within two minutes.

(4) Select A/C HI position, and noticeable increase in cold forced air should be felt.

(5) Select HEAT LO position, and forced air should become hot within two minutes.

(6) Select HEAT HI position, and noticeable increase in hot forced air should be felt.

NOTE: If performance is questionable proceed to section “TROUBLESHOOTING

HEATER” or “TROUBLESHOOTING AIR CONDITIONING for correction.

(7) After test, position climate control switch in position OFF.

NOTE Paragraphs “d”. (1) Thru (7) and “e”.: Temperature sensor is not replaced as an
assembly, thermal switches are replaced separately.

d. Removal of Thermal Switches

(1) Pull circuit breakers, 15 AMP A/C HEATER and 10 AMP HEATER-BLOWER
control.

(2) Make certain that climate control switch is in position OFF.

(3) Disconnect (TA09-7) Drain line at (TA08) cover from TA06 evaporator assembly.

(4) Remove TA08 cover.

(5) Remove the forward four and loosen the aft two AN3-4A bolts attaching the heater-
evaporator-blower assembly mount plate to the airframe.

CAUTION: TAKE CARE THAT EVAPORATOR DOES NOT FALL FROM

ATTACHMENT. ONLY LOOSEN THE ASSEMBLY AND LOWER IT
ENOUGH TO GAIN ACCESS.

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(6) Remove four #8 screws securing temperature sensor assembly to evaporator.

(7) Remove (TA06-0-5 close on rise) S2 and (TA06-0-6 open on rise) S3 thermal
switch:

(a) Remove the two wires attached to each switch by pulling quick disconnects.

(b) Remove two 4-40 screws securing each thermal switch to temp sensor board
and remove switches.

NOTE: It is not recommended to replace (TA06-0-7 re-setable to open on rise) S4 thermal

switch in the field, although if (TA06-0-7) S4 thermal switch is replaced the technician
must be proficient in soldering.

e. Installation of Thermal Switches. Install thermal switches in reverse order as removed,

Reference paragraph “d”. (1) thru (7).

f. Remove Blower Assembly from Heater-Evaporator.

(1) Pull Circuit breakers, 15 AMP A/C HEATER and 10 Amp HEATER-BLOWER
CONTROL.

(2) Disconnect (TA09-7) drain line at (TA08) cover.

(3) Remove (TA08) cover.

(4) Remove wires TA-H27B16 from stud 7 and TA-H24E14N from stud 9 terminal
block TA07-4.

(5) Remove #8 round head screws (8 PL) securing (TA06-0-1) blower assembly to
evaporator and remove blower assembly.

g. Install Blower Assembly on Heater-Evaporator. Install blower assembly in reverse order

as removed. Reference paragraph “f”, (1) thru (5).

h. Remove Heater Element – Deleted.

NOTE: Heater elements are replaced at factory overhaul only.

i. Install Heater Element – Deleted.

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HEATER ELEMENT
Figure 21.02-4

EVAPORATOR/BLOWER/HEATER ASSEMBLY
Figure 21.02-5

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5. BASIC VAPOR CYCLE DESCRIPTION.

a. If you were to paint your finger with alcohol, your finger would feel cold. This is
because the liquid alcohol takes heat away from your finger while it evaporates. If a
quickly evaporating liquid such as alcohol is placed in the container inside a box, the
temperature inside the box will drop. This is because the alcohol is evaporated absorbing
the heat from inside the box. If the gaseous alcohol is collected and cooled with cold
water, it will change back into a liquid by absorption of its heat by the cold water.

b. The vapor cycle air conditioner operates on this principle. The liquid used is the
refrigerant R134a. The heat inside the cabin is absorbed by changing the refrigerant from
a liquid to a gas and then dissipated to the outside by the changing of the refrigerant from
a gas back to a liquid.

AIR CONDITIONER SYSTEM SCHEMATIC

Figure 21.02-6

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c. General Service.

(1) Refrigerant R134a. The refrigerant used in the air conditioner is generally called
“R134a.” No other refrigerant than this should be used.

NOTE: Exercise care when handling refrigerant, as it is stored under high pressure.

(2) Compressor Oil. Polyester ISO 68 refrigerant lubricant or equivalent should be

used to ensure successful compressor operation. Use of oils other than
recommended or mixing of the oil with other oils would cause chemical reaction or
lead to lowered viscosity or deficient lubrication. Equivalent oils: EMKARATE RL
68H, distributed by Virginia KMP Corp., 4100 Platinum Way, Dallas TX 75237,
(phone 214-330-7731).

(3) General Service Instructions.

NOTE: The air conditioner system will be seriously affected if dirt, water, or air enters
the system.

(a) Always keep the working place clean and dry and free from dirt and dust.
Wipe water off from the line fitting with a clean cloth before disconnecting.

(b) Have all the necessary tools in preparation beforehand and have tools clean
and dry.

(c) Insert plugs into any disconnected refrigerant lines.

(d) Avoid contamination of compressor oil. It is hydroscopic. For details refer to

each description in this manual.

d. Safety Precautions. The refrigerant used in the air conditioning system in R134a. This
refrigerant is non-explosive, non-flammable, non-corrosive, has practically no odor, and
is heavier than air. Although R134a is classified as a safe refrigerant, certain precautions
must be observed to protect parts involved and the person working on the unit. The
following precautions are essential in handling of R134a, and their strict observation is
required along with sufficient training. Therefore, it is important that only a well-trained
serviceman should be allowed to handle the refrigerant.

(1) Liquid R134a, at normal atmospheric pressure and temperature, evaporates so

quickly that it tends to freeze anything that it contracts. Care must be taken to
prevent any liquid refrigerant from coming into contact with the skin and especially
the eyes. Most types of oil readily absorb R134a.

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(2) Always wear safety goggles when servicing any part of the refrigerant system.

(3) The refrigerant gas is odorless and colorless and breathing may become difficult due
to the lack of oxygen. Since the refrigerant gas is heavier than air and will lie close
to the floor, be especially careful when handling it in small, confined spaces.

(4) To avoid explosion, never weld, use a blow torch, solder, steam clean, bake aircraft
finish, or use excessive amounts of heat on or in, the immediate area of any part of
the air conditioning system, or refrigerant supply tank, full or empty, while they are
closed to atmosphere.

(5) The refrigerant service container has a safe strength. However, if handled
incorrectly, it will explode. Therefore, always follow the instructions on the label.
In particular, never store it in a hot location (above 126 degrees F., 52 degrees C.) or
drop it from a great height.

e. Air Contamination of Service Equipment. During servicing, use caution to keep air and
moisture from getting into refrigerant. When air enters the system, all refrigerant must be
evacuated from system prior to charging new refrigerant. Air in refrigerant has the
following harmful effects.

(1) Since the condensation temperature of the air is extremely low, the air will not be
condensed when refrigerant gas is condensed in the condenser, and the air will thus
remain in gaseous form.

(2) Consequently, the effective thermal transmission of the condenser will be reduced
and the amount of refrigerant gas to be condensed will be reduced. The pressure
rise will become proportional to the volume of the air in the system.

(3) When air and refrigerant are mixed in the system, a chemical reaction will occur and
hydrochloric acid; which will adversely affect the aluminum, copper, iron, and other
materials in the system; may be generated.

f. Tools Required.

(1) MANIFOLD GUAGE SET: Consists of a manifold with three fittings to which
refrigerant service hoses are attached; two hand valves with O-ring type seals; and
two gauges, one for the low side and the other for the high side. The low side gauge
is a compound gauge, i.e., capable of reading negative pressures down to 30 inches
of mercury (below atmospheric) and positive pressures up to about 60 p.s.i.g. The
high side gauge should have a range from zero to 600 p.s.i.g.

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(2) CHARGING HOSES: Three are required.

(3) VACUUM PUMP: Must be capable of pulling about 29.62 inches of mercury,
gauge.

(4) REFRIGERANT SOURCE: R134a is available in 15 or 30-pound disposable

cylinders, or in larger returnable cylinders. However, the preferred way to handle
refrigerant is with a charging stand or cart. These devices are equipped with
graduations to facilitate the dispensing of R134a by weight. They also have built-in
electric heaters to help force refrigerant onto the air conditioning system. This
feature is a near-necessity when the system is charged without the compressor
running. To accomplish this kind of charging the R134a cans would require the
warming of the cans by a hot water bath.

(5) LEAK DETECTOR: The use of the electronic leak detector TIF model 5650 is
recommended. Also leak detector solution conforming to MIL-L-25567 can be used
to check each fitting, hose connection, and air conditioning component.

CAUTION: THE USE OF A FLAME-TYPE LEAK DETECTOR IS NOT RECOMMENDED

FOR USE ON AN AIRCRAFT BECAUSE OF FIRE AND HEALTH HAZARD.

(6) Compressor Oil Dip Stick:

OIL DIPSTICK
Figure 21.02-7

WARNING: WORK WITH FINGERS PROTECTED WITH CLOTH AGAINST

FROSTBITE BY REFRIGERANT.

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g. Handling Service Valve. An automatic check valve is built into the service valve. When
this valve presses against the connecting fitting, that is, when the charging hose is
connected to the service valve, the valve is open. When the charging hose is
disconnected, the valve is closed automatically.

SERVICE PORT CONNECTION

Figure 21.02-8

NOTE: Always install the valve cap after using the service valve. Dirt and dust will
easily enter the valve resulting in foreign matter entering the system.

h. Handling Charging Stand. Follow manufacturer’s instructions.

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VACUUM PUMP & MANIFOLD GAUGE

Figure 21.02-9

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6. CHARGING OF REFRIGERANT

a. Handling Manifold Gauge.

NOTE: Always wear safety goggles when servicing any part of the refrigerant system. The
yellow service hose has a check valve in the end connecting to the vacuum pump or the
refrigerant tank.

(1) General

(a) There are three hoses on the manifold gauge:

1) RED= high pressure hose-connects to the high pressure service fitting

thin line.
2) BLUE= low-pressure hose connects to the low-pressure service
fitting=thick l line.
3) YELLOW= service hose connects to the vacuum pump or the refrigerant
tank.

(b) Connect Manifold gauge to service fitting (top of left corner in nose wheel
well) as follows:

1) Before connecting the manifold gauge turn the red and blue big knobs at
the gauges off (clockwise).
2) Turn the red and blue knobs on the quick disconnect couplings
counterclockwise allowing these couplings to be installed on the service
fitting.
3) Install quick disconnects couplings on service fittings, then turn the red
and blue knobs on the quick disconnect couplings clockwise to finger
tight, which opens the service port valve cores.

(2) Evacuating the System.

(a) Check the oil level in the vacuum pump.

(b) Connect the yellow service hose to the vacuum pump. Be sure the end
connecting to the vacuum pump is the end with the check end valve.

(c) Check all hose connections on the manifold gauge, service fittings, and
vacuum pump for tightness.

(d) Turn the vacuum pumps on and open the on/off valve on the vacuum pump.

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(e) Open the big blue and red knobs at the gauges.

(f) After 5 minutes the vacuum should read –29 psi or less on the blue gauge.

NOTE: If the reading is not –29 psi it is an indication for leakage.

(g) Vacuum the system for 30 minutes at -29 psi.

(h) Then turn the on/off valve on the vacuum pump off and turn the big red knob
at the gauge off. Reading on the blue gauge should remain –29 psi.

(i) Check after a minimum of 5 minutes that the reading on the gauge remains -29
psi. Any loss of vacuum is a leak.

NOTE: In case of a leak all accessible fittings should be checked for security. If the
leak persists the system must be charged with refrigerant to use a leak detector
or a leak detector spray.

(j) Turn the big blue knob at the gauge off.

(k) Make sure both red and big blue knobs at the gauges are turned off
(clockwise).

(l) Disconnect yellow service hose from vacuum pump.

(3) Charging Refrigerant

(a) Ensure both big red and big blue knobs at the gauge are turned off
(clockwise).

(b) Connect yellow service hose to R134a refrigerant tank.

(c) Open the valve on the refrigerant tank.

(d) Slightly loosen the yellow service hose fitting at the gauges until a small
amount of refrigerant escapes purging the line, and then re-tighten the yellow
service hose fitting.

(e) Now only open the big blue knob at the gauge.

WARNING: NEVER OPEN THE RED BIG KNOB (HIGH PRESSURE) AT THE
GAUGE WHEN CHARGING THE SYSTEM. IF THE MOTOR TURNS
WHEN THE LOW PRESSURE SENSING SWITCH IS ACTUATED THE
REFRIGERANT TANK CAN EXPLODE!!!!

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(f) Wait until both gauges are equal pressure and no more refrigerant is entering
the system.

(g) Turn the air conditioner on, by placing the “Climate Control Switch” on the
flight engineers panel in position “LO A/C”.

(h) Adjust the big blue knob at the gauge to read 40-50 psi while charging and
watch the sight glass on top of the receiver dryer.

NOTE: When pressure is not great enough set refrigerant tank in warm water (not
above 104 F = 40 C).

(i) Watch the sight glass (location: visible with installed mirror on the nose gear
pallet assembly), there will be bubbles in the sight glass when the system is
under charge. As soon as the sight glass is clear the system is charged, turn
the big blue knob at the gauge off.

NOTE: Overcharging this system will cause on/off cycling, poor cooling, and damage
to the pump and motor. The sight glass cannot tell you when a system is
overcharged. If you suspect an overcharge, bleed off some refrigerant until
bubbles are seen and then charge just enough to make them go away.
Sometimes R134a will look milky; do not confuse this condition with bubbles.

(j) When the refrigerant can is empty, fully close both valves of the manifold
gauge and replace the empty can with a new one. Before opening the
manifold gauge valve to change refrigerant from a new can, be sure to purge
air from inside the charging hose.

(k) Turn the refrigerant tank valve off.

(4) Disconnect Manifold Gauge:

(a) Ensure both big red and blue big knobs at the gauge are turned off(clockwise).

(b) Turn the blue and red knobs on the quick disconnect service couplings
counterclockwise. This closes the service port valve cores and allows the
couplings to be removed.

(c) Always install the protection caps on service fittings; as dirt and dust will
easily enter the fittings resulting in foreign matter entering the system.

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b. In Service Charging

(1) Initial System Pressure Test

CAUTION: COMPRESSOR MUST NOT BE RUNNING.

(a) Connect manifold gauge to service fittings and turn the (blue) low pressure
gauge valve on, (counterclockwise) the pressure should read approximately
the same as the outside air temp. (This test is performed with the system off
and not in use for an hour, allowing pressure to stabilize)

EXAMPLE: If it is 80 F on the ramp the pressure on the gauge should be 80 psi.

This is not an accurate method of checking refrigerant but it will tell you this: if on
an 80 F day the pressure is 150 psi, the system is overcharged, or if the pressure is
40 psi, the system is overcharged, and whenever the pressure reading is 10 psi or
less the system will have to evacuate and recharge.

(2) Discharging System. Refrigerant is not allowed to be discharged into the

atmosphere. A recovering stand has to be used.

(3) Charging Refrigerant.

(a) Since the charging procedures begins with the air-conditioning system
evacuated, the initial portion of the charge will be automatically drawn in by
the system vacuum. However, once the pressure within the system has
equalized with the atmospheric pressure, the remainder of the charge must be
forced into the system. This can be accomplished by either running the
system, in which case the compressor will draw the refrigerant into the low
pressure line, or if the compressor cannot run, by raising the temperature (and
hence the pressure) of the R134a in the charging can or cylinder.

1) Install the manifold gauge to the system, refer to Paragraph 6 “a”,

“HANDING MANIFOLD GAUGE”.
2) Attach the center charging hose of the manifold gauge to the refrigerant.
Loosen the charging hose at the center fitting of the manifold gauge and
purge the air from the inside charging hose.

CAUTION: COMPRESSOR MUST NOT BE RUNNING.

3) Open the high-and low-pressure valves of the manifold gauge and charge
the refrigerant into the system.

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(b) When the refrigerant charging speed is slow, immerse refrigerant can in water
to a temperature of about 104 degrees F. (40 degrees C) for a short time.

WARNING: UNDER NO CIRCUMSTANCES SHOULD THE REFRIGERANT BE IN

WATER OVER 126 DEGREES F. (52 DEGREES C). A BLOWTORCH OR
STOVE MUST NEVER BE USED TO WARM THE CAN.

CAUTION: THE SYSTEM MUST BE OFF WHEN CHARGING THROUGH THE HIGH-
PRESSURE SIDE.

(c) If the refrigerant charging rate is slow, immerse refrigerant can in water heated
to a temperature of approximately 104° F (40° C) for short time. If charging
can be done while running the compressor, proceed in the following order:

1) Shut off the high-pressure valve of the manifold gauge.

2) Run the compressor.
3) Set the Climate Control Switch to A/C HI.
4) Charge refrigerant while controlling low pressure gauge reading at 40
psi(2.8 kg/cm2, 275 kpa) or less by turning the low-pressure valve of the
manifold gauge in or out.

WARNING: (COMPRESSOR RUNNING): NEVER CHARGE REFRIGERANT

THROUGH HIGH PRESSURE SIDE (DISCHARGE SIDE) OF THE
SYSTEM SINCE THIS WILL FORCE REFRIGERANT BACK INTO
REFRIGERANT CAN AND MAY EXPLODE.

5) When the refrigerant can is empty, fully close both valves of the manifold
gauge and replace the empty can with the new one. Before opening the
manifold gauge valve to charge refrigerant from a new can, be sure to
purge air from inside the charging hose.
6) Charge the system with refrigerant until the sight glass (location visible
with the installed mirror on nose gear pallet assy) is clear of bubbles.
7) After the refrigerant has been charged into the system, close the manifold
gauge valves.

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8) Confirm that there are no leaks in the system by checking with a leak
detector.

c. Refrigerant Level Check

(1) Set Climate Control Switch to position A/C HI.

(2) Check sight glass (location: visible with installed mirror on nose gear pallet assy)
after the lapse of about five minutes. Judge according to the Table 21.02-1.

(3) The bubbles seen through the sight glass are influenced by the ambient temperature.
Since the bubbles are hard to see in comparatively low temperatures below 68 F (20
c), it is possible that a slightly larger amount of refrigerant would be filled, if
supplied according to the sight glass. Be sure to recheck the amount when it
exceeds 68 f (20 C). In higher temperature the bubbles are easy to see.

(4) When the screen in the receiver dryer is clogged, the bubbles may appear even if the
amount of refrigerant is normal. In this case, the outlet pipe of the receiver becomes
colder than the inlet side. Under normal conditions, the temperature of the inlet and
outlet fitting of the receiver dryer should be the same.

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Check Item\ Almost no Insufficient Suitable Too much

Amount of refrigerant refrigerant
Refrigerant
Temperature of Almost no High-pressure High-pressure High-pressure
high pressure and difference between side is warm side is hot and side is
low-pressure high pressure and and low- low-pressure abnormally hot.
lines. low-pressure side pressure side if side is cold.
temperature. fairly cold.
State in sight Bubbles flow The bubbles are Almost No bubbles can
glass continuously. seen at intervals transparent. be seen.
Bubbles will of 1-2 seconds. Bubbles may
disappear and appear when
something like mist engine speed is
will flow when raised and
refrigerant is nearly lowered.
gone. No clear difference exists
between these two conditions.

Pressure of High-pressure side Both pressure Both pressures Both pressure

system is abnormally low. on high and low on high and on high and
pressure sides low-pressure low-pressure
are slightly low sides are sides are
normal. abnormally
high.
Repair Stop compressor Check for gas Discharge
immediately and leakage, repairs refrigerant from
conduct an overall are required, service valve of
check. replenish, and low-pressure
charge system side.

Refrigerant Level
Table 21.02-1

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d. Refrigerant Leaks

NOTE: When repairs require replacement of coolant lines or fittings always apply NYLOG
gasket thread sealant (or equivalent).

(1) If leaks are noticeable, leaking parts should be replaced. Then the system should be
recharged.

CAUTION: DO NOT OPERATE COMPRESSOR WITH REFRIGERANT LEVEL

EXCESSIVELY LOW. IF THIS CAUTION IS NEGLECTED, A DAMAGED
COMPRESSOR MAY RESULT.

(2) If the system has been open to the atmosphere for an extended period of time, the
receiver drier MUST BE REPLACED. If leaks are slight and no bubbles are
present in the system, repair leaks and add refrigerant as necessary.

(3) Checking for Refrigerant Leaks

(a) When checking the system for leaks, the system should be operated for 10 to
15 minutes prior to checking.

CAUTION: THE USE OF A FLAME-TYPE LEAK DETECTOR IS NOT RECOMMENDED

FOR USE ON AIRCRAFT BECAUSE OF FIRE AND HEALTH HAZARDS.

(b) The use of the electronic leak detector TIF model 5650 is recommended;
however if the 5650 are not available, leak detector solution confirming to
MIL-L25567 can be used to check each fitting, hose connection, and air
conditioning components.

(4) Checking Hoses and Pipes.

(a) Check air conditioner system for damaged hoses or pipes due to interference
or friction and adjoining parts. If damage is minor, repair those affected hose
or pipes. If damage is major and there is the possibility of encountering holes,
replace the affected parts.

(b) Carefully check hoses and pipes, especially those located close to moving
parts or sharp edges of panels.

(c) Conduct a leak test whenever leakage of refrigerant is suspected and when
conducting service operations, which are accomplished by disassembly or
loosening of fittings.

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(5) Electric leak detector.
The leak detector is a delicate device
that detects small amounts of
refrigerant. In order to use the device
properly, read the manuals put out by
each maker and perform the specified
maintenance inspections.

(6) General precautions for handling detector.

(a) The probe must be correctly aimed at the point to be checked. Each fitting
must be checked around its entire periphery. Refrigerant gas is heavier than
air, so the underside of the fitting must also be checked.

(b) The probe must be held as close as possible to the checking point, within .12
in (3 mm) of the object.

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(c) The detector requires a certain length of time to react to the gas. The moving
speed of the probe must be maintained at less than 1.2 in (3 mm)/sec.

(7) Measuring Standard

(a) If any reaction is noted using a detector having a nominal sensitivity of 0.53 to
0-.88 oz. (15 to 25 g) / year, that portion checked is considered to have a
significant leak and must be repaired.

(b) The nominal sensitivity of the detector is determined under assumption that
the detector collects all leaking gas. Accordingly, the quantity of gas is
actually leaking can amount to 5 to 10 times the indicated value. Generally
speaking, leakage of 5 to 7 oz. (141 to 198) of refrigerant can cause
insufficient cooling.

(c) Oil deposited during assembling must be wiped off before inspection.
Refrigerant easily dissolves in oil and the presence of oil can cause an error in
measurement. This precaution is important when checking a used aircraft for
refrigerant leakage.

(d) If any trace of oil is noted around connection fittings, it is a sure indication
that refrigerant is leaking.

(8) Major Leak Check Points.

NOTE: When repairs require replacement of coolant lines or fittings always apply NYLOG
gasket thread sealant.

(a) COMPRESSOR:
1) Compressor shaft seal (rotate the compressor by hand).
2) Hose connections.
3) Front and rear head gaskets.
4) Service valves.

(b) CONDENSOR:
1) Condenser fitting.
2) Condenser inlet and outlet pipe connections.

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(c) REFRIGERANT LINES:

1) Lines connections.

(d) EVAPORATING HOUSING:

1) Inlet and outlet line connections.
2) Expansion valve.

(9) If a leak is detected, proceed as follows:

NOTE: When repairs require replacement of coolant lines or fittings always apply
NYLOG gasket thread sealant.

(a) Check torque on the connection fitting, and if loose, tighten to the proper
torque.

(b) If leakage continues after the fitting has been retightened, discharge refrigerant
from system, disconnect the fittings, and check its seating face for damage.
Always replace even if damage is slight.

NOTE: Refrigerant is not allowed to be discharged into the atmosphere. Recovery

strand must be used.

(c) Be sure to liberally coat both sides of the flares and threads of fittings with
appropriate refrigerant oil to prevent small leaks.

(d) Charge system with refrigerant and recheck for gas leaks. Refer to Paragraph
6 “b”, “In Servicing Charging”.

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7. AIR CONDITIONER PERFORMANCE TEST

a. With climate control switch in blower LO position, blower should operate at low speed.
Next place control switch in blower HI position and blower should operate at high speed.

NOTE: Outside air temperature should be above 65 degrees Fahrenheit, and cockpit should
be above 70 degrees Fahrenheit, for functional test “b” following.

b. With climate control switch in air condition position, blower should operate at speed
selected. When air conditioner has operated for two minutes, air from blower should be
cool and cockpit should be noticeably cooler in five minutes e.g., with supplemental air
conditioner on HI, the air temperature at the evaporator should be below 25 degrees
Fahrenheit cooler than the cockpit temperature.

8. TROUBLE DIAGNOSIS AND CORRECTIONS. The cooling performance characteristics

of any air conditioning system are inherent to each system with respect to design parameters
such as compressor, horsepower, evaporator/condenser size, weight, and airflow. The
performance of any one system will change with respective changes in the evaporator/
condenser inlet temperature and humidity. Based on previous or similar system installed in
like aircraft, if the performance is suspected to be unsatisfactory or non-operational,
troubleshoot the system.

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AIR CONDITIONING
TROUBLESHOOTING CHART
TROUBLE PROBABLE CAUSE REMARKS
Insufficient Cooling. Refrigerant Leak. HI pressure is below normal.
Lo pressure is below normal.
Check for bubbles in sight
glass. Charge with refrigerant
until bubbles disappear,
inspect for leak and repair.
Air in System. HI pressure is above normal.
Lo pressure is above normal.
Discharge system and replace
receiver dryer. Evacuate
system and recharge.
Condenser Fins Clogged. Hi pressure is above normal.
Lo pressure is above normal.
Clean fins with high power
vacuum cleaner.
Condenser Fins Damaged Hi pressure is above normal.
Blocking Air Flow. LO pressure is above normal.
Repair surface damage, only
one fin at a time.
Air Temp in Nose Wheel Well HI pressure is above normal,
TOO Hot. LO pressure is above normal.
Open FWD nose gear doors
for ground operation in very
hot climate.
System Overcharged. HI pressure is above normal.
LO pressure is above normal.
Discharge refrigerant to
correct level.
Loose Belt. HI pressure is below normal.
LO pressure is below normal.
(May be noisy) Tighten belt,
Replace if necessary
Condenser Fan Operating In HI pressure is normal
Reverse Direction. LO pressure is normal
Switch phase 1 with Phase 3
wires on condenser pallet
terminal block.
Insufficient Air Flow. Evaporator Blower Air HI pressure is normal.
Blocked. LO pressure is below normal.
Inspect evaporator and remove
blockage.

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AIR CONDITIONING
TROUBLESHOOTING CHART(continued)
TROUBLE PROBABLE CAUSE REMARKS
System Cycles OFF and ON, Refrigerant overcharged. HI pressure is above normal.
Head Pressure High. LO pressure is above normal.
Slowly and Carefully
discharge refrigerant just until
bubbles appear in sight glass
and charge with just enough
refrigerant until bubbles
disappear.
Condenser Fins Clogged HI pressure is above normal.
LO pressure is above normal.
Clean fins with high power
vacuum cleaner. Do not use
High-pressure air, damage to
fins will occur.
Condenser Fins Bent Blocking HI pressure is above normal.
Air Flow. LO pressure is normal.
Repair surface damage, only
one fin at a time.
Air in System. HI pressure is above normal.
LO pressure is above normal.
Discharge system, and replace
receiver dryer. Evacuate
system and recharge.
Condenser Fan Operating In HI pressure is above normal.
Reverse Direction (Discharge LO pressure is above normal.
Air Should Blow With High Switch phase 1 with 3 wire on
Velocity Out The Rectangular condenser pallet on terminal
Discharge Air Box). block.
Receiver Drier Installation HI pressure is above normal.
Incorrect Flow Direction. LO pressure is above normal.
(“In” is stamped near sight Install new receiver drier with
glass and must connect to the flow in correct direction.
copper line from the
condenser.).
System Cycles OFF and ON, Defective Pressure Switch. HI pressure is normal.
Head Pressure Below 320 psi. LO pressure is above normal.
Replace pressure switch.

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AIR CONDITIONING
TROUBLESHOOTING CHART(continued)
TROUBLE PROBABLE CAUSE REMARKS
Suction Pressure is Low at Screen On Inlet Side of HI pressure is above normal.
Normal Operating Expansion Valve Clogged. LO pressure is below normal.
Temperature. Remove and clean screen.
Expansion Valve Closed HI pressure is normal.
Excessively. LO pressure is below normal.
Replace expansion valve.
Insufficient Refrigerant Check for bubbles and charge
Charge. system as required.
Evaporator Fin and Tube HI pressure is normal.
Damage. LO pressure is below normal.
Repair or replace evaporator.
Receiver Drier is Restricted. HI pressure is above normal.
LO pressure is below normal.
Replace receiver/drier.
Noisy Compressor Broken Internal Parts. HI pressure is below normal.
LO pressure is below normal.
Test Compressor. Remove
drive belt, discharge
refrigerant & rotate
compressor by hand. If
“catches are felt, replace
compressor.
Low Oil Level. Restore to proper level.
Overcharged System With HI pressure is above normal.
Refrigerant. LO pressure is above normal.
Restore proper refrigerant
charge.
Compressor Operates Normal Moisture in System. HI pressure fluctuates, LO
But Air From Evaporator pressure fluctuates, from
Cycles Cold and Warm. normal to below normal.
Evacuate system, replace
receiver drier, evacuate system
again and recharge refrigerant.
Compressor Does Not Run. Low Refrigerant Pressure. (Pressure Below 40 psi Static)
Charge with refrigerant and
evacuate as required.
Compressor Does Not Run Ambient Temp to Low. Outside air temp should be
(Pressure Below 40 psi Static). above 65 degrees F when
operating aircraft.

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AIR CONDITIONING
TROUBLESHOOTING CHART(continued)
TROUBLE PROBABLE CAUSE REMARKS
Compressor Does not Run Defective Pressure Switch. Momentarily jumper wires on
(Pressure above 40 psi Static). Pressure Switch, if
Compressor runs replace
Pressure Switch.
15 AMP A/C Heater Circuit Reset circuit breaker
Breaker Popped.
Blower Motor Does Not Run A/C heater Control Circuit Reset Circuit Breaker
(pressure above 40 psi static). Breaker Popped.
Motor Damaged. Replace motor
Fan Stuck. Free fan
Compressor, and Blower run Low Blower Resistor. Replace resistor. Check for 24
on HI, Does not Run on LOW. VDC at pin.
Compressor and Blower runs Control Switch. Replace control switch.
on LOW, but does not run on Check for VDC at pin
HI.. Broken Wire. Repair wire. Check for VDC
at pin.
Water leaks out of evaporator. Drain line Restricted or Unplug and Repair Drain
Kinked. Line.
Drain Line Disconnected Connect Drain line
From Nipple on Evaporator.
Inner Aluminum Housing Not Use Black Silicone to seal
Sealed to Plastic Housing at around opening. (Install Pop-
an Air Discharge Opening. Rivets as required holding
edges together).

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9. CLEANING AND SERVICING
a. Cleaning. The air conditioning components should be wiped clean with a cloth and a
stream of low-pressure dry air.
b. At least once a month during the off-season turn the compressor at idle speed for ten
minutes.
c. Perform a complete operation and performance test annually at the beginning of the
cooling season. See PERFORMANCE TEST, Paragraph 7.
d. Repair and Servicing. Field repair is limited to repair of compressor leaks, repair of
minor leaks in accessible coil tubes, motor overhaul and repair, and replacement of
defective components.
e. Precautions for removal and installation:
NOTE: When replacing refrigerant cycle components, observe the following:
(1) Pull Air conditioner circuit breaker.
(2) Before starting work, be sure to discharge system (see System Discharge, paragraph.
6.b.(2)).
(3) After disconnecting tubes, plug all openings immediately to prevent entrance of dirt
and moisture. Compressed air must never be used to clean dirty line.

f. Compressor Oil Level Check.

CAUTION: THIS SYSTEM MUST BE DISCHARGED PRIOR TO THE OIL LEVEL
CHECK. SEE “DISCHARGING SYSTEM” FOR INSTRUCTIONS.
(1) It is not necessary to check the oil level as routine maintenance. However, should
there be a good reason to suspect an incorrect oil level, or as a system component is
being replaced, or it is specified in the diagnosis procedure to check the oil, follow
the appropriate procedure below.

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(2) Do not overcharge with oil as too much oil reduces system performance.
g. Initial Compressor Installation Oil Level Check.
NOTE: The manufacturer has specified a predetermined oil change for this system, follow
the procedure specified below. For dipstick refer to paragraph 5.f.(6).
(1) Set pallet on level surface (pallet must be removed from aircraft).
(2) Remove oil filter plug, and rotate compressor to position the internal parts to the
furthest forward position. This will allow the dipstick to be inserted past the
internal parts (off to the side).
(3) Insert dipstick to its stop position. Remove dipstick, oil level must be at 1 3/8
inches.
(4) Reinstall oil filter plug (torque 6-9 ft-lbs)

CAUTION: DISCHARGE OF R134A COOLANT FROM THE AIR CONDITIONING

SYSTEM IS REQUIRED BEFORE PERFORMING ANY MAINTENANCE
PRACTICES ACCORDING TO FOLLOWING PARAGRAPHS; H-O.
REFRIGERANT IS NOT ALLOWED TO BE DISCHARGED INTO THE
ATMOSPHERE; A RECOVERING STAND HAS TO BE USED.
h. In Service Oil Level Checks.
(1) Run the compressor 10 minutes.
(2) Recover all refrigerant from the system, being careful not lose any oil.
(3) Remove air conditioner pallet assembly (Ref. paragraph. “m”, following) and set on
level surface.

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(4) Take a dipstick reading and add or remove oil in one ounce increments to achieve 1
3/8 inches on dipstick.
(5) Reinstall air conditioner pallet assembly. (Ref. paragraph. “n” following)
i. Flush Procedures.
NOTE: Flushing of the system is advisable when replacing a compressor and when a
system has been contaminated. Only recommended flushing materials should be
used.
(1) Disconnect both hose connections to the compressor.
(2) Remove and discard the receiver-dryer.
(3) Connect the flush material container at the discharge hose connection and allow
approximately one pound of material to enter the discharge side of the container.
(4) Connect a dry vapor container at that same point, preferably dry nitrogen with
pressure set between 100 and 250 psi. Allow pressurized vapor to enter until all
flush material liquid is purged out the inlet to receiver-dryer hose connection.
(5) Remove expansion valve and clean. Using the same procedure as above, flush and
purge the liquid hose from the receiver-dryer to the expansion valve and suction
hose and evaporator.
(6) Flush tool is useful for inserting the liquid and dry vapor propellant into the hose
connections.

COMPRESSOR PALLET ASSEMBLY

Figure 21.02-10

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j. Receiver/Dryer Removal.

(1) Pull CB’s J 45 A/C HEATER-BLOWER CONTROL and I 38 A/C HEATER.

(2) Make certain that Climate Control Switch is in position OFF.

(3) Discharge system.

(4) Disconnect high-pressure coolant line from receiver-dryer, located on the nose gear
pallet assy, and plug line immediately.

(5) Remove receiver/dryer mounting clamps and remove receiver/dryer.

k. Receiver/Dryer Installation.

(1) Install receiver/dryer on air conditioning pallet in the nose wheel well with
receiver/dryer mounting clamps.

(2) Connect high-pressure coolant line to receiver/dryer.

(3) Charge system, refer to “INITIAL CHARGING OF REFRIGERANT”, Paragraph 6.

(4) Push CB’s I 38 A/C HEATER and J 45 A/C HEATER-BLOWER CONTROL in.

(5) Perform functional test according to Paragraph 4.c.

l. Expansion Valve Replacement.

(1) Pull CB’s I 38 A/C HEATER and J 45 A/C HEATER-BLOWER CONTROL.

(2) Make certain that Climate Control Switch is in position OFF.

(3) Discharge system.

(4) Replace the expansion valve including the coil.

(5) Re-attach insulation with tie-raps.

(6) Charge system, refer to “INITIAL CHARGING OF REFRIGERANT”, Paragraph 6.

(7) Push CB’s I 38 A/C HEATER and J 45 A/C HEATER-BLOWER CONTROL in.

(8) Perform functional test according to Paragraph 4.c.

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EVAPORATOR/BLOWER/HEATER ASSEMBLY
Figure 21.02-11

m. Compressor Pallet Assembly Removal.

(1) Pull CB’s I 38 A/C HEATER and J 45 A/C HEATER-BLOWER CONTROL.

(2) Make certain that Climate Control Switch is in position OFF.

(3) Discharge system.

(4) Remove nose gear door torque tube per McDonnell Douglas DC-8 Maintenance
Manual Chapter 32-22-2.

(5) Disconnect low-pressure coolant line from compressor, located in the nose gear
pallet assy, and plug line immediately.

(6) Disconnect low-pressure line from compressor, located on the nose gear pallet
assembly, and plug line immediately.

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(7) Disconnect wires from terminal block (AS3-20) as follows:

(a) Disconnect wires HV-TA-H10A12 and HV-TA-H110B12 (may be labeled

phase 3).
(b) Disconnect wires HV-TA-H10A12 and HV-TA-H111B12 (may be labeled
phase 2).
(c) Disconnect wires HV-TA-H10A12 and HV-TA-H112B12 (may be labeled
phase 1).
(d) Disconnect wires TA-H13A12N, NEUTRAL, and GROUND 28V from stud
#4.
(e) Disconnect wires TA-H19B16 and COMPRESSOR CONTROL 28 V from
stud #5.

(8) Remove AN3-6A bolts (16 places) securing compressor pallet assembly to
mounting angles.

(9) Slide compressor pallet assembly forward off mounting angles and remove from
nose gear well.

n. Compressor Pallet Assembly Installation.

NOTE: All pallet boards 35.50 inches long use TA01-N-20 pallet spacer.

(1) Slide compressor pallet assembly aft on mounting angles in the nose gear well.

(2) Install AN3-6A bolts (16 places) securing compressor pallet assy to mounting plate.

(3) Connect wires from terminal block (AS3-20) as follows:

(a) Connect wires HV-TA-H10A12 and HV-TA-H110B12 (may be labeled phase

3).
(b) Connect wires HV-TA-H11A12 and HV-TA-H111B12 (may be labeled phase
2).
(c) Connect wires HV-TA-H12A12 and HV-TA-H112B12 (may be labeled phase
1).
(d) Connect wires TA-H13A12N, NEUTRAL, and GROUND 28V to stud #4.
(e) Connect wires TA-H19B16 and Compressor Control 28V from stud #5.

NOTE: When installing factory repaired/overhauled assembly, use Tube-O to flare fitting
adapters for all aircraft with flare fitting style plumbing. For receiver/dryer outlet
fitting use TA09-N-13, and for compressor suction fitting use TA09-N-15 adapter.

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(4) Connect low-pressure line to compressor.

(5) Connect high-pressure coolant line to receiver/dryer.

(6) Install nose gear door torque tub per McDonnell Douglas DC-8 Maintenance
Manual Chapter 32-2-2.

(7) Charge system, refer to “INITIAL CHARGING OF REFRIGERANT” Paragraph 6.

(8) Push CB’s I 38 A/C HEATER and J 45 HEATER-BLOWER CONTROL in.

(9) Perform Performance test according to Paragraph 4.c.

o. Drive Belt Replacement.

(1) Pull CB’s I 38 A/C HEATER and J 45 A/C HEATER-BLOWER CONTROL.

(2) Make certain that Climate Control Switch is in position OFF.

(3) Change drive belt on pallet assy in nose wheel well, and check belt tension per
Paragraph “p” below.

(4) Push CB’s I 38 A/C HEATER and J 45 A/C HEATER-BLOWER CONTROL in.

(5) Perform performance test according Paragraph 4.c.

p. Belt Tension.

(1) Pallet assembly must be installed in aircraft.

(2) Adjust belt for moderate tension.

(3) Rotate large pullet through 2 revolutions.

(4) Tension belt to deflect 0.10 inches with 2-3 lb force applied at mid-span location.

(5) Rotate belt 2 revolutions.

(6) Re-tension belt to deflect 0.10 inches with 2-3 lbs. Force.

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q. Pressure Switch Replacement.

(1) Pull CB’s I 38 A/C HEATER and J 45 A/C HEATER-BLOWER CONTROL.

(2) Make certain that Climate Control Switch is in position OFF.

(3) Disconnect the quick disconnect of the two wires covered with a waterproofed tube.

(4) Replace pressure switch.

(5) Reconnect quick disconnect and tighten the electrical cables. Ensure they are away
from the driver belt.

(6) Push CB’s I 38 A/C HEATER and J 45 A/C HEATER-BLOWER CONTROL in.

(7) Perform performance test according to Paragraph 4.c.

r. Compressor Mounting Components Inspection. Check for:

(1) Loose belt.

(2) Broken bracket and/or compressor mounting ear, replace broken component.

(3) Missing, broken, or loose bolts at compressor and engine fixing points.

(4) Flush fit at all points and replace any broken component not fitting properly.
Torque bolts to engine using manufacturer’s specifications.

(5) Loose or wobbling crankshaft pulley, and for a center bolt torque and “bottoming”.
Repair or replace bracket.

(6) Rough idler pulley bearing. Replace if necessary.

s. Refrigerant Charge. A 0-5 psi or lower suction pressure due to a low refrigerant charge
can cause unusual noise. Restore refrigerant to proper level.

t. Oil Level. Insufficient oil can cause unusual noise. See compressor Oil Level Check.

s. Valve Noise. Broken or distorted reed valve or broken gasket.

u. Valve Plate Test. Valve plate failures (suction or discharge valve or gasket) may be
determined with the compressor installed.

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v. Discharge or Suction Valve Breakage. When compressor is operating at idle speed,

compressor makes a “clacking” sound.

w. Head Gasket Breakage. At idling speed, discharge pressure does not increase to normal
condition and suction pressure is high.

x. Pressure Balance Test of Discharge Valve and Head Gasket.

(1) Connect manifold gauge set to suction and discharge service ports.

(2) Run compressor for 5 minutes and stop.

(3) Measure elapsed time that discharge pressure is balanced to suction pressure. If less
than 2 minutes, a discharge valve or head gasket is broken.

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y. Removal of Compressor.

(1) Discharge system.

(2) Remove two coolant lines from suction and discharge ports on compressor.

(3) Remove two ¼ in bolts installed through mounting ears of compressor to belt
tensioner.

(4) Remove belt drive.

(5) Remove two ¼ in bolts with lock nuts installed through mounting ears of
compressor-to-compressor mount adapter and remove compressor.

COMPRESSOR ASSEMBLY
Figure 21.02-12

z. Installation of Compressor

(1) Install two ¼ in bolts with lock nuts as removed in paragraph “y” above..

(2) Install drive belt.

(3) Install two ¼ in bolts through mounting ears of compressor to belt tensioner as
removed in paragraph “y” above.

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(4) Adjust belt tension per paragraph “p” above.

(5) Reinstall coolant lines to suction and discharge ports on compressor, use NYLOG
gasket thread sealant #RT201B.

(6) Charge system, refer to “INITIAL CHARGING OF REFRIGERANT” Paragraph 6.

aa. Removal of Compressor Motor.

(1) Remove compressor pallet assy, reference paragraph “m” above.

NOTE: Reference IPC, Paragraph 10 for component identification

(2) Remove exhaust housing, TA05-5.

(3) Remove fan blade assembly TA01-0-19 from motor shaft.

(4) Remove condenser end plate, TA01-0-23.

(5) Remove belt guard, TA01-1.

(6) Remove drive pulley, TA01-0-11 with drive belt TA01-0-16.

(7) Disconnect motor wires from relay TA01-0-7 and ground. Cut white wire motor to
pressure switch.

(8) Remove four AN5 bolts and locknuts securing drive motor TA01-0-4 to pallet.

bb. Installation of Compressor Motor.

(1) Install four AN5 bolts and locknuts securing drive motor TA01-0-4 to pallet.

(2) Connect motor wiring to relay TA01-0-7, and ground. Splice white wire to motor
pressure switch.

(3) Install pulley TA01-0-7 with drive belt TA01-16, inspect pulley key and two set
screws for proper installation and security.

(4) Inspect belt tension, reference paragraph “p” above.

(5) Install belt guard, TA01-1.

(6) Install fan blade assy TA01-0-19 on motor shaft, inspect 2 ea. Set screws for proper
installation and security.

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(7) Install condenser end plate, TA01-0-23.

(8) Install exhaust housing, TA05-5.

(9) Install compressor pallet assy, and charge system, reference Paragraph 6.

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10. Illustrated Parts Catalog.

AIR CONDITIONING SYSTEM

Figure 21.02-13 (1 of 2)

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REF PART NO. PART NAME QTY

1 TA01 COMPRESSOR/CONDENSOR PALLET ASSY 1
TA01-N-20 PALLET SPACER ASSY 1
TA01-2 PALLET MOUNT ANGLE RH 1
TA01-3 PALLET MOUNT ANGLE LH 1
TA01-4 FILLER-PALLET MOUNT ANGLE LH 1
TA01-5 FILLER-PALLET MOUNT ANGLE RH 1
TA07-3 MOUNT-THERMINAL BLOCK 1
2 TA06 HEATER/EVAPORATOR/BLOWER ASSY 1
TA08 COVER/HEATER/EVAPORATOR/BLOWER 1
TA02-1 MOUNT SHIM RH/HT/EVAP/BLOWER 1
TA02-2 MOUNT SHIM LH/HT/EVAP/BLOWER 1
3 TA03-2 DOUBLER 1
TA09-N-100 FITTING 7/8” 1
TA09-N-200 FITTING 5/8” 1
TA09-10 GROMMETT 1
4 TA09-N-600 LINE LOW PRESSURE 1
TA09-N-12 O-RING 2
TA09-N-500 LINE HIGH PRESSURE 1
TA09-N-10 O-RING 1
5 TA09-N-300 LINE LOW PRESSURE 1
TA09-12 O-RING 1
TA09-N-400 LINE HIGH PRESSUREQ 1
TA09-N-12 O-RING 1
6 TA09-7 DRAIN LINE 1
7 TA08-1 BRACE 1
8 TA09-9 DOUBLER 1
TA03-1 DOUBLER-DRAIN 1/8 NPT 1
9 TA08-2-10 DISTRIBUTION COVER LH 1
TA08-2-11 DISTRIBUTION COVER RH 1
TA08-3 BALL LOUVER 8
TA08-6 DISTRIBUTION BOX ASSY LH 1
TA08-5 DISBRIBUTION BOX ASSY RH 1
10 TA13-1 DRAIN PUMP (OPTIONAL) 1

AIR CONDITIONING SYSTEM

Figure 21.02-13 (2 of 2)

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EVAPORATOR ASSEMBLY
Figure 21.02-14 (1 of 2)

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REF PART NO. PART NAME QTY

1 TA06-0-1 FAN/MOTOR ASSEMBLY 1
TA06-0-2 MOTOR 1
2 TA06-0-30 MOTOR MOUNT 1
3 TA06-0-3 RESISTOR 1
4 TA06-0-4 TEMP SENSOR ASSEMBLY 1
TA06-0-5 THERMAL SWITCH 1
TA06-0-6 THERMAL SWITCH 1
TA06-0-7 THERMAL FUSE 1
TA06-0-9 PLATE-TEMP SENSOR 1
5 TA06-0-12 HEATER ELEMENTS 1
6 TA06-0-32 FILTER 1
7 TA06-41 INSULATION 1 yard
8 TA06-N-170 COIL ASSEMBLY-EVAPORATOR 1
TA06-N-171 ADAPTER FITTING 1
9 TA06-N-180 EXPANSION VALVE
10 TA06-0-20 SHROUD ASSEMBLY OUTLET 1
11 TA06-0-21 SUMP 1
12 TA06-0-23 DRAIN NIPPLE 1
13 TA12-22 DEFLECTOR 1
14 TA06-0-24 SHROUD ASSEMBLY INLET 1
15 TA09-N-12 O-RING 1
16 TA06-0-26 COVER-SIDE RH 1
17 TA06-0-27 COVER-SIDE LH 1
18 TA06-0-29 MOUNT PLATE 1
TA06-0-53 SPACER 4
19 TA07-1 TERMINAL BLOCK 1
20 TA07-4 TERMINAL BLOCK 2
TA07-4-1 BRACKET TERMINAL BLOCK 2
21 TA07-3-1 BRACKET RELAY MOUNTING 1
TA07-8 RELAY-LOW BLOWER 1
TA07-9 RELAY-HIGH BLOWER 1
TA07-10 RELAY-MOTOR 1
TA07-11 RELAY-A/C CONTROL 1
22 TA06-0-44 SHROUD ASSY, LEFT 1
TA06-0-45 SHROUD ASSY, RIGHT 1
23 TA06-0-46 SHROUD ASSY, LEFT 1
TA06-0-47 SHROUD ASSY, RIGHT 1
24 TA06-0-48 STOP 2
25 TA06-0-49 THUMB SCREW 1
TA06-0-50 THREADED ROD 1
TA06-0-52 SPACER 1
26 TA09-N-10 O-RING 1
27 TA09-N-11 O-RING 1
EVAPORATOR ASSEMBLY
Figure 21.02-14 (2 of 2)

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CONDENSER ASSEMBLY
Figure 21.02-15 (1 of 3)

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REF PART NO. PART NAME QTY

1 TA01-0-1 PALLET BOARD ASSY 1
2 TA01-0-4 MOTOR 1
3 DELETED
4 TA01-N-50 RECEIVER/DRYER 1
TA01-N-51 RECEIVER/DRYER MOUNT 1
5 TA01-N-80 COMPRESSOR ASSY 1
TA01-N-90 COMPRESSOR 1
6 TA01-N-100 PULLEY ASSY-COMPRESSOR 1
TA01-N-101 KEY ADAPTER ASSY 1
TA01-N-104 PULLEY 1
TA01-N-105 BEARING 1
TA01-N-106 KEY 1
7 TA01-N-60 PRESSURE SWITCH 1
O-RING 1
8 TA01-N-390 POP OFF VALVE 1
O-RING 1
TA01-N-400 FITTING 1
O-RING 1
9 TA01-N-130 COMPRESSOR MOUNT 1
10 TA01-N-150 BUSHING MOUNT 1
11 TA01-N-140 BRACKET ASSY 1
12 TA01-0-11 PULLEY-DRIVE MOTOR 1
13 TA01-0-16 DRIVE BELT 1
14 TA01-N-170 CONDENSER ASSY 1
15 TA01-0-19 FAN ASSEMBLY 1
TA01-0-20 FAN BLADE 1
TA01-0-21 ADAPTER BUSHING-FAN 1
16 TA01N-220 END PLATE 1

CONDENSER ASSEMBLY
Figure 21.02-15 (2 of 3)

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CHAPTER 21 – AIR CONDITIONING
21.02 TECH AIR COCKPIT AIR CONDITIONING SYSTEM (STC ST145CH) (cont’d)

REF PART NO. PART NAME QTY

17 TA01-0-230 END PLATE 1
18 TA01-0-24 FAN DUCT 1
19 TA05-N-50 EXHAUST DUCT 1
20 TA01-0-28 FILTER 1
21 TA01-N-360 STUD 5
TA01-N-370 SPACER 3
AN960-06 WASHER 1
MS21042-6 NUT 1
22 TA01-N-270 SCREEN ASSY 1
23 DELETED
24 DELETED
25 TA01-N-340 LINE 1
DELETED
DELETED
26 TA01-N-350 LINE 1
27 TA01-1 GUARD ASSY 1
28 TA01-0-7 RELAY 1
TA01-0-38 BRACKET 2
*29 TA01-P-343 ADAPTER 1
*30 TA01-P-341 LINE 1
TA09-N-11 O-RING 2
*31 TA01-P-342 LINE 1
TA09-N-11 O-RING 2
32 WIRE ASSY
* Applicable to pallet S/N’s 1076P and up.

CONDENSER ASSEMBLY
Figure 21.02-15 (3 of 3)

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INTENTIONAL
BLANK

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21.03 – AIR CONDITIONING WATER SEPARATOR (70 SERIES)

TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 21.03.1

FIGURES

21.03-1 AIR CONDITIONING WATER SEPARATOR-------------------------------- 21.03.1

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INTENTIONAL
BLANK

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CHAPTER 21 – AIR CONDITIONING
21.03 AIR CONDITIONING WATER SEPARATOR (70 SERIES)

1. The purpose of this section is to provide a more detailed illustrated parts breakdown of the 70
Series Air Conditioning Water Separator than is provided in the DACO DC-8-70 IPC. The
following was extracted from the approved United Airlines DC-8-70 IPC and is applicable to
all DC-8-70 series operated by the Company.

AIR CONDITIONING WATER SEPARATOR

Figure 21.03-1 (1 of 2)

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CHAPTER 21 – AIR CONDITIONING
21.03 AIR CONDITIONING WATER SEPARATOR (70 SERIES)

ITEM PART NUMBER PART NAME QTY

Separator – Cabin Air Conditioning
A 178050-2-1 RF
Water
1 178051-1 Separator Assy 1
1A S8834B1P1 Plate – Identification Attaching Parts 1
2 MS24641-1 Screw 2
3 S8205-1 Label – Flow Direction 1
4 S8165-1 Label – Dir of Gravity 1
5 177555 Bushing Assy – Reducer 1
6 MS28778-8 Packing 1
7 4365-1103S Coupling – Clamp 1
8 S8171-112 Packing 2
9 177208 Shell Assy – Inlet 1
9A 177205 Shell Assy – Outlet 1
Insert
10 MS21208F1-15 3
EAD SCR21600A
11 177205-5 Shell 1
11A 84286-6 Condenser Assy 1
Condenser Assy
14 83237-19-600U 1
EAD SCR82851
17 84287-6-600U Support Assy 1
17E 170254-2 Valve Assy – Bypass 1
18 MS16631-4450 Ring RF
19 170552 Retainer – Packing 1
20 NAS679C08W Nut 3
21 AN960C8 Washer 6
22 NAS5402U10 Screw 3
23 MS28775-110 Packing 3
Pin
24 MS9105-36 1
EAD ER5090
25 85234-2 Shaft Assy 1
26 84042 Poppet 1
27 172468 Spring 1
28 170142-1 Cage 1
29 84287-6 Support Assy RF

AIR CONDITIONING WATER SEPARATOR

Figure 21.03-1 (2 of 2)

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CHAPTER 21 – AIR CONDITIONING

21.04 – DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC)

(STC ST01253CH)
TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 21.04.01
2. PAC CONTROL SYSTEM FUNCTIONS ----------------------------------------- 21.04.03
3. PRIMARY FILTER SYSTEM------------------------------------------------------- 21.04.04
4. PRESSURIZATION CONTROL ---------------------------------------------------- 21.04.05
5. FLOW CONTROL WIRING--------------------------------------------------------- 21.04.06
6. TEMPERATURE CONTROL ------------------------------------------------------- 21.04.10
7. RAM AIR DUCTING ----------------------------------------------------------------- 21.04.25
8. CABIN RAM AIR --------------------------------------------------------------------- 21.04.25
9. BLEED AIR DUCT ------------------------------------------------------------------- 21.04.25
10. HEAT EXCHANGER----------------------------------------------------------------- 21.04.25
11. MIX VALVES ------------------------------------------------------------------------- 21.04.25
12. FLOW CONTROL VALVE---------------------------------------------------------- 21.04.26
13. TURBINE INLET TEMP CONTROL VALVES --------------------------------- 21.04.26
14. BYPASS VALVES -------------------------------------------------------------------- 21.04.26
15. NOSE AIR SCOOP PLUGS---------------------------------------------------------- 21.04.30
16. PNEUMATIC CONTROL------------------------------------------------------------ 21.04.30
17. TORQUE VALUES ------------------------------------------------------------------- 21.04.31
18. ILLUSTRATED PARTS CATALOG----------------------------------------------- 21.04.32

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FIGURES

21.04-1 FLOW CONTROL WIRING------------------------------------------------------ 21.04.07

21.04-2 TEMP CONTROL WIRING ------------------------------------------------------ 21.04.14
21.04-3 DELIVERY AIR/TEMP CONTROL DUCTING ------------------------------ 21.04.27
21.04-4 FLOW CONTROL VALVE SCHEMATIC------------------------------------- 21.04.28
21.04-5 FLOW CONTROL VALVE ASSEMBLY -------------------------------------- 21.04.29
21.04-6 RAM AIR DUCTING -------------------------------------------------------------- 21.04.32
21.04-7 AIR DELIVERY DUCTING ------------------------------------------------------ 21.04.37
21.04-8 TEMP. CONTROL DUCTING --------------------------------------------------- 21.04.44
21.04-9 ACM ASSEMBLY ----------------------------------------------------------------- 21.04.49
21.04-10 FLIGHT ENGINEER’S CONTROLS ------------------------------------------- 21.04.52
21.04-11 NOSE AIR SCOOP PLUGS------------------------------------------------------- 21.04.53
21.04-12 PNEUMATIC CONTROL LINES ----------------------------------------------- 21.04.54

TABLES

21.04-1 TABLE OF TORQUE VALVES ------------------------------------------------- 21.04.31

JOB CARDS

21.04-1 NASI PNEUMATIC AIR CYCLE SYSTEM 3240 LANDING EDDY

CURRENT --------------------------------------------------------------------------- 21.04.55
21.04-2 NASI PNEUMATIC AIR CYCLE SYSTEM MANIFOLD PRESSURE
DECAY CHECK-------------------------------------------------------------------- 21.04.59

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)

NOTE: This section is applicable to all DC8-62 COMBI’s.

1. General

a. Aircraft modified this STC are equipped with two virtually identical NASI cabin cooling
systems located on either side of the aircraft centerline in the areas at the sides of the nose
wheel well. Each system contains a flow control valve, an air cycle cooling turbine of the
“bootstrap” type, one multipass heat exchanger, a water separator, a cooling air amp, two
bypass valves, two mix valves with interchangeable controllers, and a common control
panel.

b. The cooling systems reduce the temperature of the engine bleed air output to whatever is
required to maintain a comfortable cabin temperature. The heat extracted from the cabin
supply air during this process is rejected to cooling air which is taken into the ram air
scoops in the nose of the airplane, passed through the heat exchangers, and then
discharged overboard through fixed exhaust doors on the sides of the airplane. (For
ground operation, the cooling air for the heat exchangers is supplied by the ground air
amp.) Conditioned air from these two systems is ducted together through the main
distribution duct. Approximately fifteen percent of the left system output is routed to the
cockpit through separate ducting. The other eighty-five percent of the left system output
joins with the total output of the right system and is routed to the main cabin. Each
system will respond only to the signals from its respective temperature controller; the left
system will respond to cockpit controller signals and deliver air of the programmed
temperature to both the cockpit and cabin. Since the temperature of this air may not be in
accordance with the requirements of the main cabin, the right system output may be
adjusted to compensate for this existing unbalance.

c. For ground operation, the cooling air for the heat exchangers is supplied by the ground air
amp. GPU or engine bleed air is conditioned through the left heat exchanger, bypassing
the left ACM for increased pre-cooling before cross feeding to the right ACM system
which operates normally when ground ACM is selected.

d. In all operating modes other than “GROUND ACM”. The two cooling systems are
completely independent and normally operate in parallel at partial capacity. In the event
of one system failing or being inoperative, the remaining system is capable of
maintaining below 8,000 feet when the aircraft is at 42,000 feet with only one system
operating. In an emergency, ram air can be used for cabin ventilation. This air is
supplied from the left-hand ram air scoop of the cabin cooling system through a check
valve. Whenever the aircraft engines are operating, the normal source of air for cabin
conditioning and pressurization will be engine compressor bleed. For normal operation,
all engines will be bled with the crossover valve closed so that each pack is fed by the
engines on the adjacent wing.

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(cont’d)

e. Each air conditioner pack has a flow control valve located in the nose just forward of the
pressure bulkhead. The valve is spring-loaded closed and serves as a pack shutoff valve
in addition to its flow control function. The flow control valves are activated by the left
and right flow control valve switches located in the temp control panel on the flight
engineers panel. The flow control valve regulates air flow at all times when the system
bleed air pressure is about 10 psi ± 2 psi; below this pressure the valve automatically
closes. The flow control valve is equipped with a variable needle valve to reduce surging
during high flow control demand.

f. Engine bleed air provided by the main engines or GPU is routed through the flow control
valve to the inlet of the primary side of the heat exchanger and to the “hot” temperature
control valve in the inlet end of the cabin air delivery duct. The mix valve permits the
mixing of “hot”, “intermediate”, and “cold” temperature airflows to obtain the desired
temperature for cabin or cockpit temperature control. The following description will
trace the airflow through the air conditioning system.

(1) During full “cold” operation, all bleed air is routed through the primary section of
the heat exchanger where temperature reduction occurs by heat transfer to the ram
or air amp cooling air. (Primary and secondary heat exchanger cooling airflow is
provided by a pack cooling air amp for all ground operations. In normal flight,
cooling airflow is supplied by ram air.) The bleed air is ducted from the primary
section of the heat exchanger exit to the inlet of the compressor section of the air
cycle machine. In the compressor section of the ACM, both the pressure and
temperature of the air are increased. The air then passes through the secondary
section of the heat exchanger where ram or air amp air provides a heat sink for
cooling in the same way as in the primary heat exchanger. The higher-pressure air
is then greatly expanded as it passes through the turbine end of the ACM, resulting
in an appreciable temperature drop. The heat energy, converted by the turbine
wheel to mechanical energy, is transmitted through the turbine shaft to drive the
compressor wheel. The cold air then passes through the water separator where
excess moisture is removed and then into the ducting leading into the “cold” port of
the cabin air delivery duct.

g. The cabin mix valves for the left and right packs are controlled by the cockpit and main
cabin temperature control systems, which have provisions for both “Auto” and “Manual”
modes of operation. Their mix valves will modulate to allow “hot” air direct from the
bleed air control system to mix with “cold” air that has passed through the primary
section heat exchanger, compressor, secondary section heat exchanger, turbine and water
separator, or with bypass air from primary and secondary sections of the heat exchanger
whenever ACM bypass is selected for all operation below +4° C RAT. The position of
the temperature control valve butterfly will be whatever may be required to satisfy the
temperature requirements of the cabin air delivery duct.

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(cont’d)

h. During a high cooling demand, the bleed air passes through the cooling turbine and the
reduction in temperature may be sufficient to cause the air temperature to drop below the
local dew point. In this event, the water vapor in the bleed air will condense into fog,
water, or ice, depending on the water content of the air and the turbine discharge
temperature. The condensing of water vapor under such conditions is unavoidable;
therefore, provisions must be made to remove free water from the cabin air. A system is
also required to prevent the newly condensed water from freezing at the very low
temperatures present in the turbine discharge. The water separator in each pack is located
downstream of the cooling turbine in the cold air duct. Moisture laden cold air is ducted
into the water separator and passed inward through a conical woven Dacron bag
supported by an aluminum grillwork structure. Water droplets collect on the bag as the
air follows through it. The aluminum grillwork structure causes the air to swirl and the
centrifugal action causes the water to separate from the air. The water is then collected
and drained overboard through a drain line. To prevent icing of the water separator bag,
a thermister type sensor is located so that it senses the temperature of the air as it leaves
the water separator. This sensor provides temperature information to the 35° F control
system. The electronic control system prevents the temperature from dropping below 35°
F by causing the mix valve to modulate open. When the mix valve opens, hot bleed air is
mixed with the cold air from the turbine at the turbine discharge. The mixed air then
passes through the water separator at a minimum temperature of 35° F.

CAUTION: WHEN THE TEMP CONTROL IS IN THE “MANUAL” OR “OFF” POSITIONS

THE FLIGHT ENGINEER MUST MONITOR THE DELIVERY DUCT
TEMPERATURE TO PREVENT ICING OF THE WATER SEPARATOR WHEN
THE ACM IS ON.

2. PAC Control System Functions

a. Each air conditioning pack system is equipped with an identical ACM control system
consisting of:

(1) A compressor bypass valve and turbine bypass valve.

(2) A compressor outlet temperature transmitter with indicator and an over temp pack
shutoff thermal safety switch located downstream of the compressor outlet.
(3) A turbine inlet temperature transmitter with indicator and an over temp pack shutoff
thermal safety switch located upstream of the turbine inlet.
(4) A turbine inlet temperature transmitter and controller with a turbine inlet temp
control valve which limits turbine inlet temperature at 93° C or less.
(5) A water separator outlet temperature transmitter located just downstream of the
water separator with a 35° F temp control system, which trims hot bleed air into the
front of the water separator to maintain a minimum water separator outlet
temperature of 35° F.

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(cont’d)

(6) A delivery duct temperature transmitter with indicator and an over temp pack
shutoff thermal safety switch located just downstream of the water separator in the
cabin air delivery duct, and a delivery duct temperature transmitter and controller
with delivery duct temp control mix valve.

(a) The delivery duct temperature controller is the only temp controller which has
either a variable temperature range of +2° C to 80° C when the temp control
switch selection is “AUTO” and the temp control rheostats are used to select a
desired delivery duct temperature or temp control bypass to drive the mix
valve to a desired delivery duct temperature manually when the temp control
switch selection is “Manual”.

b. Also, the PAC system is equipped with air amplifiers, which use bleed air to induce ram
air in through the chin scoops to cool the heat exchangers on the ground. The air amp
shutoff valve is automatically open whenever the PAC system is operated on the ground
and automatically closed through the ground shift relay when the aircraft is airborne.

c. The PAC control panel is equipped with PAC on/off switches, compressor and turbine
“BYPASS VALVES”, open-closed LED indicator, “TURBINE INLET”, closed LED
indicator, and “DUCT”, “CABIN”, “TURBINE,” and “COMP” temperature indicator
selectors for which the temperature of the corresponding selection may be read on the
temperature indicator directly below the selector switch.

3. Primary Filter System

a. The primary cabin air filter was developed for the cabin air cycle systems of today. All
large transport aircraft currently manufactured use engine bleed systems for cabin air
source. These bleed air systems may become contaminated with odors by improper
service, poor ground equipment, high time APU’s, or high time on some jet engines.
Both main filters contain three cartridges each charged with .33 cu/ft of CW29-0-109 gas
filtration media with a foam filter for post media filtration. A Nomex filter sock is
installed in the main filter outlet duct as the second post media filtration filter.

b. The Nomex filter sock is machine washable and is easily extracted from the filter outlet
duct with the removal of one worm gear clamp. The filtration cartridges and foam filter
are serviced as follows:

(1) Remove the AN3-4A bolts securing the filter housing door, swing the door open on
its hinge, and remove the foam filter and three filter cartridges.
(2) Clean foam filter by rinsing with water then air dry.
(3) Recharge filter cartridges by removing the screw from the filter hold cover in the
side of each cartridge, empty spent filter media, and refill each cartridge with .33
cu/ft CW29-0-109 gas filtration media.

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(cont’d)

(4) Reinstall foam filter and three recharged filter cartridges, close filter housing door,
and reinstall the AN3-4A bolts (16 pl).

c. The primary cabin air filter system consists of two identical systems that operate in
parallel. The left filter system normally provides filtered cabin air to the flight
compartment, while the right system filters the main cabin air. However about 26 percent
of the filtered air supplied by the left system is utilized by the flight compartment, while
the remaining 75 percent is dumped in the main cabin. Although the left and right
systems are independent, they both connect to a common cabin delivery duct where the
air will mix. Therefore one spent filter left or right will result in unfiltered air delivered
to the flight compartment and the main cabin.

d. The filter maintenance schedule (service during “B” Check) must be maintained to
achieve the design requirements of system dust and odor removal. The schedule may be
shortened if recommended by in-service experience. The filter service schedule should
not be extended by more than 100 hours.

4. Pressurization Control – The flow control valve regulates engine bleed airflow to the
environmental control system for cabin pressurization and ventilation. The flow control
valve is equipped with a variable needle valve to reduce surging during high flow demand.

FLOW/PRESSURIZATION TROUBLESHOOTING CHART

TROUBLE PROBABLE CAUSE REMARKS
NO FLOW THROUGH FLOW FLOW CONTROL VALVE MANUALLY OPERATE
CONTROL VALVE (OPERATE SHUT OFF ELECTRIC SOLENOID CONTROL TO
PNEUMATIC WINDSHIELD SOLENOID INOP VERIFY. REPAIR AS REQUIRED
RAIN REMOVAL TO VERIFY PLUGGED UPSTREAM CLEAN UPSTREAM SENSING
PNEUMATIC PRESSURE TO SENSING PORT LINE PORT LINE
FWD. MANIFOLD) SENSING PORT LOOSE OR SENSING PORT REPAIR-
BROKEN TIGHTEN
FLOW CONTROL VALVE REPLACE FLOW CONTROL
UNSERVICABLE VALVE
FLOW CONTROL VALVE WILL ELECTRIC SOLENOID NOT SHUT FLOW CONTROL VALVE
NOT SHUT OFF OPERATING OFF WITH MANUAL CONTROL.
A TEST FOR 28 VDC AT
ELECTRIC CONNECTOR PER
ELECTRICAL DIAGRAM WHEN
OPERATING F/C ON-OFF
SWITCH
PRESSURIZATION SURGES DOWNSTREAM SENSING OPEN FLOW CONTROL RATE
PORT PRESSURE SURGING KNOB TO FULL INCREASE
(COUNTER CLOCKWISE)

LOUD HIGH RPM NOISE COOLING TURBINE GROUND RUN SYSTEM TO

BEARINGS VERIFY. REPLACE COOLING
TURBINE

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21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

FLOW/PRESSURIZATION TROUBLESHOOTING CHART (continued)

LOUD JACKHAMMERING WATER SERERATOR ICING VERIFY 35° F VALVE
WHEN ACM IS ON OPERATION (DELIVERY DUCT
TEMP MUST BE 35° F OR
WARMER WHEN RELATED
ACM IS ON)

LOUD CHATTERING NOISE FAULTY CHECK VALVE IN INSPECT SYSTEM CHECK

WITH ACM OFF OR ON RAM AIR OR CABIN AIR VALUES
DELIVERY DUCT

5. Flow Control Wiring – The flow control wiring figures which follow are for reference only.
Refer to the aircraft wiring diagram manual for maintenance.

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

FLOW CONTROL WIRING – LH Flow Control Valve

Figure 21.04-1 (1 of 3)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

FLOW CONTROL WIRING – RH Flow Control Valve

Figure 21.04-1 (2 of 3)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

FLOW CONTROL WIRING – Starter/Ignition Jumper

Figure 21.04-1 (3 of 3)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)
6. Temperature Control
a. The temperature control has two identical systems located on either side of the aircraft
centerline for the left and right ACM packs with the controller in the lower center of the
flight engineer’s panel. The temp control panel incorporates a left and right of the
following:

(1) Flow control valve (pack) shutoff switches with open/closed LED indicator.
(2) Flow rate control knobs to adjust the airflow into the cabin from 100% mass air
flow at full increase to 60% at full decrease.
(3) Temp control AUTO/MANUAL select switches with three-position (“WARM”,
“OFF,” and “COLD”) manual temp control switches. (The manual “COLD” and
“OFF” positions are maintained, while the “WARM” position is momentary to
prevent inadvertent duct over temp.)
(4) Max Warm and Cold mix valve position LED indicators.
(5) Cabin air delivery duct temp indicator. (The cockpit and cabin temp rheostats are
located above the ACM control panel and have a range of +2° C to +80° C delivery
duct temperature.)

b. Operating the Auto Temp Control

(1) Select the “AUTO” position with the LH (cockpit) and RH (cabin) temp control
switches.
(2) Select desired delivery duct temperature with cockpit and cabin rheostats.
(3) Occasionally monitor FWD (LH) and AFT (RH) cabin temp indicators for desired
temperatures.

c. Operating Manual Temp Controls

(1) Select the “MANUAL” position with the LH (cockpit) and RH (cabin) temp control
switches.
(2) Monitor LH and RH delivery duct temperature while holding the respective manual
temp control switch in desired direction (“WARM” or “COLD”) for 10 seconds at a
time. Wait for duct temperature to stabilize between temperature adjustments
(about 30 seconds).
(3) Occasionally monitor FWD (LH) and AFT (RH) cabin temp indicator for desired
temperatures.

d. Temperature Control System Mode Functions

(1) The NASI PAC System is designed to function in two modes of operation which
correspond with ram air temperature in two ranges:
(a) +5° C and Lower “bypass” mode.
(b) +5° C and Higher “ACM” mode.

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(cont’d)

(2) In the “bypass” mode (ACM switch “OFF”), the compressor and turbine bypass
valves open and the ACM inlet valves close, routing bleed air thru the primary and
secondary sections of the heat exchanger. From the heat exchanger, the cooled air is
routed to the cabin air delivery duct where the mix valve will trim additional hot air
in as required by the temp control setting. Delivery duct or cabin temperature is
monitored by positioning the ACM indicator selector knob to “DUCT” or “CABIN”
respectively. “TURBINE” and “COMP” positions are not monitored in “bypass”
mode. In the “ACM” mode (ACM switch “ON”), the compressor and turbine
bypass valves close routing bleed air through the ACM and associated components
to cool the air to a nominal +2° C when entering the water separator. The mix valve
will trim hot air in if required by the temp control setting. Delivery duct, cabin air,
turbine inlet, and compressor outlet temperatures are monitored by positioning the
ACM indicator selector knob to “DUCT”, “CABIN”, “TURBINE”, or “COMP”
respectively.
(3) When the “AUTO” position is selected with the temp control switch, the delivery
duct temperature range is +2° C to +80° C. When the “Manual” position is selected
with the temp control switch, the delivery duct temperature range must be regulated
by the flight engineer as follows:

(a) With ACM “ON” +2° C lower limit, +80° C upper limit.
(b) With ACM “OFF” on lower limit, +80° C upper limit.

NOTE: With ACM “ON”, if delivery duct temp is below +2° C, the water
separator will freeze and pressurization may be restricted.

e. Temp Diverter Valve

(1) General – The Temp Diverter Valve is installed in the cabin air delivery system
allowing unrestricted airflow to the RH and LH cabin air systems when in the
“NORMAL” position. LH cabin airflow is restricted to the cockpit when the Temp
Diverter Valve is actuated, forcing the RH cabin airflow into the cockpit air delivery
ducts.
(2) Operating the Temp Diverter Valve – The Temp Diverter Valve must be actuated
from its normal position when flight operations are maintained with the RH ACM
(flow control) system only or when RH (cabin temp control) temp control is used
for cockpit temp control. To operate the Temp Diverter Valve, lift guard on switch
and actuate temp diverter switch. Push switch guard down to place temp diverter in
“NORMAL” position.

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMPERATURE CONTROL SYSTEM

TROUBLESHOOTING CHART
TROUBLE PROBABLE CAUSE REMARKS
TURBINE INLET TEMP HIGH TURBINE INLET CONTROL PERFORM OPERATIONAL
(OVER 100° C) VALVE FAULTY CHECK ON CONTROL VALVE
TURBINE INLET VALVE SWAP TURBINE INLET
CONTROLLER CONTROLLER WITH CABIN
TEMP CONTROLLER AND
PERFORM CABIN TEMP
CONTROL TEST ON
SUSPECTED FAULTY
CONTROLLER
TURBINE INLET VALVE SWAP CONNECTORS AT TEMP
CONTROL TEMP PROBE PROBE (TURBINE INLET
CONTROL FOR TURBINE INLET
INDICATOR CONNECTOR)

COMPRESSOR OUTLET TEMP TURBINE INLET TEMP TOO PERFORM OPERATIONAL

TOO HIGH (OVER 190° C) HIGH (OVER 100° C) CHECK ON TURBINE INLET
CONTROL VALUE
TURBINE INLET VALVE SWAP TURBINE INLET
CONTROLLER (IF TURBINE CONTROLLER WITH CABIN
INLET TEMP IS OVER 100° C) TEMP CONTROLLER AND
PERFORM CABIN TEMP
CONTROL TEST ON
SUSPECTED FAULTY
CONTROLLER
TURBINE INLET VALVE SWAP CONNECTORS AT TEMP
CONTROL TEMP PROBE PROBE (TURBINE INLET
INLET CONTROL (IF TURBINE CONTROL FOR TURBINE INLET
INLET TEMP IS OVER 100° C) INDICATOR CONNECTOR)
COMPRESSOR OUTLET TEMP SWAP LEFT AND RIGHT
INDICATOR PROBE COMPRESSOR TEMP
INDICATOR PROBES

TEMP CONTROL INOP NO POWER TO CIRCUIT CHECK CIRCUIT BREAKER.

MANUAL & AUTO CHECK FOR 28 VDC AT FLOW
CONTROL PANEL

TEMP CONTROL WILL NOT MANIFOLD TEMP TO LOW INCREASE FLOW ON FLOW
HEAD WHEN COLD OAT (BELOW 120° C) CONTROL VALVE

AUTO TEMP CONTROL INOP. MIX VALVE TEMP SWAP MIX VALVE TEMP
MANUAL TEMP CONTROL OK CONTROLLER CONTROLLERS. SEE IF
UNSERVICEABLE CONDITION FOLLOWS
TEMP PROBE SWAP TEMP CONTROL TEMP
UNSERVICEABLE PROBE WITH DUCT TEMP
INDICATOR OR TEMP PROBE
TEMP CONTROL RHEOSTAT TEST RESISTANCE VALVES OF
UNSERVICEABLE TEMP CONTROL RHEOSTAT (0-
5 OHM)

21.04.12 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMPERATURE CONTROL SYSTEM

TROUBLESHOOTING CHART (continued)
TROUBLE PROBABLE CAUSE REMARKS
AUTO TEMP CONTROL WILL MIX VALVE TEMP SWAP MIX VALVE TEMP
NOT COOL BUT HEATS OK. CONTROLLER CONTROLLERS. SEE IF
MANUAL TEMP CONTROL OK UNSERVICEABLE CONDITION FOLLOWS

TEMP CONTROL WILL NOT 4” HOT MIX VALVE REMAINS OPERATE MANUALLY ON
COOL OPEN GROUND. IF VALVE WILL NOT
CLOSE, SWAP 4” HOT MIX
VALVES. SEE IF CONDITION
FOLLOWS
OAT TOO WARM OPERATE AT COOLER OAT
OR HIGHER ALT

TEMP CONTROL WILL NOT HEAT EXCHANGER CORE CLEAN HEAT EXCHANGER
COOL WITH COLD OAT PLUGGED CORE

PAC SYSTEM OFF SYSTEM OVERTEMP CHECK AND RECORD

AUTOMATICALLY (FLOW CONDITION INDICATOR TEMP WHEN
CONTROL VALVE CLOSED SHUTDOWN OCCURS.
LIGHT ILLUMINATES) TURBINE INLET MUST BE
UNDER 116° C. COMPRESSOR
OUTLET MUST BE UNDER 193°
C. DELIVERY DUCT MUST BE
UNDER 100° C.

f. Temperature Control Wiring - The temp control wiring figures which follow are for
reference only. Refer to the aircraft wiring diagram manual for maintenance.

Revision 12 06-01-01 21.04.13

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – LH Overtemp Control

Figure 21.04-2 (1 of 12)

21.04.14 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – RH Overtemp Control

Figure 21.04-2 (2 of 12)

Revision 12 06-01-01 21.04.15

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – LH Air Cycle Machine

Figure 21.04-2 (3 of 12)

21.04.16 06-01-01 Revision 12

AIR TRANSPORT INTERNATIONAL
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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – Cockpit Temp Control

Figure 21.04-2 (4 of 12)

Revision 12 06-01-01 21.04.17

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – LH ACM & Cabin Temp Indicator

Figure 21.04-2 (5 of 12)

21.04.18 10-22-01 Revision 13

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – RH Air Cycle Machine

Figure 21.04-2 (6 of 12)

Revision 12 06-01-01 21.04.19

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – Cabin Temp Control

Figure 21.04-2 (7 of 12)

21.04.20 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – RH ACM & Cabin Temp Indicator

Figure 21.04-2 (8 of 12)

Revision 13 10-22-01 21.04.21

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – Ground Cabin Temp Control

Figure 21.04-2 (9 of 12)

21.04.22 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – Recirc Fan Jumper

Figure 21.04-2 (10 of 12)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP CONTROL WIRING – Mix Valve Jumper

Figure 21.04-2 (11 of 12)

TEMP CONTROL WIRING – CTC Removal Jumper

Figure 21.04-2 (12 of 12)

21.04.24 06-01-01 Revision 12

AIR TRANSPORT INTERNATIONAL
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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

7. Ram Air Ducting - The ram air ducting is a 10” diameter welded aluminum tubing connected
with 10” diameter silicone rubber impregnated Nomex couplers. The ram air ducting is
connected from the chin scoops to the heat exchangers. A 3” aluminum cabin ram air duct is
connected to the aft section of the left side ram air duct. HI torque worm gear clamps are
used to secure all ram air ducting in place and on 10” diameter couplers. All HI torque worm
gear clamps installed have drilled screw heads and must be safe tied with stainless steel lock
wire. All clamps must be torqued as specified in Table 21.04-1.

8. Cabin Ram Air – Cabin altitude of 8,000 feet ASL or less must be maintained. Both flow
control valves must be shutoff with cabin unpressurized and outflow valve open. Ram
airflow into the cabin will stop when outflow valve is closed.

9. Bleed Air Duct - The bleed air duct used in the PAC System is 2 ½”, 3”, 3 ½”, 4”, and 4 ½”-
diameter stainless steel tubing with 2 ½”, 3”, 3 ½”, 4”, and 4 ½” I.D. Impregnated Nomex
Silicone-Rubber couplers connecting sections of ducting and allowing for thermal expansion
and contraction. “T” bolt clamps are used to secure all silicone rubber couplers. Aeroquip
flanges and “V” band couplings are used whenever the PAC System is connected to existing
ducting; also on all connections to mix and flow control valves. “V” band clamps are used
on all Aeroquip flanges. Stand off brackets fastened to frames are used to clamp the PAC
System ducting in place. HI torque worm gear clamps are used to secure all of the PAC
System ducting in place; all HI torque worm gear clamps installed have drilled screw heads
and must be safe tied with stainless steel lock wire. All clamps must be torqued as specified
in Table 21.04-1.

10. Heat Exchanger - The heat exchanger is a high efficiency air-to-air type all aluminum
construction. The existing ram air exhaust doors, located just AFT the heat exchangers, are
secured in a fixed position to provide optimum airflow across the heat exchangers.

11. Mix Valves - The mix valves are 4” butterfly type 28 VDC servo drive. The operating time
from open to close is approximately 90 seconds, and close to open is approximately 90
seconds. These valves are used to trim in hot bleed air as required by temp control setting to
mix with the ACM or RAM air cooled bleed air for accurate cabin and cockpit delivery duct
temperatures. (For mix valve control, reference paragraph 5. “Temperature Control”.)

Revision 12 06-01-01 21.04.25

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

12. Flow Control Valve - This unit is a normally closed flow control and shutoff valve.

a. Shut Off Operation - Butterfly shutoff operation is accomplished with the latching
solenoid energized to latch the solenoid ball on the inlet pressure port, thus closing off the
actuator air supply and venting the actuator. The actuator spring will then torque the
butterfly to the closed position.

b. Flow Control Operation - When the latching solenoid is energized to latch the ball on the
actuator vent seat and open the actuator supply pressure port, the control orifice and
actuator will be supplied with control air pressure for airflow control operation. This
control air supply pressure is supplied from an inlet upstream pressure tap and is
regulated to a desired value by the pilot pressure regulator. Control air then passes
through the control orifice and builds up pressure in the actuator chamber, moving the
butterfly toward the open position.

c. Indicator Switch - An indicator switch is provided to indicate butterfly-closed position

and is actuated by the butterfly bell crank.

d. On/Off Solenoid-Manual Control - The latch type solenoid is provided with a manual
control on the end of the solenoid.

e. Flow Limiter – A pressure override feature is provided by the flow limiter to limit
downstream pressure to an acceptable value. If downstream pressure exceeds this value,
the override opens admitting pressure to the actuator closing side. The valve will then
modulate to limit downstream pressure.

13. Turbine Inlet Temp Control Valves – The Turbine Inlet Control Valves are 3” butterfly type
28 VDC servo drive. The operating time from open to close is approximately 90 seconds,
and close to open is approximately 90 seconds. These valves are used to reduce compressor
airflow output, which in turn reduces the airflow to the turbine inlet, allowing increased
cooling time by the turbine inlet heat exchanger and controlling the turbine inlet temperature.

14. Bypass Valves – The Bypass Valves are 3” butterfly type 28 VDC servo drive. The
operating time from open to close is approximately 5-10 seconds, and close to open is
approximately 5-10 seconds. These valves are used to direct bleed airflow around the PAC
system and through the heat exchangers for all cabin and cockpit air delivery whenever ram
air temperatures are below 4° C and PAC system is shutoff.

21.04.26 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

DELIVERY AIR/TEMP CONTROL DUCTING

Figure 21.04-3

Revision 12 06-01-01 21.04.27

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

FLOW CONTROL VALVE SCHEMATIC

Figure 21.04-4

21.04.28 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

FLOW CONTROL VALVE ASSEMBLY

Figure 21.04-5

Revision 12 06-01-01 21.04.29

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

15. Nose Air Scoop Plugs.

a. The new flow control system design eliminates the use of the turbo compressor inlet
ducts, but the plugs must be heated to preclude ice build up on the nose. For this reason
the heated bleed air also has been diverted inside the air scoop plug as follows:

(1) The turbo compressor inlet ducts are designed with low-pressure pneumatic bleed
air anti-ice. The ducts are double walled aluminum with an air space between the
layers. This air space is heated with low-pressure pneumatic bleed air, which enters
near the front, flows through the air space between the layers, and enters the center
of the duct near the aft end, which has been capped off. The heated air then fills the
closed air space heating the air scoops plugs in front and exiting through the 1 ¼”
hole (previously inlet to recirculation valve). This hole must not be plugged or
obstructed.

16. Pneumatic Control.

a. The PAC System is designed to pneumatically control the mass air output of the flow
control valve to reduce surging.

b. The pneumatic control lines connect to the downstream sensing ports on the flow control
valves. From there aluminum pneumatic control lines are routed aft through the RH nose
tunnel area and up through the floor pressure panel beneath the flight engineers station.
From the floor pressure panel up to the flow control panel (in the flight engineers panel)
the control lines are ¼ I.D. flexible hose. The flexible hose control lines connect to the
outlet side of a needle valve, which is controlled by rotating the flow control knob. When
the aircraft is pressurized, the flow control knob may be rotated counter-clockwise. This
will decrease pressure from the venturi sensing port to the venturi delta P control servo,
which drives the butterfly valve open and increases the mass air flow into the aircraft.

c. When the needle valve is closed by rotating the flow control knob clockwise, the pressure
through the control line to the venturi sensing port line is increased, reducing the venturi
sensing port pressure to the delta P control servo which drives the butterfly valve closed
and reduces mass airflow to the aircraft.

21.04.30 12-03-01 Revision 14

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

17. Torque Values. All Torque values are given in inch pounds.

NOMINAL TUBE ITEM MIN MAX

O.D. (in.)
1/4 B-Nut 70 120
5/16 6061-T6 Tubing
AN3 Bolts with 30 35
MS21042-3 Nuts
Worm Gear Clamps 25 30
5/8 Width
T-Bolt Clamps
5/8 Width
NEW 30 40
IN-SERVICE 30 35

I.D. (in.) V-BAND CLAMPS

MIN MAX
2.25 39 41
3.00 49 51
3.50 49 51
4.00 49 51
4.50 39 41
5.00 59 61

TABLE OF TORQUE VALUES

Table 21.04-1

Revision 14 12-03-01 21.04.31

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

18. Illustrated Parts Catalog.

RAM AIR DUCTING – LH Ram Air Ducting

Figure 21.04-6 (1 of 5)

21.04.32 12-03-01 Revision 14

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

RAM AIR DUCTING – Top View Ram Air Ducting

Figure 21.04-6 (2 of 5)

Revision 12 06-01-01 21.04.33

AIR TRANSPORT INTERNATIONAL
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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

RAM AIR DUCTING – RH Ram Air Ducting

Figure 21.04-6 (3 of 5)

21.04.34 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

1 CW06-11-1 COUPLING 1
SS12283 CLAMP 2
2 CW06-11-1 COUPLING 1
SS12283 CLAMP 2
3 PS05-121-1 DUCTING 1
4 SS12283 CLAMP 1
5 PS05-151-1 DUCTING 1
6 CW06-11-1 COUPLING 1
SS12283 CLAMP 2
7 SS12283 CLAMP 1
8 PS05-171-1 DUCTING 1
9 AN3-4A BOLTS 12
AN960PD-10 WASHERS 24
MS21042-3 NUTS 12
10 PS05-191-1 DUCTING 1
11 CW07-25-225 CLAMP 2
12 SS12038 CLAMP 2
13 AN3-4A BOLTS 12
AN960PD-10 WASHERS 24
MS21042-3 NUTS 12
14 PS10-17-1 DUCTING 1
15 AN3-4A BOLTS 26
AN960PD-10 WASHERS 26
16 PS05-32-1 DUCTING 1
CW08-7-31 1
AN3-4A BOLTS 2
AN960PD-10 WASHERS 2
17 CW07-31-1 COUPLING 1
C310N-62-0322-S2 CLAMP 1
18 PS05-311-1 DUCTING 1
19 FLX5500-100 HOSE 1
20 PS13-7-1 AIR AMP S/O VALVE 1
PS07-91-1 ADAPTER 1
21 CW07-31-1 COUPLING 1
C310N-62-0322-S2 CLAMP 2
22 FLX5500-100 HOSE -
SS12038 CLAMPS -

RAM AIR DUCTING

Figure 21.04-6 (4 of 5)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

23 CW18-3-1 1
24 CW18-1-1 1
25 CW02-3 (LH) 1
CW02-4 (RH) 1
26 CW18-3-3 1
27 CW18-1-1 1
28 CW02-1 (LH) 1
CW02-2 (RH) 1
29 FLX5500-100 HOSE 1
30 AN3-4A BOLTS 26
AN960PD-10 WASHERS 26
31 PS10-17-1 DUCTING 1
32 AN3-4A BOLTS 12
AN960PD-10 WASHERS 24
MS21042-3 NUTS 12
33 CW07-25-225 CLAMP 2
34 PS13-7-1 AIR AMP S/O VALVE 1
PS07-91-1 ADAPTER 1
35 SS12038 CLAMP 2
36 PS05-171-2 DUCTING 1
37 SS12283 CLAMP 1
38 CW06-11-1 COUPLING 1
SS12283 CLAMP 2
39 PS05-151-2 DUCTING 1
40 SS12283 CLAMP 1
41 PS05-121-2 DUCTING 1
42 CW06-11-1 COUPLING 1
SS12283 CLAMP 2
43 CW06-11-1 COUPLING 1
SS12283 CLAMP 2
44 AN3-4A BOLTS 12
AN960PD-10 WASHERS 24
MS21042-3 NUTS 12
45 PS05-191-2 DUCTING 1

RAM AIR DUCTING

Figure 21.04-6 (5 of 5)

21.04.36 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

AIR DELIVERY DUCTING – LH Air Delivery Ducting

Figure 21.04-7 (1 of 7)

Revision 12 06-01-01 21.04.37

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

AIR DELIVERY DUCTING – Top View Air Delivery Ducting

Figure 21.04-7 (2 of 7)

21.04.38 06-01-01 Revision 12

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

AIR DELIVERY DUCTING – RH Air Delivery Ducting

Figure 21.04-7 (3 of 7)

Revision 12 06-01-01 21.04.39

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

1 PS07-511-1 DUCTING 1
2 SS12112 CLAMP 1
3 CW07-33-1 COUPLING 1
C310N-62-0425-S2 CLAMP 4
4 PS07-501-1 DUCTING 1
5 CW07-25-400 CLAMP 1
6 SS12120 CLAMP 1
7 CW07-25-450 CLAMP 2
8 SS12112 CLAMP 1
9 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
10 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
11 SS12075 CLAMP 1
12 PS07-361-1 DUCTING 1
13 SS12075 CLAMP 1
14 PS07-331-1 DUCTING 1
15 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
16 PS31-2-4.5 COUPLING 1
C310N-62-0485-S2 CLAMP 4
17 SS12075 CLAMP 1
18 PS07-341-1 DUCTING 1
19 PS07-351-1 DUCTING 1
20 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
21 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
22 PS37-1-6 CLAMP 1
23 CW12-5 DUCT OVER TEMP SWITCH 1
24 AN3-5A BOLT 1
AN960PD-10 WASHER 1
MS21042-3 NUT 1
25 PS08-11-1 DUCTING 1
26 CW15-7 TEMP PROBE 2
27 180-601040G0140 HOSE 1
28 AN919-11D 1
AS3582-018 1
AIR DELIVERY DUCTING
Figure 21.04-7 (4 of 7)

21.04.40 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

29 PS10-51-1 DUCTING 1
30 CW07-25-450 CLAMP 1
31 PS07-491-1 DUCTING 1
32 PS31-2-3.5-4 COUPLING 1
C310N-62-0485-S2 CLAMP 2
C320N-62-0375-S2 CLAMP 2
33 PS07-481-1 DUCTING 1
34 PS31-1-3.5-4 COUPLING 1
C310N-62-0425-S2 CLAMP 2
C310N-62-0375-S2 CLAMP 2
35 SS12112 CLAMP 1
36 CW07-25-300 CLAMP 1
37 PS07-471-1 DUCTING 1
38 PS13-1-3 (U1-NAS-17) VALVE 1
CW07-25-400 CLAMP 2
39 PS07-461-1 DUCTING 1
40 CW07-25-400 CLAMP 1
41 PS07-321-1 DUCTING 1
42 PS07-311-1 DUCTING 1
43 PS13-4-2 (U1-NAS-1) VALVE 1
44 CW07-25-450 CLAMP 1
45 CW07-23-1 REDUCER 1
46 CW07-25-400 CLAMP 1
47 CW07-2-21 ADAPTER 2
CW07-25-300 CLAMP 2
48 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 1
49 PS097-442-1 DUCTING 1
50 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 1
51 PS07-432-1 DUCTING 1
52 PS37-1-2.5 CLAMP 1
53 SS12075 CLAMP 1
54 SUPPORT BRACKET 1
55 PS07-451-1 ADAPTER 1
56 PS13-1-7 (U1-NAS-19) VALVE 1
CW07-25-400 CLAMP 2
57 AN816-5D WASHER 1
AIR DELIVERY DUCTING
Figure 21.04-7 (5 of 7)

Revision 12 06-01-01 21.04.41

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

58 MS20425AD3-X RIVET 23
59 TA09-9 1
60 TA03-1 1
61 PS31-2-3.5-4 COUPLING 1
C310N-62-0425-S2 CLAMP 2
C310N-62-0375-S2 CLAMP 2
62 PS21-2-4.5 COUPLING 1
C310N-62-0485-S2 CLAMP 4
63 PS07-492-1 DUCTING 1
64 CW07-25-450 CLAMP 1
65 PS10-51-1 WATER SEPERATOR 1
66 180-601040G0140 HOSE 1
67 AN919-11D 1
AS3582-018 1
68 PS37-1-6 CLAMP 1
69 CW15-7 TEMP PROBE 2
70 PS08-11-1 1
71 AN3-5A BOLTS -
AN960PD-10 WASHERS -
MS21042-3 NUTS -
72 CW12-5 DUCT OVER TEMP SWITCH 1
73 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
74 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
75 PS07-351-1 DUCTING 1
76 PS07-341-1 DUCTING 1
77 SS12075 CLAMP 1
78 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
79 SS12075 CLAMP 1
80 PS07-331-1 DUCTING 1
81 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
82 SS12075 CLAMP 1
83 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP (BEHIND DUCT) 1

AIR DELIVERY DUCTING

Figure 21.04-7 (6 of 7)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

84 PS07-361-1 DUCTING 1
CW07-25-300 CLAMP 1
85 SS12120 CLAMP 1
86 CW07-25-450 CLAMP 1
87 CW07-25-450 CLAMP 1
88 CW07-25-400 CLAMP 1
89 PS07-502-1 DUCTING 1
90 CW07-33-1 COUPLING 1
C310N-62-0425-S2 CLAMP 4
91 SS12112 CLAMP 1
92 PS07-512-1 DUCTING 1
93 SS12112 CLAMP 1
94 CW07-23-1 REDUCER 1
CW07-25-400 CLAMP 1
CW07-25-450 CLAMP 1
95 PS13-5-1 (U1-NAS-2) FLOW CONTROL VALVE 1
96 PS07-312-1 DUCTING 1
97 PS07-321-1 DUCTING 1
98 CW07-25-400 CLAMP 1
99 PS07-461-1 DUCTING 1
100 PS13-1-3 (U1-NAS-16) VALVE 1
CW07-25-400 CLAMP 2
101 PS07-472-1 DUCTING 1
102 PS31-1-3.5-4 COUPLING 1
C310N-62-0425-S2 CLAMP 2
C310N-62-0375-S2 CLAMP 2
103 SS12112 CLAMP 1
104 PS07-481-1 DUCTING 1
105 SS12095 CLAMP 1

AIR DELIVERY DUCTING

Figure 21.04-7 (7 of 7)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP. CONTROL DUCTING – LH Temp Control Ducting

Figure 21.04-8 (1 of 5)

21.04.44 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP. CONTROL DUCTING – Top View Temp Control Ducting

Figure 21.04-8 (2 of 5)

Revision 12 06-01-01 21.04.45

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DC-8 MAINTENANCE MANUAL
CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

TEMP. CONTROL DUCTING – RH Temp Control Ducting

Figure 21.04-8 (3 of 5)

21.04.46 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

1 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP (REF.) 4
2 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP (REF.) 4
3 SS12075 CLAMP 2
4 PS07-391-1 DUCTING 1
5 SS12075 CLAMP 1
6 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
7 CW15-7 TEMP PROBE 1
8 PS12-2-1 COMP OVER TEMP 1
9 PS07-371-1 DUCTING 1
10 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
11 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
12 CW15-7 TEMP PROBE 2
13 PS12-2-3 T.I. OVER TEMP SW 1
14 PS07-381-1 DUCTING 1
15 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
16 PS37-1-2.5 CLAMP (REF.) 1
17 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
18 SS12075 CLAMP 1
19 PS07-401-1 DUCTING 1
20 SS12075 CLAMP 1
21 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
22 PS07-421-1 DUCTING 1
23 PS07-431-1 DUCTING 1
24 SS12075 CLAMP 1
SUPPORT BRACKET 1
25 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 1
26 PS07-451-1 DUCTING 1
27 SS12075 CLAMP 1

TEMP. CONTROL DUCTING

Figure 21.04-8 (4 of 5)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

28 PS03-7-4 1
29 SS12095 CLAMP 1
SS12075 CLAMP 1
30 PS03-7-8 1
31 PS09-7-2 1
32 AN3-4A BOLTS 48
AN960-10 WASHERS 48
33 PS07-411-1 DUCTING (REF.) 1
34 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
35 AN3-4A BOLTS 48
AN960-10 WASHERS 48
36 PS09-7-1 1
37 PS03-7-9 1
38 PS03-7-3 1
SS12095 CLAMP 1
SS12075 CLAMP 1
39 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
40 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
41 CW15-7 TEMP PROBE 1
42 PS12-2-1 COMPR OVERTEMP SW 1
43 PS07-371-1 DUCTING 1
44 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
45 PS01-0-1 ACM ASSY 1
46 PS01-0-1 ACM ASSY 1
47 PS31-1-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
48 PS07-382-1 DUCTING 1
49 PS12-2-3 T.I. OVER TEMP SW 1
50 CW15-7 TEMP PROBE 2

TEMP. CONTROL DUCTING

Figure 21.04-8 (5 of 5)

21.04.48 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

ACM ASSEMBLY – Left Looking Inboard

Figure 21.04-9 (1 of 3)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

ACM ASSEMBLY – Right Looking Inboard

Figure 21.04-9 (2 of 3)

21.04.50 06-01-01 Revision 12

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DC-8 MAINTENANCE MANUAL
CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

1 CW07-25-300 COUPLING 2
2 SS12085 CLAMP 2
3 CW07-25-300 COUPLING 2
4 CW07-25-300 COUPLING 1
5 PS03-5-1 BRACKET ASEMBLY 1
6 PS31-1-4 COUPLING 1
C310N-62-0485-S2 CLAMP 3
7 CW07-25-300 COUPLING 3
8 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
9 CW07-25-300 COUPLING 2
10 PS37-1-2.5 CLAMP 1
11 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
12 PS37-1-2.5 CLAMP 1
13 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 4
14 PS03-5-2 BRACKET ASSEMBLY 1
15 CW07-25-300 COUPLING 1
16 CW07-25-300 COUPLING 2
17 CW07-25-300 COUPLING 2
18 SS12085 CLAMP 2
19 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 1
20 PS37-1-12.5 CLAMP 1
21 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 1
22 SS12075 CLAMP 1
23 PS37-1-2.5 CLAMP 1
24 CW07-25-300 COUPLING 2
25 PS31-3-2.5 COUPLING 1
PS33-1-2.5 CLAMP 1
26 PS37-1-2.5 CLAMP 1
27 PS31-1-4 COUPLING 1
C310N-62-0485-S2 CLAMP 1

ACM ASSEMBLY
Figure 21.04-9 (3 of 3)

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

FLIGHT ENGINEER’S CONTROLS - With Existing Mix Valve Levers Modified

Figure 21.04-10

21.04.52 06-01-01 Revision 12

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

1 CW16-1 PLUG 1
2 CW16-2 PLUG 1
3 CW16-3 PLUG 1
4 CW16-4 PLUG 1
5 CW16-5-11 CAP 4
6 SS12165 WORM GEAR CLAMP 4
7 AN970-4 WASHER 4
8 MS21042-4 NUT 4

NOSE AIR SCOOP PLUGS

Figure 21.04-11

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CHAPTER 21 – AIR CONDITIONING
21.04 DC-8-62 NASI CABIN PNEUMATIC AIR CYCLE (PAC) (STC ST01253CH)
(cont’d)

REF PART NO. PART NAME QTY

1 PS14-1 CONTROL LINE 1
2 CW11-5-11 LINE 2
3 CW11-5-9 LINE 2
AN833-4D FITTING 2
AN924-4D NUT 2
AN6227B-9 “O” RING 2
4 CW11-5-7 LINE 2
AN815-4D UNION 4
5 CW11-6-4 LINE 1
6 CW11-5-5 LINE 1
7 CW11-5-3 LINE 1
AN815-4D UNION 2
8 CW11-5-1 LINE 1
9 CW11-10-2 LINE 1
MS21902D5 UNION 1
10 CW11-9-1 LINE 1
MS21902D5 UNION 1
11 CWO4-4-4 DOUBLER 1
12 CW11-7-1 FITTING 2

PNEUMATIC CONTROL LINES

Figure 21.04-12

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CHAPTER 21 – AIR CONDITIONING

ATI-001
ATI RECURRING NON-ROUTINE
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
21.04-1
JOB TITLE
NASI PNEUMATIC AIR CYCLE SYSTEM 3240 LANDING EDDY CURRENT
Job Card Reviewed By Date
Page 1 of 4
PROCEDURE MECHANIC INSPECTOR

A. 3240 LANDINGS EDDY CURRENT INSPECTION

All holes shall be inspected with eddy current before the
inspection interval specified above based on pressurization after
installation.
A doubler template for the rivet and fitting holes is included.
The inspector should look for cracks on the surfaces of the skin
and the doubler, around fitting holes, and around rivet holes.
Any cracks emanating from any hole would be a cause to repair
the affected area.
1. Calibrate the Eddy Current instrument to establish a
reference standard. The calibration is accomplished using
the assembly shown in Figure 1.
2. The drawing for the holes inspected shall be selected from
Figure 2.
3. The path to be followed with the Eddy Current probe is
shown on the template, Figure 2.
4. The inspector should look for cracks on the surfaces of the
skin and the doubler around the fitting rivet holes. Any
cracks emanating from any hole would be a cause to repair
the affected area.
5. Record all repairs performed in the aircraft logbook.

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CHAPTER 21 – AIR CONDITIONING

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
21.04-1
JOB TITLE
NASI PNEUMATIC AIR CYCLE SYSTEM 3240 LANDING EDDY CURRENT
Job Card Reviewed By Date
Page 2 of 4

CALIBRATION STANDARD
FIGURE 1

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CHAPTER 21 – AIR CONDITIONING

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
21.04-1
JOB TITLE
NASI PNEUMATIC AIR CYCLE SYSTEM 3240 LANDING EDDY CURRENT
Job Card Reviewed By Date
Page 3 of 4

DOUBLER
FIGURE 2

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CHAPTER 21 – AIR CONDITIONING

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
21.04-1
JOB TITLE
NASI PNEUMATIC AIR CYCLE SYSTEM 3240 LANDING EDDY CURRENT
Job Card Reviewed By Date
Page 4 of 4

NOTES:
1. INSTALL USING MS2047AD4 RIVETS (42PL) AND FAY SEALING PR1422B1/2.
2. LOCATION FOR THE DOUBLER IS:
FOR DC-8-62, -72 F.S. +176.5, BL 25.0R
FOR DC-8-63, -73 F.S. –23.50, BL 25.0R
3. DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED. TOLERANCES ARE
DECIMALS.
.XX .XXX
± 0.10 ± .050

DOUBLER INSTALLATION
FIGURE 3

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CHAPTER 21 – AIR CONDITIONING

21.05 – NASI FLIGHT DECK FLOOR HEAT SYSTEM (STC ST00792CH)

TABLE OF CONTENTS

Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 21.05.1
2. FLIGHT DECK FLOOR TEMPERATURE CONTROL------------------------- 21.05.1
3. FLIGHT DECK FLOOR HEATER OPERATION-------------------------------- 21.05.1
4. SOLENOID VALVE ------------------------------------------------------------------ 21.05.2
5. TROUBLESHOOTING--------------------------------------------------------------- 21.05.2
6. WIRING DIAGRAM------------------------------------------------------------------ 21.05.3
7. ILLUSTRATED PARTS CATALOG----------------------------------------------- 21.05.4

FIGURES

21.05-1 FLIGHT DECK FLOOR HEAT WIRING DIAGRAM 21.05.3

21.05.2 ILLUSTRATED PARTS CATALOG 21.05.4

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CHAPTER 21 – AIR CONDITIONING
21.05 NASI FLIGHT DECK FLOOR HEAT SYSTEM (STC ST00792CH)

1. General

a. This system is installed only in those aircraft identified in the Effectivity section of the
Introduction to this manual. Refer to that section for effectivity of the following
procedures.

b. The NASI Flight Deck Floor Heat System utilizes unconditioned bleed air to heat the
space between the pressure bulkhead and the flight deck floor. Since the pressure
bulkhead is exposed to cold winter ground temperature and extreme cold of outside flight
level temperature, this air space between the pressure bulkhead and floor may go for
weeks without reaching much above freezing, thus the floor remains cold as well.
Therefore, NASI has developed a system to introduce hot bleed air into this cold air space
thus warming the floor.

c. When the Flight Deck Floor Heat is switched on, hot bleed air is delivered through a
normally closed solenoid valve and into an orifice/diffuser mounted on the forward
pressure bulkhead below the forward flight deck floor. A small amount of hot bleed air is
allowed to escape on the forward side of the pressure bulkhead to warm the area
immediately ahead of the flight deck instrument panel.

d. This is a small amount of bleed air delivered to the pitot line heating ducts through a
fixed 9/64 inch orifice. This will ensure warm air surrounding the pitot lines at all times
when the aircraft is operating.

2. Flight Deck Floor Temperature Control

a. The Flight Deck Floor Heat System is an ON/OFF type temperature control system. The
outside air temperature in cruise flight and the small volume of bleed air released under
the flight deck floor is such that whenever floor heat is required the system should always
work just right.

b. NASI Flight Deck Floor Heat should not be used when OAT is above 50ºF or when cabin
cold air conditioning is required.

c. The pitot line heating portion of the system is on (functioning) whenever manifold
pressure is indicated.

3. Flight Deck Floor Heater Operation

a. There is no temperature control in the NASI Flight Deck Floor Heat System. When
manifold air pressure is available at least 15 psi, the system is activated with the switch
labeled FLIGHT DECK FLOOR HEAT (circuit breaker must be set). After Floor Heat is
switched on, floor will be warmer in minutes. Pitot lines forward of forward pressure
bulkhead will be warmer in five to fifteen minutes depending on OAT.

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21.05 NASI FLIGHT DECK FLOOR HEAT SYSTEM (STC ST00792CH) (cont’d)

b. Pitot lines forward of the forward pressure bulkhead will be warmer five to fifteen
minutes (depending on OAT) after manifold pressure from engine bleed air is established
and maintained.

4. Solenoid Valve. The solenoid valve is a two way direct acting 28 VDC continuous operating
¼” orifice high temperature valve. ON is energized open, OFF is de-energized closed.

5. Troubleshooting.

TROUBLE PROBABLE CAUSE REMARKS

Flight deck floor heating system not If operating engines at idle manifold Floor will heat up after take off.
heating floor on ground, works good pressure may be insufficient
in flight

Flight deck floor heating system No electrical power to solenoid Push flight deck floor heater circuit
inoperative. valve breaker in, turn switch on, and check
for 28 VDC at solenoid valve.

Solenoid valve unserviceable Replace solenoid valve

No bleed air to solenoid valve Kink in flight deck floor heat line

Bleed air to solenoid valve, but no Solenoid valve unserviceable Replace solenoid valve
bleed air to floor heat

Bleed air to floor heat, but no bleed Manifold fitting assembly orifice Unplug orifice
air to manifold fitting assembly plugged

Both lines to manifold fitting Replace lines

assembly kinked

Bleed air to manifold fitting Fitting under floor where diffuser Remove caps and install diffuser
assembly only or manifold fitting goes is capped
assembly and one side of floor heat
only
Floor heat line kinked Replace line

Pitot line freezing while aircraft is It takes 10-15 minutes for pitot lines May take 10-15 minutes to warm
on ground to heat after engine start nose section after engine start. Time
is shortened when chin scoop anti-
ice is on

Static line freezing while in flight Pitot line heat duct disconnected Connect pitot line heat duct

Both 9/64 inch orifices in manifold

fitting assembly(CWO7-73-1) Unplug orifice
plugged

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CHAPTER 21 – AIR CONDITIONING
21.05 NASI FLIGHT DECK FLOOR HEAT SYSTEM (STC ST00792CH) (cont’d)

6. Wiring Diagram

FLIGHT DECK FLOOR HEAT WIRING DIAGRAM

Figure 21.05-1

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CHAPTER 21 – AIR CONDITIONING
21.05 NASI FLIGHT DECK FLOOR HEAT SYSTEM (STC ST00792CH) (cont’d)

7. Illustrated Parts Catalog

ITEM NO. PART NUMBER NOMENCLATURE QTY

1 CW07-75-253 FITTING ASSY 1
2 CW0-75-251 CLAMP HALF 4
3 CW07-71-1 LINE ASSY 2
4, 6 CW07-71-5 LINE ASSY 2
5, 7 CW07-71-7 LINE ASSY 2
8 CW07-71-9 LINE ASSY 1
9 CW07-71-11 LINE ASSY 1
10, 11, CW07-71-3 LINE 4
12, 13
14 CW07-73-1 MANIFOLD FITTING ASSY 1
AN816-5-4D FITTING 2
15 BLANK
16, 17 CW07-71-3 LINE 2
18 BLANK
19 BLANK
20 CW03-13-11 STUD SPACER ASSY 4
21, 22, 23 2 1/2” I.D. LOOP CLAMP 3
3/4” I.D. LOOP CLAMP 6
24 FH02-0-1 FITTING ASSY 1
25 FH01-0-6 LINE 1
26 FH01-0-3 LINE 1
27 FH01-0-5 LINE 1
28 FH01-0-4 LINE 1
29 AN924-5D TEE FITTING 1
30 AN822-5-4D ELBOW 2
AN912-2D REDUCER
31 FH04-0-1 SOLENOID VALVE 1
32 FH03-0-1 BRACKET 1
33 FH03-0-5 BRACKET 1
34 BLANK
35 MS 21919WH-5 LOOP CLAMP 2
36, 37, 3/4” I.D. LOOP CLAMP 8
38, 39
40 5/8” I.D. LOOP CLAMP 1
2 1/2” I.D. LOOP CLAMP 1
ILLUSTRATED PARTS CATALOG
Figure 21.05-2 (1 of 2)

21.05.4 06-03-02 Revision 15

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CHAPTER 21 – AIR CONDITIONING
21.05 NASI FLIGHT DECK FLOOR HEAT SYSTEM (STC ST00792CH) (cont’d)

ILLUSTRATED PARTS CATALOG

Figure 21.05-2 (2 of 2)

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INTENTIONAL
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CHAPTER 24 – ELECTRICAL POWER

TABLE OF CONTENTS
Page
24.01 BATTERY MAINTENANCE AND STORAGE---------------------------------- 24.01.1

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INTENTIONAL
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CHAPTER 24 – ELECTRICAL POWER

24.01 – BATTERY MAINTENANCE AND STORAGE

TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 24.01.1
2. MAINTENANCE PROCEDURES-------------------------------------------------- 24.01.1

FORMS

24.01-1 DC-8 BATTERY CHARGING RECORD ----------------------------------- -- 24.01.3

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CHAPTER 24 – ELECTRICAL POWER
24.01 BATTERY MAINTENANCE AND STORAGE

1. General

a. The DC-8 uses several types of reusable batteries which require routine maintenance in
order to be kept in a charged condition ready for immediate service. These types include:
(1) Aircraft battery (ship’s battery)
(2) Underwater Locator Beacon Battery
(3) Emergency Exit Indicators Light Battery Pack
(4) Emergency Light Battery Pack

b. Each type of battery has different charging requirements which are described below.

c. A Battery Charging Record, Form 24.01-1, will be initiated and maintained on each
rechargeable battery kept for shelf stock.
(1) When the battery is installed in an aircraft, the Battery Charging Record and Parts
Control Tag will be attached to the log page and sent to LIT Q/C Records Section.
(2) Batteries received direct from a vendor for immediate installation in an aircraft do
not require the use of this record. Non-rechargeable batteries do not require the use
of this record.
(3) Batteries received direct from a vendor/TOL Stores for immediate installation in an
aircraft should not require charging.

d. Charging Equipment. Batteries will be charged to the specifications below using a

variable amp battery charger such as the D+C- Air Parts type DC-002A or equivalent.

2. Maintenance Procedures

WARNING: BATTERIES MUST BE CHARGED IN A WELL VENTILATED AREA

TO PREVENT THE ACCUMULATION OF EXPLOSIVE MIXTURE OF
HYDROGEN AND OXYGEN GASES.

a. Aircraft Battery, P/N CA101N

(1) Storage. Stored at room temperature (82° F or less preferred, not to exceed 130° F),
in a clean, dry place away from all lead acid and dry cell batteries.

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CHAPTER 24 – ELECTRICAL POWER
24.01 BATTERY MAINTENANCE AND STORAGE (cont’d)

(2) Maintenance. Upon receipt for shelf stock, and at 30 day intervals thereafter, charge
for 14 hours at 3mA per battery ampere-hour rating. The CA101N is rated at 13
ampere hours; therefore it requires a charge of 39 milliamperes for 14 hours.
Record on Battery Charging Record.

b. Underwater Locator Beacon Battery

(1) Storage. Stored at room temperature (82° F or less preferred, not to exceed 130° F),
in a clean, dry place away from all nickel cadmium batteries.

(2) Maintenance. Requires no charging. Shall be tested every six months per Section
31.04 of this manual.

c. Emergency Exit Indicators Light Battery Pack

(1) Storage. Stored at room temperature (82° F or less preferred, not to exceed 130° F),
in a clean, dry place away from all lead acid batteries.

(2) Maintenance. Upon receipt for shelf stock, and at 30 day intervals thereafter, charge
for 16 to 24 hours at 350 milliamperes. Record on Battery Charging Record.

d. Emergency Light Battery Pack

(1) Storage. Stored at room temperature (82° F or less preferred, not to exceed 130° F),
in a clean, dry place away from all lead acid and nickel cadmium batteries.

(2) Maintenance. Upon receipt for shelf stock, and at 30 day intervals thereafter, charge
for 42 to 96 hours (do not exceed 96 hours) at 17-23 milliamperes. Record charging
on Battery Charging Record.

24.01.2 09-05-06 Revision 25

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CHAPTER 24 – ELECTRICAL POWER
24.01 BATTERY MAINTENANCE AND STORAGE (cont’d)

AIR TRANSPORT INTERNATIONAL

DC-8 BATTERY CHARGING RECORD
Type: P/N: S/N:

DATE & DATE & DATE & DATE & DATE & DATE &
TIME ON TIME OFF TIME ON TIME OFF TIME ON TIME OFF

DC-8 BATTERY CHARGING RECORD

Form 24.01-1

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INTENTIONAL
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TABLE OF CONTENTS
Page
25.01 CARGO SYSTEMS MAINTENANCE ----------------------------------------- 25.01.1
25.02 RESERVED FOR FUTURE USE ------------------------------------------------ 25.02.1
25.03 RESERVED FOR FUTURE USE ------------------------------------------------ 25.03.1
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/& -2 IPC ---- 25.04.1
25.05 RECURRING NON-ROUTINE JOB CARDS --------------------------------- 25.05.1
25.06 PHILIPS HEARTSTART FRX DEFIBRILLATOR 861304 ----------------- 25.06.1
25.07 MAIN CARGO DOOR SILL GUARD IPC ------------------------------------ 25.07.1
25.08 CREW SEAT COVER AND CUSHION PART NUMBERS ---------------- 25.08.1
25.09 COMBI BALL PANEL ASSEMBLY CONFIGURATION (PEMCO) ----- 25.09.1
25.10 EMERGENCY EVACUATION ROPE ----------------------------------------- 25.10.1
25.11 CREW OXYGEN REGULATORS ---------------------------------------------- 25.11.1
25.12 TEAC VE-801DC DVD VIDEO PLAYER ------------------------------------- 25.12.1
25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS------------------------- 25.13.1
25.14 RESERVED FOR FUTURE USE ------------------------------------------------ 25.14.1
25.15 MODEL 1603 SERIES TOP-FILL COFFEE BREWER ---------------------- 25.15.1
25.16 SMOKE BARRIER INTERIM REPAIRS -------------------------------------- 25.16.1

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25.01 – CARGO SYSTEMS MAINTENANCE

TABLE OF CONTENTS
Paragraph Page
1. CARGO SYSTEMS COMPONENT INSTALLATION ---------------------- 25.01.1
2. MISSING LOCK CRITERIA ----------------------------------------------------- 25.01.4
3. INSTALLATION OF THE ANCRA LATERAL ALIGNMENT KIT IN
CARGO POSITION 16 AND 17 OF DC-8-63/-71/-73 ALL-CARGO
AIRCRAFT-------------------------------------------------------------------------- 25.01.5

TABLES
25.01-1 MISSING LOCK CRITERIA ----------------------------------------------------- 25.01.4
25.01-2 INTERCHANGEABLE LOCK PART NUMBERS --------------------------- 25.01.4

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25.01 CARGO SYSTEMS MAINTENANCE

1. Cargo Systems Component Installation. Company aircraft may be equipped with different
cargo loading systems. Each system incorporates entirely different components that make up
the cargo loading system. The components are not interchangeable. Refer to the specific
section in this chapter for individual aircraft applicability. Currently, the models of cargo
doors/systems are:

a. Douglas Door with the PEMCO Cargo Loading System, original DACO installation.
These aircraft may also be modified with Extended Height Siderails (EHK). The EHK’s
cannot be used on any other cargo loading system.

This chapter contains the Illustrated Parts Catalog (IPC) for each of these systems and
maintenance instructions for general system maintenance. To ensure proper replacement
components are used on aircraft where cargo loading system maintenance is being
performed, refer to the IPC section in this chapter which lists that system’s components.

The cargo component installation procedures described below provide general guidelines for
maintenance. Some of the processes and procedures may vary slightly due to small
variations in each installation, but the general processes are the same. This, along with the
information depicted in the IPC sections, may be used to correct discrepancies of the listed
components. If more detailed information is required, contact Maintenance Control.

a. Adjustable Side Rail Installation

(1) Install adjustable side rail cross track assemblies by placing studs in ¾” diameter
holes in tiedown/seat tracks and sliding fittings ½” forward or aft. Tighten lock
plunger/stud in each crosstrack to lock fittings

(2) Position side rail by lifting plunger and sliding rail inboard or outboard on
crosstrack. After positioning, check carefully to ensure plunger is fully inserted in
¾” diameter holes in crosstrack.

(3) Attempt to lift or move rail to ensure it is secure.

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b. Fixed Side Rail Installation. The fixed side rail is secured or removed by loosening/
tightening the seat track anchor studs. Side rails are installed in 10 foot sections with
splice plates to ensure proper alignment. Some are riveted and some utilize screws, nuts
and washers. Either may be substituted for the other.

c. Rigid End Restraint Installation.

(1) Install rigid end restraint fittings at forward end of pallet position 1 and/or aft end of
rearmost pallet by placing studs in ¾” diameter holes in floor tracks and sliding
fittings ½” foreword or aft until lock plungers snap into ¾” diameter holes. Ensure
lock plungers are fully inserted in holes. If equipped with shear pins, turn pin until
it is firmly engaged in track hole.
(2) Attempt to lift or move rail to ensure it is secure.

d. End Restraint Installation.

(1) Install end restraining fittings at forward end of each pallet position 2 through next
to rearmost position. Orient fittings to fold down in forward direction except
fittings at forward end of pallet position 2, which must fold down aft.
(2) Place studs in ¾” diameter holes in tiedown tracks and slide fittings ½” forward or
aft.
(3) Lock fittings in place by pushing down and rotating lockpin knob 90°. Groove in
lockpin knob will be in forward and aft direction when fitting is locked in place. If
equipped with shear pins, turn pin until it is firmly engaged in track hole.
(4) Attempt to lift or move rail to ensure it is secure.

e. Roller Conveyor Installation.

(1) Install roller conveyors by securing long sections of roller conveyor assemblies to
floor with screws. Receptacles are provided in fuselage floor for this purpose or
they may be secured in the seat track between lock and crosstrack assemblies.
(2) Install short section of roller assemblies between crosstracks in side rail assemblies.
(3) Place studs in ¾” diameter holes in tiedown track and slide assembly ½” forward.
(Other types may include flip-up plunger, quarter turn, nut & washer, screw &
washer or fully threaded plunger.)

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(4) Rotate lockpin knob 90° to lock fitting in place. Groove in lockpin knob will be
pointing forward and aft when conveyor is locked in place. If equipped with shear
pins, turn pin until it is firmly engaged in track hole.

(5) Attempt to lift or move rail to ensure it is secure.

f. Ball Transfer Conveyor(Ball Mats) Installation.

(1) Position outer ball mat sections with side rail crosstrack centerlines in tabulated
positions.

(2) Place ball mat studs in tiedown tracks and slide conveyor forward ½”.

(3) Lock ball mats in place with lock screws or shear pins.

Note: In the cargo door area, latches for side restraint of the pallet are a part of the ball
mats. The latches are automatically locked when in raised position. To unlock
and lower latches, depress the lock arm at the bottom of the latch. To relocate the
latches in the crosstracks, remove the latch assembly by depressing the spring clip
and retracting the pins. After latch is reinstalled, check to ensure the spring clip is
between the pins.

(4) Attach center ball transfer mats by placing studs in ¾” diameter holes in tiedown
tracks.

(5) Secure center ball mat sections by pushing down and rotating lockpin knob 90°.
Groove in lockpin knob will point forward and aft when conveyors are locked in place.

(6) Attempt to lift or move rail to ensure it is secure.

g. Cargo Door Sill Conveyor Installation. Position conveyors with hook fittings over cargo
door latch spools. With lock pins raised, position supports on bottom of assembly on
cargo door latching spools. Conveyors lock to cargo door spools with spring loaded pins
in the hook fittings. Lower lock pins and depress to ensure positive lock on back side of
latching spools.

CAUTION: IF CARGO DOOR IS TO BE CLOSED, REMOVE SILL CONVEYORS.

TO REMOVE SILL CONVEYORS, PULL UP LOCK PINS AND LIFT
CONVEYORS FROM THE DOOR SILL.

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25.01 CARGO SYSTEMS MAINTENANCE(CONT’D)

2. Missing Lock Criteria.

WARNING: MISSING LOCK CRITERIA DOES NOT APPLY TO AIRCRAFT

MODIFIED PER AERONAUTICAL ENGINEERS, INC., CARGO DOOR
STC SA1063SO. NO LOCKS MAY BE MISSING FROM THIS CARGO
SYSTEM.

CAUTION: THE MAXIMUM ALLOWABLE GROSS WEIGHTS LISTED BELOW ARE

BASED ON THE STRUCTURAL ADEQUACY OF THE CARGO SYSTEM
ONLY. MAXIMUM COMPARTMENT WEIGHTS MUST BE OBSERVED.

NOTE: End stops serve the same purpose as cargo locks and will be included in the missing
lock criteria.

MISSING LOCKS ALLOWABLE

GROSS WEIGHT
RBL 45.5 RBL 24.75 BL-0 LBL 24.75 LBL -45.5
0 0 0 0 0 20,000 pounds
0 0 X 0 0 10,000 pounds
0 X 0 0 0 8,870 pounds
X 0 0 0 0 6,965 pounds
0 0 0 X 0 8,870 pounds
0 0 0 0 X 6,965 pounds
0 X 0 X 0 8,670 pounds
0 X X 0 0 7,052 pounds
X 0 0 0 X 6,965 pounds

MISSING LOCK CRITERIA

TABLE 25.01-1
X - Missing Lock

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25.01 CARGO SYSTEMS MAINTENANCE(CONT’D)

3. Installation of the ANCRA Lateral Alignment Kit in Cargo Position 16 and 17 of DC-8-71/-
73 all-cargo aircraft to accommodate position 18 cargo container. (Currently installed on
821BX, 822BX, 823BX, 825BX, 829BX)

a. The position 18 cargo container used in the DC-8 all-cargo aircraft fits longways into its
restraints in the rear of the aircraft. Consequently cargo handling personnel must rotate
the P18 container on the ballmat 90º and then push it the full length of the aircraft, where
it is loaded endways into its restraints. Alignment is generally lost as the container
moves down the aircraft, thereby creating a situation where the container must be aligned
in P18 by force, causing pallet system and sidewall damage.

b. As a result of that damage, E.O. No. 25-DC8-184 was issued which replaced the existing
roller trays in P16 and P17 with ANCRA ball tray assemblies. This makes it possible to
laterally align the P18 cargo container with minimal effort at the rear of the aircraft.

c. Figure 25-01.1 depicts the installation of ball transfer trays, part numbers 84013-10
{(1)=medium length} and 84013-11 {(2)=short length}, and pallet locks, part number
80004-11 (3) in P16 and P17.

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CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.02 RESERVED FOR FUTURE USE

1. This section is reserved for future use.

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25.03 RESERVED FOR FUTURE USE

1. This section is reserved for future use.

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25.04 – PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2,

ILLUSTRATED PARTS CATALOG
TABLE OF CONTENTS
Page

FIGURES
25.04-1A CARGO SYSTEM, P/N 50045-505-1 (DC-8-73 SERIES) ------------------- 25.04.1
25.04-1B CARGO SYSTEM, P/N 50045-505-2 (DC-8-71 SERIES) ------------------- 25.04.2
25.04-1C CARGO SYSTEM, P/N 50045-505-1/& -2 ------------------------------------- 25.04.3
25.04-2 BALL PANEL ASSEMBLY, P/N 50021-503 ---------------------------------- 25.04.6
25.04-3 BALL PANEL ASSEMBLY, P/N 50022-503 ---------------------------------- 25.04.8
25.04-4 BALL PANEL ASSEMBLY, P/N 50023-503 ---------------------------------- 25.04.10
25.04-5 BALL PANEL ASSEMBLY, P/N 50024-503 ---------------------------------- 25.04.12
25.04-6 BALL PANEL ASSEMBLY, P/N 50024-504 ---------------------------------- 25.04.14
25.04-7 BALL PANEL ASSEMBLY, P/N 50025-503 ---------------------------------- 25.04.16
25.04-8 BALL PANEL ASSEMBLY, P/N 50025-504 ---------------------------------- 25.04.18
25.04-9 BALL PANEL ASSEMBLY, P/N 50026-503 & -504------------------------- 25.04.20
25.04-10a BALL PANEL ASSEMBLY, P/N 50027-503 ---------------------------------- 25.04.22
25.04-10b BALL PANEL ASSEMBLY, P/N 50027-509 ---------------------------------- 25.04.24
25.04-11a BALL PANEL ASSEMBLY, P/N 50028-503 ---------------------------------- 25.04.26
25.04-11b BALL PANEL ASSEMBLY, P/N 50028-509 ---------------------------------- 25.04.28
25.04-12a BALL PANEL ASSEMBLY, P/N 50029-503 ---------------------------------- 25.04.30
25.04-12b BALL PANEL ASSEMBLY, P/N 50029-509 ---------------------------------- 25.04.32
25.04-13 ROLLER TRAY ASSY., P/N 20042-507, -509, -511, -513, & -565 -------- 25.04.34
25.04-14 ROLLER TRAY ASSEMBLY, P/N 90542-001-18---------------------------- 25.04.38
25.04-15 FORE & AFT RESTRAINT FITTING ASSY, P/N 50573-505-------------- 25.04.40
25.04-16 FORE & AFT RESTRAINT FITTING ASSY, P/N 50573-509-------------- 25.04.42
25.04-17 RAIL ASSEMBLY, P/N 50481-505 & -506------------------------------------ 25.04.44
25.04-18 RAIL ASSEMBLY, P/N 50781-601 --------------------------------------------- 25.04.46
25.04-19a RAIL ASSEMBLY, P/N 50911-1 ------------------------------------------------ 25.04.48
25.04-19b RAIL ASSEMBLY, P/N 50911-507 --------------------------------------------- 25.04.50
25.04-20 RAIL ASSEMBLY, P/N 50911-533 --------------------------------------------- 25.04.52
25.04-21 RAIL ASSEMBLY, P/N 50911-537 --------------------------------------------- 25.04.54
25.04-22 RAIL ASSEMBLY, P/N 50911-539 --------------------------------------------- 25.04.56
25.04-23 RAIL ASSEMBLY, P/N 50911-541 & -543------------------------------------ 25.04.58
25.04-24 RAIL ASSEMBLY, P/N 509-11-545 -------------------------------------------- 25.04.60
25.04-25 RAIL ASSEMBLY, P/N 50911-547 --------------------------------------------- 25.04.62
25.04-26 RAIL ASSEMBLY, P/N 50911-549 --------------------------------------------- 25.04.64
25.04-27 RAIL ASSEMBLY, P/N 50911-551 --------------------------------------------- 25.04.65
25.04-28 SIDE RESTRAINT ASSEMBLY, P/N 50540-1 ------------------------------- 25.04.66
25.04-29 PALLET RESTRAINT FITTING ASSEMBLY, P/N 50604-1 -------------- 25.04.67
25.04-30 SIDE REST FITTING ASSEMBY, P/N 50605-1 ------------------------------ 25.04.68

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FIGURES
Page
25.04-31 PALLET RESTRAINT FITTING, P/N 50604-521 25.04.69
25.04-32 CROSSTRACK ASSEMBLY, P/N 70568-517--------------------------------- 25.04.70
25.04-33 EXTENDED HEIGHT RAIL ASSEMBLY KIT------------------------------- 25.04.71

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25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG

CARGO SYSTEM, P/N 50045-505-1 (DC-8-73 Series)

FIGURE 25.04.01A

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25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

CARGO SYSTEM, P/N 50045-505-2 (DC-8-71 SERIES)

FIGURE 25.04-01B

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25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
1A -1 50045-505-1 CARGO HANDLING SYSTEM -73 Series RF
1B -1 50045-505-2 CARGO HANDLING SYSTEM -71 Series RF
10 50021-503 •BALL PANEL ASSEMBLY (SEE FIG. 2
FOR DETAILS) A,B 1
20 50022-503 •BALL PANEL ASSEMBLY (SEE FIG. 3
FOR DETAILS) A,B 1
30 50023-503 •BALL PANEL ASSEMBLY (SEE FIG. 4
FOR DETAILS) A,B 1
1A 70 50024-503 •BALL PANEL ASSEMBLY (SEE FIG. 5
1B 40 FOR DETAILS) A,B 1
1A 40 50024-504 •BALL PANEL ASSEMBLY (SEE FIG. 6
1B 50 FOR DETAILS) A,B 1
1A 80 50025-503 •BALL PANEL ASSEMBLY (SEE FIG. 7
1B 60 FOR DETAILS) A,B 1
1A 50 50025-504 •BALL PANEL ASSEMBLY (SEE FIG. 8
1B 70 FOR DETAILS) A,B 1
1A 90 50026-503 •BALL PANEL ASSY (SEE FIG. 9 FOR
1B 80 DETAILS) A,B 1
1A 60 50026-504 •BALL PANEL ASSY (SEE FIG. 9 FOR
1B 90 DETAILS) A,B 1
1A 100 50027-503 •BALL PANEL ASSY (SEE FIG. 10a FOR
DETAILS) A 1
1B 100 50027-509 •BALL PANEL ASSY (SEE FIG. 10b
FOR DETAILS) B 1
1A 110 50028-503 •BALL PANEL ASSY (SEE FIG. 11a FOR
DETAILS) A 1
1B 110 50028-509 •BALL PANEL ASSY (SEE FIG. 11b
FOR DETAILS) B 1
1A 120 50029-503 •BALL PANEL ASSY (SEE FIG. 12a FOR
DETAILS) A 1
1B 120 50029-509 •BALL PANEL ASSY (SEE FIG. 12b
FOR DETAILS) B 1
EFFECTIVITY: A=DC-8-73 Series
B=DC-8-71 Series

CARGO SYSTEM, P/N 50045-505-1/ & -2

FIGURE 25.04-01C (1 OF 3)

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25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
130 20042-507 •ROLLER TRAY ASSEMBLY (SEE FIG.
13 FOR DETAILS) A,B 42
1A 140 20042-509 •ROLLER TRAY ASSEMBLY (SEE FIG
13 FOR DETAILS A 1
1A 150 20042-511 •ROLLER TRAY ASSEMBLY (SEE FIG.
1B 140 13 FOR DETAILS) A,B 221
1A 160 20042-513 •ROLLER TRAY ASSEMBLY (SEE FIG.
1B 150 13 FOR DETAILS) A,B 2
1A 170 20042-565 •ROLLER TRAY ASSEMBLY (SEE FIG.
1B 160 13 FOR DETAILS) A,B 3
1B 170 90542-001-18 •ROLLER TRAY ASSEMBLY (SEE FIG.
14 FOR DETAILS) B 1
180 50573-505 •FITTING ASSEMBLY, FORE AND AFT
RESTRAINT (SEE FIG 15 FOR A,B 10
DETAILS)
190 50573-509 •FITTING ASSEMBLY, FORE AND AFT
RESTRAINT (SEE FIG 16 FOR A,B 75
DETAILS)
1A 230 50481-505 •RAIL ASSEMBLY (SEE FIG. 17 FOR
1B 200 DETAILS) A,B 1
1A 240 50481-506 •RAIL ASSEMBLY (SEE FIG. 17 FOR
1B 210 DETAILS) A,B 1
1B 220 50781-601 •RAIL ASSEMBLY (SEE FIG. 18 FOR
DETAILS) B 4
1A 200 50911-1 •RAIL ASSEMBLY (SEE FIG. 19 FOR
1B 230 DETAILS) A,B 52
1A 210 50911-507 •RAIL ASSEMBLY (SEE FIG. 19a FOR
DETAILS) A 3
1A 220 50911-533 •RAIL ASSEMBLY (SEE FIG. 20 FOR
1B 240 DETAILS) A, B 4
1B 250 50911-537 •RAIL ASSEMBLY (SEE FIG. 21 FOR
DETAILS) B 2
EFFECTIVITY: A=DC-8-73 Series
B=DC-8-71 Series

CARGO SYSTEM, P/N 50045-505-1/ & -2

FIGURE 25.04-01C (2 OF 3)

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25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
1B 260 50911-539 •RAIL ASSEMBLY (SEE FIG. 22 FOR
DETAILS) B 1
1B 270 50911-541 •RAIL ASSEMBLY (SEE FIG. 23 FOR
DETAILS) B 1
1B 280 50911-543 •RAIL ASSEMBLY (SEE FIG. 23 FOR
DETAILS) B 1
1B 290 50911-545 •RAIL ASSEMBLY (SEE FIG. 24 FOR
DETAILS) B 1
1B 300 50911-547 •RAIL ASSEMBLY (SEE FIG. 25 FOR
DETAILS) B 1
1B 310 50911-549 •RAIL ASSEMBLY (SEE FIG. 26 FOR
DETAILS) B 1
1B 320 50911-551 •RAIL ASSEMBLY (SEE FIG. 27 FOR
DETAILS) B 1
1A 280 50540-1 •SIDE RESTRAINT (SEE FIG. 28 FOR
1B 330 DETAILS) A,B 10
1A 270 50604-1 •FITTING ASSEMBLY, PALLET
1B 340 RESTRAINT (SEE FIG. 29 FOR DETAILS) A,B 3
1A 260 50605-1 •SIDE RESTRAINT (SEE FIG. 30 FOR
DETAILS) A 2
1A 310 50604-521 PALLET RESTRAINT FITTING (SEE FIG.
31 FOR DETAILS) A 5
1A 290 50080-1 SILL ASSY (SEE FIG. 25.07-1 FOR
DETAILS) A 1
1A 300 50080-501 SILL ASSY (SEE FIG. 25.07-2 FOR
DETAILS) A 1
EFFECTIVITY: A=DC-8-73 Series
B=DC-8-71 Series

CARGO SYSTEM, P/N 50045-505-1/ & -2

FIGURE 25.04-01C (3 OF 3)

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25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50021-503

FIGURE 25.04-2 (1 OF 2)

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25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FIG PART NOMENCLATURE EFFECT UNITS

ITEM NUMBER 1234567 PER
ASSY
2/ -1 50021-503 BALL PANEL ASSEMBLY (REF FIG. 1 A, B RF
FOR NHA)
-10 50891-535 •SLIDE ASSEMBLY (SEE FIG. 30 FOR 1
DETAILS) ATTACHING PARTS
20 MS35276-261 •SCREW, STOP 2
30 51780-503 •CROSS TRACK ATTACHING PARTS 1
40 30070-1 •STUD 4
50 10071-1 •PIN 1
60 5801780-505 •CROSSTRACK ATTACHING PARTS 1
70 30070-1 •STUD 4
80 3801528-1 •RETAINER ATTACHING PARTS 64
90 MS18066-36 •SET SCREW 1
100 TYE1000- •BALL TRANSFER ASSEMBLY 64
1SHD
110 50592-7 •SPRING 64
120 300382-3 •SPACER ATTACHING PARTS 64
-130 AD43H •RIVET (TOP) 4
-140 AK42H •RIVET (BOTTOM) 4
150 50030-5 •RAMP (26 IN LONG) ATTACHING 1
PARTS
-160 AK64H •RIVET (TOP) AR
-170 AK43H •RIVET (BOTTOM) AR
180 50021-13 •SKIN, TOP ATTACHING PARTS 1
-190 MS20426AD5-6 •RIVET AR
200 50021-11 •SKIN, BOTTOM ATTACHING PARTS 1
-210 MS20426AD5-6 •RIVET AR
-220 AK42H •RIVET AR
-230 50021-27 •SHIM 2
240 E60153-3 •CHANNEL AR
BALL PANEL ASSEMBLY P/N 50021-503
FIGURE 25.04-2 (2 OF 2)

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50022-503

FIGURE 25.04-3 (1 OF 2)

25.04.8 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FIG PART NOMENCLATURE EFFECT UNITS

ITEM NUMBER 1234567 PER
ASSY
3/ -1 50022-503 BALL PANEL ASSEMBLY (REF A, B RF
FIG. 1 FOR NHA)
-10 50891-535 •SLIDE ASSEMBLY (SEE FIG. 30 1
FOR DETAILS), ATTACHING
PARTS
20 MS35276-261 •SCREW, STOP 2
30 51780-503 •CROSSTRACK, ATTACHING 1
PARTS
40 30070-1 •STUD 4
50 10071-1 •PIN 1
60 51780-505 •CROSSTRACK, ATTACHING 3
PARTS
70 30070-1 •STUD 4
80 3801528-1 •RETAINER, ATTACHING PARTS 63
90 MS18066-36 •PLUNGER ASSEMBLY 1
100 TYE100-1SHD •BALL TRANSFER ASSEMBLY 63
110 50592-7 •SPRING 63
120 300382-3 •SPACER, ATTACHING PARTS 63
-130 AD43H •RIVET (TOP) 4
-140 AK42H •RIVET (BOTTOM) 4
150 50022-13 •SKIN, TOP, ATTACHING PARTS 1
-160 MS20426AD5-6 •RIVET AR
170 50022-11 •SKIN, BOTTOM, ATTACHING 1
PARTS
-180 MS20426AD5-6 •RIVET AR
-190 AK42H •RIVET AR
200 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED
BALL PANEL ASSEMBLY P/N 50022-503
FIGURE 25.04-3 (2 OF 2)

Revision 26 11-08-06 25.04.9

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50023-503

FIGURE 25.04-4 (1 OF 2)

25.04.10 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FIG PART NOMENCLATURE EFFECT UNITS

ITEM NUMBER 1234567 PER
ASSY
4/ -1 50023-503 BALL PANEL ASSEMBLY (REF A, B RF
FIG. 1 FOR NHA)
-10 50891-535 •SLIDE ASSEMBLY (SEE FIG. 26 1
FOR DETAILS), ATTACHING
PARTS
20 MS35276-261 •SCREW, STOP 2
30 51780-505 •CROSSTRACK, ATTACHING 1
PARTS
40 30070-1 •STUD 4
50 51780-504 •CROSSTRACK, ATTACHING 1
PARTS
60 30070-1 •STUD 4
70 10071-1 •PIN 1
80 3801528-1 •RETAINER, ATTACHING PARTS 54
90 MS18066-36 •PLUNGER ASSEMBLY 1
100 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 54
110 50592-7 •SPRING 54
120 300382-3 •SPACER, ATTACHING PARTS 54
-130 AD43H •RIVET (TOP) 4
-140 AK42H •RIVET (BOTTOM) 4
150 50030-5 •RAMP (11.0 IN. LONG), 1
ATTACHING PARTS
-160 AK64H •RIVET (TOP) AR
-170 AK43H •RIVET (BOTTOM)
180 50023-13 •SKIN, TOP, ATTACHING PARTS 1
-190 MS20426AD5-6 •RIVET AR
200 50023-11 •SKIN, BOTTOM, ATTACHING 1
PARTS
-210 MS20426AD4-5 •RIVET AR
-220 AK42H •RIVET AR
-230 50023-27 •SHIM 1
240 E60153-3 •CHANNEL 20 FT
-ITEM NOT ILLUSTRATED
BALL PANEL ASSEMBLY P/N 50023-503
FIGURE 25.04-4 (2 OF 2)

Revision 26 11-08-06 25.04.11

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50024-503

FIGURE 25.04-5 (1 OF 2)

25.04.12 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
5/ -1 50024-503 BALL PANEL ASSEMBLY (REF FIG A, B RF
1 FOR NHA)
10 30070-1 •STUD , ATTACHING PARTS 1
20 50394-1 •RETAINER, STUD 1
30 AN960-416L •WASHER 1
40 50095-1 •GUIDE 1
50 30070-1 •STUD 2
60 10071-1 •PIN 1
70 3801528-1 •RETAINER, ATTACHING PARTS 60
80 MS18066-36 •SET SCREW 1
90 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 60
100 50592-7 •SPRING 60
110 300382-3 •SPACER, ATTACHING PARTS 60
-120 AD43H •RIVET (TOP) 4
-130 AK42H •RIVET (BOTTOM) 4
140 50030-5 •RAMP (16.374 IN. LONG), 1
ATTACHING PARTS
-150 AK64H •RIVET (TOP) AR
-160 AK42H •RIVET (BOTTOM) AR
170 51383-1 •BRACKET, ATTACHING PARTS 1
-180 MS20426AD6 •RIVET AR
190 51382-1 •BRACKET, ATTACHING PARTS 1
-200 MS20426AD6 •RIVET AR
210 50024-21 •SKIN, TOP, ATTACHING PARTS 1
-220 MS20426AD6 •RIVET AR
230 50024-23 •SKIN, BOTTOM, ATTACHING 1
PARTS
-240 MS20426AD4-5 •RIVET AR
-250 AK42H •RIVET AR
260 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED
BALL PANEL ASSEMBLY P/N 50024-503
FIGURE 25.04-5 (2 OF 2)

Revision 26 11-08-06 25.04.13

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50024-504

FIGURE 25.04-6 (1 OF 2)

25.04.14 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
6/ -1 50024-504 BALL PANEL ASSEMBLY (REF A, B RF
FIG 1 FOR NHA)
10 30070-1 •STUD, ATTACHING PARTS 1
20 50394-1 •RETAINER, STUD 1
30 AN960-416L •WASHER 1
40 50095-1 •GUIDE 1
50 30070-1 •STUD 2
60 10071-1 •PIN 1
70 3801528-1 •RETAINER, ATTACHING PARTS 67
80 MS18066-36 •SET SCREW 1
90 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 67
100 50592-7 •SPRING 67
110 300382-3 •SPACER, ATTACHING PARTS 67
-120 AD43H •RIVET (TOP) 4
-130 AK42H •RIVET (BOTTOM) 4
140 50030-5 •RAMP (16.375 IN. LONG), 1
ATTACHING PARTS
-150 AK64H •RIVET (TOP) AR
-160 AK42H •RIVET (BOTTOM) AR
170 51383-1 •BRACKET, ATTACHING PARTS 1
-180 MS20426AD6 •RIVET AR
190 51382-1 •BRACKET, ATTACHING PARTS 1
-200 MS20426AD6 •RIVET AR
210 50024-25 •SKIN, TOP, ATTACHING PARTS 1
-220 S20426AD5-6 •RIVET AR
230 50024-23 •SKIN, BOTTOM, ATTACHING 1
PARTS
-240 MS20426AD4-5 •RIVET AR
-250 AK42H •RIVET AR
260 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY P/N 50024-504

FIGURE 25.04-6 (2 OF 2)

Revision 26 11-08-06 25.04.15

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY 50025-503

FIGURE 25.04-7 (1 OF 2)

25.04.16 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
7/ -1 50025-503 BALL PANEL ASSEMBLY (REF A, B RF
FIG 1 FOR NHA)
10 30070-1 •STUD, ATTACHING PARTS 1
20 2891394-1 •RETAINER, STUD 1
30 AN960-416L •WASHER 1
40 3891395-1 •GUIDE 1
50 30070-1 •STUD 2
60 10071-1 •PIN 1
70 3801528-1 •RETAINER, ATTACHING PARTS 55
80 19301 •PLUNGER ASSEMBLY 1
90 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 55
100 50590 •SPRING 55
110 3889382-501 •SPACER,. ATTACHING PARTS 55
-120 AD43H •RIVET (TOP) 4
130 AK42H •RIVET (BOTTOM) 4
140 3800383-1 •BRACKET, ATTACHING PARTS 1
-150 MS20426AD6 •RIVET AR
160 3800382-1 •BRACKET, ATTACHING PARTS 1
-170 MS20426AD6 •RIVET AR
180 50025-21 •SKIN, TOP, ATTACHING PARTS 1
-190 MS20426AD5-6 •RIVET AR
200 50025-19 •SKIN, BOTTOM, ATTACHING 1
PARTS
-210 MS20426AD4-5 •RIVET AR
-220 AK42H •RIVET AR
230 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY 50025-503

FIGURE 25.04-7 (2 OF 2)

Revision 26 11-08-06 25.04.17

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50025-504

FIGURE 25.04-8 (1 OF 2)

25.04.18 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
8/ -1 50025-504 BALL PANEL ASSEMBLY (REF A, B RF
FIG. 1 FOR NHA)
10 30070-1 •STUD, ATTACHING PARTS 1
20 50394-1 •RETAINER, STUD 1
30 AN960-416L •WASHER 1
40 50095-1 •GUIDE 1
50 30070-1 •STUD 2
60 10071-1 •PIN 1
70 3801528-1 •RETAINER, ATTACHING PARTS 61
80 MS18066-36 •SET SCREW 1
90 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 61
100 50592-7 •SPRING 61
110 3009382-3 •SPACER, ATTACHING PARTS 61
-120 AD43H •RIVET (TOP) 4
-130 AK42H •RIVET (BOTTOM) 4
140 51383-1 •BRACKET, ATTACHING PARTS 1
-150 MS20426AD6 •RIVET AR
160 51382-1 •BRACKET, ATTACHING PARTS 1
-170 MS20426AD6 •RIVET AR
180 50025-25 •SKIN, TOP ATTACHING PARTS 1
-190 MS20426AD5-6 •RIVET AR
200 50025-23 •SKIN, BOTTOM ATTACHING 1
PARTS
-210 MS20426AD4-5 •RIVET AR
-220 AK42H •RIVET AR
230 E60153-3 •CHANNEL AR

-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY P/N 50025-504

FIGURE 25.04-8 (2 OF 2)

Revision 26 11-08-06 25.04.19

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50026-503(Shown) & -504 (Opposite)

FIGURE 25.04-9 (1 OF 2)

25.04.20 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
9/ -1 50026-503 BALL PANEL ASSEMBLY (REF FIG. 1 A, B RF
FOR NHA)
-2 50026-504 BALL PANEL ASSEMBLY (OPPOSITE A, B RF
ITEM 1) (REF FIG. 1 FOR NHA)
10 30070-1 •STUD, ATTACHING PARTS 1
20 50394-1 •RETAINER, STUD 1
30 AN960-416L •WASHER 1
40 50095-1 •GUIDE 1
50 30070-1 •STUD 2
60 10071-1 •PIN 1
70 3801528-1 •RETAINER, ATTACHING PARTS 58
80 MS18066-36 •SET SCREW 1
90 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 58
100 50592-7 •SPRING 58
110 3009382-3 •SPACER, ATTACHING PARTS 58
-120 AD43H •RIVET (TOP) 4
-130 AK42H •RIVET (BOTTOM) 4
140 50030-5 •BRACKET, ATTACHING PARTS 1
-150 AK64H •RIVET (TOP) AR
-160 AK42H •RIVET (BOTTOM) AR
170 51383-1 •BRACKET, ATTACHING PARTS 1
-180 MS20426AD6 •RIVET AR
190 51382-1 •BRACKET, ATTACHING PARTS 1
-200 MS20426AD6 •RIVET AR
210 50026-21 •SKIN, BOTTOM (50026-503 PANEL) 1
-220 50026-25 •SKIN, BOTTOM (50026-504 PANEL) 1
-230 MS20426AD5-6 •RIVET AR
240 50026-19 •SKIN, BOTTOM (FOR 50026-503 1
PANEL)
-250 50029-23 •SKIN, BOTTOM (FOR 50026-504) 1
-260 MS20426AD4-5 •RIVET AR
-270 AK42H •RIVET AR
280 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY P/N 50026-503 & 504

FIGURE 25.04-9 (2 OF 2)

Revision 26 11-08-06 25.04.21

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50027-503

Figure 25.04-10a (1 OF 2)

25.04.22 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FIG PART NOMENCLATURE EFFECT UNITS

ITEM NUMBER 1234567 PER
ASSY
10a/ -1 50027-503 BALL PANEL ASSEMBLY (REF FIG. A RF
1 FOR NHA)
10 30070-1 •STUD 8
20 10071-1 •PIN 1
30 50032-11 •BLOCK 1
-40 MS202426AD6-11 RIVET 2
50 3801528-1 •RETAINER 70
60 MS18066-36 •PLUNGER ASSY 1
70 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 70
80 50592-7 •SPRING 70
90 300382-3 •SPACER, ATTACHING PARTS 70
-100 AD43H •RIVET (TOP) 4
-110 AK42H •RIVET (BOTTOM) 4
-120 50568-1 •CROSSTRACK ASSY ATTACH 2
PARTS
-130 AK53H •RIVET (TOP) AR
-140 AK43H •RIVET (BOTTOM) AR
150 50289-3 •CROSSTRACK 1
160 50569-1 •FITTING 1
-170 HL329-5-8 ••PIN
-180 HL86-5 ••COLLAR
190 50030-5 RAMP ATTACHING PARTS
-200 AK64H •RIVET (TOP) AR
-210 AK43H •RIVET (BOTTOM) AR
220 50027-25 •SKIN, TOP 1
-230 MS20426AD5-6 •RIVET AR
-240 AK53H •RIVET AR
250 50027-23 •SKIN, BOTTOM 1
-260 MS20426AD4-5 •RIVET AR
-270 AK42H •RIVET AR
280 50027-7 •DOUBLER 1
-290 MS20426AD4-5 •RIVET 4
300 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY P/N 50027-503

Figure 25.04-10a (2 OF 2)

Revision 26 11-08-06 25.04.23

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50027-509

FIGURE 25.04-10b (1 OF 2)

25.04.24 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
10b/ -1 50027-509 BALL PANEL ASSEMBLY (REF FIG. B RF
1 FOR NHA), ATTACHING PARTS
10 10071-1 •PIN 1
20 30070-1 •STUD 8
30 70568-517 •CROSSTRACK ASSEMBLY (SEE 2
FIG. 31 FOR DETAILS)
40 3001528-1 •RETAINER, ATTACHING PARTS 74
50 19301 •PLUNGER ASSEMBLY 1
60 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 74
70 50590 •SPRING 74
80 3889382-501 •SPACER, ATTACHING PARTS 74
-90 AD43H •RIVET (TOP) 4
-100 AK42H •RIVET (BOTTOM) 4
110 50032-11 •BLOCK, PIN, ATTACHING PARTS 1
-120 MS20426AD6-11 •RIVET 2
130 50027-7 •DOUBLER, ATTACHING PARTS 1
-140 MS20426AD4-5 •RIVET 8
150 50030-5 •RAMP (13.75 IN. LONG), 1
ATTACHING PARTS
-160 AK64H •RIVET (TOP) AR
-170 AK43H •RIVET (BOTTOM) AR
180 50030-5 •RAMP (12.25 IN. LONG), 1
ATTACHING PARTS
-190 AK64H •RIVET (TOP) AR
-200 AK43H •RIVET (BOTTOM) AR
210 50045-29 •SKIN, TOP 1
-220 MS20426AD5-5 •RIVET (USE AK53RIVET AT AR
LIMITED ACCESS)
230 50045-27 •SKIN, BOTTOM, ATTACHING 1
PARTS
-240 MS20426AD4-5 •RIVET (USE AK42H RIVET AT AR
LIMITED ACCESS)
250 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY P/N 50027-509

FIGURE 25.04-10b (2 OF 2)

Revision 26 11-08-06 25.04.25

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY 50028-503

Figure 25.04-11a (1 OF 2)

25.04.26 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FIG PART NOMENCLATURE EFFECT UNITS

ITEM NUMBER 1234567 PER
ASSY
11a/ -1 50028-503 BALL PANEL ASSEMBLY (REF FIG. A RF
1 FOR NHA)
10 30070-1 •STUD 12
20 10071-1 •PIN, KEY LOCK 1
30 50032-11 •BLOCK, PIN 1
-40 MS20426AD6-11 •RIVET A/R
50 50528-3 •RETAINER 61
60 MS18066-36 •SET SCREW 61
70 PE1000-1-BL •BALL TRANSFER (blue) 61
80 50592-7 •SPRING 61
90 300382-3 •SPACER 61
150 50568-1 •CROSSTRACK ASSY 2
160 50569-9 •BUMPER ASSY 2
220 50568-509 •CROSSTRACK ASSY 1
230 50569-9 •BUMPER ASSY 1
-240 HL329-5-8 •PIN 10
-250 HL86-5 •COLLAR 10
260 50030-5 •RAMP (44,000 inches long) 1
ATTACHING PARTS
-270 AK64H •RIVET AR
-280 AK43H •RIVET AR
290 50028-25 •TOP SKIN, ATTACHING PARTS 1
-300 MS20426AD5-6 •RIVET AR
-310 AK53H •RIVET AR
320 50028-23 •BOTTOM SKIN, ATTACHING 1
PARTS
-330 MS20426AD4-5 •RIVET AR
-340 AK42H •RIVET ATTACHING PARTS AR
350 50028-7 •DOUBLER, ATTACHING PARTS 1
-360 MS20426AD4-5 •RIVET 8
370 E60153-3 •CHANNEL AR

BALL PANEL ASSEMBLY 50028-503

Figure 25.04-11a (2 OF 2)

Revision 26 11-08-06 25.04.27

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY 50028-509

FIGURE 25.04-11b (1 OF 2)

25.04.28 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
11b/ -1 50028-509 BALL PANEL ASSEMBLY (REF B RF
FIG. 1 FOR NHA), ATTACHING
PARTS
10 10071-1 PIN 1
20 30070-1 STUD 12
30 70568-517 •CROSSTRACK ASSEMBLY (SEE 3
FIG. 31 FOR DETAILS)
40 3001528-1 •RETAINER, ATTACHING PARTS 60
50 19301 •PLUNGER ASSEMBLY 1
60 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 60
70 50590 •SPRING 60
80 3889382-501 •SPACER 60
-90 AD43H •RIVET (TOP) 4
-100 AK42H •RIVET (BOTTOM) 4
110 50032-11 •BLOCK, PIN, ATTACHING PARTS 1
-120 MS20426AD6-11 •RIVET 2
130 50027-7 •DOUBLER, ATTACHING PARTS 1
-140 MS20426AD4-5 •RIVET 8
150 50045-29 •SKIN, TOP, ATTACHING PARTS 1
-160 MS20426AD5-6 •RIVET (USE AK53H RIVET AT AR
LIMITED ACCESS)
170 50045-27 •SKIN, BOTTOM, ATTACHING 1
PARTS
-180 MS20426AD4-5 •RIVET (USE AK42H RIVET AT AR
LIMITED ACCESS)
190 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY P/N 50028-509

FIGURE 25.04-11b (2 OF 2)

Revision 26 11-08-06 25.04.29

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50029-503

Figure 25.04-12a (1 OF 2)

25.04.30 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FIG PART NOMENCLATURE EFFECT UNITS

ITEM NUMBER 1234567 PER
ASSY
12A/ -1 50029-503 BALL PANEL ASSEMBLY (REF A RF
FIG. 1 FOR NHA)
-10 50891-579 •SLIDE ASSY 1
20 MS35276-261 •SCREW, STOP 3
30 51780-509 •CROSSTRACK, ATTACHING 1
PARTS
40 30070-1 •STUD 4
50 10071-1 •PIN 1
60 51780-511 •CROSSTRACK, ATTACHING 2
PARTS
70 30070-1 •STUD 4
80 3801528-1 •RETAINER, ATTACHING PARTS 57
90 MS18066-36 •SET SCREW 1
100 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 57
110 50592-7 •SPRING 57
120 3009382-3 •SPACER 57
-130 AD43H •RIVET(TOP) 4
-140 AK42H •RIVET(BOTTOM) 4
150 50030-5 •RAMP AR
-160 AK64H •RIVET(TOP) AR
-170 AK43H •RIVET(BOTTOM) AR
180 50029-17 •SKIN, TOP ATTACHING PARTS 1
-190 MS20426AD5-6 •RIVET AR
200 50029-15 •SKIN, BOTTOM ATTACHING 1
PARTS
-210 MS20426AD5-6 •RIVET AR
-220 AK42H •RIVET AR
-230 50029-27 •SHIM 2
240 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY P/N 50029-503

Figure 25.04-12a (2 OF 2)

Revision 26 11-08-06 25.04.31

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

BALL PANEL ASSEMBLY P/N 50029-509

FIGURE 25.04-12b (1 OF 2)

25.04.32 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
12b/ - 50029-509 BALL PANEL ASSEMBLY (REF B RF
1 FIG. 1 FOR NHA)
10 3001528-1 •RETAINER, ATTACHING PARTS 65
20 19301 •PLUNGER ASSEMBLY 1
30 TYE1000-1SHD •BALL TRANSFER ASSEMBLY 65
40 50590 •SPRING 65
50 3889382-501 •SPACER, ATTACHING PARTS 65
-60 AD43H •RIVET 4
-70 AK42H •RIVET 4
80 50030-5X13.25 •RAMP, ATTACHING PARTS 1
-90 AK64H •RIVET, TOP 1
-100 AK43H •RIVET, BOTTOM 1
-120 MS20426AD5-6 •RIVET (USE AK53H RIVET AT AR
LIMITED ACCESS)
130 50029-29 •SKIN, BOTTOM, ATTACHING 1
PARTS
-140 MS20426AD4-5 •RIVET (USE AK42H RIVET AT AR
LIMITED ACCESS)
150 50029-27 •SHIM 2
160 E60153-3 •CHANNEL AR
-ITEM NOT ILLUSTRATED

BALL PANEL ASSEMBLY P/N 50029-509

FIGURE 25.04-12b (2 OF 2)

Revision 26 11-08-06 25.04.33

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ROLLER TRAY ASSEMBLY P/N 20042-507, 509, 511, 513 AND 565
FIGURE 25.04-13 (1 OF 4)

25.04.34 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
13/ -1 20042-507 ROLLER TRAY ASSEMBLY (REF A,B RF
FIG. 1 FOR NHA)
20042-509 ROLLER TRAY ASSEMBLY (REF A RF
FIG. 1 FOR NHA)
20042-511 ROLLER TRAY ASSEMBLY (REF A, B RF
FIG. 1 FOR NHA)
20042-513 ROLLER TRAY ASSEMBLY (REF A, B RF
FIG. 1 FOR NHA)
20042-565 ROLLER TRAY ASSEMBLY (REF A, B RF
FIG. 1 FOR NHA)
10 30070-1 •STUD - ATTACHING PARTS 2
20 MS21042-4 •NUT 1
30 AN960-416L •WASHER 1
40 10071-1 •PIN 1
50 50032-11 •BLOCK - ATTACHING PARTS 1
60 AN509-10R11 •SCREW 2
70 AN960-10L •WASHER 2
80 MS21042-3 •NUT 2
90 16100-503-26-29 •ROLLER ASSEMBLY - ATTACHING 19
PARTS
100 HAIR-2 •SPRING PIN 2
110 20042-11 •TRAY 1
-120 20042-509 ROLLER TRAY ASSEMBLY (REF FIG. RF
1 FOR NHA)
130 30070-1 •STUD - ATTACHING PARTS 2
140 MS21042-4 •NUT 1
150 AN960-416L •WASHER 1
160 10071-1 •PIN 1
170 50032-11 •BLOCK - ATTACHING PARTS 1
180 AN509-10R11 •SCREW 2
190 AN960-10L •WASHER 2
200 MS21042-3 •NUT 2
210 16100-503-26-29 •ROLLER ASSEMBLY - ATTACHING 4
PARTS
220 HAIR-2 •SPRING PIN 2
230 20042-13 •TRAY 1
-240 20042-511 ROLLER TRAY ASSEMBLY (REF FIG. RF
1 FOR NHA)

ROLLER TRAY ASSEMBLY P/N 20042-507, 509, 511, 513 AND 565
FIGURE 25.04-13 (2 OF 4)

Revision 26 11-08-06 25.04.35

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
13/ 250 30070-1 •STUD - ATTACHING PARTS 2
290 MS21042-4 •NUT 1
270 AN960-416L •WASHER 1
280 10071-1 •PIN 1
290 50032-11 •BLOCK - ATTACHING PARTS 1
300 AN509-10R11 •SCREW 2
310 AN960-10L •WASHER 2
320 MS21042-3 •NUT 2
330 16100-503-26-29 •ROLLER ASSEMBLY - ATTACHING 3
PARTS
340 HAIR-2 •SPRING PIN 2
350 20042-15 •TRAY 1
-360 20042-513 ROLLER TRAY ASSEMBLY (REF FIG. RF
1 FOR NHA)
370 30070-1 •STUD - ATTACHING PARTS 2
380 MS21042-4 •NUT 1
390 AN960-416L •WASHER 1
400 10071-1 •PIN 1
410 50032-11 •BLOCK - ATTACHING PARTS 1
420 AN509-10R11 •SCREW 2
430 AN960-10L •WASHER 2
440 MS21042-3 •NUT 2
450 16100-503-26-29 •ROLLER ASSEMBLY - ATTACHING 18
PARTS
460 HAIR-2 •SPRING PIN 2
470 20042-67 •TRAY 1
-480 20042-565 •ROLLER TRAY ASSEMBLY (REF RF
FIG. 1 FOR NHA)
490 30070-1 •STUD ATTACHING PARTS 2
500 MS21042-4 •NUT 1
510 AN960-416L •WASHER 1
520 10071-1 •PIN, KEY LOCK 1
530 50032-11 •BLOCK ATTACHING PARTS 1
540 AN509-10R11 •SCREW 2
550 AN960-10L •NUT 2

ROLLER TRAY ASSEMBLY P/N 20042-507, 509, 511, 513 AND 565
FIGURE 25.04-13 (3 OF 4)

25.04.36 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
13/ 560 MS21042-3 •WASHER 2
570 16100-503-26-29 •ROLLER ASSEMBLY ATTACHING 18
PARTS
580 HAIR-2 •SPRING COTTER PIN 2
590 20042-67 •TRAY

ROLLER TRAY ASSEMBLY P/N 20042-507, 509, 511, 513 AND 565
FIGURE 25.04-13 (4 OF 4)

Revision 26 11-08-06 25.04.37

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ROLLER TRAY ASSEMBLY P/N 90542-001-18

FIGURE 25.04-14 (1 OF 2)

25.04.38 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL L. L. C.
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (CONT’D)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
14/ -1 90542-001-18 ROLLER TRAY ASSEMBLY (REF RF
FIG. 1 FOR NHA)
10 30070-1 •STUD - ATTACHING PARTS 2
20 MS21042-4 •NUT 1
30 AN960-416L •WASHER 1
40 10071-1 •PIN 1
50 50032-11 •BLOCK - ATTACHING PARTS 1
60 AN509-10R11 •SCREW 2
70 MS21042-3 •NUT 2
80 AN960-10L •WASHER 2
90 16100-503-26-29 •ROLLER ASSEMBLY - ATTACHING 19
PARTS
100 WW-22 •SPRING PIN 2
110 90542-3-18 •TRAY, ROLLER 1

ROLLER TRAY ASSEMBLY P/N 90542-001-18

FIGURE 25.04-14 (2 OF 2)

Revision 33 07-29-09 25.04.39

AIR TRANSPORT INTERNATIONAL L. L. C.
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
23.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (CONT’D)

FORE AND AFT RESTRAINT FITTING ASSEMBLY P/N 50573-505

FIGURE 25.04-15 (1 OF 2)

25.04.40 05-20-04 Revision 21

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
15/ -1 50573-505 FITTING ASSEMBLY, FORE AND A, B RF
AFT RESTRAINT (REF FIG. 1 FOR
NHA)
10 30070-1 •STUD 2
20 10057-17 •SHAFT - ATTACHING PARTS 2
30 MS24665-149 •COTTER PIN 2
40 50052-1 •SPRING 1
50 50052-2 •SPRING 1
60 50053-1 •SPRING 1
70 50053-2 •SPRING 1
80 AN960-516L •WASHER 4
90 50054-3 •PAWL 1
100 50055-3 •PAWL 1
110 AN565C1032H6 •SETSCREW 2
120 50040-1 •PIN 2
130 50039-1 •SPRING 2
140 50954-505 •BASE 1
-150 601-41 •LOCTITE AR

FORE AND AFT RESTRAINT FITTING ASSEMBLY P/N 50573-505

FIGURE 25.04-15 (2 OF 2)

Revision 26 11-08-06 25.04.41

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FORE AND AFT RESTRAINT FITTING ASSEMBLY P/N 50573-509

FIGURE 25.04-16 (1 OF 2)

25.04.42 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
16/ -1 50573-509 FITTING ASSEMBLY, FOR AND A, B
AFT RESTRAINT (REF FIG. 1 FOR
NHA)
10 30070-1 •STUD 2
20 16100-503-26-33 •ROLLER ASSEMBLY - ATTACHING 2
PARTS
30 MS24665-151 •COTTER PIN 2
40 10057-17 •SHAFT - ATTACHING PARTS 2
50 MS24665-151 •COTTER PIN 2
60 50052-1 •SPRING 1
70 50052-2 •SPRING 1
80 50053-1 •SPRING 1
90 50053-2 •SPRING 1
100 AN960-516L •WASHER 4
110 50054-3 •PAWL 1
120 50055-3 •PAWL 1
130 AN565C1032H6 •SETSCREW 2
140 50040-1 •SPIN 2
150 50039-1 •SPRING 2
160 50954-509 •BASE 1
170 601-41 •LOCTITE AR

FORE AND AFT RESTRAINT FITTING ASSEMBLY P/N 50573-509

FIGURE 25.04-16 (2 OF 2)

Revision 26 11-08-06 25.04.43

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY 50481-505(Shown) & -506(Opposite)

FIGURE 25.04-17 (1 OF 2)

25.04.44 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
17/ -1 50481-505 RAIL ASSEMBLY (REF FIG. 1 FOR A, B RF
NHA)
-2 50481-506 RAIL ASSEMBLY (OPPOSITE A, B RF
ITEM 1) (REF FIG 1 FOR NHA)
10 30070-1 •STUD 4
20 50040-1 •PIN, PLUNGER LOCK - 2
ATTACHING PARTS
30 AN565C1032-HG •SET SCREW 1
40 50039-1 •SPRING 2
50 50481-3 •RUB STRIP - ATTACHING 1
PARTS
60 HL329-5-7 •PIN 2
70 HL329-5-13 •PIN 4
80 HL70-5 •COLLAR 6
90 50646-3 •RAIL (FOR 50481-505 RAIL ASSY) 1
-100 50646-4 •RAIL (FOR 50481-506 RAIL ASSY) 1

RAIL ASSEMBLY P/N 50481-505 & -506

FIGURE 24.04-17 (2 OF 2)

Revision 26 11-08-06 25.04.45

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N 50781-601

FIGURE 25.04-18 (1 OF 2)

25.04.46 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
18/ -1 50781-601 SIDE RAIL ASSEMBLY (REF FIG. 1 B RF
FOR NHA)
10 50731-1 •FOOT, SIDE RAIL - ATTACHING 2
PARTS
20 10071-1 •PIN, KEYLOCK 1
30 AN509-416R16 •SCREW 2
40 50611-1 •PIVOT, SIDE RAIL 4
50 MS21042-L6 •NUT 4
60 50612-1 •WASHER 4
70 50609-1 •SPRING, SPIRAL TORSION 4
80 50608-1 •BUSHING, SIDE RESTRAINT 8
90 50725-1 •SLIDE PIN - ATTACHING PARTS 2
100 AN320-6 •NUT 2
110 AN960-616L •WASHER 2
120 MS24665-300 •COTTER PIN 2
130 50727-3 •SINGLE ARM 2
140 50728-3 •CLEVIS ARM 2
150 50730-1 •RAIL, RETRACTABLE SIDE 1
RESTRAINT
160 50362-529 •CROSSTRACK SCREWLOCK - 2
ATTACHING PARTS
170 10071-1 •PIN 2
180 30070-1 •STUD 4

RAIL ASSEMBLY P/N 50781-601

FIGURE 25.04-18 (2 OF 2)

Revision 26 11-08-06 25.04.47

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N 50911-1

FIGURE 25.04-19a (1 OF 2)

25.04.48 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
19a/ -1 50911-1 RAIL ASSEMBLY (REF FIG. 1 FOR A, B RF
NHA)
10 10071-1 •PIN, KEY LOCK 4
20 30070-1 •STUD 8
30 50953-3 •CROSSTRACK ATTACHING 2
PARTS
40 MS35276-261 •SCREW 2
-50 50891-539 •SLIDE ASSEMBLY, SIDE RAIL 1
60 50890-3 •SIDE RAIL 1
70 50583-1 •PLUNGER ASSEMBLY 2
80 50852-1 •SPRING ATTACHING PARTS 2
90 MS20253-2-134 •PIN 1

RAIL ASSEMBLY P/N 50911-1

FIGURE 25.04-19a (2 OF 2)

Revision 26 11-08-06 25.04.49

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N 50911-507

FIGURE 25.04-19b (1 OF 2)

25.04.50 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FIG PART NOMENCLATURE EFFECT UNITS

ITEM NUMBER 1234567 PER
ASSY
19b/ -1 50911-507 RAIL ASSEMBLY (REF FIG. 1 FOR A RF
NHA)
10 10071-1 •PIN, KEY LOCK 4
20 30070-1 •STUD 8
30 50953-3 •CROSSTRACK ATTACHING 2
PARTS
40 MS35276-261 •SCREW 2
-50 50891-583 •SLIDE ASSEMBLY, SIDE RAIL 1
60 50890-5 •SIDE RAIL 1
70 50583-1 •PLUNGER ASSEMBLY 2
80 50852-1 •SPRING ATTACHING PARTS 2
90 MS20253-2-134 •PIN 1

RAIL ASSEMBLY P/N 50911-507

FIGURE 25.04-19b (2 OF 2)

Revision 26 11-08-06 25.04.51

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N 50911-533

FIGURE 25.04-20 (1 OF 2)

25.04.52 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
20/ -1 50911-533 RAIL ASSEMBLY (SEE FIG. 1 FOR A, B RF
NHA)
10 10071-1 •PIN, KEY LOCK 4
20 30070-1 •STUD 8
30 50953-5 •CROSSTRACK ATTACHING 2
PARTS
40 MS35276-261 •SCREW 2
-50 50891-585 •SLIDE ASSEMBLY, SIDE RAIL 1
60 50890-7 •SIDE RAIL 1
70 50583-1 •PLUNGER ASSEMBLY 2
80 50852-1 •SPRING ATTACHING PARTS 2
90 MS20253-2-134 •PIN 1
100 50755-1 •FITTING, ADJUSTABLE 2
ATTACHING PARTS
110 MS35206-258 •SCREW 1

RAIL ASSEMBLY P/N 50911-533

FIGURE 25.04-20 (2 OF 2)

Revision 26 11-08-06 25.04.53

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N 50911-537

FIGURE 25.04-21 (1 OF 2)

25.04.54 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
21/ -1 50911-537 RAIL ASSEMBLY, SIDE B RF
RESTRAINT (REF FIG. 1 FOR
NHA)
-10 50891-583 •SLIDE ASSEMBLY, SIDE RAIL - 1
ATTACHING PARTS
20 MS35276-261 •SCREW, STOP 2
30 50583-1 ••PLUNGER, LOCK ASSEMBLY - 2
ATTACHING PARTS
40 MS20253-2-150 ••PIN 1
-50 50583-3 •••BODY 1
-60 50583-5 •••ARM 1
70 50852 •••SPRING, COMPRESSION 1
80 50890-5 ••RAIL, SLIDE ASSEMBLY 1
90 10071-1 •PIN, KEYLOCK 2
100 30070-1 •STUD 8
110 50953-13 •CROSSTRACK, RAIL ASSEMBLY 2

RAIL ASSEMBLY P/N 50911-537

FIGURE 25.04-21 (2 OF 2)

Revision 26 11-08-06 25.04.55

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N 50911-539

FIGURE 25.04-22 (1 OF 2)

25.04.56 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
22/ -1 50911-539 RAIL ASSEMBLY, SIDE B RF
RESTRAINT (REF FIG. 1 FOR
NHA)
-10 5895891-579 •SLIDE ASSEMBLY, SIDE 1
RESTRAINT RAIL - ATTACHING
PARTS
20 MS35276-261 •SCREW, STOP 3
30 479582-1 ••PLUNGER, LOCK - 3
ATTACHING PARTS
40 MS20523-2-150 •••PIN 1
50 2895852-1 ••SPRING, COMPRESSION 1
60 5895890-579 •RAIL 1
70 10071-1 •PIN, KEYLOCK 2
80 30070-1 •STUD 12
90 50953-11 •CROSSTRACK, RAIL ASSEMBLY 2
100 50953-9 •CROSSTRACK, RAIL ASSEMBLY 1

RAIL ASSEMBLY P/N 50911-539

FIGURE 25.04-22 (2 OF 2)

Revision 26 11-08-06 25.04.57

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N’S 50911-541 AND -543

FIGURE 25.04-23 (1 OF 2)

25.04.58 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
23/ -1 50911-541 RAIL ASSEMBLY, SIDE B RF
RESTRAINT (REF FIG. 1 FOR NHA)
50911-543 RAIL ASSEMBLY, SIDE B RF
RESTRAINT (REF FIG. 1 FOR NHA)
-10 50891-583 •SLIDE ASSEMBLY, SIDE 1
RESTRAINT - ATTACHING PARTS
20 MS35276-261 •SCREW, STOP 2
30 50583-1 ••PLUNGER, LOCK ASSEMBLY - 2
ATTACHING PARTS
40 MS20523-2-150 ••PIN 1
-50 50583-3 •••BODY 1
-60 50583-5 •••ARM 1
70 50852 •••SPRING, COMPRESSION 1
80 50890-5 ••RAIL, SLIDE ASSEMBLY 1
90 10071-1 •PIN, KEYLOCK 4
100 30070-1 •STUD 8
110 50953-15 •CROSSTRACK, RAIL ASSEMBLY 2
-120 50911-543 RAIL ASSEMBLY, SIDE RF
RESTRAINT (SEE FIG. 1 FOR NHA)
-130 50891-539 •SLIDE ASSEMBLY, SIDE 1
RESTRAINT - ATTACHING PARTS
140 MS35276-261 •SCREW, STOP 2
150 50583-1 ••PLUNGER, LOCK ASSEMBLY - 2
ATTACHING PARTS
160 MS20523-2-150 ••PIN 1
-170 50583-3 •••BODY 1
-180 50583-5 •••ARM 1
190 50852 •••SPRING, COMPRESSION 1
200 50890-7 ••RAIL, SLIDE ASSEMBLY 1
210 10071-1 •PIN, KEYLOCK 4
220 30070-1 •STUD 8
230 50953-15 •CROSSTRACK, RAIL ASSEMBLY 2

RAIL ASSEMBLY P/N’S 50911-541 AND -543

FIGURE 25.04-23 (2 OF 2)

Revision 26 11-08-06 25.04.59

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N 50911-545

FIGURE 25.04-24 (1 OF 2)

25.04.60 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
24/ -1 50911-545 RAIL ASSEMBLY, SIDE B RF
RESTRAINT (REF FIG. 1 FOR
NHA)
-10 5895891-535 •SLIDE ASSEMBLY, SIDE 1
RESTRAINT RAIL
20 4759583-1 ••PLUNGER, LOCK - 2
ATTACHING PARTS
30 MS20523-2-150 ••PIN 1
40 2895852-1 ••SPRING, COMPRESSION 1
50 5895890-535 ••RAIL 1
60 10071-1 •PIN, KEYLOCK 1
70 30070-1 •STUD 8
80 5801790-505M •CROSSTRACK, SIDE RESTRAINT 1
90 5801780-503M •CROSSTRACK, SIDE RESTRAINT 1

RAIL ASSEMBLY P/N 50911-545

FIGURE 25.04-24 (2 OF 2)

Revision 26 11-08-06 25.04.61

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

RAIL ASSEMBLY P/N 50911-547

FIGURE 25.04-25 (1 OF 2)

25.04.62 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)
ILLUSTRATED PARTS LIST
FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
25/ -1 50911-547 RAIL ASSEMBLY, SIDE B RF
RESTRAINT (REF FIG. 1 FOR
NHA)
-10 5895891-535 •SLIDE ASSEMBLY, SIDE 1
RESTRAINT RAIL
20 4759583-1 ••PLUNGER, LOCK - 2
ATTACHING PARTS
30 MS20523-2-150 ••PIN 1
40 2895852-1 ••SPRING, COMPRESSION 1
50 5895890-535 ••RAIL 1
60 10071-1 •PIN, KEYLOCK 1
70 30070-1 •STUD 8
80 5801780-505M •CROSSTRACK, SIDE RESTRAINT 1
90 5801780-503M •CROSSTRACK, SIDE RESTRAINT 1

RAIL ASSEMBLY P/N 50911-547

FIGURE 25.04-25 (2 OF 2)

Revision 26 11-08-06 25.04.63

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
26/ -1 50911-549 RAIL ASSEMBLY, SIDE RESTRAINT B RF
(REF FIG. 1 FOR NHA)
-10 5895891-535 •SLIDE ASSEMBLY, SIDE 1
RESTRAINT RAIL
20 4759583-1 ••PLUNGER, LOCK - ATTACHING 2
PARTS
30 MS20523-2-150 ••PIN 1
40 2895852-1 ••SPRING, COMPRESSION 1
50 5895890-535 ••RAIL 1
60 30070-1 •STUD 8
70 5801780-505M •CROSSTRACK, SIDE RESTRAINT 2
RAIL ASSEMBLY P/N 50911-549
FIGURE 25.04-26

25.04.64 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
27/ -1 50911-551 RAIL ASSEMBLY, SIDE RESTRAINT B RF
(REF FIG. 1 FOR NHA)
-10 5895891-535 •SLIDE ASSEMBLY, SIDE 1
RESTRAINT RAIL
20 4759583-1 ••PLUNGER, LOCK - ATTACHING 2
PARTS
30 MS20523-2-150 ••PIN 1
40 2898582-1 ••SPRING, COMPRESSION 1
50 5895890-535 ••RAIL 1
60 10071-1 •PIN, KEYLOCK 1
70 30070-1 •STUD 8
80 5801780-505M •CROSSTRACK, SIDE RESTRAINT 1
90 5801780-504M •CROSSTRACK, SIDE RESTRAINT 1
RAIL ASSEMBLY P/N 50911-551
FIGURE 25.04-27

Revision 26 11-08-06 25.04.65

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
28/ -1 50540-1 RESTRAINT ASSEMBLY, SIDE (REF A, B RF
FIG.1 FOR NHA)
10 MS16624-1025 •RING 4
20 50539-1 •PIN 4
30 50123-501 •SPRING 2
40 NAS43DD-5-23 •SPACER 2
50 50542-1 •LOCK ARM 1
60 50543-1 •LINK 2
70 50449-1 •SPRING CUP - ATTACHING PARTS 1
80 MS20426AD4-5 •RIVET 2
90 50541-1 •LATCH 1
SIDE RESTRAINT ASSEMBLY P/N 50540-1
FIGURE 25.04-28

25.04.66 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
29/ -1 50604-1 FITTING ASSEMBLY, PALLET A, B RF
RESTRAINT (REF FIG. 1 FOR
NHA)
10 30070-1 •STUD 2
20 10071-1 •PIN 2
30 50604-3 •FITTING 1
PALLET RESTRAINT FITTING ASSEMBLY P/N 50604-1
FIGURE 25.04-29

Revision 26 11-08-06 25.04.67

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
30/ -1 50605-1 FITTING ASSEMBLY, SIDE REST A RF
(REF FIG. 1 FOR NHA)
10 30070-1 •STUD 2
20 10071-1 •PIN 1
30 50605-3 •FITTING 1
SLIDE REST FITTING ASSEMBLY P/N 50605-1
FIGURE 25.04-30

25.04.68 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
31/ 1 50604-521 PALLET RESTRAINT FITTING A RF
10 10071-1 •PIN, KEY LOCK 1
20 30070-1 •STUD 2
30 50604-19 •FITTING 1
PALLET RESTRAINT FITTING P/N 50604-521
FIGURE 25.04-31

Revision 26 11-08-06 25.04.69

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
32/ -1 70568-517 CROSSTRACK ASSEMBLY, SIDE RF
RESTRAIN (REF FIG. 10 AND 11
FOR NHA)
10 50035-9 •SPACER - ATTACHING PARTS 2
20 MS16998-43 •CAPSCREW 2
30 AN935-416 •WASHER, LOCK 2
40 50035-11 •SPACER - ATTACHING PARTS 1
50 MS16998-43 •CAPSCREW 4
60 AN935-416 •WASHER, LOCK 4
70 70034-29 •RAIL, CROSSTRACK 1
80 70034-30 •RAIL, CROSSTRACK 1
CROSSTRACK ASSEMBLY P/N 70568-517
FIGURE 25.04-32

25.04.70 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
33/ -1 50881-EHK SIDE RAIL ASSEMBLY RF

10 50881-509 •SIDE RAIL ASSEMBLY 38” 60

20 50881-519 •SIDE RAIL ASSEMBLY 54” 1
30 50881-515 •SIDE RAIL ASSEMBLY 26” 4

EXTENDED HEIGHT RAIL ASSEMBLY KIT

Figure 25.04-33 (1 of 5)

Revision 26 11-08-06 25.04.71

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

FOOT REPAIR KIT - 50731-3HK

EXTENDED HEIGHT RAIL ASSEMBLY KIT

Figure 25.04-33 (2 of 5)

25.04.72 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
33/ -1 50881-509 SIDE RAIL ASSEMBLY 38” RF

10 50830-11 •SIDE RAIL 1

20 50731-KIT •FOOT REPAIR KIT 2

EXTENDED HEIGHT RAIL ASSEMBLY KIT

Figure 25.04-33 (3 of 5)

Revision 26 11-08-06 25.04.73

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
32/ -1 50881-515 SIDE RAIL ASSEMBLY 26” RF

10 50830-15 •SIDE RAIL 1

20 50731-KIT •FOOT REPAIR KIT 2

EXTENDED HEIGHT RAIL ASSEMBLY KIT

Figure 25.04-33 (4 of 5)

25.04.74 11-08-06 Revision 26

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 EQUIPMENT & FURNISHINGS
25.04 PEMCO CARGO HANDLING SYSTEM, P/N 50045-505-1/ & -2, ILLUSTRATED
PARTS CATALOG (cont’d)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
32/ -1 50881-519 SIDE RAIL ASSEMBLY 54” RF

10 50830-19 •SIDE RAIL 1

20 50731-KIT •FOOT REPAIR KIT 3

EXTENDED HEIGHT RAIL ASSEMBLY KIT

Figure 25.04-33 (5 of 5)

Revision 26 11-08-06 25.04.75

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CHAPTER 25 EQUIPMENT & FURNISHINGS

INTENTIONAL
BLANK

25.04.76 11-08-06 Revision 26

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DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS

25.05 – RECURRING NON-ROUTINE JOB CARDS

TABLE OF CONTENTS
Page

RECURRING NON-ROUTINE JOBCARDS

25.05-1 LOOSE EQUIPMENT INVENTORY------------------------------------------- 25.05.1
25.05-2 SUPERNUMERARY CONVERSION FOR UP TO 36 SEATS –
INSTALLATION------------------------------------------------------------------- 25.05.7
25.05-2A SUPERNUMERARY CONVERSION FOR UP TO 36 SEATS –
REMOVAL-------------------------------------------------------------------------- 25.05.9
25.05-3 RECONFIGURE COMBI AIRCRAFT TO FULL CARGO FREIGHTER
AIRCRAFT ONLY USING 125” PALLETS. ---------------------------------- 25.05.11
25.05-3A RECONFIGURE COMBI AIRCRAFT FROM FULL FREIGHTER
BACK TO COMBI AIRCRAFT CONFIGURATION ------------------------ 25.05.12

FIGURES
25.05-1 FLIGHT DECK STATIONS ------------------------------------------------------ 25.05.6

Revision 23 12-07-05 25.05- i

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CHAPTER 25 - EQUIPMENT & FURNISHINGS

INTENTIONAL
BLANK

25.05-ii 12-07-05 Revision 23

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

25.05-1
JOB TITLE
Loose Equipment Inventory
Job Card Reviewed By Date
Page 1 of 6
Mechanic Inspector
A. Perform loose equipment inventory of Non-Emergency equipment using the
following table:
FDS QTY QTY IN- QTY OUT-
AREA ITEM INSTALLED COMING GOING
FLIGHT DECK
2 FLIGHT ENGINEER’S TOOL KIT 1
4 HEADSET 1
6 SECURITY WAND 1
7 SUN VISOR 1
HEADSET 1
MICROPHONE 1
8 NORMAL CHECKLIST 1
QUICK REFERENCE HANDBOOK 1
9 HANDSET 1
10 NORMAL CHECKLIST 1
11 SUN VISOR 1
HEADSET 1
MICROPHONE 1
12 NORMAL CHECKLIST 1
QUICK REFERENCE HANDBOOK 1
13 SPARE LOG BOOK 1
16 FUEL DRAIN CRANK 1
17 HEADSET 1
MICROPHONE 1
18 LOG BOOK 1
21 PORTA-POTTI 1
22/23 COAT HANGER 3
TOILET PAPER ROLLS 2
TRASH CONTAINER 1
22/25 HAZMAT SPILL KIT 1

Revision 29 10-29-07 25.05.1

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

25.05-1
JOB TITLE
Loose Equipment Inventory
Job Card Reviewed By Date
Page 2 of 6
QTY QTY IN- QTY OUT-
AREA ITEM INSTALLED COMING GOING
23 OVEN 1
COFFEE POT 1
24 CARGO DOOR CRANK 1
FUEL SUMP SCREWDRIVER 1
GEAR PINS 3
25 WATER JUG 1
COMBI SEAT BELT EXTENDERS 3
AIRCRAFT LIBRARY
2 DE-ICE/ANTI-ICE MANUAL 1
2 GENERAL OPERATIONS MANUAL 1
2 DC-8 MINIMUM EQUIPMENT LIST 1
2 COCKPIT OPERATING MANUAL 1
2 FMS OPERATORS MANUAL 1
2 TAWS OPERATORS MANUAL 1
2 JEPPESSEN NAVIGATION KIT 1
12 PERFORMANCE HANDBOOK 1
12 AIRPORT ANALYSIS 1
13 SPARE PARTS KIT INVENTORY 1
20 FORMS KIT 1
24 ATI AFM SUPPLEMENT MANUAL 1
24 GROUND SERVICES MANUAL 1
24 AIRCRAFT OPERATING MANUAL 1
24 HAZARDOUS MATERIALS 1
MANUAL
24 FUELING MANUAL 1
B Pit GENERAL MAINTENANCE 1
MANUAL
B Pit DC-8 MAINTENANCE MANUAL 1
B Pit WIRING DIAGRAM MANUALS 1

25.05.2 10-29-07 Revision 29

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

25.05-1
JOB TITLE
Loose Equipment Inventory
Job Card Reviewed By Date
Page 3 of 6
QTY QTY IN- QTY OUT-
AREA ITEM INSTALLED COMING GOING

A PIT
CURTAINS (SET OF 3) 3
HEADSET, GROUND INTERCOM
with CORD (COMBI/-73) 1
LADDER 1
TOW BAR 1
FIRE BLANKETS 5
B PIT
DACO DC-8 MM, SRM & IPC TAPES 1
& READER(COMBI)
BRAKE ASSEMBLIES 2
CURTAINS (SET OF 3) 3
NLG WHEEL & TIRE ASSEMBLY 2
MLG WHEEL & TIRE ASSEMBLY 2
C PIT
TAIL STAND 1
FAK PARTS MISC.
D PIT
CURTAINS (SET OF 3) 3

NOTE: Due to aircraft differences, the specific location and quantity of some items may vary.

Mechanic Inspector
B. Perform loose equipment inventory of Emergency equipment using the
following table (Reference ATI DC-8 MM 16.02.):

QTY QTY IN- QTY OUT-

AREA ITEM INSTALLED COMING GOING

COCKPIT
-62/-72 -70
COMBI FREIGHTER
ESCAPE ROPES-EMERGENCY 3 2
WINDOW EXITS
LIFE RAFT 1 1(a)
NOTE: (a) Installed for over water operations only.

Revision 29 10-29-07 25.05.3

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

25.05-1
JOB TITLE
Loose Equipment Inventory
Job Card Reviewed By Date
Page 4 of 6
QTY QTY IN- QTY OUT-
AREA ITEM INSTALLED COMING GOING
-62/-72 -70
COMBI FREIGHTER
PORTABLE BREATHING 1 1
EQUIPMENT (PBE)
OXYGEN MASKS – QUICK DON 5 5
SMOKE GOGGLES 5 5
LIFE VESTS 5 5
CRASH AXE 1 1
HALON FIRE EXTINGUISHER 1 1
WATER FIRE EXTINGUISHER 1
FIRST AID KIT 1
MEDICAL KIT 1
COMMUNICATOR (HAND HELD 1
RADIO)
COURIER AREA
ESCAPE ROPE-MAIN CABIN DOOR 1 1
LIFE RAFT 1(a)
PBE 6 1
PORTABLE O2 BOTTLE (NOTE-IN 1
LAVATORY)
FULL FACE MASK (NOTE-IN 1
LAVATORY)
OXYGEN MASKS – QUICK DON 2/1(b)
LIFE VESTS 2/1(b)
HALON FIRE EXTINGUISHER 3 1
CREW OXYGEN BOTTLE (OR IN 2 2
‘C’ PIT-LOCATION/QUANTITY
MAY VARY)
WATER FIRE EXTINGUISHERS 2
COMMUNICATOR 1
PROTECTIVE GARMENT-FIRE 1
RESISTANT NOMEX SUIT
APPLICATOR WAND 1
MEGAPHONE 1
EMERGENCY LOCATOR 1
TRANSMITTER
NOTES: (a) Installed for over water operations only.
(b) 2 installed on –71’s and 1 on –73’s.

25.05.4 10-29-07 Revision 29

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

25.05-1
JOB TITLE
Loose Equipment Inventory
Job Card Reviewed By Date
Page 5 of 6
QTY QTY IN- QTY OUT-
AREA ITEM INSTALLED COMING GOING

COMBI PASSENGER COMPARTMENT

ESCAPE SLIDES-AFT RIGHT & 2
LEFT DOORS
LIFE RAFTS 2
PBE 2
PORTABLE OXYGEN BOTTLE 3
LIFE VESTS (OVERHEAD BIN) 3(c)
LIFE VESTS (JUMPSEAT) 2
HALON FIRE EXTINGUISHERS 2
WATER FIRE EXTINGUISHER 1
FIRST AID KITS 2
COMMUNICATOR 1
PROTECTIVE GARMENT 1
PASSENGER OXYGEN BOTTLES 3(d)
SPARE O2 MASKS 3
DOOR BARRIER STRAPS 2
EMERGENCY FLASHLIGHTS 2
MEGAPHONE 1
FA DEMO KIT 1
BIO-HAZARD CLEANUP KIT 1
AUTOMATIC EXTERNAL 1
DEFIBRILLATOR (AED)
SEAT BELT EXTENDERS 3
SLIDE “ARMED” STRAP 2
DOOR “OPENED” SAFETY STRAP 2
NOTES: (c) Plus 1 for each passenger seat.
(d) 1 bottle is for emergency medical use.

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CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

25.05-1
JOB TITLE
Loose Equipment Inventory
Job Card Reviewed By Date
Page 6 of 6

FLIGHT DECK STATIONS

Figure 25.05-1

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25.05 RECURRING NON-ROUTINE JOB CARDS (CONT’D) [COM 2.03]
ATI RECURRING NONROUTINE ATI-001
A/C NUMBER LOG PAGE DATE STATION JOB CARD NUMBER

25.05-2
JOB TITLE
Supernumerary Conversion for up to 36 Seats - INSTALLATION
Job Card Reviewed By Date

Page 1 of 2
Mechanic Inspector
I. General:

QTY Required Material

1-12 Approved triple seats with approved seat belts, and Passenger
Safety Briefing Cards installed.
3-36 Life Vests (1 for each seat position installed)
3-36 Personal Breathing Equipment (PBE) (1 for each seat position
installed)
3-36 Flashlights (1 for each seat position)
3 UHF Portable two way radios*
2 Bull Horns*
1 Emergency Slide System* (installed at L2 door)
1 16 lb. or larger Halon Fire Extinguisher
1 46 Person Life raft with ELT
1 “FASTEN SEATBELT/NO SMOKING/USE OXYGEN” Sign
(Quick disconnect type)
(* Items in excess of FAR requirement)
II. Tasks:
A. Remove existing cargo roller system. Store roller system in “B” pit and
prepare a COMAT form in accordance with GMM COMAT procedures.
B. Install up to twelve sets of approved triple seats in the seat tracks
provided in the floor IAW Supernumerary Seat Configuration Table 1
(see reverse). Install the seats starting from the aft most position.
C. Install the remainder of the Required Material (above) after checking the
ATI Emergency Equipment Tag on each item to ensure no item has
exceeded the approved inspection interval.
(Life raft and portable fire extinguisher are to be secured as loose
equipment. Secure the second bullhorn in the companionway for use by
the flight crew.)
D. Operationally check the “FASTEN SEAT BELT/NO SMOKING/USE
OXYGEN” sign.
E. Initiate a logbook entry stating “Supernumerary Seats Installed IAW
ATI Recurring Non-Routine Job Card 25.05-2, configuration XXX.”
FAX a copy of log page and completed job card to MX Control. Attach
this completed and signed Job Card to the log page and forward to Q/C
Records.

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CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS (CONT’D) [COM 2.03]
ATI RECURRING NONROUTINE ATI-001
A/C NUMBER LOG PAGE DATE STATION JOB CARD NUMBER

25.05-2
JOB TITLE
Supernumerary Conversion for up to 36 Seats - INSTALLATION
Job Card Reviewed By Date

Page 2 of 2

CONFIGURATION POSITION(s) SEATS

1 P18 & P19 15
2 P17 & P18/19 18 & 12
3 P17 18
4 P16 & P17 18 & 18
SUPERNUMERARY SEAT CONFIGURATIONS
Table 1

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CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS (CONT’D)
ATI RECURRING NONROUTINE ATI-001
A/C NUMBER LOG PAGE DATE STATION JOB CARD NUMBER

25.05-2A
JOB TITLE
Supernumerary Conversion for up to 36 Seats - REMOVAL
Job Card Reviewed By Date
Page 1 of 1
Mechanic Inspector
I. General:

QTY Required Material

1 Cargo roller system, to include end stops, pallet locks, roller
trays and side rails. (Should be stored in ‘B’ pit from previous
removal).
II. Tasks:
A. Remove all seats installed. Inspect seat assemblies to identify damage
and install unserviceable tags if required. Protect seat assemblies and return
to ATI Stores.
B. Remove the following safety equipment:

3-36 Life Vests (1 for each seat position installed)

3-36 Personal Breathing Equipment (1 for each seat position installed)
3 UHF Portable two way radios
2 Bull Horns
1 Emergency Slide System
1 16 lb. or larger Halon Fire Extinguisher
1 46 Person Life Raft
1 “FASTEN SEATBELT/NO SMOKING/USE OXYGEN” Sign
Inspect all safety equipment as it is removed to identify damage or
equipment approaching inspection due date. Install unserviceable tags on
items if required. Return all items to ATI Stores.
C. Install cargo roller system to include end stops, pallet locks, roller trays
and side rails in the proper locations IAW ATI M/M 25.01
D. Initiate a log book entry stating “Supernumerary Seats Removed IAW
ATI Recurring Non-Routine Job Card 25.05-2A.” FAX a copy of log
page and completed job card to MX Control. Attach this completed and
signed Job Card to the log page and forward to Q/C Records.

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CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS(cont’d)
ATI RECURRING NONROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

25.05-3
JOB TITLE
Reconfigure Combi Aircraft to Full Cargo freighter Aircraft only using 125” pallets.
Job Card Reviewed By Date
Page 1 of 1
Mechanic Inspector

I. General:
This maintenance practice provides for the de-activation of the passenger systems that
are not required during the operation of a Combi Aircraft as a Freighter only Aircraft
utilizing 125” pallets.
II. Tasks:
A. Oxygen Systems:
1. Turn off all passenger and Emergency bottles located in the passenger
compartment. I/A/W DACO M.M. 35-00
B. Potable Water:
1. Drain all Potable water from storage tanks I/A/W DACO M.M. 38-10-0 Pg.
304
2. Drain water from all Hot Water Heaters stored under lavatory sinks. I/A/W
DACO M.M. 38-10-0
3. Blow out all water lines to prevent algae from growing, and from bursting
during winter operation.
C. Toilets:
1. Flush, rinse and leave empty all lavatory toilets I/A/W DACO M.M. 38-30-0
Pg. 201.
D. Electrical:
1. Gain Access to the Cabin area circuit breaker panel located above the R2
service door. Pull all circuit breakers for the following items; OVENS,
HOTCUPS, COFFEE MAKERS, CABIN COVE LIGHTS, PAX.
ENTERTAINMENT SYSTEMS, TOILET FLUSH MOTORS, HOT WATER
HEATERS, WATER COMPRESSOR, AND/OR WATERPUMP.
2. Tag galley power switch on F/E instrument panel “DO NOT OPERATE”
E. Misc. Equipment
1. Ensure all loose equipment is secured, example Hot Water cups, Coffee pots,
etc.
2. Ensure both aft entry doors girt bars are stowed and slide is NOT ARMED.
3. Remove all left over perishable food, water, and garbage.
4. Close smoke barrier door and lock from cargo compartment side. Padlock key
to be given to flight crew.
F. Log Book Sign Off:
1. Make an entry into Log Book stating the Aircraft was re-configured I/A/W
ATI Recurring Non-Routine making reference to this Job Card and that no
persons can be carried or allowed in passenger compartment and aircraft is
release for freight only operation.
2. Notify Dispatch / Operations there is to be a change in the Weight and Balance
so they may reference the Operation Weight Form for each individual Aircraft.

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CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.05 RECURRING NON-ROUTINE JOB CARDS(cont’d)
ATI RECURRING NONROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

25.05-3A
JOB TITLE
Reconfigure Combi Aircraft from full Freighter back to Combi aircraft Configuration
Job Card Reviewed By Date
Page 1 of 1
Mechanic Inspector

I. General:
This maintenance practice provides for the Re-activation of the passenger systems that
are required during the operation of a Combi Aircraft from a Freighter only Aircraft
utilizing 125” pallets.
NOTE: Obtain key from flight crew and unlock passenger compartment.
II. Tasks:
A. Oxygen Systems:
1. Turn on all passenger and Emergency Oxygen bottles located in the passenger
compartment. I/A/W DACO M.M. 35-00.
B. Potable Water
1. Fill all Potable water storage tanks I/A/W DACO M.M. 38-10-0 Pg. 304
2. Ensure water is in all Hot Water Heaters stored under lavatory sinks. I/A/W
DACO M/,/ 38-10-0.
C. Toilets
1. Flush, rinse and Fill all lavatory toilets I/A/W DACO M.M. 38-30-0 Pg. 201
D. Electrical:
1. Gain Access to the Cabin area circuit breaker panel located above the R2
service door. Push in all circuit breakers for the following items; OVENS,
HOT CUPS, COFFEE MAKERS, CABIN COVE LIGHTS, PAC.
ENTERTAINMENT SYSTEMS, TOILET FLUSH MOTORS, HOT WATER
HEATERS, WATER COMPRESSOR, AND/OR WATER PUMP.
2. Remove “DO NOT OPERATE” tag from F/E position galley power switch.
E. Misc. Equipment
1. Ensure all loose equipment is returned to its original position, example Hot
Water cups, Coffee pots, etc.
2. Ensure both aft entry doors girt bars are stowed and slide in NOT ARMED.
F. Operational Check:
1. Carry out an operational check off all items that were re-activated to ensure
their operation.
G. Log Book Sign Off:
1. Make an entry into Log Book stating the Aircraft was re-configured I/A/W
ATI Recurring Non-Routine making reference to this Job Card.
2. Notify Dispatch / Operations there is to be a change in the Weight and Balance
so they may reference the Operating Weight Form for each individual Aircraft.

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25.06 – PHILIPS HARTSTART FRX

DEFIBRILLATOR 861304
TABLE OF CONTENTS

Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 25.06.1

2. HEARTSTART FRX USE ----------------------------------------------------------- 25.06.3

3. AFTER USING THE HEARTSTART FRX --------------------------------------- 25.06.8

4. MAINTAINING THE HEARTSTART FRX -------------------------------------- 25.06.8

FIGURES
25.06-1 HEARTSTART FRX DEFIBRILLATOR--------------------------------------- 25.06.1

25.06-2 GREEN ON/OFF BUTTON ------------------------------------------------------ 25.06.3

25.06-3 OPEN PADS CASE ---------------------------------------------------------------- 25.06.4

25.06-4 PADS ICON ------------------------------------------------------------------------- 25.06.4

25.06-5 PADS PLACEMENT -------------------------------------------------------------- 25.06.4

25.06-6 CAUTION LIGHT & SHOCK BUTTON--------------------------------------- 25.06.5

25.06-7 SHOCK BUTTON------------------------------------------------------------------ 25.06.6

25.06-8 I-BUTTON -------------------------------------------------------------------------- 25.06.6

25.06-9 INFANT/CHILD KEY INSERTION -------------------------------------------- 25.06.7

TABLES
25.06-1 TROUBLESHOOTING TABLE #1 --------------------------------------------- 25.06.11

25.06-2 TROUBLESHOOTING TABLE #2 --------------------------------------------- 25.06.12

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25.06 PHILIPS HEARTSTART FRX DEFIBRILLATOR 861304

1. General

a. The Philips HeartStart FRx Defibrillator 861304 is an automated external defibrillator

(AED). After applying the AED’s electrodes to the patient’s chest, the AED
automatically analyzes the patient’s electrocardiogram (ECG) and advises the operator to
push the button and deliver a shock if needed. The AED uses one button and guides the
operator through the rescue using a combination of voice prompts, audible alerts, and
visible indicator.

HEARTSTART FRX DEFIBRILLATOR

Figure 25.06-1

b. Setting Up the AED

(1) HeartStart SMART Pads II (989803139261)

(a) Open the SMART Pads II package and take out the Pads Case. Do not open
the pads case until you need to use the pads in an emergency. Plug the pads
cable connector into the connector port on the AED. Store the unopened Pads
Case in the pocket provided in the defibrillator carry case.
(b) Pads package is labeled with a use-by date of at least two years from date of
manufacture. The expiration date for the SMART Pads II is listed on the
outside of the package and the Pads Case.

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25.06 PHILIPS HEARTSTART FRX DEFIBRILLATOR 861304 (cont’d)

(2) TSO C-142 Battery (989803139301)

(a) Open the battery package and remove the battery. Place the bottom end of the
battery into the bottom of the compartment on the back of the AED, then
firmly press down the top (latch) end of the battery into the compartment until
it clicks into place.
(b) The manufacturer’s date of the battery is listed on the outside of the battery.
The standby life of the battery is typically four years when stored and
maintained according to the directions provided. When new, the battery
provides a minimum of 200 shocks or 4 hours of operating time at 25° C.
(c) Never charge, short circuit, puncture, deform, incinerate, heat above 60° C, or
expose contents to water. Remove the battery when discharged.

(3) Buttons/Lights (see Figure 25.06-1)

(a) Green Ready Light – Blinks when the defibrillator is in standby mode (ready
for use); solid when the defibrillator is being used (including running self-
tests).
(b) Green On/Off Button – Pressing the On/Off button when the defibrillator is in
standby mode turns the defibrillator on; pressing and holding the On/Off
button for one second when the defibrillator is on turns the defibrillator off
and disarms the defibrillator. In addition, pressing the On/Off button stops the
battery insertion self-test that automatically runs when a battery is inserted.
(c) Blue i-button (Information Button) – Pressing the i-button while it is flashing
during a patient care pause provides CPR Coaching; pressing it while it is
flashing and the defibrillator is chirping provides troubleshooting guidance.
Pressing it until it beeps at other times provides summary information about
the defibrillator’s last clinical use. Pressing it briefly in standby mode gives
device status.
(d) Caution Light – Flashes during rhythm analysis; is on but not flashing when a
shock is advised, as a reminder not to touch the patient.
(e) Orange Shock Button – If a shock is needed, flashes when the defibrillator is
charged. The defibrillator directs the user to press the Shock button to deliver
a shock to the patient.
(f) Pads Placement LEDs – Flash when AED is turned on; off once pads are
placed on patient.
(g) Low Battery Indicator – Alarm chirps and flashing blue i-button. [See
paragraph 4.d.(3)]

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25.06 PHILIPS HEARTSTART FRX DEFIBRILLATOR 861304 (cont’d)

2. HeartStart FRx Use

a. If you think someone is in Sudden Cardiac Arrest (SCA), quickly get the AED and bring
it to the victim’s side.

NOTE: If the victim is an infant or child, see 2.c. for treating infants and children.

CAUTION: CHECK THE IMMEDIATE ENVIRONMENT FOR FLAMMABLE GASES. DO

NOT USE THE AED IN THE PRESENCE OF FLAMMABLE GASES, SUCH AS
AN OXYGEN TENT. HOWEVER, IT IS SAFE TO USE THE AED ON
SOMEONE WEARING AN OXYGEN MASK.

b. There are three basic steps to using the HeartStart FRx Defibrillator to treat someone who
may be in sudden cardiac arrest.

(1) Press the green On/Off button.

(a) Press the On/Off button to turn on the AED. (See Figure 25.06-2.)
(b) The AED tells you to remove all clothes from the person’s chest. If necessary,
rip or cut off the clothing to bare the person’s chest.

GREEN ON/OFF BUTTON

Figure 25.06-2

(2) Follow the AED’s voice instructions.

(a) Remove the SMART Pads II case from the AED carrying case. Clean and dry
the patient’s skin and, if necessary, clip or shave excessive chest hair to ensure
pads have good contact with the bare skin.
(b) Open the pads case as shown in Figure 25.06-3. Peel off one pad.

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OPEN PADS CASE

Figure 25.06-3

(c) Pads placement is very important. The icons on the pads placement diagram
on the AED front panel will be flashing to help guide you. (See Figure 25.06-
4.) Place the pad on the patient’s bare skin exactly as shown in Figure 25.06-
5. Press the adhesive portion of the pad down firmly. Then repeat this with
the other pad.

PADS ICON
Figure 25.06-4

PADS PLACEMENT
Figure 25.06-5

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(3) Press the flashing orange Shock button if instructed.

(a) As soon as the HeartStart FRx detects that the pads are attached to the patient,
the pads icons turn off. The AED begins analyzing the patient’s heart rhythm.
It tells you that no one should be touching the patient and the Caution light
begins flashing as a reminder. (See Figure 25.06-6.)

CAUTION LIGHT & SHOCK BUTTON

Figure 25.06-6

NOTE: Keep the patient still and keep any movement around the patient to a
minimum during rhythm analysis. Do not touch the patient or the pads
while the Caution light is on solid or flashing. If the AED is unable to
analyze due to electrical “noise,” it will tell you to stop all movement and
remind you not to touch the patient.

(b) If a shock is needed, the Caution light stops flashing and stays on, and the
orange Shock button starts flashing. The AED tells you to press the flashing
orange button. (See Figure 25.06-7.) You must press the Shock button for a
shock to be delivered. When you press the Shock button, the AED tells you
that the shock has been delivered. Then it automatically analyzes the heart
rhythm again to see if another shock is needed. If not, the defibrillator tells
you it is safe to touch the patient, instructs you to begin CPR, and invites you
to press the flashing blue i-button for CPR Coaching if desired.

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SHOCK BUTTON
Figure 25.06-7

NOTE 1: The AED will only deliver a shock if the flashing orange Shock button
is pressed when the instruction is given. If the Shock button is not
pressed within 30 seconds after the instruction, the AED will disarm
itself and give a reminder to make sure emergency medical services
have been called and then begin a CPR interval. This is designed to
minimize interruption of CPR and help ensure ongoing patient support.

NOTE 2: While waiting for you to press the Shock button, the AED will continue
to analyze the heart rhythm. If the patient’s rhythm changes before you
press the Shock button and a shock is no longer needed, the defibrillator
will disarm and tell you a shock is not advised.

(c) If a shock is not needed, the blue i-button comes on solid to show that it is safe
to touch the patient. (See Figure 25.06-8.) The AED also tells you to assess
the patient and perform CPR if needed. Then the AED invites you to press the
flashing blue i-button for CPR Coaching if desired.

i-BUTTON
Figure 25.06-8

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(d) For CPR Coaching, press the flashing blue i-button during the first 30 seconds
of the patient care pause to activate CPR Coaching. (If the Infant/Child Key is
inserted, the CPR Coaching provided will be for infant/child CPR.) When the
pause is over, the AED tells you to stop CPR so it can analyze the patient’s
heart rhythm. The motion caused by CPR can interfere with analysis so be
sure to stop all motion when instructed.

c. Treating Infants and Children – If the victim is under 55 pounds or 8 years old, use the
Infant/Child Key.

(1) Insert the Infant/Child Key into the slot at the top center of the front panel of the
AED (see Figure 25.06-9). The pink portion of the Key pivots and fits into the slot,
with the front of the Key lying flat on the surface of the AED so the infant/child
pads placement diagram is visible. (The back of the Infant/Child Key also has a
diagram showing how to insert it.)

INFANT/CHILD KEY INSERTION

Figure 25.06-9

(2) Turn on the AED and follow instructions to remove all clothing from the torso to
bare both the chest and the back.
(3) Place the pads on the child’s front and back, as illustrated on the Key. It does not
matter which pad is placed on the chest or back.

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NOTE: It does not matter whether you insert the Infant/Child Key before or
immediately after turning on the AED. However, the Key should be
inserted before placed the pads on the patient.

(4) With the Infant/Child Key inserted, the AED will announce “Infant/Child Mode,”
automatically reduce the defibrillation energy from the adult dose of 150 Joules to
50 Joules, and provide optional infant/child CPR Coaching.

CAUTION IF THE INFANT/CHILD KEY IS REMOVED DURING USE, THE AED

WILL ANNOUNCE “ADULT MODE”. ANY SHOCKS DELIVERED
WILL BE AT ADULT ENERGY AND OPTIONAL CPR COACHING
WILL BE FOR ADULT CPR.

3. After Using the HeartStart FRx

a. Check the outside of the AED for signs of damage, dirt, or contamination. If you see
signs of damage, contact Philips for technical support. If the defibrillator is dirty or
contaminated, clean it according to the guidelines in paragraph 4.c, “Cleaning the AED”.

b. Plug the cable connector for a new set of SMART Pads II into the AED (do not open the
pads case). Check supplies and accessories for damage and expiration dates. Replace
any used, damaged, or expired items. For directions on changing the pads and replacing
the battery, see 1.b. The single-use pads must be replaced after being used.

c. Remove the battery for five seconds; then reinstall it to run the battery insertion self-test
to check the operation of the defibrillator. When the test is complete, check that the
green Ready light is blinking.

d. Return the AED to its storage location so it will be ready for use when needed.

4. Maintaining the HeartStart FRx

a. Routine Maintenance

(1) The HeartStart FRx AED performs a self-test every day. In addition, a battery
insertion self-test is run whenever a battery is installed in the device. The AED’s
extensive automatic self-test features eliminate the need for any manual calibration.

WARNING: ELECTRICAL SHOCK HAZARD. DO NOT OPEN THE

HEARTSTART FRX, REMOVE ITS COVERS, OR ATTEMPT
REPAIR. THERE ARE NO USER-SERVICEABLE
COMPONENTS IN THE HEARTSTART FRX. IF REPAIR IS
REQUIRED, RETURN THE AED TO AN AUTHORIZED
SERVICE CENTER.

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(2) Do not leave the defibrillator without a set of pads connected. The defibrillator will
start chirping and the i-button will start flashing.

(3) Do not store the AED with the Infant/Child Key installed.

(4) The HeartStart FRx AED runs a daily self-test. As long as the green Ready light is
blinking, it is not necessary to test the defibrillator by initiating a battery insertion
self-test. This uses battery power and risks draining the battery prematurely.

b. Periodic Checks – Other than the checks recommended after each use of the PowerHeart
FRx AED (see paragraph 3), maintenance is limited to periodically checking the
following:

(1) Check the green Ready light. If the green Ready light is not blinking, see paragraph
4.d, “Testing and Troubleshooting,” below.
(2) Replace any used, damaged, or expired supplies and accessories.
(3) Check the outside of the defibrillator. If you see cracks or other signs of damage,
contact Philips for technical support.

c. Cleaning the AED

(1) The outside of the HeartStart FRx can be cleaned with a soft cloth dampened in
soapy water, chlorine bleach (2 tablespoons per quart or liter of water), ammonia-
based cleaners, or 70% isopropyl (rubbing) alcohol. It is recommended that the
carry case be cleaned with a soft cloth damped in soapy water.
(2) Do not use strong solvents such as acetone or acetone-based cleaners, abrasive
materials, or enzymatic cleaners to clean the AED and accessories.
(3) Do not immerse the AED in fluids. Do not sterilize the AED or its accessories.

d. Testing and Troubleshooting

(1) The HeartStart FRx Defibrillator automatically tests its battery, connected SMART
Pads II, and internal circuitry every day. It alerts you if it finds a problem.

(2) You can also test the defibrillator at any time by removing the battery for five
seconds and then reinstalling it. This test takes about one minute. Because the
battery insertion self-test is very detailed and uses battery power, running it more
often than necessary will drain the battery prematurely. It is recommended that you
run the battery insertion self-test only:

(a) When the defibrillator is first put into service.

(b) After each time the defibrillator is used to treat a patient.
(c) When the battery is replaced.
(d) When the defibrillator may have been damaged.

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NOTE: If the AED turns off when you install the battery instead of running the
battery insertion self-test, check to be sure that the pads case is not open.
If the pads case is open, the AED assumes that it may be in use and so
will not run the self-test.

(3) Troubleshooting

(a) The AED’s green Ready light is your guide to knowing if the defibrillator is
ready to use. The defibrillator chirps and the i-button flashes to alert you to a
problem.
(b) If the Ready light is blinking – The AED has passed the battery insertion self-
test and the last periodic self-test and is therefore ready for use.
(c) If the Ready light is solid – The AED is in use or running a self-test.
(d) If the Ready light is off, the AED is chirping, and the i-button is flashing – A
self-test error has occurred, there is a problem with the pads, the Infant/Child
Key has been left installed, or the battery is low. Press the i-button for
instructions.
(e) If the Ready light is off but the AED is not chirping and the i-button is not
flashing – There is no battery inserted, the battery is depleted, or the AED
needs repair. Insert/replace battery and run the self-test. As long as the AED
passes the self-test, you can be assured it is ready for use.

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25.06 PHILIPS HEARTSTART FRX DEFIBRILLATOR 861304 (cont’d)

Troubleshooting while the AED is being used (Green Ready light is solid)
AED Says: Possible Cause: Recommended Action:
…To replace the battery The battery is nearly depleted. The Install a new battery immediately.
immediately AED will turn off unless a new
battery is installed.
…To plug in pads The pads connector has been Plug in the pads connector.
connector unplugged.
…To replace pads. The pads have been damaged Replace the damaged pads.
The pads have been peeled from Replace the pads on patient with
the case but have not been new pads to continue with the
successfully attached to the patient. rescue.
There may be a problem with the
pads.
…To press the pads The pads are not properly applied Make sure the pads are sticking
firmly to the skin to the patient. completely to the patient’s skin.
…To make sure the pads The pads are not making good If the pads are not sticking, dry the
have been removed from contact with the patient’s bare patient’s chest and shave or clip
the case chest because of moisture or any excessive chest hair.
…The pads should not be excessive hair.
touching the patient’s The pads are touching each other. Reposition the pads.
clothing The pads may not have been Make sure pads are not in the case
…To make sure the pads removed from the case or may be or on patient’s clothing.
connector is fully on the patient’s clothing.
inserted. Pads connector is not fully Make sure the pads connector is
inserted. fully inserted.
If the voice instruction continues after you do these things, replace the
pads set.
…To stop all motion The patient is being moved or Stop CPR; do not touch the
jostled. patient. Minimize patient motion.
If the patient is being transported,
stop the vehicle.
The environment is dry and Responders and bystanders should
movement around the patient is minimize motion, particularly in
causing static electricity to dry environments that can
interfere with ECG analysis. generate static electricity.
Radio or electrical sources are Check for possible causes of radio
interfering with ECG analysis. and electrical interference and turn
them off or remove them from the
area.
…The shock was not The pads may not be making good Press the pads firmly to the
delivered contact with the patient’s skin. patient’s chest.
The pads may be touching each Make sure the adhesive pads are
other. correctly positioned on the patient.
The pads may be damaged. Replace the pads.
…The shock button was Shock has been advised but the When next prompted, press the
not pressed shock button has not been pressed Shock button to deliver shock.
within 30 seconds.
TROUBLESHOOTING TABLE #1
Table 25.06-1

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25.06 PHILIPS HEARTSTART FRX DEFIBRILLATOR 861304 (cont’d)

Troubleshooting while the AED is not being used (Green Ready light is not on)
Behavior: Possible Cause: Recommended Action:
Chirps or i-button flashes The battery power is low or the Press the blue i-button. Replace
pads need to be replaced. the battery of pads if instructed.
The pads may be damaged or the Replace the pads with a new set
adhesive is dried out. and do not open the case until
pads are needed in an emergency.
The pads case may be open. Make sure the pads case is closed.
The defibrillator may have been Make sure the pads are properly
turned off without a pads set installed.
installed.
The Training Pads II set has been Remove the Training Pads II set
left in the defibrillator. and replace it with a set of
SMART Pads II.
The Infant/Child Key may have Remove the Infant/Child Key.
been left installed.
The defibrillator has been stored Remove the battery for five
outside the recommended seconds; then reinstall it to start
temperature range. the battery insertion self-test. If it
fails, insert a new battery to repeat
the test. If it fails again, do not
use the defibrillator. If it passes,
store the defibrillator within the
recommended temperature range.
The defibrillator has detected an Contact Philips for service if
error during a self-test or cannot needed.
perform a self-test, or the Shock
button is damaged.
No chirping and/or i- The battery is missing or Remove the battery for five
button does not flash completely depleted. seconds; then reinstall it to start
the battery insertion self-test. If it
(or) fails, insert a new battery and
repeat the test. If it fails again, do
not use the defibrillator.
No response to pressing i- The defibrillator may have been Contact Philips for service.
button damaged.

TROUBLESHOOTING TABLE #2
Table 25.06-2

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25.07 – MAIN CARGO DOOR SILL GUARD IPC

TABLE OF CONTENTS
Page

FIGURES
25.07-1 FORWARD SILL ASSEMBLY -------------------------------------------------- 25.07.1
25.07-2 AFT SILL ASSEMBLY ----------------------------------------------------------- 25.07.3
25.07-3 ROSENBALM DOOR SILL GUARD DESIGN SPECIFICATIONS ------ 25.07.5

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25.07 MAIN CARGO DOOR SILL ILLUSTRATED PARTS CATALOG

FORWARD SILL ASSEMBLY

Figure 25.07-1 (1 of 2)

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25.07 MAIN CARGO DOOR SILL ILLUSTRATED PARTS CATALOG(CONT’D)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
1/ -1 50080-1 SILL ASSEMBLY, FORWARD RF

10 20091-1 •SIDE GUIDE 1

20 AN509-416R13 ••SCREW 3
30 AN365-428C ••NUT 3
40 AN960-416 ••WASHER 3

50 16900-501-26-32 •ROLLER ASSEMBLY 6

60 MS24665-227 ••COTTER PIN 2

70 20082-1 •LUG 12
80 AN509-10R12 ••SCREW 2
90 AN509-10R10 ••SCREW(USED IN 2 PLACES ONLY) 2
100 AN364-1032 ••NUT 2
110 AN960-10L ••WASHER 2

120 50080-5 •RAMP 1

130 20085-507 •LOCK PIN ASSEMBLY 2

140 20085-5 ••HANDLE 1
150 20085-11 ••SPRING 1
160 20085-7 ••PIN 1

170 50084 •SUPPORT 3

180 AN509-10R8 ••SCREW 3

190 50080-11 •BUMPER 1

200 50080-3 •SILL 1

FORWARD SILL ASSEMBLY

Figure 25.07-1 (2 OF 2)

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25.07 MAIN CARGO DOOR SILL ILLUSTRATED PARTS CATALOG(CONT’D)

AFT SILL ASSEMBLY

Figure 25.07-2 (1 OF 2)

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25.07 MAIN CARGO DOOR SILL ILLUSTRATED PARTS CATALOG(CONT’D)

ILLUSTRATED PARTS LIST

FIG PART NOMENCLATURE EFFECT UNITS
ITEM NUMBER 1234567 PER
ASSY
2/ -1 50080-501 SILL ASSEMBLY, AFT RF

10 20091-1 •SIDE GUIDE 1

20 AN509-416R13 ••SCREW 3
30 AN365-428C ••NUT 3
40 AN960-416 ••WASHER 3

50 16900-501-26-32 •ROLLER ASSEMBLY 8

60 MS24665-227 ••COTTER PIN 2

70 20082-1 •LUG 12
80 AN509-10R12 ••SCREW 2
90 AN509-10R10 ••SCREW(USED IN 2 PLACES ONLY) 2
100 AN364-1032 ••NUT 2
110 AN960-10L ••WASHER 2

120 50080-9 •RAMP 1

130 20085-507 •LOCK PIN ASSEMBLY 2

140 20085-5 ••HANDLE 1
150 20085-11 ••SPRING 1
160 20085-7 ••PIN 1

170 50084 •SUPPORT 3

180 AN509-10R8 ••SCREW 3

190 50080-13 •BUMPER 1

200 50080-7 •SILL 1

AFT SILL ASSEMBLY

Figure 25.07-2 (2 OF 2)

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25.07 MAIN CARGO DOOR SILL ILLUSTRATED PARTS CATALOG(CONT’D)
IPC for piece parts is same as for P/N’s 50080-1 and -501 on preceding pages. This drawing for
Rosenbalm door aircraft only. Drawing provides measurement for location of piece parts.

ROSENBALM DOOR SILL GUARD DESIGN SPECIFICATIONS

Figure 25.07-3

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25.08 – CREW SEAT COVER AND CUSHION PART NUMBERS

TABLE OF CONTENTS
Paragraph Page
1. PURPOSE --------------------------------------------------------------------------- 25.08.1

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25.08 CREW SEAT COVER AND CUSHION PART NUMBERS

1. Purpose. To provide part numbers for crew seat covers and cushions.

a. Fire Blocked (FB) cushions are required on the Observer and Navigator seats only but
may be used in Fire Retardant (FR) positions.

PILOT F/O F/E OBSERVER NAVIGATOR

SEAT P/N 5641031-X 5641031-X 5641032-X 5641034-X 5641033-X
SEAT
BOTTOM BI081291-32 BI081291-32 BI081291-34 BI081291-34 BI081291-34
COVER
BACKREST
COVER BI081291-31 BI081291-31 BI081291-31 BI081291-31 BI081291-31
SEAT BI081291-22M BI081291-22M BI081291-24M BI081291-4 BI081291-4
CUSHION (FR) (FR) (FR) (FB) (FB)
BACKREST BI081291-21M BI081291-21M BI081291-21M BI081291-1 BI081291-1
CUSHION (FR) (FR) (FR) (FB) (FB)
L/H ARMREST
COVER BI081291-11 BI081291-11 BI081291-13 N/A BI081291-13
R/H ARM
REST COVER BI081291-12 BI081291-12 BI081291-14 N/A BI081291-14

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25.09 – COMBI BALL PANEL ASSEMBLY

CONFIGURATION (PEMCO)
TABLE OF CONTENTS
Paragraph Page
1. GENERAL--------------------------------------------------------------------------- 25.09.1

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25.09 COMBI BALL PANEL ASSEMBLY CONFIGURATION (PEMCO)

1. The following part numbers are effective for the Pemco Ball Panel Assemblies installed on
the listed COMBI’s.

Part Number 41CX 71CX 799AL

50021-503* X X
50021-507 X
50022-503* X X
50022-507 X
50023-503* X X
50023-507 X
50024-503* X X
50024-504* X X
50024-507 X
50024-508 X
50025-503* X X
50025-504* X X
50025-507 X
50025-508 X
50026-503* X X
50026-504* X X
50026-507 X
50026-508 X
50027-503* X X
50027-507 X
50028-503* X X
50028-507 X
50029-503* X X
50029-507 X

* Ball Panel Assembly IPC in section 25.04.

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25.10 – EMERGENCY EVACUATION ROPE

TABLE OF CONTENTS
Paragraph Page
1. PURPOSE --------------------------------------------------------------------------- 25.10.1
2. LIST ---------------------------------------------------------------------------------- 25.10.1

TABLES
25.10-1 EMERGENCY EVACUATION ROPE IPC ------------------------------------ 25.10.1

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25.10 EMERGENCY EVACUATION ROPE

1. Purpose - To provide a replacement parts list for the emergency evacuation rope as detailed
in ATI E.O. 25-DC8-314.

2. List

ITEM NOMENCLATURE PART NUMBER

1 Drawing AE4610
2 Doubler AE4610-11
3 Anchor Ring 11251
4 Anchor Plate 20050
5 Shim AE4610-12
6 Placard AE4610-13
7 Rope AE4610-14
8 Bag AE4610-16

EMERGENCY EVACULATION ROPE PARTS LIST

Table 25.10-1

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25.11 – CREW OXYGEN REGULATORS

TABLE OF CONTENTS
Paragraph Page
1. PURPOSE --------------------------------------------------------------------------- 25.11.1
2. LIST ---------------------------------------------------------------------------------- 25.11.1

TABLES
25.11-1 CREW OXYGEN REGULATORS IPC----------------------------------------- 25.11.1

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25.11 CREW OXYGEN REGULATORS (DC-8-71 SERIES AIRCRAFT)

1. Purpose - To provide a replacement parts list for the Ex-United DC-8-71 Crew Oxygen
Regulator and associated equipment as detailed in ATI E.O. 35-DC8-196R6.

2. List

ITEM P/N: NOMENCLATURE PILOT/FO F/E OBSERVERS

1 15830M O2 Regulator 2 ea. 1 ea. 2 ea.
2 358-1465 V Mask (Incl. Hose) 2 ea. 0 0
3 358-1511 V Mask (Incl. Hose) 0 1 ea. 2 ea.
4 322-70 Smoke Goggles 2 ea. 1 ea. 2 ea.
5 80036300 Connector 2 ea. 1 ea. 2ea.
6 JJ033 Mic-Jack Connector 2 ea. 1 ea. 2 ea.
7 MS22055 H-12 Hose 0 0 1 ea.
8 MS22055 H-18 Hose 0 0 1 ea.
9 MS22055 H-48 Hose 2 ea. 1 ea. 0
10 AN737TW34-38 Clamp 4 ea. 2 ea. 4 ea.
11 AN816-5D Union 2 ea. 1 ea. 2 ea.
12 M83248/1-905 Packing 2 ea. 1 ea. 2 ea.
13 BAC12CB04-06 Screw 0 2 ea. 4 ea.
14 AN340-4 Nut 0 2 ea. 4 ea.

O2 REGULATORS PARTS LIST

Table 25.11-1

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25.12 – TEAC VE-801DC DVD VIDEO PLAYER

TABLE OF CONTENTS

Paragraph Page
1. INTRODUCTION ----------------------------------------------------------------- 25.12.1
2. FUNCTIONS AND OPERATION ---------------------------------------------- 25.12.2
3. FAULT ISOLATION PROCEDURES & ERROR DISPLAY -------------- 25.12.10

FIGURES

25.12-1 VE-801DC VIDEO ENTERTAINMENT PLAYER FRONT PANEL-------- 25.12.1

TABLES

25.12-1 LOCAL INTERFACE CONTROL FUNCTIONALITY ------------------------ 25.12.8

25.12-2 FAULT ISOLATION----------------------------------------------------------------- 25.12.10
25.12-3 ERROR DISPAY --------------------------------------------------------------------- 25.12.13

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25.12 TEAC VE-801DC DVD VIDEO PLAYER

1. Introduction

a. The TEAC VE-801DC VRU is a single deck video player designed for use in airplane
entertainment systems. The VE-801DC reproduces video with 500 lines (or better) of
resolution and high fidelity audio. The VE-801DC incorporates two stereo audio outputs,
allowing for up to two two-stereo language tracks. Remote control, status inquiry, and
interrogation of Built-In Test Equipment (BITE) information are controllable via an RS-
485/RS-232 or IR serial data bus.

VE-801DC VIDEO ENTERTAINMENT PLAYER FRONT PANEL

Figure 25.12-1

b. The video player can be cleaned using a commercially available DVD/CD-Rom cleaning
disc (3M AV-104 or equivalent).

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25.12 TEAC VE-801DCDVD VIDEO PLAYER (cont’d)

2. Functions and Operation

a. Functions – Throughout this section, certain terms are used to describe unique
characteristics, conditions, or modes of the VE-801DC VEP. The following is a list of
applicable terms and a brief description of each. The term “indicator” is used to describe
a Light Emitting Diode (LED) located on the VEP front panel.

(1) STOP – STOP mode is indicated by termination of video output and illumination of
the STOP indicator for the player. During STOP mode, the disc does not advance in
any direction.

(2) PAUSE – PAUSE mode is indicated by illumination of the PAUSE indicator for the
player. During PAUSE mode, the disc does not advance in any direction, video
output is active, and the picture is still.

(3) PLAY – PLAY mode is indicated by the illumination of the PLAY indicator for the
disc player. During PLAY mode, the disc advances in the forward direction and the
video output exists.

(4) SKIP FORWARD – SKIP FORWARD mode is indicated by the illumination of

SKIP/SCAN indicator for the player. During SKIP FORWARD, video output is
terminated, and the disc advances in the forward direction to the next segment and
begins playback.

(5) SKIP REVERSE – SKIP REVERSE mode is indicated by the illumination of the
SKIP/SCAN indicator for the player. During SKIP REVERSE, video output is
terminated, and the disc advances in the reverse direction to the next segment and
begins playback.

(6) SCAN FORWARD – SCAN FORWARD mode is indicated by the simultaneous

illumination of the PLAY and SKIP/SCAN indicators for the player. During SCAN
FORWARD, video output is active and the disc advances in the forward direction at
a rate of six times normal play speed.

(7) SCAN REVERSE – SCAN REVERSE mode is indicated by the simultaneous

illumination of the PLAY and SKIP/SCAN indicators for the player. During SCAN
REVERSE, video output is active and the disc advances in the reverse direction at a
rate of six times normal play speed.

(8) MENU MODE – The menuing keys control DVD menuing. There are six unique
keys designated as menuing controls. These keys are MENU, UP, DOWN, LEFT,
RIGHT, and ENTER. The directive menuing keys (all menuing keys with the
exception of the MENU key) operate if, and only if, the disc is in the STOP mode.
The MENU key is active at all times when a disc is loaded into the VE-801DC.

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(9) POWER ON/OFF – The power distributed to the 801DC deck is individually
controlled. The VE-801DC DVD deck provides a front panel display to indicate
that the deck has power applied. Applied power is controllable from both Discrete
and ARINC 628 command.

(10) DISC IN – The term DISC IN is used to describe a condition when a DVD disc is
actually loaded into an individual transport mechanism. The VE-801DC notifies the
user of a DISC IN condition by illuminating the DISC IN indicator. All other
indicators, with the exception of the STOP indicator, remain non-illuminated unless
a DISC IN condition is detected.

(11) DEW – Under environmental conditions of high relative humidity and decreasing
temperatures, the DVD laser optical system can accumulate moisture (dew). In dew
conditions, DVD deck Normal Operations could damage the laser optical system
and/or the media. The VE-801DC has the capability to sense dew conditions. If the
DVD deck enters dew-sensing mode with or without media installed, a dew light on
the front panel turns on. When media is installed, the DVD deck will continue to
read the media until it is physically disabled by dew.

b. Operation – The following section describes manual control of the VE-801DC.

(1) Movie Mode – The VE-801DC operates in two modes: Movie Mode and Menu
Mode. While in the Movie Mode, the VEP acts as a normal video player.

(a) Available Functions – The following represents a list of available functions

and modes provided to the user while in MOVIE MODE.

1) SCAN REWIND
2) SCAN FORWARD
3) PLAY
4) STOP
5) PAUSE
6) SKIP FORWARD
7) SKIP REVERSE
8) DISC EJECT

(b) Applying Power to the Disc Player – The power distributed to the VE-801DC
is controlled by discrete, RS-485/RS-232 or IR command or local control.
Under normal operation, the VE-801DC operates under the control of either
the CSCP, SCU, or VSCU (whichever is applicable) associated with the PES.
One or more of the above-mentioned system components have the ability to
externally turn the VE-801DC on and off.

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(c) Inserting a Disc

1) Before a disc can be inserted into the player, the VE-801DC must be
powered on. When the VE-801DC is on, the player’s POWER indicator
illuminates. Also, prior to inserting a disc into the player, check that the
DISC IN indicator is not illuminated, which would indicate that there is
already a disc in the transport mechanism.
CAUTION: DO NOT INSERT A DISC INTO A PLAYER THAT
ALREADY HAS ONE INSERTED. THE UNIT HAS A
METAL SHUTTER THAT CLOSES OFF THE LOADING
SLOT. TRYING TO INSERT A DISC INTO A PLAYER
ALREADY CONTAINING A DISC MAY CAUSE
PERMANENT DAMAGE TO THE DISC.
2) The VE-801DC contains an automatic, motorized disc loading system.
To load a disc into the player, grasp the disc from the center hole and/or
sides and carefully insert the disc into the disc-loading slot located on the
front of the unit. Apply only enough pressure to engage the automatic
loading system. The disc should be inserted with the title label SIDE up.

(d) Playing a Disc

1) Before a disc can be played by the VE-801DC, the unit must be powered
on. When the VE-801DC is on, the POWER indicator illuminates. Also,
the player does not enter the PLAY mode unless there is a disc loaded in
the selected player.
2) Press the PLAY Control Key located on the front panel of the VEP. The
PLAY Control Key is located under the player’s disc loading slot.
3) The PLAY mode can be initiated from any other mode. Pressing the
PLAY Control Key overrides the current player mode and begins disc
playback.

(e) Skip Reversing a Disc

1) Before the VE-801DC can enter the SKIP REVERSE mode, the unit must
be powered on. When the VE-801DC is on, the POWER indicator
illuminates. Also, the player does not enter the SKIP REVERSE mode
unless there is a disc loaded in the player.
2) Briefly press the SKIP/SCAN Reverse Key located on the front panel of
the VEP to enter SKIP REVERSE mode. The SKIP/SCAN Reverse Key
is located directly under that player’s disc loading slot.
3) The SKIP REVERSE mode can only be initiated from the PLAY mode.
If the SKIP/SCAN Reverse Key is pressed and held longer than a full
second while in the PLAY mode, the SCAN REVERSE mode is initiated.

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(f) Skip Forwarding a Disc

1) Before the VE-801DC can enter the SKIP FORWARD mode, the unit
must be powered on. When the VE-801DC is on, the player’s POWER
indicator illuminates. Also, the player does not enter the SKIP
FORWARD mode unless there is a disc loaded in the selected player.
2) Briefly press the SKIP/SCAN Forward Key located on the front panel of
the VEP. The SKIP/SCAN Forward Key is located directly under that
player’s disc loading slot.
3) The SKIP FORWARD mode can be initiated from the PLAY mode. If
the SKIP/SCAN FORWARD Key is pressed and held longer than a full
second while in the PLAY mode, the SCAN FORWARD mode is
initiated.

(g) Scanning a Disc (Forward)

1) Before the VE-801DC can enter the SCAN FORWARD mode, the unit
must be powered on. When the VE-802DC is on, the player’s POWER
indicator is illuminated. Also, the player does not enter the SCAN
FORWARD mode unless there is a disc loaded in the selected player.
2) To enter the SCAN FORWARD mode, press and hold for more than one
second the SKIP/SCAN FORWARD Key while the player is in the
PLAY mode. The SKIP/SCAN FORWARD Key is located on the front
panel of the VEP. The SKIP/SCAN FORWARD Key is located directly
under that player’s disc loading slot.
3) The SCAN FORWARD mode can only be initiated from the PLAY
mode. If the SKIP/SCAN FORWARD Key is briefly pressed while in the
PLAY mode, the SKIP FORWARD mode is initiated.
4) If the SKIP/SCAN FORWARD key is continuously held in SCAN
FORWARD mode, the regular SCAN FORWARD (6x speed) and the
high speed SCAN FORWARD (30x speed) alternately occur.

(h) Scanning a Disc (Reverse)

1) Before the VE-801DC can enter the SCAN REVERSE mode, the unit
must be powered on. When the VE-801DC is on, the player’s POWER
indicator illuminates. Also, the player does not enter the SCAN
REVERSE mode unless there is a disc loaded in the selected player.
2) To enter SCAN REVERSE mode, press and hold for more than one
second the SKIP/SCAN REVERSE Key while the selected player is in
the PLAY mode. The SKIP/SCAN REVERSE Key is located on the
front panel of the VEP. The SKIP/SCAN REVERSE Key is located
directly under that player’s disc loading slot.

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3) The SCAN REVERSE mode can only be initiated from the PLAY mode.
If the SKIP/SCAN REVERSE Key is briefly pressed while in the PLAY
mode, the SKIP REVERSE mode is initiated.
4) If the SKIP/SCAN REVERSE key is continuously held in SCAN
REVERSE mode, the regular SCAN REVERSE (6x speed) and the high
speed SCAN REVERSE (30x speed) alternately occur.

(i) Stopping a Disc

1) Before the VE-801DC can enter the STOP mode, the unit must be
powered on. When the VE-801DC is on, the player’s POWER indicator
illuminates. Also, the player does not enter the STOP mode unless there
is a disc loaded in the selected player.
2) Press the STOP Key located on the front panel of the VEP. The STOP
Key is located directly under that player’s disc loading slot.
3) The STOP Key can be used to terminate PLAY, SKIP REVERSE, SKIP
FORWARD, SCAN FORWARD, SCAN REVERSE, and PAUSE
modes.

(j) Pausing a Disc

1) Before the VE-801DC can enter the PAUSE mode, the unit must be
powered on. When the VE801DC is on, the player’s POWER indicator
illuminates. Also, the player does not enter the PAUSE mode unless
there is a disc loaded in the selected player.
2) Press the PAUSE Key located on the front panel of the VEP. The
PAUSE Key is located directly under that player’s disc loading slot.

(k) Ejecting a Disc

1) Before a disc can be ejected from the VE-801DC, the unit must be
powered on. When the VE-801DC is on, the player’s POWER indicator
illuminates
2) Press the Eject Key located on the front panel of the VEP. The EJECT
Key is located to the right of that player’s disc loading slot.
3) Pressing the Eject Key terminates any and all current VEP modes and
ejects the disc.

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(2) Menu Mode – The menuing keys control DVD menuing. There are six unique keys
designated as menuing controls. These keys are defined as MENU, UP, DOWN,
LEFT, RIGHT, and ENTER. The directive menuing keys (all menuing keys with
the exception of the MENU key) operate if, and only if, the disc is in the STOP
mode. The MENU key shall be active at all times when a disc is loaded into the
VE-801DC.

(a) MENU – The MENU key initiates the activation of the current DVD disc’s
menu program. If the current DVD disc does not have embedded menu
information, then the MENU key will be ignored.
(b) UP – The UP key allows the user to navigate through the menu in the upward
direction. The UP key allows control as limited and governed by the disc’s
meta data.
(c) DOWN – The DOWN key allows the user to navigate through the menu in the
down direction. The DOWN key allows control as limited and governed by
the disc’s meta data.
(d) LEFT – The LEFT key allows the user to navigate through the menu in the
left-hand direction. The LEFT key will allow control as limited and governed
by the disc’s meta data.
(e) RIGHT – The RIGHT key allows the user to navigate through the menu in the
right-hand direction. The RIGHT key allows control as limited and governed
by the disc’s meta data.
(f) ENTER – The ENTER key allows the user to select the current menu
selection. The ENTER key allows control as limited and governed by the
disc’s meta data.

c. Test – The unit conducts a self-test upon power-up. If no faults are detected, the unit will
proceed to normal operations. If faults are detected, the unit will proceed to a non-or
semi-non-operational state. Depending upon the type of error detected, the unit may
perform with limited functionality. The test result is stored in a non-volatile memory
within the unit. The stored information is retrievable at the time of shop maintenance.

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LOCAL INTERFACE CONTROL FUNCTIONALITY

Table 25.12-1

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d. Connector Pin-Out

(1) AC115V
(2) AC115V RTN
(3) 28V DC
(4) 28V DC GND
(5) CHASSIS GND
ON CONTROL IN
(6) (OPEN=OFF / GROUND = ON)
OFF CONTROL IN
(7) (OPEN = OFF / GROUND = ON)
(8) ON INDICATOR OUT
(9) PLAY INDICATOR OUT
(10) AUDIO CH1 HI
(11) AUDIO CH1 LO
(12) AUDIO CH2 HI
(13) AUDIO CH2 LO
(14) AUDIO CH3 HI
(15) AUDIO CH3 LO
(16) AUDIO CH4 HI
(17) AUDIO CH4 LO
(18) AUDIO SHIELD
(19) RS-485 DATA HI
(20) RS-485 DATA LO
(21) DATA SHIELD
(22) BITE OUT
(23) PAUSE IN
(24) VIDEO SHIELD
(25) VIDEO 100 OHM HI
(26) VIDEO 100 OHM LO
(27) INFRARED INPUT +
(28) INFRARED INPUT –
(29) AC 3 Serial Digital Signal Output
(30) VIDEO OUT UNBAL COREXIAL 50 OHM
(31) VIDEO Y UNBAL COREXIAL 50 OHM
(32) VIDEO C UNBAL COREXIAL 50 OHM

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3. Fault Isolation Procedures & Error Display

PROBLEM CAUSES REMEDY

POWER LED does not Power Supply is not properly Connec tht eunit correctly to
illuminate when the POWER connected to the unit. the ARINC connector.
button on the control panel is Connect Power Supply
pressed. correctly to the unit.
Unit is not properly Connect the pin ARINC 7 to
grounded. the ground (GND).
The unit has been used in an Wait until interior of the unit
environment where the is cooled off before use.
internal temperature exceeds
the specified
DVD video discs cannot be Disc was not inserted Insert the disc label side up.
played or discs come out correctly.
without playing when Wrong format disc. DVD The unit will only play
inserted. discs are region coded. The region indicated by the last
last digit of the VE-801DC digit of the unit’s part
indicates which region can be number.
playing on the unit.
RETURN TO PLAY was Do not select RETURN TO
selected on the MENU PLAY when the MENU
screen. screen is activated
immediately after the
insertion of a disc.
Time interval between insert It may be impossible to insert
and eject disc. discs immediately after a
disc is ejected. Wait a few
seconds before inserting the
disc again.
DEW inside the unit. Allow the unit to sit for up to
two hours with the power
ON. In some cases,
operation is possible upon
dew detection.

FAULT ISOLATION
Table 25.12-2 (1 of 3)

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PROBLEM CAUSES REMEDY

CD-DA discs cannot be Disc was not inserted Insert the disc label side up.
played or discs come out correctly.
without playing when Dirty disc. Wipe the disc with a clean
inserted. soft cloth.
Wrong format disc. DVD The unit will only play
discs are region coded. The region indicated by the last
last digit of the VE-801DC digit of the unit’s part
indicates which region can be number.
played on the unit. Do not play SACD and DVD
AUDIO discs.
Time interval between insert It may be impossible to insert
and eject disc. discs immediately after a
disc is ejected. Wait a few
seconds before inserting the
disc again.
DEW inside the unit. Allow the unit to sit for up to
two hours with the power
ON. In some cases,
operation is possible upon
dew detection.
No sound output from the Incorrect connection to the Check the connection to the
speaker or headphone, or the amplifier, speaker, and amplifier, speaker, and
sound is distorted. headphone. headphone.
Adjust sound volume of the
amplifier.
Dirty disc. Wipe the disc with a clean
soft cloth.
Wrong format disc. DVD The unit will only play
discs are region coded. The region indicated by the last
last digit of the VE-801DC digit of the unit’s part
indicates which region can be number.
played on the unit.
PAUSE, SKIP, or SCAN is Press PLAY button to return
activated. to normal playback. Sound
is not generated during these
Modes.

FAULT ISOLATION
Table 25.12-2 (2 of 3)

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PROBLEM CAUSES REMEDY

No multi-channel sound Wrong format disc. Sound may not be
output from the speaker or reproduced or may be
headphone, or no sound intermittently reproduced
output from certain channel. depending on the conditions
of the disc.
CD-DA disc are played. Sound output only from
AUDIO CH1 and AUDIO
CH2 when CD-DA disc are
played.
No multi-channel sound Select sound of multi-
selected. channel (such as 5.1ch) on
the MENU screen of the
disc.
No digital sound output. Wrong format disc. Use discs with digital sound
recorded.
Do not play SACD. They do
not output digital sound.
A difference in audio level Difference in recording Adjust audio levels
between DVD and CD-DA is system. accordingly.
noted.
Conditions that have been set RIGHT button arrow was Press the same button
change or disappear. accidentally pressed. repeatedly until the original
subtitle setting returns.
DOWN button arrow was Press the same button
accidentally pressed. repeatedly until the original
language returns.
Power supply is turned OFF. Any operation of the
POWER button on the front
panel or the power off
command from the discrete
or serial interface will erase
all settings and return to the
initial conditions. Do not
turn the POWER OFF.
A new disc is inserted and Do not insert and play a new
played. disc. Language and subtitle
settings default to the initial
setting of a new disc.
Error display. Front panel See Table 25.12-3. See Table 25.12-3.
LED’s flash.

FAULT ISOLATION
Table 25.12-2 (3 of 3)

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NOTE: When the WAIT indicator on the front panel flashes, an error or errors may have
occurred. The relationship between the flashing indicators and actual errors are as
follows:

DISPLAY OF LED ACTUAL ERROR COUNTERMEASURES

WAIT is flashing (POWER One or both of the built-in If flashing does not stop after
is ON). FANs are not operating, but the power supply is turned
the interior temperature is not OFF once and turned ON
so high as the shutdown again, request for service.
temperature.
WAIT is flashing (POWER Internal temperature of VE- Turn OFF the power supply
is OFF). 801DC exceeds the specified and wait until the internal
value resulting in thermal temperature of the unit
shutdown. lowers below the specified
value, and turn ON the
power supply again.
WAIT and POWER are Electrical or mechanical Failure may be temporary.
flashing. FAIL has occurred in VE- Turn OFF the power supply
801DC. and then turn it ON again. If
flashing occurs repeatedly,
request for service.
WAIT and STOP are The inserted disc is Reset the disc correctly or
flashing. unplayable. (Information on wipe it clean if it is
the disc being played is not contaminated. Also, check
readable.) that the FORMAT of the disc
is correct.

NOTE: When these error displays have appeared, eliminate the causes.

ERROR DISPLAY
Table 25.12-3

a. Condensation – When the equipment is brought in from a cold condition to inside the
airplane or used right after heaters are turned on, the equipment may not properly
function due to water droplets on the functioning parts or lens. In such cases, leave the
equipment sitting for one to two hours with the power ON. After a while, normal playing
or downloading becomes possible.

b. Although the equipment has passed the rigorous test for aircraft standard, it may not, in a
rare case, properly function due to out-of-specification strong noise interference. In case
of such an occurrence, turn off the power and then restart the operation after about a
minute.

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INTENTIONAL
BLANK

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25.13 – MONOGRAM EXECUTIVE AIRCRAFT TOILETS

TABLE OF CONTENTS
Paragraph Page
1. GENERAL------------------------------------------------------------------------------ 25.13.1

2. DESCRIPTION ------------------------------------------------------------------------ 25.13.1

3. DESCRIPTION OF COMPONENTS ----------------------------------------------- 25.13.1

4. OPERATION --------------------------------------------------------------------------- 25.13.2

5. SERVICING INSTRUCTIONS------------------------------------------------------ 25.13.3

6. ILLUSTRATED PARTS LIST ------------------------------------------------------ 25.13.4

FIGURES

25.13-1 TOILET ASSEMBLY-------------------------------------------------------------- 25.13.4

25.13-2 CARTRIDGE ASSEMBLY ------------------------------------------------------- 25.13.8

25.13-3 DRAIN VALVE ASSEMBLY---------------------------------------------------- 25.13.11

25.13-4 TIMER ASSEMBLY--------------------------------------------------------------- 25.13.13

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INTENTIONAL
BLANK

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25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2

1. General – The toilet assembly described in this manual is part of the waste system installed
on the ex-United DC-8-71 series aircraft. The toilet collects waste products and uses
recirculated flush water for rinsing the sides of the bowl. Waste material is collected and
held in the toilet tank until serviced.

2. Description

a. The toilet mounts in a rigid aluminum frame (some models) which can be conveniently
installed to suit a wide range of aircraft structures. The toilet unit clamps into the
mounting frame by means of detachable holdown rods. The complete toilet can be
disconnected and lifted out of its mounting, or re-installed within a few minutes.

b. All mating junctions of toilet tank and bowl are sealed. A perforated spray rinse fitting
located in the top of the tank rinses the inside walls of the tank during ground servicing.
(On models equipped with a fixed filter cartridge assemblies, the tank is rinsed by the
pump’s built-in rinse system.) For ultimate sanitation and ease of maintenance, the entire
toilet structure (except for motor and wiring) is constructed of heavy duty plastics,
stainless steel, and no-corrosive metals. The toilet bowl is constructed of highly polished
stainless steel.

c. The toilet may be serviced in either of two methods, depending upon the aircraft
installation. On aircraft equipped with a sewage drain, the unit is mounted over the drain
and is cleaned by opening the tank drain valve, which allows waste material to empty
into the sewage drain. The inside of the tank is rinsed by connecting a water hose to the
service panel on the exterior of the aircraft. In aircraft not equipped with a sewage drain,
the toilet is serviced by removing the shroud, disconnecting the power input plug and
toilet vent, and unclamping the unit after which the toilet can be carried out of the
aircraft. Refer to paragraph 5 “Servicing Instructions” for detailed servicing information.

d. All toilet models may be used as a static chemical toilet by removing the restrictor or
opening the separator at the bottom of the bowl.

3. Description of Components

a. Timer and Mounting Bracket – This unit includes the electrical power input connector
and the timer, compactly mounted on a bracket which is secured to the top of the tank.
All of the electrical wiring for the toilet is thus localized to one area of the toilet. The
toilet flush button extends upward from the timer and is conveniently located beside the
toilet seat. When the flush button is fully depressed, switch contacts within the timer are
closed to energize the motor. The switch remains closed until the timer has completed its
cycle of 9 seconds, after which the contacts open, disconnecting power to the motor
section of the cartridge.

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b. Cartridge or Motor Pump Filter Assembly – The cartridge (3500 Series & 4910 Series)
consists of a motor, pump, and filter in one compact unit. The motor is mounted on the
upper end of a gear train that drives both the filter and pump which extends into the tank.
The filter is comprised of a plastic basket, the sides of which have multiple horizontal
slotted openings and a solid bottom. The filter basket rotates at approximately 80 RPM.
Two stationary plastic combs support the basket on opposite sides, with the teeth of the
combs extending into the slotted openings in the basket. The motor pump filter assembly
(3511, 3512, or 3519 Series) consists of motor, static Teflon coated perforated filter,
pump impeller, and rotating spray nozzle housing. Both the cartridge and motor pump
filter assembly are designed as complete units and are easily removable for service and
replacement.

c. Drain Valve – A spring-loaded, neoprene plunger is located in a valve seat in the bottom
of the toilet tank. The valve is actuated by a cable terminating outside the toilet top area.
In typical aircraft installations, the cable is extended to a ground servicing panel or
suitable location accessible from the exterior of the aircraft. In this arrangement, the
toilet waste contents can be emptied into the aircraft drain and all necessary servicing
accomplished from outside the aircraft, quickly and efficiently.

d. Liquid Level Transmitter – The liquid level transmitter is a solid state electronic device
capable of sensing two discrete points of fill on the toilet tank and transmitting an
electronic signal for precharge level or full-tank level. The level sensors are located on
an inside wall of the tank and the transmitter is mounted on the top of the tank.

4. Operation – The flushing cycle is initiated by depressing and releasing a timer button
adjacent to the toilet which actuates a motor-driven pump and filter for a pre-timed interval
(approximately 9 ± 1 seconds). During the 9 second cycle, flushing liquid cascades in a thin
curtain over the complete inner surface of the toilet bowl from a flush channel surrounding
the upper rim of the bowl. Waste material is carried directly to the tank and prevented from
re-entry by means of a restrictor or separator in the bottom of the bowl. Flushing liquid is
filtered out of the tank through the self-cleaning rotary filter (or fixed filter) and is pumped
up to the flush channel surrounding the toilet bowl. The motor-pump and filter are designed
as a single modular assembly. Some models are referred to as a cartridge, which can be
quickly removed and replaced if overhaul or maintenance is required.

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5. Servicing Instructions

a. Charging of Toilet

(1) The recommended initial charge of flushing liquid is a mixture of water and one
packet (two ounces) of Monogram Monochem Toilet Chemical. The required
quantity of water for any toilet model should be enough for the cartridge or motor
pump filter assembly to flush the toilet without starvation.

NOTE: The cartridge or motor pump filter assembly may be run dry (with no flushing
fluid) without damage to the pump.

(2) To protect the toilet recirculation system against freezing temperatures, add an
automotive anti-freeze to the flushing liquid in the ratio recommended by the anti-
freeze manufacturer.

b. Aircraft with Sewage Service Panel

(1) Connect external sewage hose and tank flush hose to service panel.
(2) Actuate cable to open toilet drain valve and dump waste into sewage line.
(3) Turn flush water on and run water through service flush fitting for approximately
three minutes with the drain valve open. Release cable to close drain valve and fill
tank with approximately four gallons of water.
(4) Turn water off and open drain valve to empty water from tank. Close the drain
valve.
(5) If desired, toilet operation can be checked as follows:

(a) Fill tank with approximately two gallons of clear water.

(b) Operate toilet for at least three complete flush cycles and observe flushing
action. When filter is free of foreign material, flushing should be vigorous and
consistent with a curtain of water completely covering the inside of the bowl
throughout the entire flush cycle.
(c) If flushing action is not satisfactory, contact Maintenance Control for further
instructions.
(d) Drain tank and clean toilet bowl with wet sponge and mild disinfectant.

(6) Charge the empty tank through the bowl or through the service panel flush fitting
with the required amount of water and one packet (two ounces) of Monogram
Monochem as indicated in paragraph 5.a.
(7) Disconnect sewage and water lines from the service panel.

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6. Illustrated Parts List

a. Toilet Assembly

TOILET ASSEMBLY
Figure 25.13-1 (1 of 4)

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UNITS
FIG. PART EFF.
NOMENCLATURE PER
ITEM NUMBER CODE
ASSY.
1 4620-2 TOILET ASSY RF
5 4643-1 SEAT & COVER ASSY 1
10 (NS) 2393-20 HARDWARE SET, HINGE POST 1
15 (NS) 2393-7 BUMPER, FRONT 2
20 (NS) 2393-21 BUMPER, REAR SNAP-IN 2
25 4638-2* SHROUD ASSY 1
30 (NS) 2258-102-2 BUMPER, FRONT (BONDED) 5
BUMPER, REAR SIDES
35 (NS) 2258-102-3 2
(BONDED)
40 (NS) 2258-102-5 BUMPER, REAR (BONDED) 1
45 4519 DELETED
50 2364-2 DECAL, UNIT IDENT. 1
55 11016-2 DECAL, FLUSH BUTTON 1
60 11016-3 DECAL, GROUND FLUSH 1
65 11016-5 DECAL, VENT TUBE 1
70 11016-10 DECAL, SERVICE INSTRUCTION 1
75 11016-11 DECAL, DRAIN VALVE 1
80 11016-12 DECAL, POWER INPUT 1
90 CS-16 CLAMP, HOSE (V66295) 1
95 4632-1 TUBE, TYGON 1
100 4629-2 TUBE, FLUSH 1
105 4691 ELBOW 1
110 4626 BOWL ASSY (FRO 4698-4) 1
4698-4 BOWL ASSY 1
115 NAS679C3M NUT 6
120 AN960C10L WASHER 6
125 4648 GASKET, BOWL 1
140 4684-3 SEPARATOR ASSY 1
145 C10DK3 CLAMP (V81872) 2
* Supplied as loose item. A = 4620-2 (SN 001 thru 456)
NS Not Shown B = 4620-2 (SN 457 & Subs)

TOILET ASSEMBLY
Figure 25.13-1 (2 of 4)

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UNITS
FIG. PART EFF.
NOMENCLATURE PER
ITEM NUMBER CODE
ASSY.
150 NAS679C3M NUT 2
155 AN960C610L WASHER 6
160 3749 SPACER 2
CARTRIDGE ASSY (See Figure
165 3500-5 A 1
25.13-2 for details.)
CARTRIDGE ASSY (See Figure
3500-12 B 1
25.13-2 for details.)
170 NAS679C06M NUT 8
175 AN960C6 WASHER 8
DRAIN VALVE ASSY (See Figure
185 4650-4 1
25.13-3 for details.
190 NAS679C06M NUT 8
195 AN960C6 WASHER 8
205 NAS1291C04M NUT 4
210 AN960C4L WASHER 4
215 AN515C4-6 SCREW 4
HARNESS ASSY, TIMER (USED
220 4633 1
WITH 11059-13 TIMER)
TIMER ASSY, SOLD STATE (FRO
225 11059-13 1
11059-53)
TIMER ASSY, SOLID STATE (See
11059-53 1
Figure 25.13-4 for details.)
230 AN507C632R5 SCREW 4
235 4631-3 BRACKET, TIMER 1
240 NAS679C06M NUT 4
245 AN960C6L WASHER 4
250 AN931-10-14 GROMMET 1
255 4687 FITTING, GROUND FLUSH INLET 1
265 NAS679C06M NUT 4
270 AN960C6L WASHER 4
GASKET, GROUND FLUSH
275 4313 2
INLET FITTING
280 4690 NOZZLE ASSY 1
285 4687 FITTING, VENT 1
* Supplied as loose item. A = 4620-2 (SN 001 thru 456)
NS Not Shown B = 4620-2 (SN 457 & Subs)

TOILET ASSEMBLY
Figure 25.13-1 (3 of 4)

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25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2 (cont’d)

UNITS
FIG. PART EFF.
NOMENCLATURE PER
ITEM NUMBER CODE
ASSY.
290 NAS679C06M NUT 4
295 AN960C6L WASHER 4
300 4313 GASKET, VENT 1
305 4640 HANDLE 2
310 NAS501-3-6A BOLT 4
315 2392-25 WASHER 8
310 4641 THUMB NUT, KNURLED 3
315 2392-25 WASHER 8
320 4641 THUMB NUT, KNURLED 3
325 4637-2 HOLD-DOWN ROD 3
330 4635 MOUNTING FRAME ASSY 1
335 4634 BRACKET, HOLD-DOWN ROD 3
340 NAS679C06M NUT 6
345 AN960C6L WASHER 6
350 4623-2 TANK & TOP ASSY 1
* Supplied as loose item. A = 4620-2 (SN 001 thru 456)
NS Not Shown B = 4620-2 (SN 457 & Subs)

TOILET ASSEMBLY
Figure 25.13-1 (4 of 4)

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25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2 (cont’d)

b. Cartridge Assembly

CARTRIDGE ASSEMBLY
Figure 25.13-2 (1 of 3)

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25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2 (cont’d)

UNITS
FIG. PART
NOMENCLATURE PER
ITEM NUMBER
ASSY.
1 3500-5 CARTRIDGE ASSY RF
2 3505-2 MOTOR ASSY, DC (FRO 4910) 1
4910 MOTOR ASSY, DC (FRO 4910-32) 1
4910-32 MOTOR ASSY, DC 1
3 AN515C632-8 SCREW 3
FUSE HOLDER (V71400) (USED ON 3505-
5 HHJ 1
2)
FUSE, SLOW BLOW (V71400) (USED ON
6 MDX3 1
3505-2)
7 NOT USED
9 4910-15 SPACER 1
10 MS28775-21 O-RING 1
11 MS28775-007 O-RING 1
12 3501-4 MOUNTING PLATE ASSY 1
13 AN515C632-8 SCREW 4
14 AN960C6L WASHER 4
15 CS-16 CLAMP, HOSE (V66295) 2
16 4632-2 HOSE, DISCHARGE 1
17 4670 GASKET, MTG PLATE 1
18 3314 COUPLING 1
19 3310 GASKET, GEAR HOUSING 1
20 3315 RETAINER, GREASE 1
21 MS16624-4025 RING, RETAINER 1
22 3309 GEAR, FILTER DRIVE SHAFT 1
23 3303 WIPER BLADE 2
24 AN515C632-6 SCREW 2
25 3302 FILTER BASKET 1
26 3503-2 SHAFT, FILTER DRIVE 1
28 AN515C632-6 SCREW 2
29 AN960C6L WASHER 2
30 MS16624-4025 RING, RETAINER 1
31 3306 IMPELLER 1

CARTRIDGE ASSEMBLY
Figure 25.13-2 (2 of 3)

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25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2 (cont’d)

UNITS
FIG. PART
NOMENCLATURE PER
ITEM NUMBER
ASSY.
WASHER, THRUST (1 MINIMUM, ADD
32 AN960C416L MORE AS REQUIRED TO TAKE UP AR
SHAFT END PLAY)
33 3502-2 SHAFT, IMPELLER DRIVE 1
34 3504-4 TUBE, DISCHARGE 1
35 AN515C632-6 SCREW 3
36 AN960C6L WASHER 3
37 3507-2 SPACER TUBE 1
38 AN515C632-6 SCREW 7
39 AN960C6L WASHER 7
40 3304 HOUSING, GEAR 1
41 3301 HOUSING, PUMP 1

CARTRIDGE ASSEMBLY
Figure 25.13-2 (3 of 3)

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25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2 (cont’d)

c. Drain Valve Assembly

DRAIN VALVE ASSEMBLY

Figure 25.13-3 (1 of 2)

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CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2 (cont’d)

UNITS
FIG. PART
NOMENCLATURE PER
ITEM NUMBER
ASSY.
DRAIN VALVE ASSY (See Figure 25.13-1
1 (NS) 4650-4 RF
for NHA)
40 MS24566-1B PULLEY 1
45 MS24665-148 PIN, COTTER (REPLD BY MS24665-151) 1
MS24665-151 PIN, COTTER (REPLS BY MS24665-148) 1
50 AN960C10L WASHER, FLAT 1
55 MS9463-08 PIN, CLEVIS 1
60 99-022-094-0500 PIN, ROLL (V72962) 1
65 4681-2 CABLE 1
80 4678-4 COVER 1
85 NAS679C06M NUT, SELF-LOCKING 4
90 AN960C6 WASHER, FLAT 4
95 12300-16 SPRING 1
100 RS62S SPIROLOX (V80756) 1
105 RSN112S SPIROLOX (V80756) 2
110 4651 HOUSING 1
120 PRP568-114 DELETED
125 4802-53 RING, DOUBLER 1
130 MS24630-24 DELETED
MS24626-20 SCREW 4
135 4802-27 BOOT 1
140 NAS679C6M NUT, SELF-LOCKING 1
145 4672-1 PLATE 1
150 4801-11 SEAL 1`
155 4673 PLATE, SUPPORT 1
160 4801-12 PLUG, SEAL 1
165 4676-9 VALVE STEM 1
170 4670* GASKET, DRAIN VALVE ASSY 1
* ITEM SUPPLIED LOOSE

DRAIN VALVE ASSEMBLY

Figure 25.13-3 (2 of 2)

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25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2 (cont’d)

d. Timer Assembly

TIMER ASSEMBLY
Figure 25.13-4 (1 of 2)

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CHAPTER 25 - EQUIPMENT & FURNISHINGS
25.13 MONOGRAM EXECUTIVE AIRCRAFT TOILETS, P/N 4620-2 (cont’d)

UNITS
FIG. PART
NOMENCLATURE PER
ITEM NUMBER
ASSY.
TIMER ASSY, SOLID STATE (See Figure
1 (NS) 11059-63 RF
25.13-1 for NHA)
2 (NS) 11059-44-3 TIMER & SWITCH ASSY 1
3 AN507C832R10 SCREW 2
4 11059-12-33 PRINTED CIRCUIT BOARD ASSY 1
5 NAS679C04M NUT 2
6 AN960C4 WASHER 3
6A MS35333-70 WASHER, LOCK 1
7 5411-23 LUG, TERMINAL (V86928) 1
8 MS51957-15 SCREW 2
9 MS25089-3G SWITCH 1
10 MS25082B11 NUT 1
11 .640X.875X.022 WASHER, INTERNAL TOOTH 1
12 11059-12-1 PLATE ASSY 1
13 AD202 DELETED
13A AD18-183 DISCONNECT, FEMALE (V0W1Z2) 2
14 MS3100F16S-1P CONNECTOR, RECEPTACLE 1
15 MS35489-4 GROMMET 1
16 11060-1 DECAL, IDENTIFICATION 1
17 11059-1 ENCLOSURE 1

TIMER ASSEMBLY
Figure 25.13-4 (2 of 2)

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25.14 RESERVED FOR FUTURE USE

1. Reserved for future use.

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25.15 – MODEL 1603 SERIES TOP-FILL COFFEE BREWER

TABLE OF CONTENTS

Paragraph Page
1. DESCRIPTION ------------------------------------------------------------------------ 25.15.1

2. OPERATION--------------------------------------------------------------------------- 25.15.1

3. IN-SERVICE CLEANING ----------------------------------------------------------- 25.15.2

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25.15 MODEL 1603 SERIES TOP-FILL COFFEE BREWER

1. Description – The model 1603 is an aviation quality general purpose, top-fill coffee brewer.
This coffee brewer brews up to 54 oz. of coffee per brew cycle and may be used with either
loose coffee or with a commercial pillow pack. Using distilled water in the operation of this
machine will prevent the build-up of water deposits in the coffee brewer’s heater assembly.

2. Operation

a. For slide units only: To operate the slide feature, depress both slide release levers at once
and move unit in or out until it latches into position.
b. Press both pot/brew basket retainer latches down and remove brew basket.
c. Install a paper coffee filter with the appropriate amount of coffee into brew basket or
insert a pillow pack. For proper operation, use 3 ¼” diameter x 2 3/8” high paper coffee
filters (8-12 cup size).
d. Pres both pot/brew basket retainer latches down and return brew basket to brewer.
e. Press both pot/brew basket retainer latches down and remove carafe.
f. Fill carafe with water and pour into the water fill port (top of brewer). Avoid overfilling
the water tank by watching tank level sight gauge.

NOTE: To prevent carafe overflow, make certain that the amount of water poured in
the coffee brewer does not exceed the capacity of the carafe (54 oz.). DO NOT
add water during the brew cycle. Remember that the carafe must be able to
hold the amount of water poured into the coffee brewer tank.

g. Return empty carafe to coffee brewer.

h. Switch coffee brewer to ON position to begin the brew cycle.
i. When brew cycle is complete, remove the brew basket and discard coffee grounds.

NOTE: When the water level falls below 4 cups on the tank level sight gauge, 4 cups of
water still remain in the water tank.

j. Remove carafe from the coffee brewer and serve. When not serving coffee, ALWAYS
return the carafe to the coffee brewer to keep the coffee hot and for flight safety.
ON/OFF switch must be in the ON position to keep the coffee warm.

CAUTION: ONCE ALL COFFEE IS SERVED, SHUT OFF POWER SWITCH.

CARAFE IS NOT TO BE HEATED EMPTY.

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25.15 MODEL 1603 SERIES TOP-FILL COFFEE BREWER (cont’d)

3. In-Service Cleaning

WARNING: TURN OFF ALL POWER TO COFFEE BREWER COMPARTMENT AND

ALLOW UNIT TO COOL.

a. Daily

(1) Use a damp cloth only. Wipe all areas of the brewer where coffee may have
splashed.
(2) Rinse brew basket after final use, while still damp.
(3) Clean carafe and brew basket with any mild dishwashing detergent.

CAUTION: DO NOT USE COMMERCIAL CLEANING AGENTS SUCH AS

BATHROOM OR KITCHEN CLEANERS. SOME (PARTICULARLY
AEROSOL SPRAY TYPES) CONTAIN INGREDIENTS WHICH
CHEMICALLY ATTACK PLASTIC PARTS CAUSING THEM TO
CRACK OR BREAK.

b. Monthly – Flush mineral deposits from the coffee brewer using any automatic coffee
brewer cleaning solution available from local retail outlets. Cycle cleaning solution
through the water fill port on the brewer according to package instructions.

NOTE: If you are experiencing extended brewing times, it may be desirable to perform
this cleaning more often than monthly.

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CHAPTER 25 - EQUIPMENT & FURNISHINGS

25.16 – SMOKE BARRIER INTERIM REPAIRS

TABLE OF CONTENTS

Paragraph Page
A. GENERAL------------------------------------------------------------------------------ 25.16.1

B. DAMAGE LIMITS FOR INTERIM REPAIR------------------------------------- 25.16.1

C. INTERIM REPAIR INSTRUCTIONS --------------------------------------------- 25.16.1

D. LOGBOOK ENTRY & TRACKING OF INTERIM REPAIR ------------------ 25.16.1

FIGURES

25.16-1 SMOKE BARRIER INTERIM BARRIER--------------------------------------- 25.16.2

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25.16 – SMOKE BARRIER INTERIM REPAIRS

TABLE OF CONTENTS

Paragraph Page
A. GENERAL------------------------------------------------------------------------------ 25.16.1

B. DAMAGE LIMITS FOR INTERIM REPAIR------------------------------------- 25.16.1

C. INTERIM REPAIR INSTRUCTIONS --------------------------------------------- 25.16.1

D. LOGBOOK ENTRY & TRACKING OF INTERIM REPAIR ------------------ 25.16.1

FIGURES

25.16-1 SMOKE BARRIER INTERIM BARRIER--------------------------------------- 25.16.2

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25.16 SMOKE BARRIER INTERIM REPAIRS

A. General

1. This section provides a minor interim repair to the smoke barrier assembly installed in
DC-8 freighters.

2. The interim repair is limited to the time frame specified below and must be permanently
repaired or replaced after that date.

3. The interim repair cannot be used for damage exceeding the limits specified below.
Damage greater than specified requires replacement of the barrier.

4. The interim repair instructions must be followed completely to ensure the continued
integrity of the smoke barrier.

B. Damage Limits for Interim Repair

1. Maximum rip/tear limits cannot exceed two tears, 24 inches in length per barrier.

2. Maximum puncture/hole limits cannot exceed six holes, 4 inches in diameter per barrier.

C. Interim Repair Instructions (Figure 25.16-1)

1. Lightly sand areas of the smoke barrier to be repaired.

CAUTION: DO NOT USE ANY SOLVENTS OR CLEANERS TO CLEAN THE BARRIER

PRIOR TO INSTALLING THE INTERIM REPAIR. SOLVENTS MAY
REMOVE THE FIRE RETARDANT TREATMENT.

2. Apply bag bin tape (conforming to FAR 25.853 specifications) to both sides of the
damage. The tape must extend 2 inches beyond both ends and edges of the damage.
Multiple layers of tape may be used to complete the interim repair. Ensure the tape
adheres to the smoke barrier.

D. Logbook Entry and Tracking of Interim Repair

1. Enter into the logbook a discrepancy and corrective action of the interim repair.

2. Enter into the deferred maintenance log an item to track the interim repair with a
Category D limit of 120 days.

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25.16 SMOKE BARRIER INTERIM REPAIRS (cont’d)

SMOKE BARRIER INTERIM BARRIER

Figure 25.16-1

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CHAPTER 26- FIRE PROTECTION

TABLE OF CONTENTS
Page
26.01 RESERVED FOR FUTURE USE ------------------------------------------------- 26.01.1
26.02 RESERVED FOR FUTURE USE ------------------------------------------------- 26.02.1
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION ---------------------------- 26.03.1
26.04 FIRE CONTAINMENT COVERS ------------------------------------------------ 26.04.1
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM---------------------------------------------------------- 26.05.1
26.06 INSPECT/TEST ENGINE FIRE EXTINGUISHING SYSTEM
RECURRING NON-ROUTINE JOB CARD ------------------------------------ 26.06.1

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26.01 RESERVED FOR FUTURE USE

1. This section is reserved for future use.

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26.02 RESERVED FOR FUTURE USE

1. This section is reserved for future use.

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26.03 – COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT

SMOKE DETECTION DESCRIPTION & OPERATION
TABLE OF CONTENTS

Paragraph Page
1. GENERAL---------------------------------------------------------------------------- 26.03.1
2. COMBI AIRCRAFT SMOKE DETECTOR – REMOVAL /
INSTALLATION AND TEST ----------------------------------------------------- 26.03.8

FIGURES

26.03-1 COMBI SERVICE DETECTION SYSTEM------------------------------------- 26.03.4

26.03-2 SMOKE DETECTOR CONTROL AND INDICATOR PANEL ------------- 26.03.5
26.03-3 COMBI SMOKE DETECTOR WIRING DIAGRAM-------------------------- 26.03.6

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CHAPTER 26-FIRE PROTECTION
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION
1. General: A smoke detection system monitors main cabin air for the presence of smoke,
which is indicative of a smoke or fire condition. If smoke is detected by one or several
detectors, the flight engineer and aft cabin personnel are notified by warning light(s) and an
aural warning.
a. Combi Aircraft Main Deck Cargo Compartment Smoke Detection
(1) A smoke detection system monitors main deck cargo compartment air for smoke. If
smoke is detected by a detector, the flight engineer is notified by warning lights and
an aural warning horn. These warnings are duplicated in the aft passenger cabin.
Both the cockpit and the aft cabin can silence the warning horn in their particular
area only by momentarily depressing the associated “silence switch.”
(2) The main deck cargo compartment smoke detection system is divided into zones by
pallet positions which cover the entire length of the main cargo deck. Each smoke
detector has a smoke detection circuit. The manufacturer has adjusted the smoke
detector circuits to activate when the sampled air contains a smoke saturation of 5
percent. Upon activation, the smoke detector furnishes the flight crew an indication
that the monitored zone contains a 5 percent or greater smoke saturation. A test
switch is provided at the flight engineer’s instrument panel to test all the smoke
detectors. Each smoke detector has two (2) separate pick-up points within its zone.
(3) Each smoke detector is supplied with a constant sampling air flow by a common
vacuum manifold. The vacuum manifold is connected to an ejector valve which is
powered by the LH pneumatic system. Pneumatic air supply to the ejector valve is
controlled by an electrically actuated gate valve. Vacuum pressure is monitored in
the cockpit by a low pressure light on the smoke detector control panel. The light
will illuminate when vacuum in the manifold falls below seven inches of water.
b. Operation and Test
(1) The main cabin smoke detection system is operational whenever the 28 VDC LH
emergency bus is powered, the SMOKE DETECTION AND MAIN DECK
CARGO circuit breakers are set, air pressure is available to the LH pneumatic
system, and the detector system is armed (normal).

(2) The main cabin smoke detection system may be tested at the flight engineer’s
instrument panel. A rotary test switch is provided to test all smoke detectors.

(3) Operating a test switch simulates a smoke condition at the smoke detectors, causing
a fire signal (light and aural) if all circuits are operative. Air supply is not required
to test the detectors.

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CHAPTER 26-FIRE PROTECTION
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION (cont’d)

c. System Description. The main smoke detection system covers the entire main deck cargo
area. The following is a list of items that comprise the system with a brief description of
each item’s purpose:

(1) Pressure Line and Attaching Fittings. The pressure line attaches to the LH
pneumatic air duct and supplies low air pressure to the shut-off valve.

(2) Shut-off valve. The shut-off valve is connected to the pressure line and controls air
supply to the ejector valve.

(3) Ejector and Pressure Switch

(a) The ejector receives low pressure pneumatic air from the shut-off valve pressure
and develops the vacuum required to operate the smoke detection system.

(b) A vacuum switch monitors the vacuum developed by the ejector and supplies an
electrical air flow/no air flow signal to the Smoke Detection/Test panel located on
the flight engineer’s panel. If the switch does not detect sufficient vacuum to
operate the system, it supplies a no air signal to the Smoke Detection/Test panel,
illuminating the LOW VACUUM annunciator. Specifically, when the vacuum
falls below 7 (+/- 1) inches of water, the pressure switch closes, illuminating the
LOW VACUUM annunciator. The pressure switch will open, extinguishing the
LOW VACUUM annunciator, when the vacuum is 11 (+/- 1) inches of water or
greater.

(4) Vacuum Line and Attaching Fittings. The vacuum line is connected to the ejector
and supplies vacuum to the vacuum manifold connected at the other end.

(5) Vacuum Manifold and Attaching Fittings. The vacuum manifold supplies vacuum
to each smoke detector.

(6) Smoke Detectors and Associated Draw-Through Air Sampling Pick-ups. Each
pallet position contains a detector. The detector receives vacuum from the vacuum
manifold. The detectors monitor the draw-through air samples supplied by two
balanced sampling pick-ups. If a detector detects smoke in the draw-through air, it
furnishes an electrical signal to the Smoke Detection/Test panel located on the
flight engineer’s panel. This signal causes the associated annunciator lamp to
illuminate and the aural warning to sound. A lamp is also illuminated in the aft
cabin and an aural warning in that compartment will sound.

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CHAPTER 26-FIRE PROTECTION
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION (cont’d)

(7) Smoke Detection/Test Panel. The Smoke Detection/Test Panel contains a rotary
test switch, zone annunciator lamps, warning horn, system off/normal guarded
switch, low vacuum annunciator lamp, and an aural alert silence switch.

(a) Each annunciator lamp circuit monitors the output of its associated smoke
detector. Should a smoke detector activate, the associated annunciator lamp
illuminates.

(b) When the rotary TEST switch is in a normal position, the system operates
normally (lights out, no aural warning) unless smoke detected. Positioning the
TEST switch to any other position supplies a test signal to that smoke detector
and its associated light will illuminate in conjunction with an aural warning.
The aural warning can be silenced by depressing the SILENCE SWITCH. The
light will remain illuminated until the TEST SWITCH is rotated to another
position or back to normal.

(c) The low vacuum annunciator lamp circuit monitors the output signal from the
Vacuum. Pressure switch. When the switch detects insufficient vacuum, it
sends a signal to the Smoke Detection/Test panel, causing the low vacuum
annunciator lamp to illuminate.

(d) Circuit Breakers: The Combi smoke detector system uses three 5 amp 28 VDC
circuit breakers powered by the LH emergency bus. One circuit breaker
supplies power to operate the pneumatic shut-off valve and the LOW
VACUUM warning light circuit. The remaining two(2) circuit breakers apply
power to the smoke detectors and their associated warning lights. One of the
CB’s powers the odd numbered detectors, the other CB powers the even
numbered detectors.

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26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE DETECTION DESCRIPTION AND
OPERATION (cont’d)

COMBI SERVICE DETECTION SYSTEM

Figure 26.03-1

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CHAPTER 26-FIRE PROTECTION
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION (cont’d)

SMOKE DETECTOR CONTROL AND INDICATOR PANEL

Figure 26.03-2

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CHAPTER 26-FIRE PROTECTION
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION (cont’d)

COMBI SMOKE DETECTOR WIRING DIAGRAM

Figure 26.03-3(1 OF 2)

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CHAPTER 26-FIRE PROTECTION
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION (cont’d)

COMBI SMOKE DETECTOR WIRING DIAGRAM

Figure 26.03-3(2 OF 2)

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CHAPTER 26-FIRE PROTECTION
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION (cont’d)

2. COMBI Aircraft Smoke Detector - Removal/Installation and Test

a. The smoke detectors used in the main deck cargo smoke detection system are located in
the ceiling of each pallet position of the main deck. For removal/installation, perform the
prepare-for removal steps, then the removal/installation procedures for the desired unit.
All smoke detectors are identical and removal/installation is described in procedures 4
and 5.

b. Prepare for Removal. Open the CARGO SMOKE DETECTOR circuit breakers (3)
located on the 28 VDC LH emergency bus.

c. Remove Smoke Detector.

(1) Disconnect electrical connector from smoke detector.

CAUTION: USE CARE WHEN REMOVING FLEXIBLE TUBING FROM

SMOKE DETECTOR INPUT/OUT TUBES. IF FLEXIBLE
TUBING WILL NOT COME OFF USING NORMAL FORCE, CUT
TUBING FROM SMOKE DETECTOR INPUT/OUT TUBES AND
REPLACE FLEXIBLE TUBING.

Note: Make sure that method of vacuum tube connections/routing is identified

and repeated on installation.

(2) Disconnect rubber vacuum tube connections by removing clamps and sliding rubber
tubes off detector inlet and outlet tubes and plug tubes.

(3) Remove detector.

e. Install Smoke Detector .

(1) Make sure the CARGO SMOKE DETECTOR CIRCUIT BREAKERS are open.

(2) Mount the smoke detector.

(3) Remove plug from vacuum tubes.

(4) Slide and clamp rubber tubes onto smoke detector inlet and outlet tubes.

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CHAPTER 26-FIRE PROTECTION
26.03 COMBI AIRCRAFT MAIN DECK CARGO COMPARTMENT SMOKE
DETECTION DESCRIPTION AND OPERATION (cont’d)

(5) Attach electrical connector to smoke detector.

(6) Perform operational test (paragraph f.).

f. Operational Test Procedures

(1) Close CARGO SMOKE DETECTOR circuit breakers on 28 VDC LH emergency

bus.

(2) Provide electrical power

(3) Operational Test

(a) Press to test the warning light for any smoke detector to be tested.

(b) Rotate test switch to smoke detector position to be tested. Warning light for
selected position should illuminate and aural warning horn should sound. Press
AURAL ALERT SILENCE switch to silence horn. Warning light should
remain illuminated until test switch is moved to another position or normal.

Note: Combi Aircraft are equipped with an aural and visual warning system in
the aft passenger cabin. During any smoke detector system testing, both
aural and visual warnings should be confirmed in the aft cabin. Caution
should be taken not to alarm passengers that may occupy the aft cabin
during smoke detector system testing. The aft cabin aural warning can not
normally be silenced from the cockpit and it may be necessary to station
personnel in the aft cabin to eliminate unnecessary confusion and
immediately silence the horn during testing.

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26.04 – FIRE CONTAINMENT COVERS (FCCs)

TABLE OF CONTENTS

Paragraph Page
1. AKRO FIREGUARD AF1001 FIRE CONTAINMENT COVER ------------ 26.04.1

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26.04 FIRE CONTAINMENT COVERS (FCCs)

WARNING: ATI COMBI/CARGO CARRIAGE WILL BE LIMITED TO PALLETS

USING FIRE CONTAINMENT COVERS.

1. Akro Fireguard AF1001 Fire Containment Cover

a. General. The Akro Fireguard AF1001 FCC is a non-fitted tarpaulin designed to be

covered with a standard cargo net. The base material is a woven fiberglass fabric
impregnated with a fire-resistant neoprene coating The fabric is seamed using Kevlar
and Nomex into a tarpaulin form with the perimeter edges hemmed.

b. Recommended Handling Instructions. The woven glass fabric may cause individuals to
initially experience temporary skin irritation as result of handling. First time users may
be especially susceptible to skin irritation.

(1) Recommended handling instructions include:

(a) Avoid contact with skin.

(b) Sensitive individuals should were log sleeves and gloves.
(c) Eye protection is not required for normal use but suggested as part of routine
safety practices.
(d) Good general ventilation is recommended.

(2) First Aid Measures:

(a) For Eyes: If irritation occurs flush eyes with clean, cold water under low
pressure.
(b) For Skin: If irritation occurs flush skin with clean, cold water, followed by
washing with mild soap and cold water rinse.
(c) For Inhalation: Move to well ventilated area free from risk of further exposure.

b. Installation/Application Instructions.

(1) Cover the cargo and pallet with the AF1001 FCC.
(2) Ensure the cover reaches to the pallet on all sides.
(3) Roll excess fabric in a manner so as to not interfere with the cargo net fastening
system. Ensure there are no gaps between the rolls and the base pallet.
(4) Secure the cover to the pallet with a standard cargo net.

c. Damage Limitations. The maximum amount of damage allowed on a FCC is any one of
the following (per face of the cargo pallet):

(1) 4” X 4” “L” shape tear

(2) 8” straight tear
(3) 2” diameter puncture

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CHAPTER 26-FIRE PROTECTION
26.04 FIRE CONTAINMENT COVERS (FCCs) (cont’d)

d. Repair Procedures. FCC’s exceeding damage limitations must be immediately removed

from service until the applicable repairs are made. Repair kits, P/N AF1010, can be
obtained from Stores. All repairs must be accomplished in accordance with the
manufacturer’s specifications and instructions which are included with each repair kit.

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26.05 – LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE

SUPPRESSION SYSTEM (STC ST00746LA-D & ST00984LA-D)
TABLE OF CONTENTS

Paragraph Page
1. DESCRIPTION AND OPERATION---------------------------------------------- 26.05.01
2. SDU REMOVAL / OPERATION ------------------------------------------------- 26.05.15
3. ADJUSTMENT / TEST------------------------------------------------------------- 26.05.23
4. CCU / SCU AND CCU / CM REMOVAL / INSTALLATION --------------- . 26.05.30
5. CONTROL DISPLAY UNIT REMOVAL / INSTALLATION --------------- 26.05.32
6. CONFIGURATION MODULE REMOVAL, INSTALLATION, AND
COPY PROCEDURE --------------------------------------------------------------- 26.05.33
7. FIRE SUPPRESSION SYSTEM DESCRIPTION AND OPERATION------ 26.05.36
8. FIRE SUPPRESSION SYSTEM CCU & SCU ADJUSTMENT / TEST ---- 26.05.42
9. FIRE SUPPRESSION SYSTEM PRESSURE / FLOW TEST & SYSTEM
RESTORATION --------------------------------------------------------------------- 26.05.50
10. FIRE SUPPRESSION SYSTEM FIRE EXTINGUISHING (FIREX)
BOTTLE REMOVAL / INSTALLATION--------------------------------------- 26.05.56
11. FIRE SUPPRESSION SYSTEM DIVERTER VALVE REMOVAL /
INSTALLATION -------------------------------------------------------------------- 26.05.60
12. FIRE SUPPRESSION SYSTEM DIVERTER VALVE SQUIB
REMOVAL / INSTALLATION --------------------------------------------------- 26.05.63
13. FIRE SUPPRESSION SYSTEM EXTINGUISHER (FIREX) BOTTLE
SQUIBS REMOVAL / INSTALLATION---------------------------------------- 26.05.65
14. CARGO COMPARTMENT FIRE SUPPRESSION SYSTEM SCU
REMOVAL / INSTALLATION --------------------------------------------------- 26.05.68
15. FIRE SUPPRESSION SYSTEM BOTTLE 2 FLOW RESTRICTOR
REMOVAL / INSTALLATION --------------------------------------------------- 26.05.71

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TABLE OF CONTENTS
(CONT’D)

16. FIRE SUPPRESSION SYSTEM BOTTLE 2 TEMPERATURE

COMPENSATED REGULATOR REMOVAL / INSTALLATION --------- 26.05.74
17. FIRE SUPPRESSION SYSTEM BOTTLE 2 PARTICULATE FILTER
REMOVAL / INSTALLATION --------------------------------------------------- 26.05.76
18. FIRE SUPPRESSION SYSTEM POST HALON DISCHARGE
MAINTENANCE -------------------------------------------------------------------- 26.05.78
19. DC-8 ILLUSTRATED PARTS CATALOG ------------------------------------- 26.05.81
20. WIRING DIAGRAMS -------------------------------------------------------------- 26.05.89

FIGURES

26.05-1 CDU LOCATION DETAILS ------------------------------------------------------ 26.05.12

26.05-2 SDU VIEWS-------------------------------------------------------------------------- 26.05.13
26.05-3 CCU REAR VIEW ------------------------------------------------------------------ 26.05.14
26.05-4 SDU, CCU, SCU, AND FIRE BOTTLE LOCATIONS ------------------------ 26.05.22
26.05-5 SDU SETUP BUTTON ------------------------------------------------------------- 26.05.27
26.05-6 CCU MOUNTING & LOCATION IN THE MID ACCESSORY
COMPARTMENT ------------------------------------------------------------------- 26.05.31
26.05-7 FIRE DETECTION & SUPPRESSION SYSTEM DEPLOYMENT
SEQUENCE -------------------------------------------------------------------------- 26.05.39
26.05-8 SUPPRESSION SYSTEM COMPONENT LOCATIONS IN CARGO
BAYS---------------------------------------------------------------------------------- 26.05.41
26.05-9 INTERCONNECT PLUMBING COMPONENT LOCATION --------------- 26.05.54
26.05-10 CARGO BAY PLUMBING COMPONENT LOCATION--------------------- 26.05.55
26.05-11 FIREX BOTTLE COMPONENT LOCATION---------------------------------- 26.05.59
26.05-12 DIVERTER VALVE COMPONENT LOCATION ----------------------------- 26.05.62
26.05-13 BOTTLE SQUIB COMPONENT LOCATION --------------------------------- 26.05.67
26.05-14 SCU COMPONENT BAY LOCATION------------------------------------------ 26.05.69

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FIGURES
(CONT’D)

26.05-15 SCU COMPONENT LOCATION------------------------------------------------- 26.05.70

26.05-16 REGULATOR & FILTER ASSEMBLY COMPONENT LOCATION ------ 26.05.73
26.05-17 SMOKE DETECTION IPC -------------------------------------------------------- 26.05.81
26.05-18 FIRE SUPPRESSION UNIT IPC-------------------------------------------------- 26.05.87
26.05-19 SMOKE DETECTION/FIRE SUPPRESSION WDG 26-23-00, PAGE 1
(-62/-72 EFFECTIVITY) ----------------------------------------------------------- 26.05.89
26.05-20 SMOKE DETECTION WDG 26-23-00, PAGE 4 (-71/-73
EFFECTIVITY) ---------------------------------------------------------------------- 26.05.91

TABLES

26.05-1 INDICATIONS ON CDU AFTER POWER-UP SELF-TEST ---------------- 26.05.05

26.05-2 INDICATIONS ON CONTROL DISPLAY UNIT ----------------------------- 26.05.05
26.05-3 CDU INDICATIONS ON BOTTLE DEPLOYMENT------------------------- 25.05.05
26.05-4 CDU INDICATIONS ON BOTTLE 1 FAILED -------------------------------- 26.05.06
26.05-5 MAINTENANCE FAULT DISPLAYS ------------------------------------------ 26.05.07
26.05-6 SDU LOCATIONS – DC-8-71/-73 ----------------------------------------------- 26.05.15
26.05-7 SDU LOCATIONS – DC-8-62/-72/COMBI ------------------------------------ 26.05.16
26.05-8 SPREAD SPECTRUM VIEWER ------------------------------------------------- 26.05.26
26.05-9 SCU LED INDICATIONS --------------------------------------------------------- 26.05.34
26.05-10 SCU OUTPUT CABLING DESIGNATORS ----------------------------------- 26.05.44

DATA SHEETS

26.05-1 DC-8-71/-73 ON AIRCRAFT SMOKE DETECTOR

CHARACTERIZATION ------------------------------------------------------------ 26.05.28
26.05-2 DC-8-62/-72 ON AIRCRAFT SMOKE DETECTOR
CHARACTERIZATION ------------------------------------------------------------ 26.05.29

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (S.T.C. ST00746LA-D & ST00984LA-D)

NOTE: Paragraphs 1 through 6 plus 19 and 20 are applicable to all aircraft unless stated
otherwise. Any information applicable to only DC-8-62/-72/COMBI aircraft in
these sections has been placed in brackets, bolded, and italicized. Example:
[Suppressant Control Unit (SCU)]. Paragraphs 7 through 18 are applicable only to the
DC-8-62/-72 COMBI aircraft.

1. Description and Operation

a. General

(1) Securaplane’s Cargo Compartment Smoke Detection System is based upon

wireless-spread spectrum technology. This system provides indication of fires
originating in the cargo compartments of transport aircraft. To minimize the
amount of wiring required, decrease system weight, and increase reliability, radio
communication links replace wiring between various units of the system. Multiple
smoke sensor units (SDU) are mounted in the ceiling of each cargo compartment.
Each sensor has a radio transmitter to signal conditions to a Central Control Unit
(CCU), which is located on the Station 680 Bulkhead, Mid Accessories
Compartment. The CCU contains system control and logic and is linked by wiring
to a Control Display Unit (CDU) located on the shelf to the right of the Flight
Engineer’s (FE) Panel. The CDU displays system status and alarms to the flight
crew.

(2) The system includes these parts:

(a) Smoke Sensors (SDU)/Identification Plugs

(b) Central Control Unit (CCU)/Configuration Module
(c) Control Display Unit (CDU)
(d) Lower Cargo Fire Light
(e) [Suppressant Control Unit (SCU)]

(3) The cargo compartment smoke detection system uses 28 VDC power. The power is
supplied through two [four] 1 AMP circuit breakers on the circuit breaker panel.

b. Component Details (Reference Figure 26.05-1)

(1) Cargo Smoke Sensor (SDU)/Identification Plugs

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
(a) Cargo Smoke Detectors are nineteen each; ten in the forward two cargo
compartments and nine in the aft cargo compartment overhead cargo liners.
[The DC8-62/-72 series are sixteen each; eight in the forward cargo
compartment overhead cargo liners and eight in the aft cargo compartment
overhead cargo liners.] These smoke detectors monitor their respective cargo
compartments for the presence of smoke and/or heat. Thirteen or fifteen
Identification Plugs are used to differentiate between forward and aft cargo
compartment smoke detector locations. These are P/N 100-1026-04 for the
forward cargo bay forward zone (Cargo Bay A), 100-1026-05 for the forward
cargo bay aft zone (Cargo Bay B), 100-1026-06 for the aft cargo bay forward
zone (Cargo Bay C) and 100-1026-07 for the aft cargo bay aft zone (Cargo
Bay D). [In the DC8-62/-72 Series, these are P/N marked 100-1026-01 and
not banded (black color) for the forward cargo bay and 100-1026-02 and
color banded (red) for the aft cargo bay.] A lanyard is used to secure the
Identification Plug to the respective cargo compartment mounting location. A
lexan guard encloses the SDU and lanyard preventing any interference with
existing aircraft components, harnesses or flight control cables. Two non-
rechargeable, 3.6V lithium thionyl batteries power each smoke detector. With
the batteries and ID Plugs installed, the SDU transmits its location, serial
number, and general condition to the CCU every 30 seconds.
(b) The SDU transmits the RF signal that is received by the Central Control Unit
(CCU). The RF signal is received by the CCU and processed, and any alarm
or fault data is sent via wiring harness to the Control Display Unit (CDU)
located in the cockpit.
(2) Central Control Unit (CCU) and Configuration Module – The CCU with
configuration module is located in the Mid Accessories compartment on the forward
side of the center wing tank on the forward spar stiffeners at FS 680.0 and right of
BL 0.0 between RBL 29.0 and RBL 35.0. The CCU is mounted at the top of the
center wing tank and is mounted horizontally. The CCU is the control center for the
system and monitors the smoke detectors and other system components. The CCU
communicates with the cockpit Control Display Unit (CDU) mounted in the F.O.’s
P5 overhead panel through a RS 422 communications bus and with the forward and
aft cargo compartment smoke detectors through a Spread Spectrum transmission
link. The CCU contains all of the decision-making capabilities of the system. The
CCU receives inputs from the compartment smoke detectors and determines if it is
necessary to illuminate the FWD FIRE LED, AFT FIRE LED, or MX LED located
in the CDU. The CCU is arranged in a two-channel arrangement with both channels
operating completely independently of the other channel, and both are fully capable
of performing all system functions and annunciations.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
a) The Configuration Module (CM) is installed into an external port on the end
of the CCU. The CM is an EPROM and after the system has been
characterized, stores non-volatile memory of the system configuration
including SDU serial numbers and quantities assigned to each cargo
compartment. The CM is intended to stay with the aircraft in the event a CCU
may be replaced.
WARNING: THE MATED CONFIGURATION MODULE (CM) IS
INSTALLED ON THE CCU THROUGH AN EXTERNAL
CONNECTION PORT AND SECURED WITH A LANYARD
TO THE AIRCRAFT. THE CM RETAINS VITAL SYSTEM
INFORMATION UNIQUE TO THE AIRCRAFT IT IS
INSTALLED ON AND IS INTENDED TO STAY WITH THE
AIRCRAFT EVEN IF THE CCU/[SCU] IS REMOVED OR
REPLACED.
(3) Control Display Unit (CDU) - The CDU is located in the flight deck on a shelf just
aft of the Flight Engineer’s station or in the FE Panel and is used as the control
interface for the system to the flight and ground crews. It provides the flight crew
with Smoke Detection/Fire Suppression alarm reporting and the ground crews with
system operational status and Built-In Test (BIT) capabilities. The CCU reports
system status to the CDU using two redundant RS-422 serial links. The CDU
displays this information in the form of indicator lights and a ten character
alphanumeric display. Displayed information includes maintenance information
and system status. The CDU contains all of the LED’s necessary for maintenance,
dispatch, and fire indication information. The CDU, like the CCU, is also arranged
as an independent two-channel design. The CDU has discrete outputs that also
drive the FIRE WARNING light and MASTER CAUTION lights in the event an
alarm condition is detected or the LAMP TEST button on the CDU is depressed.
[(4) Suppression Control Unit (SCU) – The Suppression Control Unit (SCU) located
in the air conditioning mix compartment centered between locations RBBL 15.04
and RBBL 6.25. The SCU communicates with the CCU via dual, RF radio data
links. The SCU is used in the event of a deployment command from the flight
crew. When a fire occurs, the cockpit crew enters a fire command on the CDU.
The SCU receives the command from the CCU, then actuates pyrotechnic squibs
to discharge the bottles to the selected compartment. Once initiated, an automatic
discharge sequence rapidly floods the affected cargo compartment with the
contents of the first bottle and then meters the contents of the second bottle into
the cargo compartment at a slower rate. This sequence is designed to prevent re-
ignition of a fire for a minimum period of 60 minutes, in order to meet the fire
suppression requirements of 14 CFR 121.314. The SCU is powered from the
circuit breakers located on the P18 circuit breaker panel. See Figure 26.05-14
“SCU Component Bay Location” for further SCU location details.]

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
c. Operation
(1) Functional Description
(a) Smoke is detected by photo electric smoke sensors located in the ceiling of the
lower two forward cargo compartments (cargo bay A and B) and lower two aft
cargo compartments (cargo bay C and D).
1) When smoke is detected by an SDU, an RF spread spectrum transmission
is made to the CCU and continues transmitting at a rate of four times
every five seconds as long as smoke is present.
2) When the CCU has received a smoke transmission from two SDUs in the
same bay, fire indication signaling is sent to the CDU.
3) The CDU illuminates its fire warning lights and places a message in its
alphanumeric display.
4) The Master Warning Light on the First Officer position illuminates.
(b) In normal operation it requires two smoke sensors to detect smoke in either
cargo compartment, or one sensor to detect smoke and its temperature to be
above 150º F, to cause a fire alarm.
(c) The detection system is designed in such a way that it can withstand one
failure of a smoke sensor in any of the cargo compartments and still function
in the Minimum Equipment List (MEL) mode. When the system is in the
MEL mode the MX light and System OK light are illuminated simultaneously.
If a bay has more than one faulty sensor, the MX light and the SYS OK light
are both illuminated allowing for dispatch with a CAT C (10 Day) deferrable
maintenance item. See Table 26.05-5 “Maintenance Fault Displays” for
Single Bay Dispatch operation.
(d) Should two or more SDU’s fail or two or more maintenance faults be detected
in a given cargo compartment, both the SYS OK and MX LED’s will be
illuminated and a FWD A/FWD B INOP or AFT C/AFT D INOP message
will be automatically displayed in the MX DISPLAY window. (It is not
necessary to press MX Test to display this MX message.) With a “Cargo
Compartment” INOP message, the aircraft may still dispatch; however, no
cargo/freight/baggage may be loaded in the “INOP’d” compartment until the
MX fault has been corrected.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
SYS OK LIGHT MX LIGHT
DISPATCH CONDITION
(Green) (Amber)
ON OFF Normal, OK to Dispatch
ON ON* Defer for Maintenance (MEL), OK to Dispatch
OFF ON System not OK, not OK to Dispatch
OFF OFF Verify AC Power, Press Lamp Test, not OK to Dispatch
* May not dispatch with cargo loaded in specified bay with an unsolicited “FWD INOP” or “AFT INOP” (2-
Bay) or a “FWDA INOP,” “FWDB INOP,” “AFTC INOP,” or “AFTD INOP” (4-Bay message).

INDICATIONS ON CDU AFTER POWER-UP SELF-TEST

Table 26.05-1
(e) Fault and Fire Indications are shown in the tables that follow.
(f) Table 26.05-2 shows the CDU indicator status and the alphanumeric displayed
message based on the various conditions.
SYS OK FIRE INDICATORS
MX LIGHT ALPHA-NUMERIC
CONDITION LIGHT
(Amber) AFT FIRE FWD FIRE DISPLAY
(Green)
NORMAL Illuminated Extinguished Extinguished Extinguished BLANK
FWD A (OR B) FWD A (OR B)
Illuminated Extinguished* Extinguished Illuminated
FIRE FIRE
AFT C (OR D) AFT C (OR D) FIRE
Illuminated Extinguished* Illuminated Extinguished
FIRE
* Providing no faults are latched when smoke is detected
NOTE: “Illuminated” = Light ON; “Extinguished” = Light OFF.

INDICATIONS ON CONTROL DISPLAY UNIT

Table 26.05-2
(g) [Table 26.05-3 shows the indicator status and the alphanumeric displayed
messages during a halon deployment. Table 26.05-3 and 26.05-4 apply to
DC8-62/-72 only.]
SYS OK ALPHA-
MX LED DISCHARGE LEDs
LED NUMERIC
(AMBER)
CONDITION (GREEN) BTL 1 BTL 2 DISPLAY

NORMAL Illuminated Extinguished Extinguished Extinguished BLANK

Arm Switch selected Illuminated Extinguished* Extinguished Extinguished SYS ARMED

SYSTEM
Arm Switch not
UNARMED
selected and fire Illuminated Extinguished* Extinguished Extinguished
UNABLE TO
button pressed
DEPLOY
* Providing no faults are latched when smoke is detected

[CDU INDICATONS ON BOTTLE DEPLOYMENT]

Table 26.05-3 (1 of 2)

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
SYS OK DISCHARGE LEDs ALPHA-
MX LED
CONDITION LED NUMERIC
(AMBER) BTL 1 BTL 2
(GREEN) DISPLAY
When bottle 1 is
Illuminated Extinguished* Illuminated Extinguished BLANK
discharged
After 15 minutes (45
minute metered
Illuminated Extinguished* Illuminated Blinking BTL2 DISCH
discharge from bottle
2 occurs)
When bottle 2 is
Extinguished Illuminated Illuminated Illuminated BLANK
discharged
* Providing no faults are latched when smoke is detected

[CDU INDICATONS ON BOTTLE DEPLOYMENT]

Table 26.05-3 (2 of 2)
(h) [Table 26.05-4 shows the indicators and alphanumeric displayed messages
when the system does not receive BTL 1 data within 40 seconds after the
command to deploy halon is issued.]
SYS OK ALPHA-
MX LED DISCHARGE LEDs
LED NUMERIC
(AMBER)
CONDITION (GREEN) BTL 1 BTL 2 DISPLAY

NORMAL Illuminated Extinguished Extinguished Extinguished BLANK

FWD or AFT fire

Illuminated Extinguished Blinking Extinguished BTL1 DISCH
button depressed
Bottle 1 does not
discharge within 40 Extinguished Illuminated Blinking Blinking BTL2 DISCH
seconds

[CDU INDICATIONS ON BOTTLE 1 FAILED]

Table 26.05-4
(i) Failed Component Indications are shown in the table that follows (Table
26.05-5). The maintenance function of the system shall display the messages
and function as described below:
1) While the system is in normal operating mode, press and hold the MX
TEST switch for two seconds to display the first fault.
2) Press the MX TEST switch to cycle through all the faults. The display
returns to blank when all faults have been displayed.
3) If all faults have not been displayed and the MX TEST switch has not
been pressed for fifteen minutes, the display shall return to a blank
message.
4) With each of the faults below an “(A)” or “(B)” shall appear to denote
which channel detected the fault. If both channels detect a fault then
neither “(A)” nor “(B)” shall appear.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
5) When a fault is observed on the MX Display, reset circuit breakers [SCU
CHA, SCU CHB,] CCU CHA, and CCU CHB. Resetting of the circuit
breakers is required to clear faults observed on the MX Display. Note
that when power is lost to the CCU Channel B (CCU CHB Circuit
Breaker), the CDU MX Display will not illuminate.
DISPLAYED ITEM
FAULT ISOLATION
(Press MX TEST to MEANING MAINTENANCE ACTION
METHODS
view message)
SYSTEM OK No failure. System
operating normally.
LINK DOWN Communication between Check that the RS 422 lines Replace CDU. If fault
the CDU and CCU failed are intact. If lines OK fault persists, replace CCU.
lies in CCU or CDU.
[SCU Suppression Control Unit Recycle power per Note 1 Check that SCU Copy
Failed. below. Procedure has been
SCU (A) A Side failed Note: An incorrect SCU completed. If fault persists
SCU (B) B Side failed configuration module can remove and replace SCU.]
also look like a failed SCU.
CDU Control Display Unit Recycle power per Note 1 If fault persists remove and
failed. below. replace CDU.
CDU (A) A side failed
CDU (B) B side failed
F xxxxx Forward Sensor S/N Replace batteries and recheck
xxxxx failed. by recycling power per Note 1
A xxxxx Aft Sensor S/N xxxxx below. If still not functional,
failed. remove and replace sensor,
(See Note 2.) add new sensor S/N, and
F xxxxx(A) (A) and (B) indicate CCU Channel A or B delete old per characterization
F xxxxx(B) which channel detected receiver is not receiving the procedure. MEL=1 detector
A xxxxx(A) failure. If both channels SDU transmission on the failure per cargo bay. See
A xxxxx(B) detected fault, neither (A) Channel indicated (X). This “FWD INOP” and “AFT
nor (B) appear. message is commonly INOP” for Single Bay
(See Note 2.) misinterpreted as an SDU Dispatch Operation.
fault. Most cases replacing
the CCU will eliminate
repeated (A) or (B) faults.
NOTE 1: Pull Circuit Breakers CCU CHA and CCU CHB and make certain to reset in the following order: 1st
CCU CHA, 2nd CCU CHB.
[Pull circuit breakers SCU CHA, SCU CHB, CCU CHA, and CCU CHB located on the lower EPC
circuit breaker panel. Then sequentially reset all of these breakers.]
NOTE 2: If a “Mxxxxx” is displayed, the CCU has interpreted an RF signal through to be a Main or Mid Cargo
Compartment SDU and at some point has been commanded to accept the MAIN or MID Cargo
Compartment Smoke Detector. The “M” prefix is NOT used on any 2 or 4 Bay class “E” systems.
The SDU serial number may be deleted but the MAIN/MID “compartment” will still exist. You must
replace the Configuration Module to clear this fault message.

MAINTENANCE FAULT DISPLAYS

Table 26.05-5 (1 of 5)

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DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
DISPLAYED ITEM
FAULT ISOLATION
(Press MX TEST to MEANING MAINTENANCE ACTION
METHODS
view message)
FxxxxxBAT Forward sensor S/N SDU has been faulted and Replace batteries and recycle
xxxxx battery low. failed for a low battery. power per Note 1 below.
AxxxxxBAT Aft sensor S/N xxxxx Transmitted for 25 minutes
battery low w/ BAT BIT before it
(See Note 2) stopped reporting in.
[Fail Squib Halon bottle 1, halon Check for open circuit in Remove and replace SCU.]
Fail Squib(A) bottle 2, forward diverter, interconnect cables
Fail Squib(B) or aft diverter squib between SCU and halon
failed. bottles and squibs. Check
for possible bottle failures.
?0? CNT? Seen ONLY during initial Indicates that the CM has no Perform system
system installation or memory of SDU quantities characterization procedure to
installation of a new or serial numbers or cargo ensure that all detector serial
configuration module. compartments. numbers/ compartments has
been accepted.
FWD CNT? FWD SDU count. Not Run Spread Spectrum If the SDU count is less than
enough detectors as Viewer to determine how the quantity required for the
determined by the CM many and what SDU serial cargo compartment, perform
memory in FWD numbers are installed. the SDU characterization
compartment or a larger procedure to accept the correct
number of detectors have number of detectors for the
been accepted than cargo compartments.
required for the FWD If the quantity of detectors is
cargo compartment. larger than the quantity
required for this compartment,
the CCU Configuration
Module’s memory will have to
be cleared and the system
characterized.
MAIN or MID CNT? Smoke system has at Proceed to the “MAIN or CCU Configuration Module’s
some time been MID CNT?” Maintenance memory will have to be
commanded to accept a Action. cleared and the system re-
MAIN or MID RF signal characterized.
or the system has
misinterpreted a RF
signal.
NOTE 1: Pull Circuit Breakers CCU CHA and CCU CHB and make certain to reset in the following order: 1st
CCU CHA, 2nd CCU CHB.
[Pull circuit breakers SCU CHA, SCU CHB, CCU CHA, and CCU CHB located on the lower EPC
circuit breaker panel. Then sequentially reset all of these breakers.]
NOTE 2: If a “Mxxxxx” is displayed, the CCU has interpreted an RF signal through to be a Main or Mid Cargo
Compartment SDU and at some point has been commanded to accept the MAIN or MID Cargo
Compartment Smoke Detector. The “M” prefix is NOT used on any 2 or 4 Bay class “E” systems.
The SDU serial number may be deleted but the MAIN/MID “compartment” will still exist. You must
replace the Configuration Module to clear this fault message.

MAINTENANCE FAULT DISPLAYS

Table 26.05-5 (2 of 5)

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
DISPLAYED ITEM
FAULT ISOLATION
(Press MX TEST to MEANING MAINTENANCE ACTION
METHODS
view message)
AFT CNT? AFT SDU count. Not Run Spread Spectrum If the SDU count is less than
enough detectors as Viewer to determine how the quantity required for the
determined by the CM many and what SDU serial cargo compartment, perform
memory in AFT cargo numbers are installed. the SDU characterization
compartment or a larger procedure to accept the correct
number of detectors have number of detectors for the
been accepted than cargo compartments.
required for the AFT If the quantity of detectors is
cargo compartment. larger than the quantity
required for this compartment,
the CCU Configuration
Module’s memory will have to
be cleared and the system re-
characterized.
CCU CM CCU CM not installed or Clear CCU Configuration
CCU has a bad/incorrect module memory and re-
configuration module characterize the system. If the
installed. problem persists or the
Configuration Module will not
clear properly, remove and
replace the Configuration
Module. If the error goes
away with new CM installed,
perform the characterization
procedure.
NOTE: The new CM will
contain no system memory. If
problem persists, replace
CCU.
CCU COM CCU COM has failed. Remove and replace CCU.
CCU RX CCU has a failed spread Remove and replace CCU.
CCU RX (A) spectrum receiver.
CCU RX (B) (A) & (B) indicate which
channel detected failure.
If both channels detected
fault, neither (A) nor (B)
appear.
NOTE 1: Pull Circuit Breakers CCU CHA and CCU CHB and make certain to reset in the following order: 1st
CCU CHA, 2nd CCU CHB.
[Pull circuit breakers SCU CHA, SCU CHB, CCU CHA, and CCU CHB located on the lower EPC
circuit breaker panel. Then sequentially reset all of these breakers.]
NOTE 2: If a “Mxxxxx” is displayed, the CCU has interpreted an RF signal through to be a Main or Mid Cargo
Compartment SDU and at some point has been commanded to accept the MAIN or MID Cargo
Compartment Smoke Detector. The “M” prefix is NOT used on any 2 or 4 Bay class “E” systems.
The SDU serial number may be deleted but the MAIN/MID “compartment” will still exist. You must
replace the Configuration Module to clear this fault message.

MAINTENANCE FAULT DISPLAYS

Table 26.05-5 (3 of 5)

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DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

DISPLAYED ITEM
FAULT ISOLATION
(Press MX TEST to MEANING MAINTENANCE ACTION
METHODS
view message)
CCU (A) (B) Link between CCU sides Remove and replace CCU.
A and B has failed.
CCU TX1 CCU has a failed spread [May be accompanied by Remove and replace CCU.
spectrum transmitter. SCU faults at power up.]
CCU TX2 CCU has a failed spread [May be accompanied by Remove and replace CCU.
spectrum transmitter. SCU faults at power up.]
FWD INOP Two or more faults or MX LED and SYS OK LED At least one compartment must
(Automatically failed detectors in forward illuminated. MX Display remain operational to maintain
Displayed to Alert bay. displays FWD INOP when the SYS OK LED.
Ground and Flight two detectors have failed or
Crews) two faults are detected in a No cargo or baggage may be
FWD cargo compartment. carried in forward bay.
This message cannot be (Single Bay Dispatch
removed until the fault is Operation.)
corrected.
AFT INOP Two or more faults or MX LED and SYS OK LED At least one compartment must
(Automatically failed detectors in aft bay. illuminated. MX Display remain operational to maintain
Displayed to Alert displays AFT INOP when the SYS OK LED.
Ground and Flight two detectors have failed or
Crews) two faults are detected in an No cargo or baggage may be
AFT cargo compartment. carried in aft bay.
This message cannot be (Single Bay Dispatch
removed until the fault is Operation.)
corrected.
Fxxxxx FALSE FWD compartment SDU MX LED and SYS OK LED Check the integrity/seal of the
ALARM s/n xxxxx has been illuminated. If two plastic sensor head cover on
faulted for a false alarm. detectors have FALSE the SDU. Look for any
(See Note 2.) A single detector detected alarms, the system will abnormal environmental
something and was not revert to Single conditions/ freight that may
confirmed by a second Compartment Dispatch have caused a False Alarm,
SDU in the FWD Operation. i.e., Cargo/freight, GPU,
compartment within 15 deicing, etc.
minutes of first alarm. Replace faulted FWD
compartment SDUs.
NOTE 1: Pull Circuit Breakers CCU CHA and CCU CHB and make certain to reset in the following order: 1st
CCU CHA, 2nd CCU CHB.
[Pull circuit breakers SCU CHA, SCU CHB, CCU CHA, and CCU CHB located on the lower EPC
circuit breaker panel. Then sequentially reset all of these breakers.]
NOTE 2: If a “Mxxxxx” is displayed, the CCU has interpreted an RF signal through to be a Main or Mid Cargo
Compartment SDU and at some point has been commanded to accept the MAIN or MID Cargo
Compartment Smoke Detector. The “M” prefix is NOT used on any 2 or 4 Bay class “E” systems.
The SDU serial number may be deleted but the MAIN/MID “compartment” will still exist. You must
replace the Configuration Module to clear this fault message.

MAINTENANCE FAULT DISPLAYS

Table 26.05-5 (4 of 5)

26.05.10 12-02-02 Revision 16

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DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

DISPLAYED ITEM
FAULT ISOLATION
(Press MX TEST to MEANING MAINTENANCE ACTION
METHODS
view message)
Axxxxx FALSE AFT cargo compartment MX LED and SYS OK LED Check the integrity/seal of the
ALARM SDU s/n xxxxx has been illuminated. If two plastic sensor head cover on
faulted for a false alarm. detectors have FALSE the SDU. Look for any
(See Note 2.) A single detector detected alarms, the system will abnormal environmental
something and was not revert to Single conditions/ freight that may
confirmed by a second Compartment Dispatch have caused a False Alarm,
SDU in the AFT cargo Operation. i.e., Cargo/freight, GPU,
compartment within 15 deicing, etc.
minutes of first alarm. Replace faulted AFT cargo
compartment SDUs.
[Blank MX Channel B of the CCU Press LAMP TEST button If MX DISPLAY is
DISPLAY and MX cannot drive the MX on CDU. illuminated, remove and
LED is illuminated – Display or a MX Display replace CCU. If MX
with or without SYS failure has occurred. DISPLAY does not
OK LED illuminated. illuminate, remove and
replace the CDU.]
[BTL1 PRESS Halon bottle 1 pressure is Check of open circuit in the Remove and replace SCU or
low or check for open interconnect cabling replace bottle pressure
pressure switch. between SCU and Halon switch.]
bottle. Check for pressure
switch failure.
[BTL2 PRESS Halon bottle 2 pressure is Check for open circuit in Remove and replace SCU or
low or check for open the interconnect cabling replace bottle pressure
pressure switch. between SCU and Halon switch.]
bottle. Check for pressure
switch failure.
NOTE 1: Pull Circuit Breakers CCU CHA and CCU CHB and make certain to reset in the following order: 1st
CCU CHA, 2nd CCU CHB.
[Pull circuit breakers SCU CHA, SCU CHB, CCU CHA, and CCU CHB located on the lower EPC
circuit breaker panel. Then sequentially reset all of these breakers.]
NOTE 2: If a “Mxxxxx” is displayed, the CCU has interpreted an RF signal through to be a Main or Mid Cargo
Compartment SDU and at some point has been commanded to accept the MAIN or MID Cargo
Compartment Smoke Detector. The “M” prefix is NOT used on any 2 or 4 Bay class “E” systems.
The SDU serial number may be deleted but the MAIN/MID “compartment” will still exist. You must
replace the Configuration Module to clear this fault message.

MAINTENANCE FAULT DISPLAYS

Table 26.05-5 (5 of 5)

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

-62/-72 CDU (Smoke Detection and Suppression)

CDU LOCATION DETAILS

Figure 26.05-1

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

SDU Setup
Button

Battery,
Shown with
Shown w/ Lubricant
Battery & Applied to
Retaining Battery
Clip Battery
Contacts *
Installed Retaining
Positive (+) Clip (2 ea.)
Polarity
Symbol
Shown on
Holder &
Circuit Board

SDU Front View with Grill SDU Battery (2 ea.)

Removed and Rotated 270 P/N 160-1173-01
Degrees from Above View

* Application of Conductive Lubricant shown slightly exaggerated for pictorial purposes.

Contact Circuit Works, Chemtronics Inc. at (800) 645-5244 for CW7100 Silver lubricant.

SDU VIEWS
Figure 26.05-2

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

CCU REAR VIEW

Figure 26.05-3

26.05.14 12-02-02 Revision 16

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DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

2. SDU Removal/Operation

a. General - This procedure has these tasks:

(1) Removal of the Cargo Compartment Smoke Detector.

(2) Installation of the Cargo Compartment Smoke Detector.
(3) Replacement of Cargo Compartment Smoke Detector Batteries.

b. SDU Removal Procedures

(1) References:
(a) Table 26.05-6 and 26.05-7.
(b) Figure 26.05-4.

(2) Access (Location Zones):

(a) Forward Cargo Compartments.
(b) Aft Cargo Compartments.

(3) Access Panels:

(a) Forward Cargo Compartment Door 1 and 2.
(b) Aft Cargo Compartment Door 1 and 2.

c. Prepare for the Removal

(1) Open the applicable (forward or aft) cargo compartment door.

(2) Open and tag circuit breakers CCU CHA, CCU CHB, [SCU CHA, and SCU CHB]
on the lower EPC circuit breaker panel.

d. Faulty SDU Removal

(1) At applicable FS, remove cargo liner tape and note correct orientation of SDU.
Remove four mounting screws and lower SDU.

FWD Frame AFT Frame

SDU SDU
Station Station
SDU (FWDA 1) 130 (L) SDU (AFTC 1) 1050
SDU (FWDA 2) 130 (R) SDU (AFTC 2) 1070
SDU (FWDA 3) 170 SDU (AFTC 3) 1190
SDU (FWDA 4) 310 SDU (AFTC 4) 1230
NOTE: Typical SDU locations. Approved deviations may exist.

SDU LOCATIONS - DC-8-71/-73

Table 26.05-6 (1 of 2)

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
FWD Frame AFT Frame
SDU SDU
Station Station
SDU (FWDA 5) 370 (L) SDU (AFTC 5) 1370 (L)
SDU (FWDA 6) 370 (R) SDU (AFTD 1) 1370 (R)
SDU (FWDB 1) 490 (L) SDU (AFTD 2) 1470
SDU (FWDB 2) 490 (R) SDU (AFTD 3) 1490
SDU (FWDB 3) 530 SDU (AFTD 4)
SDU (FWDB 4) 590
NOTE: Typical SDU locations. Approved deviations may exist.

SDU LOCATIONS - DC-8-71/-73

Table 26.05-6 (2 of 2)

SDU S1 (fwd cargo bay) FS 310, LBL 30.0

SDU S2 (fwd cargo bay) FS 290, RBL 20.5
SDU S3 (fwd cargo bay) FS 420, LBL 30.0
SDU S4 (fwd cargo bay FS 420, RBL 29.5
SDU S5 (fwd cargo bay) FS 510, LBL 30.0
SDU S6 (fwd cargo bay) FS 490, RBL 29.5
SDU S7 (fwd cargo bay) FS 590, LBL 16.0
SDU S8 (fwd cargo bay) FS 590, RBL 20.5
SDU S9 (aft cargo bay) FS 1030, LBL 6.0
SDU S10 (aft cargo bay) FS 1030, RBL 6.0
SDU S11 (aft cargo bay) FS 1110, LBL 6.0
SDU S12 (aft cargo bay) FS 1110, RBL 14.0
SDU S13 (aft cargo bay) FS 1210, LBL 6.0
SDU S14 (aft cargo bay) FS 1210, RBL 6.0
SDU S15 (aft cargo bay) FS 1330, LBL 6.0
SDU S16 (aft cargo bay) FS 1330, RBL 6.0
SDU LOCATIONS – DC-8-62/-72/COMBI
Table 26.05-7
(2) On back of SDU, grasp connector barrel of Identification Plug and disconnect
(gently pull) connector from SDU.
NOTE: The ID Plug lanyard should remain attached to the aircraft or mounting
structure.
(3) Repeat procedure for any other smoke detectors to be removed (if applicable).

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

e. SDU Battery Maintenance

(1) SDU Battery Removal
(a) On applicable SDU, make note of grill orientation (for proper reinstall) and
remove four attachment screws (screws are captive) and grill.
(b) Insert a small flat blade screwdriver in one end of plastic battery cover.
(c) Gently pry on end of battery cover and remove cover.
(d) Repeat steps (a) through (c) for other battery cover and remove batteries.
NOTE: If the battery retaining clips (locking tabs) are broken, replace the clips.
(2) Conductive Lubricant Application – Use Circuit Works CW7100 Silver Lubrication
(Conductive) or approved equivalent material
(a) Using a small wire brush, clean the battery holder contact points on the
negative and positive sides of both holders removing any film or
contamination that may be present.
(b) Wipe contact area clean using isopropyl or denatured alcohol and a q-tip or
clean cloth.
(c) Using your finger or small syringe, apply the lubricating compound to the
holder contact points.
(d) Using a small wire brush, clean the battery contact points on the negative and
positive sides of both batteries removing any film or contamination which may
be present.
(e) Using your finger or small syringe, apply a small amount of the lubricating
compound to the battery contact points.
CAUTION: WHEN USING CONDUCTIVE LUBRICATING COMPOUND,
ENSURE THAT THE COMPOUND IS ONLY APPLIED TO THE
ENDS OF THE BATTERY AND AT THE INDIVIDUAL BATTERY
HOLDER CONTACT POINTS. USE CARE IN ENSURING THAT NO
GREASE COMES IN CONTACT WITH THE SDU CIRCUIT BOARD.
NOTE: If the battery holder(s) are damaged or display severe contamination, replace the
SDU (P/N 100-0649-01). If the SDU batteries are damaged or display severe
contamination, replace the batteries.
f. SDU Battery Installation
(1) Install batteries making sure that the install date is written on the battery label.
Position battery so that this date is visible with the grill installed.
NOTE: Make certain of correct Battery Polarity. (Ref. Fig. 26.05-2. Battery
Polarity is also stamped on SDU PC board.)

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
(2) After installing the lubricated battery into the battery holder, rotate the battery 360
degrees with your finger in order to evenly distribute the protective layer of
compound.
(3) Position cover over each battery and push down over battery until fully seated.
(4) Position SDU grill and secure with four screws.
(5) Close circuit breakers CCU CHA, CCU CHB, [SCU CHA, and SCU CHB.]
(6) After 2 ½ minutes, verify that the SYS OK LED is lit.
(7) Press MX TEST and note that “SYSTEM OK” is displayed on CDU MX Display.
NOTE: As long as the SDU batteries are not removed from the SDU for more than five
minutes (10 for new MOD CCU’s) continuously on a given SDU, the SDU
will NOT be faulted for not reporting in. It is recommended that the SDU
batteries be greased in pairs, one SDU at a time. It is not necessary to cycle
power or re-acquire or re-characterize the SDU’s! In the event an SDU is
faulted, cycle the two CB’s (CHA and CHB) located in the cockpit to clear the
SDU fault. If the fault continues to be displayed, check the SDU for correct
battery installation.
g. SDU Installation
(1) References:
(a) Table 26.05-6 and 26.05-7.
(b) Figure 26.05-4.
(c) Applicable Data Sheet 26.05-1 or Data Sheet 26.05-2.
(2) Access (Location Zones):
(a) Forward Cargo Compartment.
(b) Aft Cargo Compartment.
(3) Access Panels:
(a) Forward Cargo Compartment Door.
(b) Aft Cargo Compartment Door.
h. Prepare for the Installation of Cargo Compartment SDU Sensors
(1) Open the applicable (forward or aft) cargo compartment door.
(2) Open and tag circuit breakers CCU CHA, CCU CHB, [SCU CHA, and SCU CHB]
on the circuit breaker panel.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
i. Install Cargo Compartment SDU
WARNING: WHEN INSTALLING SDUs, EXERCISE EXTREME CARE TO
PROPERLY COIL IDENTIFICATION PLUG LANYARD INSIDE
OF LANYARD GUARD.
NOTE: Ensure a P/N 100-1026-04 identification plug is used in the forward cargo bay A,
P/N 100-1026-05 identification plug is used in the forward cargo bay B, P/N 100-
1026-06 identification plug is used in the aft cargo bay C, and P/N 100-1026-07
identification plug is used in the aft cargo bay D.
[Ensure a P/N 100-1026-01 identification plug is used in the forward cargo
compartment and a P/N 100-1026-02 identification plug is used in the aft cargo
compartment.]
(1) Position identification plug into socket on the back of SDU by aligning keyway and
push connector barrel until connector is fully seated. Gently pull on lanyard end to
verify connector is locked in place.
(2) At the applicable FS (see Table 26.05-6), properly rotate the SDU, and ensure
Identification Plug Lanyard is coiled inside the Lanyard Guard when seating SDU to
cargo compartment ceiling and secure with four screws. Apply a 3” band of Cargo
Liner Tape around the SDU mounting flange so that the grill may be removed.
(3) Repeat procedure for any other SDUs to be installed (if applicable).
(4) Remove tags and close circuit breakers CCU CHA and CCU CHB on circuit
breaker panel.
(5) Perform Smoke Detector Characterization Procedure per paragraph “2.j.”
j. Characterization and Installation of an Installed SDU Smoke Sensor – When installing
the system in an aircraft for the first time or when system components are removed and
replaced, the system will require set up of the SDUs, CCU, and SCU to program the
transmitter/receiver ID codes. The following is the set-up procedure:
(1) Using the applicable Data Sheet 26.05-1 or 26.05-2, record the smoke detector serial
numbers in FWD Compartments A and B and AFT Compartments C and D [Fwd
Compartment A and AFT Compartment B].
(2) Supply electrical power if not already done, and set circuit breakers CCU CHA,
CCU CHB, [SCU CHA, and SCU CHB] located on the lower EPC panel..
(3) Perform the SDU characterization and installation per the following test procedure
and fill out the applicable Data Sheet 26.05-1 or 26.05-2.
(a) Depress MX SETUP on the CDU for a minimum of five seconds (until MX
DISPLAY illuminates).
(b) The MX Display will show the following message: “ENTERING SETUP
MODE. RELEASE MX SETUP TO BEGIN ACQUIRING SENSORS.”
(c) Release the MX SETUP button.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
(d) The MX Display will show the following message: “ACQUIRING
SENSORS. DEPRESS MX SETUP WHEN ALL SENSORS FOUND.”
NOTE: The system is now waiting for all Smoke Detector Units (SDUs) to
report in. During setup, “report in” is accomplished by manually
sending data from each SDU as shown in the following steps.
(e) Depress and release the Setup Button (Reference Fig. 26.05-5) on the
replacement SDU or SDUs in the Forward and Aft Cargo Bays.
1) The operator in the lower bays should record the serial number of the
replacement SDU or SDUs in the aircraft after pressing the SDU
button(s). Serial numbers can be found inside the grill of the SDUs.
2) The CDU MX Display will indicate each SDU serial number as the SDU
buttons are depressed.
3) Examples of MX Display indications during SDU button depressions are
as follows: “Fxxxxx yy.ydB, Axxxxx yy.ydB”. “F” = Forward cargo
bay, “A” = Aft bay, “xxxxx” = SDU serial number, “yy.y” = SDU RF
level in dB.
(f) When all buttons on the replacement SDUs have been depressed, again
depress the MX Setup Button on the CDU.
1) The following message will be observed on the MX Display: “DONE
WITH SENSOR CONFIGURATION.” (This message appears and
quickly extinguishes. The first detector to be accepted is then displayed.)
2) The CCU now has acquired a list of all SDUs and the operator now must
individually accept the SDUs.
(g) Release the MX Setup Button on the CDU.
1) The following message showing the first detector that checked in will
now be observed on the MX Display: “<Fxxxxx or Axxxxx> TO
ACCEPT PRESS SETUP. TO REJECT PRESS MX TEST.”

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
(h) Follow the directions shown on the MX Display, depressing MX Setup to
accept detectors and MX Test to reject detectors until all detectors recorded in
step (e) 1) above are accepted.
NOTE: Airport R.F. emissions or other installed aircraft operating in the
vicinity may cause undocumented numbers/serial numbers to be
received by the CCU and added to the group of sensor serial
number candidates shown on the MX Display during this step.
These SDUs must be rejected by depressing the MX Test Button
when solicited to accept or reject. The minimum dB level required
to accept an SDU is 20dB for Mod 3 or lower CCU’s and 5dB for
all CCU’s Mod 4 or higher.
(i) When all detectors have been accepted or rejected, the following message will
appear on the MX Display: “DONE WITH SENSOR CONFIGURATION.
TO ACCEPT PRESS MX SETUP. TO REJECT PRESS MX TEST.”
(j) Depress and release the MX Setup button if the configuration of detectors is
correct. If an error has been made, do not press the MX Setup button and go
to steps 1) thru 4) below.
1) Press and release MX Test Button if the list of sensors is incorrect.
2) The MX Display will “blank”.
3) By pressing the MX Test button, the operator will abort the Setup
Procedure completely (return to original system configuration). No
record of new detector serial numbers or quantities entered will be
recorded.
4) Repeat the steps beginning with 2.j.(2) if the configuration is incorrect.
(k) The CDU will go blank, the green SYS OK LED should illuminate within a
few minutes, and the MX LED will be extinguished if performed correctly. If
an error has been made, the MX LED will illuminate within a few minutes.
Press the MX TEST button to determine the configuration fault and repeat the
setup procedure.
NOTES:
(1) The characterization procedure has to be repeated for the new CM.
(2) If a configuration module is over programmed (too many SDU serial
numbers have been entered), the CM must be re-programmed. (See
Section 14.)
(3) The CM retains a memory of the minimum quantity of SDUs required in
each compartment and must be maintained.
(4) The minimum quantity of SDUs in a compartment may be raised but
never lowered. SDUs should always be replaced by removing and adding
an equal number of SDUs.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
k. Restore the aircraft to its usual condition.
(1) Close the applicable (forward or aft) cargo compartment door.
(2) Remove the electrical power if it is no longer required.

SDU, CCU, SCU, AND FIRE BOTTLE LOCATIONS

Figure 26.05-4

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

3. Adjustment/Test

a. General - The four [two] lower cargo compartments have SDUs installed in the cargo
ceiling liners. When the concentration of smoke at the sensor reaches a set threshold, the
SDU sends a “SMOKE” alarm data bit to the CCU.

(1) This procedure has these tasks:

(a) Circuit Test Channel A.

(b) Lamp Test Channel A.
(c) Circuit Test Channel B.
(d) Lamp Test Channel B.
(e) Smoke Detector Test.
(f) Operational System Test.

(2) References:

(a) Figure 26.05-1.

(b) Figure 26.05-2.

b. Smoke System Preparations and Circuit Tests

(1) Open circuit breakers CCU CHA, CCU CHB, [SCU CHA, and SCU CHB] located
on the lower EPC circuit breaker panel.
(2) Perform the Smoke System Circuit Test on Channel A.

(a) Circuit Test of Channel A – This test verifies that the installed system powers
up in Channel A in the expected state.

1) Apply aircraft power to the smoke system components by closing the

breakers listed below.

Identification Breaker Label Breaker Number Location

CCU Channel A CCU CHA CH5001 Lower EPC CB Panel
[SCU Channel A SCU CHA Lower EPC CB Panel]

NOTE: Ensure CCU CHB and [SCU CHB] circuit breakers are open
(pulled).
(b) Channel A Lamp Test - This test verifies that the CDU is correctly wired to
the CCU and aircraft fire warning light. The lamp test button will illuminate
all lamps on the CDU excluding the maintenance display.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
1) Identify the lamp test button on the CDU. Depress and hold the lamp test
button. Verify that the following occur:
a) All CDU indicators illuminate, excluding the maintenance display.
b) The Master Warning lights located on the FO’s side of the glareshield
illuminate.
c) With LAMP TEST button depressed, press the “MASTER FIRE
WARN” annunciator on the glareshield and ensure the light resets.
d) The “LWR CARGO FIRE” remote annunciator on the FE station is
illuminated (if installed).
2) Release the lamp test button.

1) The Master Warning light extinguishes and all CDU LEDs

extinguish, except for the MX and SYS OK LEDs.
NOTE: The CDU MX Display will not illuminate when the CCU
CHB breaker is pulled.
(c) Circuit Test of Channel B – This test verifies that the installed system powers
up in Channel B in the expected state.
1) Apply aircraft power to the smoke system components by closing the
breakers listed below.
Identification Breaker Label Breaker Number Location
CCU Channel B CCU CHA CH5001 Lower EPC CB Panel
[SCU Channel B SCU CHA Lower EPC CB Panel]

NOTE: Ensure CCU CHA and [SCU CHA] circuit breakers are open
(pulled).
(b) Channel B Lamp Test - This test verifies that the CDU is correctly wired to
the CCU and fire warning lights. The lamp test button will illuminate all
lamps on the CDU including the maintenance display.
1) Identify the lamp test button on the CDU. Depress and hold the lamp test
button. Verify that the following occur:
a) All CDU indicators illuminate, including a checkerboard pattern of
pixels on the CDU MX DISPLAY.
b) The Master Warning light located on the FO’s side of the glareshield
illuminates.
c) With LAMP TEST depressed, press the “MASTER FIRE WARN”
annunciator on the glareshield and ensure the light resets.
d) The “LWR CARGO FIRE” remote annunciator on the FE Station is
illuminated (if installed).

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SUPPRESSION SYSTEM (cont’d)

2) Release the lamp test button.

a) The Master Warning light extinguishes and all CDU LEDs extinguish
except for the MX and SYS OK LEDs.

c. Smoke System Preparations and Smoke Tests – Supply electrical power and open circuit
breakers CCU CHA, CCU CHB, [SCU CHA, and SCU CHB] located on the Lower EPC
circuit breaker panel.

(1) Equipment:

(a) SDU Tester (Artificial Smoke Spray), P/N 25S (McMaster Carr P/N 6638T21)
or equivalent smoke source.

(2) Apply aircraft power to the CCU by pushing in the following breakers:

Identification Breaker Label Location

CCU Channel A and CCU CHA
Lower EPC Circuit Breaker Panel
CCU Channel B CCU CCB
[SCU Channel A and SCU CHA
Lower EPC Circuit Breaker Panel]
SCU Channel B SCU CHB

d. Smoke Detection Test – Spread Spectrum Viewer Mode

NOTE: The Spread Spectrum Viewer Mode (SSV) is a useful troubleshooting mode in
which the operator may view SDU serial numbers installed on a particular
aircraft or what dB levels they are transmitting and may verify correct
configurations, as well as compare dB levels on suspected trouble components.

(1) The correct operation of the SDUs can be verified by viewing the CDU MX Display
in the spread spectrum viewer mode. This mode shows all SDUs installed on a
given aircraft by compartment, serial number, and dB level as received by the CCU.
(2) The spread spectrum viewer mode is entered by simultaneously pressing both the
MX TEST and the MX SETUP buttons for a period of at least 5 seconds.
(3) The lowest serial number SDU in the forward most cargo compartment will be
displayed first (automatically). To view the next sensor status, press the MX TEST
button. After all SDUs have been displayed in the first compartment, the SDUs will
be displayed for the next rear cargo compartment, again lowest serial number to
highest serial number. After all aircraft sensors are viewed, the MX Display screen
will go blank.
(4) When in the spread spectrum viewer mode, the display will continuously display
(and update every 30 seconds if allowed to scroll) the signals received from the
selected SDU being read from the CCU Channel B receiver only. The data will be
similar to that shown in Table 26.05-8.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
SENSOR STATUS MX DISPLAY EXAMPLES
FWD Sensor – Normal Operation Fxxxxx 69.3dB
AFT Sensor – Normal Operation Axxxxx 69.3dB
FWD Sensor w/ ALARM bit set Fxxxxx 69.3dB SMOKE
AFT sensor w/ ALARM bit set Axxxxx 70.3dB SMOKE
FWD sensor w/ SETUP bit set Fxxxxx 70.3dB SETUP
AFT sensor w/ SETUP bit set Axxxxx 70.3dB SETUP
FWD sensor w/ BATTERY bit set Fxxxxx 70.3dB BATT
AFT sensor w/ BATTERY bit set Axxxxx 70.3dB BATT
FWD sensor w/ TEMPERATURE bit set Fxxxxx 70.3dB TEMP**
AFT sensor w/ TEMPERATURE bit set Axxxxx 70.3dB TEMP**

SPREAD SPECTRUM VIEWER

Table 26.05-8
(5) After 15 minutes in viewing mode (no additional activity), the display will go blank
and the spread spectrum viewer mode will have to be re-entered if required.
(6) Other data BITs may be shown in the MX display as shown.
(7) A “SMOKE” suffix indicates the SDU is Alarming. A “SETUP” suffix indicates
the setup button on the SDU has been pushed and the SDU is sending a setup
transmission. A “BATT” suffix indicates the SDU has detected a low battery
condition. A “TEMP” suffix indicates the SDU internal temperature (not ambient in
the cargo compartment) BIT has detected either a high (150° F) or a low (32° C)
temperature. The TEMP suffix is common during cold winter months and does not
affect the SDU operation. A high “TEMP” may be seen in conjunction with an
Alarm condition.
e. Perform the System Smoke Test
(1) FWD Cargo Compartment Smoke Detector Individual Alarm Test – This ensures
the individual FWD cargo compartment smoke detector units detect and transmit a
smoke alarm signal that is received by the CCU Channel A and Channel B. A
minimum of two people is required to perform this test – one person in the FWD
lower cargo compartment and one person in the cockpit. Proceed as follows:
(a) Enter the spread spectrum viewer as previously described. This should
capture the first smoke detector. Example: Fxxxxx 53.4dB.
(b) Spray a small amount of smoke into the selected SDU.
(c) Verify that the MX Display changes by adding a SMOKE suffix. Example:
Fxxxxx 53.4dB SMOKE.
(d) Clear the smoke from the detector by gently blowing air into the sensor head.
Verify that the SMOKE suffix is no longer displayed on the CDU MX
Display.
(e) Advance to the next smoke detector by pressing MX TEST after the SMOKE
suffix is no longer displayed on the CDU MX Display.
(f) Repeat steps (a) to (e) for each detector location in the FWD cargo
compartment.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
NOTE: Between tests allow time for the simulated smoke to clear from the
sensors prior to proceeding to the next SDU test. Gently blowing
air into each sensor head that has been exposed to smoke will
hasten the clearing process. Failure to allow smoke to clear will
cause a Fire Alarm.
(2) FWD Cargo Compartment Two Detector Alarm Test – This procedure tests the
operation of the smoke system when two smoke detectors detect smoke in the FWD
cargo compartment and produce visual alarming in the cockpit.
(a) Spray a small amount of smoke into the two selected SDUs in the FWD cargo
compartment within 30 seconds.
NOTE: It is important that the smoke be applied to the second detector within a
time period of 30 seconds after spraying the first detector to ensure that the
first detector continues to detect smoke.
(b) Verify the following after smoke has been applied to the second sensor:
1) FWD fire indicator on the CDU illuminates.
2) MX Display reads “FWD FIRE”.
3) Master Warning light located on the glare shield illuminates.
4) Clear smoke from both detectors.
(3) AFT Cargo Compartment Smoke Detector Alarm Tests – Repeat steps (1) and (2)
above for Forward B Cargo Bay, Aft C Cargo Bay, and Aft D Cargo Bay. [Repeat
steps (1) and (2) for the Aft Cargo Bay.]
f. If it is necessary to perform the Configuration Module Copy Procedure using the SCU
copy port, see section 14.

SDU SETUP BUTTON

Figure 26.05-5

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

CARGO BAY DATA CDU ACTIONS

Smoke Detector Accept at CDU (Press Reject at CDU
Fwd Cargo Bay A
Serial No. MX Setup SW) (Press MX Test)
Smoke Detector S1 FA
Smoke Detector S2 FA
Smoke Detector S3 FA
Smoke Detector S4 FA
Smoke Detector S5 FA
Smoke Detector S6 FA

Fwd Cargo Bay B

Smoke Detector S7 FB
Smoke Detector S8 FB
Smoke Detector S9 FB
Smoke Detector S10 FB

Aft Cargo Bay C

Smoke Detector S11 AC
Smoke Detector S12 AC
Smoke Detector S13 AC
Smoke Detector S14 AC
Smoke Detector S15 AC

Aft Cargo Bay D

Smoke Detector S16 AD
Smoke Detector S17 AD
Smoke Detector S18 AD
Smoke Detector S19 AD

Aircraft S/N____________________________ Date_______________________________

Operator______________________________

DC-8-71/-73 ON AIRCRAFT SMOKE DETECTOR CHARACTERIZATION

Data Sheet 26.05-1

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

CARGO BAY DATA CDU ACTIONS

Smoke Detector Accept at CDU (Press Reject at CDU
Fwd Cargo Bay
Serial No. MX Setup SW) (Press MX Test)
Smoke Detector S1 F
Smoke Detector S2 F
Smoke Detector S3 F
Smoke Detector S4 F
Smoke Detector S5 F
Smoke Detector S6 F
Smoke Detector S7 F
Smoke Detector S8 F

Aft Cargo Bay

Smoke Detector S9 A
Smoke Detector S10 A
Smoke Detector S11 A
Smoke Detector S12 A
Smoke Detector S13 A
Smoke Detector S14 A
Smoke Detector S15 A
Smoke Detector S16 A

Aircraft S/N_____________________________ Date__________________________

Operator________________________________

[DC-8-62/-72 ON AIRCRAFT SMOKE DETECTOR CHARACTERIZATION]

Data Sheet 26.05-2

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

4. Central Control Unit (CCU)/[Suppression Control Unit (SCU)] and CCU/[SCU]

Configuration Module (CM) Removal/Installation

a. General

(1) This procedure has these tasks:

(a) Removal of the CCU/[SCU].
(b) Installation of the CCU/[SCU].

(2) References:
(a) Figure 26.05-6.

(3) Access:
(a) Location Zones:
1) Forward Compartment.
2) 680 Mid Accessories Compartment.
(b) Access Panels:
1) Forward Cargo Compartment Door.
2) Aft Cargo Compartment Door.

b. Prepare for the Removal.

(1) Open these circuit breakers and attach “DO NOT CLOSE” tags: CCU CHA, CCU
CHB, [SCU CHA, and SCU CHB] located on the circuit breaker panel.
(2) Open a forward bay cargo door.
(3) Remove the Blkd Panels at the aft end of the forward cargo compartment to gain
access to the Mid Accessory Panel or open the mid-accessory compartment access
door (AC Belly) to gain access to the CCU/[SCU].

c. Remove the CCU/[SCU] located near FS 680, RBL 29.0 at the top of the center wing
tank front spar.

(1) Disconnect the electrical harness connector from the CCU/[SCU]. Cap and
temporarily stow the harness.
(2) Remove the two screws from the Configuration Module and remove module from
CCU/[SCU]. Retain hardware for reinstallation.

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SUPPRESSION SYSTEM (cont’d)
WARNING: THE MATED CONFIGURATION MODULE (CM) IS INSTALLED
ON THE CCU/[SCU] THROUGH AN EXTRENAL CONNECTION
PORT AND SECURED WITH A LANYARD TO THE AIRCRAFT.
THE CM RETAINS VITAL SYSTEM INFORMATION UNIQUE
TO THE AIRCRAFT IT IS INSTALLED ON AND IS INTENDED
TO STAY WITH THE AIRCRAFT EVEN IF THE CCU/[SCU] IS
REMOVED OR REPLACED.
(3) Unplug the Configuration Module and allow to temporarily hang from the lanyard.
NOTE: Configuration Module is not removed from aircraft mounting stud unless
it is being replaced.
(4) Remove the four screws that attach the CCU/[SCU] to its mounting bracket and
retain for reinstallation.
d. Install the CCU/[SCU].
(1) Position the CCU/[SCU] on its mounting bracket. Ensure the correct orientation to
the wire harness.
(2) Install four screws that attach the CCU/[SCU] to its mounting bracket.
(3) Reattach the CCU/[SCU] end of the ground strap to the mount screw it was
removed from.
(4) Install the Configuration Module into the CCU/[SCU] with two screws.
(5) Connect the electrical connector to the CCU/[SCU].
(6) Close these circuit breakers and remove the “DO NOT CLOSE” tags: CCU CHA,
CCU CHB, [SCU CHA, and SCU CHB] on the circuit breaker panel.
(7) Supply electrical power if not already done.
(8) Check CDU/[SCU], MX LED for “SYSTEM OK” display.

CCU MOUNTING & LOCATION IN THE MID ACCESSORY COMPARTMENT

Figure 26.05-6

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SUPPRESSION SYSTEM (cont’d)

5. Control Display Unit (CDU) Removal/Installation

a. General

(1) This procedure has these tasks:

(a) Removal of the CDU.
(b) Installation of the CDU.

(2) References:
(a) Figure 26.05-1.

(3) Access:
(a) Location Zones – Flight Deck.
(b) Access Panels – Shelf to the right of the Flight Engineer’s instrument panel.

b. Prepare for the Removal

(1) Open these circuit breakers and attach “DO NOT CLOSE” tags: CCU CHA, CCU
CHB, [SCU CHA, and SCU CHB] on the circuit breaker panel.

c. CDU Removal

(1) Unlatch the four dzus fasteners from the CDU and remove the CDU from its mount.
(2) Disconnect the electrical connector from the CDU and remove from aircraft. Cap,
coil, and stow the harness connector.

d. CDU Installation

(1) Verify the 2 CCU/[SCU] circuit breakers are open. (No power is applied to the
system.)
(2) Reconnect the electrical connector the CDU.
(3) Position the CDU in its housing and latch the 4 dzus fasteners.
(4) Close these circuit breakers and remove the “DO NOT CLOSE” tags: CCU CHA,
CCU CHB, [SCU CHA, and SCH CHB] on the circuit breaker panel.
(5) Supply electrical power if not already done.
(6) With power to the system, verify that the SYS OK LED is illuminated and the MX
LED is extinguished. This may take up to ten minutes.
(7) Check CDU, MX LED for “SYSTEM OK” display.

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SUPPRESSION SYSTEM (cont’d)

6. Configuration Module Removal, Installation, and Copy Procedure

a. Configuration Module Removal and Installation.

(1) Configuration Module (CM) Removal.

(a) Open these circuit breakers and attach “DO NOT CLOSE” tags: CCU CHA,
CCU CHB, [SCU CHA, and SCU CHB] located on the circuit breaker panel.
(b) Open a forward bay cargo door.
(c) Remove the Blkd Panels at the aft end of the forward cargo compartment to
gain access to the Mid Accessory Panel or open the mid-accessory
compartment access door (AC Belly) to gain access to the CCU/[SCU].
(d) Remove and retain the two screws that secure the Configuration Module to the
CCU/[SCU].
(e) Unplug the Configuration Module from the CM port.
(f) Disconnect the CM lanyard from the aircraft frame. Retain hardware.
(e) Remove the Configuration Module.

(2) Configuration Module (CM) Installation.

(a) Install the new Configuration Module into the CM port.

(b) Install the 2 screws, retained in step (1)(d) that attaché the CM to the
CCU/[SCU]. Do not over-torque screws. Torque hand-tight.
(c) Attach the CM lanyard to the airframe using hardware retained in step (1)(f).
(d) Remove the “DO NOT CLOSE” tags and close CCU CHA, CCU CHB, [SCU
CHA, and SCU CHB] circuit breakers located on the circuit breaker panel.
(e) Verify the MX LED is illuminated.
(f) Depress the MX TEST button and verify that the MX DISPLAY reads: “?0?
CNT?”.

NOTE: For new CM’s only.

(e) Perform a complete system characterization procedure.

NOTE: It is NOT necessary to perform a system recharacterization when ONLY

replacing a CCU/SCU. System configuration memory is stored in the
Configuration Module.

b. Perform the Configuration Module Copy Procedure using the SCU copy port.

(1) Perform this procedure to configure A CCU and A SCU Configuration Module.
(2) Open SCU CHA, SCU CHB, CCU CHA, and CCU CHB circuit breakers located on
the lower EPC panel.

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SUPPRESSION SYSTEM (cont’d)

(3) Perform the CCU Configuration Module Copy Procedure per the following:
(4) Gain access to the air conditioning mix compartment by removing the forward cargo
compartment rear bulkhead. Access the SCU positioned in a location centered
between location LBL 6.25 and LBL 15.04 at STA 540.
(5) Remove the four screws from SCU copy port cover and remove cover as shown in
Figure 26.05-2.
(6) Remove the two mounting screws from the CCU configuration module and remove
module as shown in Figure 26.05-3.
(7) Insert the CCU configuration module into the SCU copy port connection.
(8) Reset circuit breakers SCU CHA and SCU CHB, not CCU CHA or CCU CHB.
(9) On SCU, press and release copy mode switch (red).

(a) The LED in the SCU Copy Port will indicate system status as follows in Table
26.05-9.

(10) On SCU, press and release copy mode switch (red).

(a) Result: The green copy LED illuminates when the copying process is
complete.
(b) When copying is complete, the green copy LED will be illuminated (not
blinking).

(11) Open circuit breakers SCU CHA and SCU CHB located on the lower EPC panel.
(12) Remove CCU configuration module from SCU.
(13) Insert CCU configuration module in CCU and secure with two screws.
(14) Position SCU copy port cover and secure with four screws.
(15) Set these four circuit breakers located on the Lower EPC panel and remove the “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(16) After approximately one minute, the SYS OK LED will illuminate if system is
functioning normally.
(17) Re-install the forward cargo compartment rear bulkhead.

LED INDICATION STATUS

OFF Normal state
On – Solid (after button depression) OK (Programmed)
Blinks (after button depression) Possible faulty CCU configuration module
Off (after button depression) Faulty SCU (Faulty SCU Configuration
Module)

SCU LED INDICATIONS

Table 26.05-9

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c. Clearing the CCU Configuration Module (CM) Memory and System Re-characterization
NOTE: This procedure is only accomplished when the CCU Configuration Module has
been improperly programmed. Perform this procedure to configure the CCU
and SCU Configuration Modules.
(1) Open these four circuit breakers that are located on the Lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(2) Gain access to the air conditioning mix compartment by removing the FWD cargo
compartment rear bulkhead. Access the SCU positioned in a location centered
between locations LBL 6.25 and LBL 15.04 at STA 540.
(3) Remove the four screws from SCU copy port cover and remove cover as shown in
Figure 26.05-2.
(4) Remove the two mounting screws from the CCU configuration module and remove
module as shown in Figure 26.05-3.
(5) Remove the two mounting screws from the SCU configuration module and remove
the module as shown in Figure 26.05-15.
(6) Install the CCU Configuration Module into the SCU Configuration Module port,
secure with two screws, and re-attach lanyard.
(7) Install the SCU Configuration Module into the SCU Copy Port.
(8) Set circuit breakers SCU CHA and SCU CHB and remove the “DO NOT CLOSE”
tags from these breakers.
NOTE: The LED in the SCU Copy Port will indicate system status as follows in
Table 26.05-9.
(9) On SCU, press and release copy mode switch (red).
(a) Result: The green copy LED illuminates when the copying process is
complete.
(b) When copying is complete, the green copy LED will be illuminated (not
blinking).
(10) Open circuit breakers SCU CHA, SCU CHB located on the Lower EPC panel and
install “DO NOT CLOSE” tags.
(11) Remove the Configuration Module from the SCU Copy Port.
(12) Insert this configuration module in the CCU Configuration Module port, secure with
two screws, and re-attach lanyard.
NOTE: The SCU and CCU Configuration Modules now have reversed their
Configuration Module port positions.
(13) Position SCU copy port cover and secure with four screws.
(14) Set these four circuit breakers located on the Lower EPC panel and remove the “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(15) Perform the steps in 2.j. to re-characterize the system.

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
[NOTE: Paragraphs 7 through 18 dealing with the cargo compartment fire suppression
(FSS) system apply only to DC-8-62/-72 aircraft.]
7. Fire Suppression System (FSS) Description and Operation
a. General
(1) The Securaplane Cargo Compartment FSS is used to control or extinguish fires in
the forward or aft cargo compartments by the deployment of a fire extinguishing
agent (halon). Halon is stored in two bottles (20 lbs. each) and is deployed through
the use of electrically actuated pyrotechnic squibs.
(2) The system includes these parts (Reference Figure 26.05-7):
(a) Fire Extinguishing Bottles (two)
(b) Diverter Valve
(c) Flow Restrictor*
(d) Temperature Compensated Regulator*
(e) Particulate Filter*
(f) Discharge Nozzles/Tubing/Cone Filters
(g) Suppressant Control Unit (SCU)
(h) Central Control Unit (CCU)
(i) Control Display Unit (CDU)
* = Comprise components of the Regulator and Filter Assembly, IPC item 5.
(3) The FSS uses 28 VDC power. The power is supplied through the circuit breakers
on the lower EPC panel.
b. Component Details
(1) Cargo Fire Extinguishing Bottles - There are two cargo fire extinguishing bottles
located behind the right bulkhead in the forward end of the aft cargo compartment
between STA 1020 and STA 1060. Each bottle is a hermetically sealed container,
which is filled with bromotriflouromethane (halon) and nitrogen. The nitrogen is
added to increase the pressure in the bottle. The bottle includes one discharge head,
a temperature compensated pressure switch, and a filler/safety port.
(a) One discharge head is installed on each bottle to release the halon to the
applicable areas. The electrical receptacles on the extinguishing bottles for
firing of the squibs are keyed differently to prevent cross connection of the
wiring. The discharge heads contain a disc that holds the halon in the bottle.
When the disc is broken, then the halon from the bottle is released through the
discharge ports into the tubing. An electrically stimulated squib ruptures the
disc. The squib breaks the disc using shock wave propagation (a small
explosion), not a mechanical cutting device.

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SUPPRESSION SYSTEM (cont’d)
(b) The Temperature Compensated Pressure Switch (TCPS) includes a reference
chamber which is filled with a Halon/Nitrogen mixture similar to that in the
fire extinguisher. The slightly higher pressure in the bottle holds a bellows in
a stroked position. The bellows is attached to a magnet which holds the reed
switch closed. If a small amount of pressure leaks out of the extinguisher, the
bellows strokes, moving the magnet and opening the reed switch. The design
has a fail-safe feature such that if the reference chamber leaks (to the bottle
pressure), the bellows will stroke, again opening the switch.
(c) The Safety Port incorporates a rupture disc that will release the contents of the
bottle if the pressure in the bottle gets too high. The safety port is also used to
fill the bottle.
(2) Diverter Valve – The diverter valve is located adjacent to the bottle 1 extinguishing
bottle. Flex tubing connects the diverter valve to the extinguishing bottles. There
are two electrical receptacles (which are keyed differently to prevent cross
connection of the wiring) for firing of the diverter squibs. The diverter squibs are
used to direct the halon to either the forward or aft cargo compartment. The firing
of the diverter valve squibs is deployed by the SCU.
(3) Flow Restrictor Valve – The Flow Restrictor Valve is located below and between
the bottle 1 and bottle 2 extinguishing bottles, and hard tubing connects the flow
restrictor valve to the interconnect tubing tee and the Temperature Compensated
Regulator. When the second bottle is discharged, the Flow Restrictor Valve
maintains the halon concentration to the cargo compartments for up to 165 minutes.
(4) Discharge Nozzles/Tubing/Cone Filters - There are five FIREX nozzles in the fire
suppression system, three are located in the forward cargo compartment ceilings and
two are located in the aft cargo compartment ceilings. Hard tubing connects the
FIREX nozzles to the diverter valve. There are two cone filter elements located in
the fire suppression system. One is located at the bottle squib port of bottle 1 and
one is located at the bottle squib port of bottle 2.

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SUPPRESSION SYSTEM (cont’d)
(5) The Suppression Control Unit (SCU) – The SCU, located just forward of the
suppression bottles in the aft cargo bay behind the right forward sidewall between
STA 1000 and STA 1020, communicates with the CCU via dual, RF radio data
links. The SCU is used in the event of a deployment command from the flight crew.
When a fire occurs, the cockpit crew enters a fire command on the Control Display
Unit (CDU). The SCU receives the command from the CCU and then actuates
pyrotechnic squibs to discharge the bottles to the selected compartment. Once
initiated, an automatic discharge sequence rapidly floods the affected compartment
with the contents of the first bottle and then meters the contents of the second bottle
into the compartment at a slower rate. This sequence is designed to prevent re-
ignition of a fire for a minimum period of 180 minutes to meet the fire suppression
requirements of 14 CFR 121.314.

c. Operation

(1) Functional Description

(a) Deployment of the fire-extinguishing agent is achieved by the firing of the

pyrotechnic squibs. The SCU, when in deployment mode, fires the
appropriate diverter squib first, followed closely by the firing of the squib on
the first halon bottle. After a time period of 15 minutes, the squib on the
second bottle is automatically fired to maintain the halon concentration.
Halon is plumbed from the diverter valve assembly to the nozzles located in
the cargo compartments. The diverter valve squibs are used to direct the halon
to either the forward or the aft cargo compartments.
(b) When the squib explosion ruptures the applicable discharge disc, the halon
flows through the applicable discharge port into the tubing to the nozzles. The
nozzles spray the halon throughout the cargo compartment. Flooding the
compartment with halon gas decreases the amount of oxygen in the
compartment and extinguishes the fire. The halon does not leave any residue
and does not require any cleanup afterwards.
(c) After an extinguishing bottle is discharged, you must make sure there are no
disc particles in the tubing or nozzles and you must replace the extinguishing
bottle.

(2) Testing

(a) SCU, CCU, Squib Test – When the fire suppression/smoke detection system is
powered on, the SCU checks the continuity of the diverter squibs and
extinguishing squibs via Built-in-Test (BIT).
(b) Pressure Switch Test – When the fire suppression/smoke detection system is
powered on, the SCU checks the continuity of the pressure switch via Built-in-
Test (BIT).

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

FIRE DETECTION & SUPPRESSION SYSTEM DEPLOYMENT SEQUENCE

Figure 26.05-7 (1 of 2)

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

FIRE DETECTION & SUPPRESSION SYSTEM DEPLOYMENT SEQUENCE

Figure 26.05-7 (2 of 2)

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SUPPRESSION SYSTEM (cont’d)

SUPPRESSION SYSTEM COMPONENT LOCATIONS IN CARGO BAYS

Figure 26.05-8

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SUPPRESSION SYSTEM (cont’d)
8. Fire Suppression System CCU & SCU Adjustment/Test
a. General
(1) To check out the electronics of the CCU and the SCU, a test unit is used to simulate
the squib loads and pressure switches of the actual halon distribution system. The
Test unit is referred to as the Halon Test Assembly. The test assembly simulates the
impedance of the diverter squibs and bottle pressure switches. When connected in
place of the actual diverter and halon bottle assemblies, the Halon Test Assembly
allows for the simulated firing of the fire suppression system without the actual
release of suppressing agent.
(2) This procedure tests the squib circuit/pressure switch circuit.
b. Squib Circuit/Pressure Switch Circuit Test
(1) The test assembly contains circuitry for measuring and verifying the squib drive
currents and output pulse durations. If a valid signal is detected at a simulated squib
load, an indicator LED is illuminated. There is an indicator LED for each squib in
the system. Additionally there are switches in series with the simulated squibs to
allow for the testing of open loads. The basic operation of the Halon Test Assembly
is briefly described below.
(a) On/Off Switch – When set to the “ON” position, it applies 120 VAC power to
the test assembly.
(b) Reset Switch – Momentary contact switch that when depressed resets the
indicator latches.
(c) Power On Indicator – When illuminated, it indicates power is applied to the
test assembly
(d) FWD DIV Indicator – When illuminated, it indicates a valid forward diverter
squib fire command has been issued. (S1)
(e) AFT DIV Indicator – When illuminated, it indicates that a valid aft diverter
squib fire command has been issued. (S2)
(f) Mid Diverter Indicator – Not used for this aircraft. (S3)
(g) SPARE – Reserved for future use. (S4)
(h) BTL 1 Indicator – When illuminated, it indicates a valid bottle 1 squib fire
command (halon discharge) has been issued. (S5)
(i) BTL 2 Indicator – When illuminated, it indicates a valid bottle 2 squib fire
command (halon discharge) has been issued. (S6)
(j) BTL 1 Pressure Switch. (S7)
(k) BTL 2 Pressure Switch. (S8)
(j) Toggle Switches – There are eight toggle switches (S1-S8) which allow for the
simulation of open squibs and for manually controlling the state of the
pressure switches.

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SUPPRESSION SYSTEM (cont’d)

NOTE: If the smoke system is armed and halon is discharged mistakenly during
smoke system testing or in any other situation, halon bottle #1 will release
its contents very quickly into the selected cargo compartment. Halon
bottle #2 does not normally begin its discharge for 15 minutes after the
bottle #1 discharge. It is thus possible to save the contents of bottle #2 if
smoke system breakers SCU CHA, SCU CHB, CCU CHA, and CCU
CHB are pulled quickly after the bottle #1 discharge.

CAUTION: IF BOTTLE #1 DOES NOT DE-PRESSURIZE PROPERLY,

BOTTLE #2 WILL AUTOMATICALLY DISCHARGE AT A
METERED RATE 40 SECONDS AFTER THE HALON
DISCHARGE COMMAND OCCURS.

(2) During normal operation, the unit power switch is in the “ON” position and all
squib and bottle switches are in the closed position. The reset switch should be
depressed prior to performing any testing. Depending upon the testing being
performed, the squib OPEN/CLOSE switches will be set to various positions.

(a) For testing of the squib driver energy content, the squib set switches (S1-S6)
should be in the “CLOSE” position.
(b) For simulation of open squibs, any given squib switch or combination of squib
switches may be set to the “OPEN” position.

(3) The BOTTLE 1 and BOTTLE 2 pressure switches are simulated by the BTL 1 and
BTL 2 PRESSURE SWITCHES. These switches will normally be in the “AUTO”
position but can be set to the “OFF” position to simulate pressure switch activation
(low pressure).

c. Prepare for the Squib Test.

(1) Perform Cargo Compartment Smoke Detection System Adjustment/Test if not

already accomplished.
(2) Perform Cargo Compartment Smoke Detection System SDU/Configuration Module
Adjustment/Test if not already accomplished.
(3) Halon Test Assembly Hookup:

(a) Equipment – Halon Test Assembly (Field Test Set) TE 1034-02.

(b) Location Zones – Aft Cargo Compartment.
(c) Access Panels – Aft Cargo Compartment.

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SUPPRESSION SYSTEM (cont’d)

(4) Test Setup:

(a) Prior to system test, the electrical connectors to the diverter valve assembly
and halon bottles must be disconnected from the diverter and bottle assembly.
These connectors should now be connected to the halon test assembly TE
1034-02 as indicated in Table 26.05-10 below. It may be necessary to
temporarily remove cable ties securing the cable bundles to the aircraft to
allow for connecting the cable bundles to the test assembly.

AIRCRAFT CONNECTOR HALON TEST

SIGNAL NAME
DESIGNATION ASSEMBLY REF.
Forward Diverter Squib D9510P J2
Mid Divert Squib (Not
D9512P J7
used for this aircraft)
Aft Diverter Squib D9511P J1
Bottle1 Squib D9506P J3
Bottle2 Squib D9508P J4
Bottle1 Pressure Switch D9507P J5
Bottle2 Pressure Switch D9509P J6

SCU OUTPUT CABLING DESIGNATORS

Table 26.05-10

(b) Supply electrical power if not already accomplished.

(c) This test simulates the deployment of halon into the cargo compartments. The
testing is performed with one side of the SCU powered and the other
unpowered. The testing will require two people – one in the cockpit and one
in the forward cargo compartment near the SCU and Halon Test Assembly.
Install the Halon Test Assembly prior to performing this test. This procedure
will consist of the following tests:

1) Forward Compartment
a) SCU Channel A and CCU Channel B powered – This test simulates
the deployment of halon into the forward cargo compartment using
Channel A of the SCU and Channel B of the CCU.
b) SCU Channel B and CCU Channel A powered – This test simulates
the deployment of halon into the forward cargo compartment using
Channel B of the SCU and Channel A of the CCU.
NOTE: CCU CHB circuit breaker must be set for activation of the
MX Display, thus this test will not produce MX Display
messages.

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2) Aft Compartment

a) SCU Channel A and CCU Channel B powered – This test simulates

the deployment of halon into the aft cargo compartment using
Channel A of the SCU and Channel B of the CCU.
b) SCU Channel B and CCU Channel A powered – This test simulates
the deployment of halon into the aft cargo compartment using
Channel B of the SCU and Channel A of the CCU.

NOTE: CCU CHB circuit breaker must be set for activation of the
MX Display, thus this test will not produce MX Display
messages.

NOTE: These conditions are not a normal configuration for the

system and therefore it is acceptable for the “SYS OK”
LED to be extinguished, as well as for the BTL 1 and BTL
2 LEDs on the CDU not to correspond with the Halon Test
Assembly LEDs.

(d) Forward Compartment (SCU Channel A, CCU Channel B)

1) Open SCU CHA, SCU CHB, CCU CHA, and CCU CHB circuit breakers.
These are located behind the FO’s position on the lower EPC panel.
2) Turn on power to the Halon Test Assembly and depress the RESET push-
button. All squib indicator LEDs should now be extinguished.
3) Set the BTL 1 PRESSURE SWITCH to “MANUAL” and leave the BTL
2 PRESSURE SWITCH in the “AUTO” position. (Check that Halon
Test Set Squib test switches S1 to S8 are all in the “CLOSED” position.)
4) Close circuit breaker SCU CHA and CCU CHB. Make certain that SCU
CHB and CCU CHA breakers are pulled.
5) Arm the suppression system by lifting the red ARM switch guard on the
CDU and toggling the ARM switch to the “UP” position.
6) “SYS ARMED” message will now be visible on the MX Display.
7) Wait at least two seconds after raising ARM switch and then press the
FWD DISCH push button on the CDU. The Halon Test Set FWD DIV
LED will illuminate.

NOTE: The RESET LED will also illuminate when a discharge button
on the CDU is depressed as a part of the test set functionality.
After pressing the FWD DISCH button, observe that the BTL 1
LED on the Halon Test Set illuminates approximately two
seconds after the FWD DIV LED illuminates. If the reset light
illuminates and the BTL 1 and FWD DIV LEDs do not
illuminate during this step, there is an SCU malfunction.

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SUPPRESSION SYSTEM (cont’d)
8) Observe that after approximately 40 seconds from the BTL 1 LED being
illuminated that the BTL 2 LED has illuminated on the Halon Test Assy.
9) Toggle the Arm Switch on the CDU to the “DOWN” (Disarmed)
position.
(e) Forward Compartment Test (SCU Channel B, CCU Channel A) – MX Display
is inoperative.
1) Open the four Smoke System Breakers that are located behind the First
Officer’s position on the lower EPC panel.
2) Depress the RESET button on the Halon Test Set. All squib indicator
LEDs should now be extinguished.
3) Set the BTL 1 Pressure Switch to “MANUAL” AND THE btl 2 Pressure
Switch in the “AUTO” position (if not already done).
4) Close the circuit breakers labeled SCU CHB and CCU CHA. Make
certain that SCU CHA and CCU CHB breakers are pulled.
5) Arm the suppression system by raising the red ARM switch guard on the
CDU and toggling the ARM switch to the “UP” position. SYS ARMED
messed will not be displayed on the MX Display.
6) Wait at least two seconds after raising the ARM swich and then press the
FWD DISCH push button on the CDU. The Halon Test Set FWD DIV
LED will illuminate.

NOTE: The reset LED will also illuminate when a discharge button on
the CDU is depressed as a part of the test set functionality. After
pressing the FWD DISCH button, observe that the BTL 1 LED
on the Halon Test Set illuminates approximately two seconds
after the FWD DIV LED illuminates. If the reset light
illuminates and the BTL 1 and FWD DIV LEDs do not
illuminate during this step, there is an SCU malfunction.

7) Observe that after approximately 40 seconds from the BTL 1 LED being
illuminates that the BTL 2 LED has illuminated on the Halon Test Set.
8) Toggle the ARM switch on the CDU to the “DOWN” (Disarmed)
position.

(f) Aft Compartment (SCU Channel A, CCU Channel B)

1) Open all four Smoke System Circuit Breakers that are located behind the
First Officer’s position on the lower EPC panel.
2) Depress the RESET push-button on the Halon Test Set. All squib
indicator LEDs should now be extinguished.
3) Set the BTL 1 PRESSURE SWITCH to “MANUAL” and leave the BTL
2 PRESSURE SWITCH in the “AUTO” position (if not already done).

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4) Close the breakers SCU CHA and CCU CHB. Make certain that SCU
CHB and CCU CHA breakers are pulled.
5) Arm the suppression system by lifting the red ARM switch guard on the
CDU and toggling the ARM switch to the “UP” position. “SYS
ARMED” message will be displayed on the MX Display.
6) Wait at least two seconds after raising the ARM switch and then press the
AFT DISCH push-button on the CDU. The Halon Test Set AFT DIV
LED will illuminate.
NOTE: The RESET LED will also illuminate when a discharge button
on the CDU is depressed as a part of the test set functionality. If
the RESET LED illuminates and the BTL 1 and AFT DIV LEDs
do not illuminate during this step, there is a SCU malfunction.
7) Observe that after approximately 40 seconds from the BTL 1 LED being
illuminated that the BTL 2 LED has illuminated on the Halon Test Set.
8) Toggle the Arm Switch on the CDU to the “DOWN” (Disarmed)
position.
(g) Aft Compartment (SCU Channel B, CCU Channel A) – MX Display is
inoperative.
1) Open all four smoke system breakers that are located behind the FO’s
position on the lower EPC panel.
2) Depress the RESET push-button on the Halon Test Set. All squib
indicator LEDs should now be extinguished.
3) Set the BTL 1 PRESSURE SWITCH to “MANUAL” and the BTL 2
PRESSURE SWITCH in the “AUTO” position (if not already done).
4) Close the breakers labeled SCU CHB and CCU CHA. Make certain that
SCU CHA and CCU CHB breakers are pulled.
5) Arm the suppression system by raising the red ARM switch guard on the
CDU and toggling the ARM switch to the “UP” position. SYS ARMED
message will not be displayed on the MX Display.
6) Wait at least two seconds after raising the ARM switch and then press the
AFT DISCH push-button on the CDU. The Halon Test Set AFT DIV
LED will illuminate.
NOTE: The RESET LED will also illuminate when a discharge button
on the CDU is depressed as a part of the test set functionality.
After pressing the AFT DISCH button, observe that the BTL 1
LED On the Halon Test Set illuminates approximately two
seconds after the AFT DIV lED illuminates. If the reset light
illuminates and the BTL 1 and AFT DIV LEDs do not illuminate
during this step, there is an SCU malfunction.

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SUPPRESSION SYSTEM (cont’d)

7) Observe that after approximately 40 seconds from the BTL 1 LED being
illuminated that the BTL 2 LED has illuminated on the Halon Test Set.
8) Toggle the ARM switch on the CDU to the “DOWN” (Disarmed)
position.

(h) Final Channel A and Channel B Test – This test checks the operation of the
SCU and CCU with both channels A and B powered.

1) Open Smoke System breakers SCU CHA, SCU CHB, CCU CHA, and
CCU CHB. These breakers are located on the Lower EPC circuit breaker
panel.
2) Depress the RESET button on the Halon Test Set. All squib indicator
lights should now be extinguished.
3) Set the BTL 1 pressure switch on the Halon test set to the “MANUAL”
position.
4) Set the BTL 2 pressure switch on the Halon test set to the “AUTO”
position.
5) Close the four smoke system breakers SCU CHA, SCU CHB, CCU CHA,
and CCU CHB that are located behind the First Officer’s position on the
lower EPC panel.
6) Arm the suppression system by raising the ARM switch guard on the
CDU and toggling the ARM switch to the “UP” position.
7) Wait at least two seconds and then press the FWD DISCH push button
the CDU.

NOTE: The reset light will light when a discharge button the CDU is
depressed as a part of the test set functionality. If the reset light
illuminates and the BTL and FWD DIV lights do not illuminate
during this step, there is an SCU malfunction.

8) Observe that the FWD DIV and BTL 1 LEDs are illuminated on the
Halon Test Set approximately two seconds after pressing the FWD
DISCH switch.
9) Observe that after approximately 40 seconds from the BTL 1 LED being
illuminated, the BTL 2 LED on the Halon Test Set has illuminated.
10) Toggle the ARM switch on the CDU to the “DOWN” (disarmed)
position.
11) Press and hold down the CDU MX TEST button until the MX Display
illuminates.
12) Press and release the MX TEST button again. Observe that the MX
Display reads “BTL2 PRESS”.
13) Press and release the MX TEST button again. Observe that the MX
Display reads “SQUIB FAIL”.

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14) Observe that the CDU MX LED is illuminated and the SYS OK LED is
extinguished.
15) Open smoke system breakers SCU CHA, SCU CHB, CCU CHA, and
CCU CHB.
16) Remove Test Set TE 1034-02 and reinstall smoke system cabling routed
from SCU to the appropriate squibs on the fire bottle assembly. (See
section 8.c. for installation details.)

(i) Final System Operational Test with Halon Bottle System Re-attached – This
test checks the functionality of the complete smoke detection and suppression
system.

1) Close the four smoke system breakers that are located behind the FO’s
position on the lower EPC panel.
2) After approximately one minute, the SYS OK LED will illuminate if
system is functioning normally.

(j) Put the airplane back to its usual condition.

1) Remove the electrical power.

2) Install new Nylon ties (if applicable) and reconnect all connectors to
aircraft.
3) Install the rear bulkhead panel in the AFT end of the forward cargo
compartment.
4) Close the aft cargo compartment door if not proceeding to the next test.

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SUPPRESSION SYSTEM (cont’d)

9. Fire Suppression System Pressure/Flow Test & System Restoration

a. General

(1) The fire suppression system discharge tubes require a pressure test after the system
integrity has been compromised, and a flow test is to be performed after the system
has been discharged to make sure there is not blockage in the discharge lines.
Additionally, an internal check of the bottle interconnect plumbing must be
performed to make certain no fragments of the rupture disc remain trapped in the
tubing between the No. 1 extinguishing bottle & interconnect tubing tee fitting and
the No. 2 extinguishing bottle & the Flow Restrictor Valve. There are three separate
and distinct plumbing ‘circuits’ in the halon distribution system:

(a) The bottle interconnect plumbing.

(b) The aft distribution system.
(c) The forward distribution system.

(2) These systems are normally sealed from each other by the diverter valve, which is
normally closed except when halon is being deployed. For these reasons, the bottle
interconnect plumbing and the forward & aft distribution systems must be
pressure/flow tested separately.

(3) This procedure has these tasks:

(a) Discharge tube pressure test.

(b) Extinguishing bottle interconnect plumbing internal check.
(c) Discharge tube flow test.

b. Discharge Tube Pressure Test

(1) Equipment:

(a) Source-Pressure, capable of supplying 100 ± 10 psig.

(b) Shut-Off Valve.
(c) Regulator and Pressure Gauge.
(d) Tube Plugs, AN806-10 or equivalent.

(2) Access:
(a) Location Zones:
1) Forward Cargo Compartment.
2) Aft Cargo Compartment.

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(b) Access Panels:

1) Forward Cargo Compartment – 3 ceiling panels at nozzle locations.
2) Aft Cargo Compartment – 2 ceiling panels at nozzle locations.

(3) Prepare for the Test.

(a) Open the aft cargo door.

(b) Remove the lining at the forward right end of the aft cargo compartment
between STA 1020 and STA 1060 to get access to the fire extinguishing bottle
installation.

(4) Perform the Bottle Interconnect Plumbing Test. (Reference Figure 26.05-9.)

(a) Remove the cap from the AN827-10D cross. Supply a regulated source of
clean, dry nitrogen or air. The source shall be regulated to 100 ± 10 psig and
shall have a shut-off valve between the regulator and the pressure gauge.
(b) Connect a hose from the pressure gauge to the cross.
(c) With the regulator closed, open the hand valve on the source pressure.
(d) Slowly open the regulator pressurizing the bottle interconnect tubing and set
the regulated pressure to 100 ± 10 psig. Close the shut-off valve and watch
the pressure gauge. There may be an initial decay because of temperature
change, but this should stabilize in a few minutes.
(e) After a few minutes, note the pressure on the pressure gauge and start the
timer. Allow a minimum of two minutes to elapse and note the pressure on
the pressure gauge.
(f) Verify that the pressure leak rate does not exceed 1 psig per minute. If
pressure drop is in excess of the allowable, check all fittings and torque the
nuts to 330 to 360 inch pounds for flared tubing and 380 to 450 inch pounds
for distribution tubing ± 20 inch pounds if necessary.
(g) When the test is complete, disconnect the pressure source and re-torque the
cap on the cross.
(5) Perform the Forward Distribution System Tubing Test.
(a) Disconnect both of the forward discharge nozzles from the distribution tubes
and retain parts. Plug one tube with an AN806-10 plug (or equivalent).
(Reference Figure 26.05-10.)
(b) Supply a regulated source of clean, dry nitrogen or air. The source shall be
regulated to 100 ± 10 psig and shall have a shut-off valve between the
regulator and the pressure gauge.
(c) Connect a hose and proper adapter from the pressure gauge to the
disconnected tubing.
(d) With the regulator closed, open the hand valve on the source pressure.

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CHAPTER 26 – FIRE PROTECTION
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SUPPRESSION SYSTEM (cont’d)

(e) Slowly open the regulator pressurizing the bottle interconnect tubing and set
the regulated pressure to 100 ± 10 psig. Close the shut-off valve and watch
the pressure gauge. There may be an initial decay because of temperature
change, but this should stabilize in a few minutes.
(f) After a few minutes, note the pressure on the pressure gauge and start the
timer. Allow a minimum of two minutes to elapse and note the pressure on
the pressure gauge. Verify that the pressure leak rate does not exceed 1 psig
per minute. If pressure drop is in excess of the allowable, check all fittings
and torque the nuts to 330 to 360 inch pounds for flared tubing and 380 to 450
inch pounds for distribution tubing if necessary.
(g) When the test is complete, disconnect the pressure source and reconnect both
of the forward discharge nozzles to the distribution tubes and re-torque the
nuts to 330 to 360 inch pounds for flared tubing and 380 to 450 inch pounds
for distribution tubing.
(h) Ensure nozzle is installed above cargo liner and nozzle flange is below the
cargo liner.
(i) Connect nozzle to plate using four retaining screws.

(6) Perform the Aft Distribution System Tubing Test.

(a) Disconnect both of the aft discharge nozzles from the distribution tubes and
retain parts. Plug one tube with an AN806-10 plug (or equivalent).
(Reference Figure 26.05-10.)
(b) Supply a regulated source of clean, dry nitrogen or air. The source shall be
regulated to 100 ± 10 psig and shall have a shut-off valve between the
regulator and the pressure gauge.
(c) Connect a hose and proper adapter from the pressure gauge to the
disconnected tubing.
(d) With the regulator closed, open the hand valve on the source pressure.
(e) Slowly open the regulator pressurizing the bottle interconnect tubing and set
the regulated pressure to 100 ± 10 psig. Close the shut-off valve and watch
the pressure gauge. There may be an initial decay because of temperature
change, but this should stabilize in a few minutes.
(f) After a few minutes, note the pressure on the pressure gauge and start the
timer. Allow a minimum of two minutes to elapse and note the pressure on
the pressure gauge. Verify that the pressure leak rate does not exceed 1 psig
per minute. If pressure drop is in excess of the allowable, check all fittings
and torque the nuts to 330 to 360 inch pounds for flared tubing and 380 to 450
inch pounds for distribution tubing, if necessary.
(g) When the test is complete, disconnect the pressure source and reconnect both
of the forward discharge nozzles to the distribution tubes and re-torque the
nuts to 330 to 360 inch pounds for flared tubing and 380 to 450 inch pounds
for distribution tubing.

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CHAPTER 26 – FIRE PROTECTION
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SUPPRESSION SYSTEM (cont’d)
(h) Ensure nozzle is installed above cargo liner and nozzle flange is below the
cargo liner.
(i) Connect nozzle to plate using four retaining screws.
(j) Put the airplane back to its usual condition.
1) Install the sidewall at the forward right side of the aft cargo compartment.
2) Close the forward cargo compartment door if not proceeding to the next
test.
3) Close the aft cargo compartment door if not proceeding to the next test.

c. Extinguisher Bottle Interconnect Plumbing, Internal Check.

(1) Access:
(a) Location Zones – Forward Cargo Compartment.
(b) Access Panels – Forward Cargo Compartment Door.
(2) Prepare for the Test.
(a) Open the aft cargo door.
(b) Remove the sidewall at the forward right side of the aft cargo compartment
between STA 1020 and STA 1060 to get access to the fire extinguishing bottle
installation.

(3) Reference:
(a) Figure 26.05-9.

(4) Perform the Extinguisher Bottle Interconnect Plumbing, Internal Check.

(a) Remove the tubing located between the No. 2 Fire Bottle & Flow Restrictor
Valve. There are one ea. cone filters located in each end of the tubing. If
debris is present and not easily removed by cleaning or other means, replace
cone filters.
(b) Remove the tubing located between the No. 1 Fire Bottle & Tee Fitting. There
is one ea. cone filter located in the end of the tubing that attaches to the No. 1
Fire Bottle. If debris is present and not easily removed by cleaning or other
means, replace cone filter.
(c) Install removed tubing and re-torque nuts.
(d) Disconnect Flex Hose from the outboard end of the Diverter Valve to purge
forward cargo compartment distribution tubing.
(e) Connect a pressure source to the disconnected Flex Hose.

1) Make sure air is flowing through all nozzles in the forward cargo
compartment.

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CHAPTER 26 – FIRE PROTECTION
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SUPPRESSION SYSTEM (cont’d)
(f) Remove the pressure source from the disconnected Flex Hose.
(g) Connect the Flex Hose to the outboard end of the Diverter Valve and torque.
(h) Disconnect Flex Hose from the inboard end of the Diverter Valve to purge aft
cargo compartment distribution tubing.
(i) Connect a pressure source to the disconnected Flex Hose.

1) Make sure air is flowing through all nozzles in the aft cargo compartment.

(j) Remove the pressure source from the disconnected Flex Hose.
(k) Connect the Flex hose to the inboard end of the Diverter Valve and torque.

INTERCONNECT PLUMBING COMPONENT LOCATION

Figure 26.05-9

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

CARGO BAY PLUMBING COMPONENT LOCATION

Figure 26.05-10

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

10. Fire Suppression System Fire Extinguishing (Firex) Bottle Removal/Installation

a. General

(1) There are two Cargo Fire Extinguisher Bottles installed in the forward right area of
the aft bay behind the gill liner between STA 1020 and STA 1060.
(2) This procedure has tasks to remove and install the cargo fire extinguisher bottles.

b. Firex Bottle Removal Procedures. (Reference Figure 26.05-11.)

(1) Equipment:
(a) Squib Protective Cover.
(b) Discharge Port Cap (Supplied with the fire extinguishing bottles).
(c) Squib Protective Cover (Pacific Scientific P/N MIL-C-83723/60-210AN).

(2) References:
(a) Figure 26.05-11.

(3) Access:
(a) Location Zones – Aft Cargo Bay.
(b) Access Panels – Aft Cargo Compartment Door.

(4) Prepare for the Removal

(a) Open these four circuit breakers that are located on the lower EPC panel and
attach “DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU
CHB.
(b) Open the aft cargo door.
(c) Remove the right sidewall in the forward right area of the aft bay between
STA 1020 and STA 1060.

WARNING: DO NOT TOUCH THE SQUIB BEFORE YOU

PERFORM THE PROCEDURES FOR DEVICES THAT
ARE SENSITIVE TO ELECTROSTATIC DISCHARGE.
ELECTROSTATIC DISCHARGE CAN CAUSE THE
FIRE BOTTLE TO RELEASE ITS CONTENTS
SUDDENLY AND CAUSE INJURY TO PERSONS AND
DAMAGE TO EQUIPMENT.

(d) Before touching the squibs, review procedure for devices that are sensitive to
electrostatic discharge.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

(5) Firex Bottle Removal. (Reference Figure 26.05-11.)

(a) Disconnect the bottle squib and pressure switch electrical connectors from the
applicable bottle.

WARNING: PUT A PROTECTIVE COVER ON THE FIRE BOTTLE

SQUIB. IF YOU DO NOT PUT A PROTECTIVE COVER
ON THE FIRE BOTTLE SQUIB, THE FIRE BOTTLE
CAN RELEASE ITS CONTENTS SUDDENLY AND
CAUSE INJURY TO PERSONS.

(b) Install a protective cover (Pacific Scientific P/N MIL-C-83723/60-210AN) on

the applicable bottle(s) squib.
(c) Loosen the nut on the bottle’s Discharge Outlet Output Port.
(d) Remove bottle mounting bolts.

NOTE: Make certain to properly support the bottles to prevent damage to

structure and bottles.

(e) Remove Bottle #1 and/or Bottle #2 by carefully twisting bottle while sliding
the bottle discharge tubing out of the discharge outlet.
(f) Remove the used filter screen from the open end of the discharge tube for
Bottle #1 and Bottle #2 and install a new filter screen (Pacific Scientific P/N
52100295-1, Filter, Inline Conical).

c. Firex Bottle Installation Procedures. (Reference Figure 26.05-11.)

(1) Access:
(a) Location Zones - Behind the sidewall in the forward right side of the aft bay
between STA 1020 and STA 1060.
(b) Access Panels – Aft Cargo Compartment Door.

(2) Prepare for the Installation.

(a) Open these four circuit breakers located on the lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(b) Open the aft cargo door.
(c) Remove the sidewall in the forward right side of the aft bay between STA
1020 and STA 1060.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

(3) Firex Bottle Installation

WARNING: DO NOT MOVE THE BOTTLE WITHOUT A CAP ON THE

PORTS. DO NOT LET THE BOTTLE HIT THE AIRPLANE.
BE CAREFUL NOT TO CAUSE DAMAGE TO THE BOTTLE.
DAMAGE TO THE BOTTLE CAN CAUSE THE FIRE
BOTTLE TO RELEASE ITS CONTENTS SUDDENLY AND
CAUSE INJURY TO PERSONS AND DAMAGE TO
EQUIPMENT.

(a) Before you install the bottle(s), make sure the bottle weight does not exceed
the weight marked on the bottle’s I.D. plate by more than 0.1 pounds.

NOTE: The measured weight of the bottle includes the charged bottle, the
discharge outlets, the ground lug, and the squibs. If the squibs are
not installed on the bottle, do not install them. Weigh the squibs as
loose parts. Include the weight of the squibs in the measured weight
but do not install them. If the squibs are installed, weight the bottle
with the squibs installed. Remove the protective caps when you
weigh the parts.

(b) Place the fire extinguisher bottle(s) in the mounting plate with respect for the
correct orientation by aligning the discharge outlet port with the tubing. Then
slide the open end of the discharge tube into the discharge outlet.
(c) If the bottle’s discharge output port will not align with the discharge tube, then
perform these steps:

1) Remove the lockwire from the gland nuts.

2) Loosen the bottle’s discharge outlet gland nut.
3) With the bottle held in its mounting position, adjust the discharge outlet
for proper alignment with the discharge tube and then insert the discharge
tube into the discharge outlet, making sure that a new filter screen is first
inserted into the discharge tube. (See step 10.b.(5)(f) above.)
4) Tighten the gland nut to 540 ± 20 in. lbs. and safety wire.

(d) Secure the bottle(s) by installing the strap assembly and torque the socket head
bolts to 15 in. lbs.
(e) Tighten the bottle(s) discharge outlet nut that is attached to the discharge tube.
(f) Connect the electrical connectors to the applicable bottle.
(g) Perform Discharge Tube Pressure Test per section 9.b.

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CHAPTER 26 – FIRE PROTECTION
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SUPPRESSION SYSTEM (cont’d)
(4) Put the airplane back to its usual condition.
(a) Install the sidewall at the forward right end of the aft cargo compartment if not
proceeding to the next procedure.
(b) Close the aft cargo door.
(c) Remove the electrical power if it is not necessary.
(d) Set these four circuit breakers located on the lower EPC panel and remove
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.

FIREX BOTTLE COMPONENT LOCATION

Figure 26.05-11

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

11. Fire Suppression System Diverter Valve Removal/Installation

a. General

(1) There is one Diverter Valve installed on the bottle assembly located behind the
forward right sidewall in aft bay between STA 1020 and STA 1060.
(2) This procedure has a task to remove and install the Diverter Valve.

b. Diverter Valve Removal Procedures. (Reference Figure 26.05-12.)

(1) Equipment:
(a) Squib Protective Cover

(2) References:
(a) Figure 26.05-12.

(3) Access:
(a) Location Zones - Forward right side of the aft bay.
(b) Access Panels – Aft Cargo Compartment Door.

(4) Prepare for the Removal

(a) Open these four circuit breakers located on the lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(b) Open the aft cargo door.
(c) Remove the sidewall located in front right area of the aft bay between STA
1020 and STA 1060.

WARNING: DO NOT TOUCH THE SQUIB BEFORE YOU DO THE

PROCEDURES FOR DEVICES THAT ARE SENSITIVE
TO ELECTROSTATIC DISCHARGE. ELECTRO-
STATIC DISCHARGE CAN CAUSE THE FIRE BOTTLE
TO RELEASE ITS CONTENTS SUDDENLY AND
CAUSE INJURY TO PERSONS AND DAMAGE TO
EQUIPMENT.

(d) Before you touch the squibs, perform the procedure for devices that are
sensitive to electrostatic discharge.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

(5) Diverter Valve Removal

(a) Disconnect the electrical connectors from the Diverter Valve.

WARNING: PUT A PROTECTIVE COVER ON THE DIVERTER

VALVE SQUIBS. IF YOU DO NOT PUT A
PROTECTIVE COVER ON THE DIVERTER VALVE
SQUIBS, THE DIVERTER VALVE SQUIBS CAN
SUDDENLY FIRE AND CAUSE INJURY TO PERSONS.

(b) Put a protective cover on the Diverter Valve Squibs.

(c) Remove the B-Nuts from the tubing where the tubing attaches to the Diverter
Valve.
(d) Remove Diverter Valve mounting hardware.
(e) Remove Diverter Valve from the mounting plate.

c. Diverter Valve Installation

(1) Install Diverter Valve to mounting plate and secure with mounting hardware.
(2) Connect the B-Nuts where the tubing attaches to the Diverter Valve and torque.
(3) Remove the protective cover on the Diverter Valve Squibs.
(4) Connect the electrical connectors to the Diverter Valve.
(5) Perform Discharge Tube Pressure Test per section 9.b.

d. Put the airplane back to its normal condition.

(1) Install sidewall located in the forward right side of the aft cargo bay if not
proceeding to the next procedure.
(2) Close the aft cargo door.
(3) Remove the electrical power if it is not necessary.
(4) Set these four circuit breakers located on the lower EPC panel and remove “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.

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DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

DIVERTER VALVE COMPONENT LOCATION

Figure 26.05-12

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DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

12. Fire Suppression System Diverter Valve Squib Removal/Installation

a. General

(1) There are two Diverter Squibs mounted on the diverter valve that is located in
behind the sidewall in the front right side of the aft bay between STA 1020 and STA
1060.
(2) This procedure has a task to remove and install the Diverter Valve Squibs.

b. Diverter Valve Squibs Removal Procedures. (Reference Figure 26.05-12.)

(1) Equipment:
(a) Squib Protective Cover.
(b) ¾” wrench.

(2) References:
(a) Figure 26.05-12.

(3) Access:
(a) Location Zones – Aft Cargo Bay.
(b) Access Panels – Aft Cargo Compartment Door.

(4) Prepare for the Diverter Valve Squib Removal.

(a) Open these four circuit breakers located on the lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(b) Open the aft cargo door.
(c) Remove the sidewall at the front right side of the aft bay between STA 1020
and STA 1060.

WARNING: DO NOT TOUCH THE SQUIB BEFORE YOU DO THE

PROCEDURES FOR DEVICES THAT ARE SENSITIVE
TO ELECTROSTATIC DISCHARGE. ELECTRO-
STATIC DISCHARGE CAN CAUSE THE FIRE BOTTLE
TO RELEASE ITS CONTENTS SUDDENLY AND
CAUSE INJURY TO PERSONS AND DAMAGE TO
EQUIPMENT.

(d) Before you touch the squibs, perform the procedure for devices that are
sensitive to electrostatic discharge.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

(5) Diverter Valve Squib Removal

(a) Disconnect the electrical connectors from the Diverter Valve.

WARNING: PUT A PROTECTIVE COVER ON THE DIVERTER

VALVE SQUIBS. IF YOU DO NOT PUT A
PROTECTIVE COVER ON THE DIVERTER VALVE
SQUIBS, THE DIVERTER VALVE SQUIBS CAN
SUDDENLY FIRE AND CAUSE INJURY TO PERSONS.

(b) Put protective covers on the Diverter Valve Squibs.

(c) Remove faulty Diverter Valve Squib(s) using a ¾” wrench.

c. Diverter Valve Squib Installation

(1) Reinstall new squib(s) and torque with a ¾” wrench to 90-100 inch pounds.
(2) Remove the protective cover on the Diverter Valve Squibs.
(3) Connect the electrical connectors to the Diverter Valve.

d. Put the airplane back to its normal condition.

(1) Install the sidewall at the front right side of the aft cargo bay between STA 1020 and
STA 1060 if not proceeding to the next procedure.
(2) Close the aft cargo door if not proceeding to the next procedure.
(3) Remove the electrical power if it is not necessary.
(4) Set these four circuit breakers located on the lower EPC panel and remove “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
13. Fire Suppression System Extinguisher (Firex) Bottle Squibs Removal/Installation
a. General - There are two Cargo Firex Bottles behind the sidewall in the right front section
of the aft cargo bay between STA 1020 and STA 1060.
b. Firex Bottle Squibs Removal Procedures. (Reference Figure 26.05-13.)
(1) Equipment:
(a) Replacement Squib, P/N 30903852 with squib protective cover installed.
(b) Squib O-ring, P/N NAS1612-05.
(c) Squib Protective Cover.
(d) Discharge Port Cap (supplied with the fire extinguishing bottles).
(e) ¾” wrench.
(f) Squib safety cap.
(g) Safety wire.
(h) Anti-static bag.
(i) Inspection mirror.
(2) References:
(a) Figure 26.04-13.
(3) Access:
(a) Location Zones – Aft cargo bay.
(b) Access Panels:
1) Aft Cargo Compartment Door.
2) Forward right sidewall between STA 1020 and STA 1060.
(4) Prepare for the Firex Bottle Squib Removal
(a) Open these four circuit breakers located on the lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(b) Open the forward cargo door.
(c) Remove the lining at the aft end of the forward cargo compartment to get
access to the air conditioning distribution bay.
WARNING: DO NOT TOUCH THE SQUIB BEFORE YOU
PERFORM THE PROCEDURES FOR DEVICES THAT
ARE SENSITIVE TO ELECTROSTATIC DISCHARGE.
ELECTROSTATIC DISCHARGE CAN CAUSE THE
FIRE BOTTLE TO RELEASE ITS CONTENTS
SUDDENLY AND CAUSE INJURY TO PERSONS AND
DAMAGE TO EQUIPMENT.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

(d) Before you touch the squibs, review the procedure for devices that are
sensitive to electrostatic discharge.

(5) Firex Bottle Squib Removal

(a) Disconnect the squib electrical connector from the applicable bottle. The
bottle squib is located on the bottom of the bottle.
(b) Install squib safety cap over squib electrical connector.
(c) Note installation of safety wire for reinstallation shown below.
(d) Cut and remove squib safety wire from squib ¾” nut and the outlet connector.
(e) Remove the squib using a ¾” wrench.
(f) Place a safety cap over the squib discharge port.
(g) Place the removed squib into an anti-static bag and seal the bag.
(h) Return squib to Pacific Scientific for disposal.

c. Firex Bottle Squib Installation

(1) Before you touch the replacement squib, review procedure for devices that are
sensitive to electrostatic discharge.
(2) Remove the squib discharge port safety cap.
(3) Install a new squib O-ring on the threaded end of the squib.
(4) Install the replacement squib with connector safety cap installed and torque to 90-
100 inch pounds using a ¾” wrench.
(5) Install a new squib safety wire through the safety wire hole located on the squib ¾”
nut, twist safety wire, and route per notes taken in step 12.b.(5)(c) above.
(6) Remove safety cap from squib connector.
(7) Install mating connector on bottom of squib.
(8) Remove mating connector and inspect squib connector pins for straightness.
(9) Replace squib if pins are bent after first inspecting mating connector for damage.
(10) If replacing other bottle squib, perform steps 12.c.1. through 10. again.
(11) Reinstall mating connector.

d. Put the airplane back to its normal condition.

(1) Install the sidewall in the front right side of the aft bay if not proceeding to the next
procedure.
(2) Close the aft cargo door if not proceeding to the next procedure.
(3) Remove the electrical power if it is not necessary.
(4) Set these four circuit breakers located on the lower EPC panel and remove “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

BOTTLE SQUIB COMPONENT LOCATION

Figure 26.05-13

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
14. Cargo Compartment Fire Suppression System Suppression Control Unit (SCU)
Removal/Installation
a. General – This procedure has these tasks:
(1) Removal of the Suppression Control Unit (SCU).
(2) Installation of the Suppression Control Unit (SCU).
b. SCU Removal Procedures
(1) References:
(a) Figure 26.05-14.
(b) Figure 26.05-15.
(2) Access:
(a) Location Zones:
1) Aft Cargo Compartment.
2) Behind the right middle sidewall in the aft cargo bay between STA 1080
and STA 1100.
(b) Access Panels – Aft Cargo Compartment Door.
(3) Prepare for the SCU Removal
(a) Open these four circuit breakers located on the lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(b) Open the aft cargo door.
(c) Remove the sidewall in front right side of aft bay between STA 1080 and STA
1100.
(4) Suppression Control Unit (SCU) Removal
(a) Disconnect the electrical connector(s) from the SCU.
(b) Remove the two screws from the Configuration Module and remove module
from SCU. Retain hardware for reinstallation.
WARNING: THE MATED CONFIGURATION MODULE (CM) IS
INSTALLED ON THE CCU/[SCU] THROUGH AN
EXTERNAL CONNECTION PORT AND SECURED WITH A
LANYARD TO THE AIRCRAFT. THE CM RETAINS VITAL
SYSTEM INFORMATION UNIQUE TO THE AIRCRAFT IT
IS INSTALLED ON AND IS INTENDED TO STAY WITH
THE AIRCRAFT EVEN IF THE CCU/[SCU] IS REMOVED
OR REPLACED.
NOTE: Configuration Module is not removed from aircraft ground stud.
(c) Remove the six screws that attach the SCU to the SCU mounting bracket and
retain for reinstallation.

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c. SCU Installation

(1) Position the SCU on the SCU mounting bracket.

(2) Install the six screws that attach the SCU to the SCU mounting bracket.
(3) Install the Configuration Module into the SCU with two screws.
(4) Connect the electrical connector(s) to the SCU.
(5) Set these four circuit breakers located on the lower EPC panel and remove the “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(6) Supply electrical power if not already done.
(7) Check CDU, MX Display for the message “SYSTEM OK”. This message is
viewed on the MX Display by first pressing and holding down the MX Test Button.

SCU COMPONENT BAY LOCATION

Figure 26.05-14

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SUPPRESSION SYSTEM (cont’d)

SCU COMPONENT LOCATION

Figure 26.05-15

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
15. Fire Suppression System Bottle 2 Flow Restrictor Removal/Installation
a. General
(1) There is one Bottle #2 Flow Restrictor installed at the fire suppression bottle
location behind the sidewall in the forward right side of the aft cargo bay between
STA 1020 and STA 1060.
(2) This procedure has a task to remove and install the Bottle #2 Flow Restrictor.
(3) Replace the Flow Restrictor if Firex bottles are discharged.
b. Bottle #2 Flow Restrictor Removal Procedures. (Reference Figure 26.05-16.)
(1) Equipment:
(a) Replacement Bottle #2 Flow Restrictor.
(2) References:
(a) Figure 26.05-16.
(3) Access:
(a) Location Zones – Aft Cargo Bay.
(b) Access Panels – Aft Cargo Compartment Door.
(4) Prepare for the Bottle #2 Flow Restrictor Removal
(a) Open these four circuit breakers located on the lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(b) Open the aft cargo door.
(c) Remove the sidewall in the front right side of the aft cargo bay between STA
1020 and STA 1060.
WARNING: DO NOT TOUCH THE BOTTLE #2 FLOW
RESTRICTOR BEFORE YOU DO THE PROCEDURES
FOR DEVICES THAT ARE SENSITIVE TO
ELECTROSTATIC DISCHARGE. ELECTRO-STATIC
DISCHARGE CAN CAUSE THE FIRE BOTTLES TO
RELEASE THEIR CONTENTS SUDDENLY AND
CAUSE INJURY TO PERSONS AND DAMAGE TO
EQUIPMENT.

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SUPPRESSION SYSTEM (cont’d)

(5) Bottle #2 Flow Restrictor Removal

(a) Disconnect the valve input tubing from the right and left side of the Flow
Restrictor by loosening and removing the connection nuts.
(b) Remove the valve.

c. Bottle #2 Flow Restrictor Installation.

(1) Connect the valve to the output tubing by attaching its output connection nut and
torque.
(2) Connect the valve to the input tubing by attaching its input connection nut and
torque.
(3) Perform the Discharge Tube Pressure Test, section 8.b.

d. Put the airplane back to its normal condition.

(1) Install the sidewall in the right forward area of the aft cargo bay between STA 1020
and STA 1060.
(2) Close the aft cargo door.
(3) Remove the electrical power if it is not necessary.
(4) Set these four circuit breakers located on the lower EPC panel and remove “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(5) Observe the CDU, making sure the green SYS OK LED is illuminated and the MX
LED is extinguished.

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SUPPRESSION SYSTEM (cont’d)

REGULATOR & FILTER ASSEMBLY COMPONENT LOCATION

Figure 26.05-16

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CHAPTER 26 – FIRE PROTECTION
26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)
16. Fire Suppression System Bottle 2 Temperature Compensated Regulator Removal/Installation
a. General
(1) There is one Bottle #2 Temperature Compensated Regulator installed at the fire
suppression bottle location behind the sidewall in the forward right side of the aft
cargo bay between STA 1020 and STA 1060.
(2) This procedure has a task to remove and install the Bottle #2 Temperature
Compensated Regulator.
(3) Replace the Temperature Compensated Regulator if Firex bottles are discharged.
b. Bottle #2 Temperature Compensated Regulator Removal Procedures. (Reference Figure
26.05-16.)
(1) Equipment:
(a) Replacement Bottle #2 Temperature Compensated Regulator.
(2) References:
(a) Figure 26.05-16.
(3) Access:
(a) Location Zones – Aft Cargo Bay.
(b) Access Panels – Aft Cargo Compartment Door.
(4) Prepare for the Bottle #2 Temperature Compensated Regulator Removal
(a) Open these four circuit breakers located on the lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(b) Open the aft cargo door.
(c) Remove the sidewall in the front right side of the aft cargo bay between STA
1020 and STA 1060.
WARNING: DO NOT TOUCH THE BOTTLE #2 TEMPERATURE
COMPENSATED REGULATOR BEFORE YOU DO
THE PROCEDURES FOR DEVICES THAT ARE
SENSITIVE TO ELECTROSTATIC DISCHARGE.
ELECTRO-STATIC DISCHARGE CAN CAUSE THE
FIRE BOTTLES TO RELEASE THEIR CONTENTS
SUDDENLY AND CAUSE INJURY TO PERSONS AND
DAMAGE TO EQUIPMENT.

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SUPPRESSION SYSTEM (cont’d)

(5) Bottle #2 Temperature Compensated Regulator Removal

(a) Disconnect the Temperature Compensated Regulator input tubing from the
right and left side of the Regulator by loosing and removing the connection
nuts.
(b) Remove the mounts that attach the Temperature Compensated Regulator
bracket to the mounting plate and retain screws and mounting nut.
(c) Remove the Temperature Compensated Regulator.

c. Bottle #2 Temperature Compensated Regulator Installation.

(1) Install new Regulator to its bracket.

(2) Attach Regulator bracket to the mounting plate using the mounting screws and
mounting nut.
(3) Connect the Regulator to the output tubing by attaching its output coupling nut and
torque.
(4) Connect the valve to the input tubing by attaching its output coupling nut and
torque.
(3) Perform the Discharge Tube Pressure Test, section 8.b.

d. Put the airplane back to its normal condition.

(1) Install the sidewall in the right forward area of the aft cargo bay between STA 1020
and STA 1060.
(2) Close the aft cargo door.
(3) Remove the electrical power if it is not necessary.
(4) Set these four circuit breakers located on the lower EPC panel and remove “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(5) Observe the CDU, making sure the green SYS OK LED is illuminated and the MX
LED is extinguished.

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CHAPTER 26 – FIRE PROTECTION
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SUPPRESSION SYSTEM (cont’d)
17. Fire Suppression System Bottle 2 Particulate Filter Removal/Installation
a. General
(1) There is one Bottle #2 Particulate Filter installed at the fire suppression bottle
location behind the sidewall in the forward right side of the aft cargo bay between
STA 1020 and STA 1060.
(2) This procedure has a task to remove and install the Bottle #2 Flow Restrictor.
(3) Replace the Flow Restrictor if Firex bottles are discharged.
b. Bottle #2 Particulate Filter Removal Procedures. (Reference Figure 26.05-16.)
(1) Equipment:
(a) Replacement Bottle #2 Particulate Filter
(2) References:
(a) Figure 26.05-16.
(3) Access:
(a) Location Zones – Aft Cargo Bay.
(b) Access Panels – Aft Cargo Compartment Door.
(4) Prepare for the Bottle #2 Particulate Filter Removal
(a) Open these four circuit breakers located on the lower EPC panel and attach
“DO NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(b) Open the aft cargo door.
(c) Remove the sidewall in the front right side of the aft cargo bay between STA
1020 and STA 1060.
WARNING: DO NOT TOUCH THE BOTTLE #2 FLOW
RESTRICTOR BEFORE YOU DO THE PROCEDURES
FOR DEVICES THAT ARE SENSITIVE TO
ELECTROSTATIC DISCHARGE. ELECTRO-STATIC
DISCHARGE CAN CAUSE THE FIRE BOTTLES TO
RELEASE THEIR CONTENTS SUDDENLY AND
CAUSE INJURY TO PERSONS AND DAMAGE TO
EQUIPMENT.

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CHAPTER 26 – FIRE PROTECTION
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SUPPRESSION SYSTEM (cont’d)

(5) Bottle #2 Flow Particulate Filter Removal

(a) Disconnect the Particulate Filter input tubing from the right and left side by
loosening and removing the Filter’s connection nuts.
(b) Remove the mounts that attach the Particulate Filter bracket to the mounting
plate and retain screws.
(c) Remove the Particulate Filter.

c. Bottle #2 Particulate Filter Installation.

(1) Install new Particulate Filter to its bracket.

(2) Attach Particulate Filter bracket to the mounting plate using the mounting screws.
(3) Connect the Particulate Filter to the output tubing by its output coupling nut and
torque.
(4) Connect the Particulate Filter to the input tubing by attaching its output coupling nut
and torque.
(5) Perform the Discharge Tube Pressure Test, section 8.b.

d. Put the airplane back to its normal condition.

(1) Install the sidewall in the right forward area of the aft cargo bay between STA 1020
and STA 1060.
(2) Close the aft cargo door.
(3) Remove the electrical power if it is not necessary.
(4) Set these four circuit breakers located on the lower EPC panel and remove “DO
NOT CLOSE” tags: SCU CHA, SCU CHB, CCU CHA, and CCU CHB.
(5) Observe the CDU, making sure the green SYS OK LED is illuminated and the MX
LED is extinguished.

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CHAPTER 26 – FIRE PROTECTION
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SUPPRESSION SYSTEM (cont’d)
18. Fire Suppression System Post Halon Discharge Maintenance
a. General
(1) This section is used to identify the maintenance actions required after Halon from
the Lower Cargo Smoke Detection and Fire Suppression System has been
intentionally or accidentally deployed into the cargo compartment.
(2) Note that if the Suppression System is inadvertently deployed, Bottle #2 may be
saved by removing power from the Central Control and Suppression Control Units.
This is accomplished by pulling (opening) the four circuit breakers (2 CCU, 2 SCU)
located in the cockpit. The circuit breakers must be pulled within 14 minutes of the
Bottle #1 being fired to prevent the Bottle #2 from being automatically discharged
by the SCU. Once the circuit breakers are pulled, the firing sequence will be
permanently stopped and the second bottle will not be discharged, even when the
circuit breakers are reset.
b. This procedure identifies the following tasks:
(1) Halon Bottle Assembly (PN 34200409-1) Refurbish/Replacement (2)
(2) Flow Restrictor (Metering) Valve Assembly (PN 52000857-1) Replacement (1)
(3) Diverter Valve Assembly (PN 52000859-1) Refurbish/Replacement (1)
(4) Filter (Cone) (PN 52100295-1) Clean/Replacement
(5) Inspect Halon Nozzles and Tubing
WARNING: DO NOT BEGIN ANY MAINTENANCE UNTIL YOU HAVE
PERFORMED THE PROCEDURES IDENTIFIED FOR DEVICES
THAT MAY BE SENSITIVE TO ELECTROSTATIC DISCHARGE.
FAILURE TO PREVENT ELECTROSTATIC DISCHARGE MAY
CAUSE THE HALON BOTTLES TO RELEASE THEIR
CONTENTS SUDDENLY AND CAUSE INJURY TO PERSONS
AND/OR DAMAGE TO EQUIPMENT.
c. Post Halon Discharge Maintenance:
(1) Remove the #1 Halon Bottle per section 10, “Fire Suppression System Fire
Extinguishing (Firex) Bottle Removal/Installation”.
(a) Return the bottle to Pacific Scientific for refurbishment, or the bottle may be
refurbished by an Approved FAA Repair Station by:
1) Replacing the ruptured disc,
2) Replacing the fill fitting,
3) Replacing the squib cartridge,
4) Refill Halon,
5) Perform approved ATP.
(b) Install new or refurbished Halon Bottle per section 10.

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(2) Remove the #2 Halon Bottle per section 10 (if discharged).
(a) Return the bottle to Pacific Scientific for refurbishment, or the bottle may be
refurbished by an Approved FAA Repair Station by:
1) Replacing the ruptured disc,
2) Replacing the fill fitting,
3) Replacing the squib cartridge,
4) Refill Halon,
5) Perform approved ATP.
(b) Install new or refurbished Halon Bottle per section 10.
(3) Remove the Flow Restrictor (Metering) Valve Assembly per section 15, “Fire
Suppression System Bottle 2 Flow Restrictor Removal/Installation,” (if Bottle #2
was discharged).
(a) Return Flow Restrictor (Metering) Valve to Pacific Scientific for
refurbishment.
(b) Install new Flow Restrictor (Metering) Valve per section 15.
(4) Remove the Diverter Valve Assembly per section 11, “Fire Suppression System
Diverter Valve Removal/Installation”.
WARNING: THERE ARE TWO SQUIB CARTRIDGES LOCATED ON THE
DIVERTER VALVE ASSEMBLY. ONLY ONE SQUIB
CARTRIDGE WILL HAVE BEEN FIRED. THE OTHER SQUIB
CARTRIDGE IS STILL “LIVE” AND CARE SHOULD BE TAKEN
TO PREVENT ELECTROSTATIC DISCHARGE DURING VALVE
REMOVAL.
(a) Return diverter valve to Pacific Scientific for refurbishment, or the diverter
valve may be refurbished by an approved FAA Repair Station.
1) Remove squib cartridge from valve per Section 12, “Fire Suppression
System Diverter Valve Squib Removal/Installation,” prior to transporting.
2) If refurbishing at an approved FAA Repair Station:
a) Disassemble and clean as required.
b) Inspect the valve seals.
c) Replace the squib cartridge.
d) Perform approved ATP and Leak Test.

(b) Install new Diverter Valve per section 11.

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SUPPRESSION SYSTEM (cont’d)
(5) Locate and replace/clean the In-line Conical (Cone) Filters (PN 52100295-1).

(a) Locate Cone Filter at Bottle #1 outlet/tubing connection. Clean filter with a
brush and cleaning solvent and dry, or remove and replace with new.
(b) Locate Cone Filter at Bottle #2 outlet/tubing connection. Clean filter with a
brush and cleaning solvent and dry, or remove and replace with new.
(c) Locate Cone Filter at the Metering Valve inlet/tubing connection. Clean filter
with a brush and cleaning solvent and dry, or remove and replace with new.

(6) Inspect FIREX Nozzles and Suppression Tubing.

(a) Visually inspect the 2 FIREX Nozzles located in the affected cargo
compartment for obvious damage or blockage.
(b) Visually inspect the Halon Tubing from the #1 and #2 Halon Bottles to the 2
FIREX Nozzles located in the affected cargo compartment for obvious
damage or blockage.
(c) Perform System Leak/Pressure Test on the Suppression tubing per section 9,
“Fire Suppression System Pressure/Flow Test & System Restoration”.

(7) Inspect the Smoke Detector Units.

(a) Ensure no SDU’s are still alarming.

1) FIRE LED on the CDU located in the cockpit should be off.

2) Using the Spread Spectrum Viewer may also verify that no SDU’s are
still transmitting with the ALARM BIT set.

(b) Visually inspect the SDU sensor head (filter screen), located just inside of the
SDU grill for signs of contamination or blockage. If contamination is noted,
clean by blowing low pressure, clean, dry compressed air.
(c) Ensure sensor cap is fully seated.

(8) Perform Complete Suppression System Test.

(a) After all components have been inspected, removed, and replaced per above
steps, perform a complete Suppression System Test per section 7, “Fire
Suppression System Description and Operation”.
(b) TE-1034-01 or –02 Halon Test Box will be required for this test.

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19. DC-8 Illustrated Parts Catalog
NOTE: For purposes of this IPC’s affectivity code, “A” shall refer to –71/-73 series aircraft,
whereas “B” shall refer to –62/-72 series aircraft. Parts designated neither “A” nor “B”
are effective for -62, -71, -72, and -73 series aircraft.

a. Supplier’s Name and Address List

Cage Code Vendor

OTMJ9 Securaplane Technologies
10800 Mavinee Dr.
Tucson, AZ 85737
520-297-0844
05167 Pacific Scientific HTL/KIN-TECH Division
1800 Highland Avenue
Duarte, CA 91010
626-359-9317
30528 Hollingsead International
2226 Goodyear Ave
Ventura, CA 93003
805-535-2466

SMOKE DETECTION IPC

CDU
Figure 26.05-17 (1 of 6)

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
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SMOKE DETECTION IPC

CB Panel A & B and Cargo Fire Protection Placard
Figure 26.05-17 (2 of 6)

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SUPPRESSION SYSTEM (cont’d)

SMOKE DETECTION IPC

CCU/[SCU]
Figure 26.05-17 (3 of 6)

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SMOKE DETECTION IPC

Smoke Detector
Figure 26.05-17 (4 of 6)

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SUPPRESSION SYSTEM (cont’d)
NOTE: For purposes of this table’s affectivity code, “A” shall refer to -71/-73 series aircraft,
whereas “B” shall refer to –62/-72 series aircraft. Parts designated neither “A” nor “B”
are effective for –62, -71, -72, and -73 series aircraft.
FIG. PART EFF. UNITS PER
DESCRIPTION
ITEM NUMBER CODE ASSY
1 100-0120-03 Control Display Unit (CDU) A 1
Control Display Unit (CDU), CD-002
1 100-0120-12 B 1
(Supercedes 100-0120-05), OTMJ9
NS 120-2503-01 •CDU MX Setup Button Cover Plate 1
2 2TC6-1 Circuit Breaker, 1 amp A 2
7274-11-1 Circuit Breaker, 1 amp B 4
3 40272-07 Placard 30528 (CCU CHB) 1
4 40272-05 Placard 30528 (CCU CHA) 1
NS 40272-03 Placard 30528 (SCU CHB) B 1
NS 40272-01 Placard 30528 (SCU CHA) B 1
5 STB130-4 Base Assembly 1
6 22539-001 •Cap, Annunciator 1
7 1819 •Bulb 1
NS X-D4N Relay, 2 Pole 35334 2
NS SO-1064-001 Base, Relay 2 Pole 35334 2
NS 40390-01 Placard 30528 1
8 40376-01 Placard, Cargo Loading 30528 4
9 100-1052-01 Central Control Unit (CCU), OTMJ9 A 1
9 100-0127-01 Central Control Unit (CCU), OTMJ9 B 1
Suppression Control Unit (SCU),
NS 100-1019-01 1
OTMJ9
NS 80101-01 Shroud, CCU 1
10 AN960JD8L Washer 1
11 NAS1801-08-6 Screw 1
12 80101-02 Plate, CCU Mounting 30528 1
NS 100-1024-03 CCU Configuration Module A 1
NS 100-1024-01 CCU Configuration Module B 2

Usage Codes
DC8-71/-73 Series Aircraft A
DC8-62/-72 Series Aircraft B
SMOKE DETECTION IPC
Parts List
Figure 26.05-17 (5 of 6)

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SUPPRESSION SYSTEM (cont’d)

FIG. EFF. UNITS

PART NUMBER DESCRIPTION
ITEM CODE PER ASSY
MS24693-4B
NS Screw 2
100-0679-01
Smoke Detector Unit (SDU),
13 100-0649-01 A/B 19/16
OTMJ9
13a 160-1173-02 •Battery, OTMJ9 2 each
13b 569-1028C •Battery Clip, OTMJ9 2 each
NS 160-1305-01 Dome Grill Assy. 1 each
14 AN960JD10L Washer 4
15 NAS1801-3-8 Screw 4
16 100-1026-04 ID Plug (Cargo Bay A) Blue A 6
17 100-1026-05 ID Plug (Cargo Bay B) White A 4
18 100-1026-06 ID Plug (Cargo Bay C) Green A 5
19 100-1026-07 ID Plug (Cargo Bay D) Orange A 4
ID Plug (Forward Cargo Bay)
20 100-1026-01 B 8
Black, OTMJ9
ID Plug (Aft Cargo Bay) Red,
21 100-1026-02 B 8
OTMJ9
22 MS24693-C50 Screw 2
23 AN960JD8L Washer 2
24 MS21042L08 Nut 2
25 80100-03 Lanyard Guard 30528 A 19
80100-03 Lanyard Guard 30528 B 16
26 MS24693-C27 Screw 2
27 AN960JD6L Washer 2
28 MS21042L06 Nut 2
29 80100-07 Plate, Mounting 30528 A 19
80100-07 Plate, Mounting 30528 B 16
30 MS20426AD4-11 Rivet 6

Usage Codes
DC8-71/-73 Series Aircraft A
DC8-62/-72 Series Aircraft B

SMOKE DETECTION IPC

Parts List
Figure 26.05-17 (6 of 6)

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FIRE SUPPRESSION UNIT IPC

Figure 26.05-18 (1 of 2)

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SUPPRESSION SYSTEM (cont’d)

ITEM PART UNITS PER

DESCRIPTION
NO. NUMBER ASSY.
1 34800010-1 Fire Ext. 2170 Cu. In 2
NS 30903852 •Squib 1
NS NAS1612-05 •O-Ring, Squib 1
2 Not Used
3 Not Used
4 Not Used
5 52001090-1 Regulator & Filter Assembly, 05167 1
36500036-1 •Flow Restrictor Valve 1
36500035-1 •Temp Compensated Regulator 1
36500033-1 •Particulate Filter 1
6 52100388-1 Tubing Assy. Formed, 05167 1
7 52100390-1 Tubing Assy. Formed, 05167 1
8 52100295-1 Filter, Inline Conical, 05167 2
9 Not Used
10 AN827-10D Cross, Flared Tube, 05167 1
11 AN929A10 Cap, Assy., 05167 1
12 52100391-1 Tubing Assembly Formed, 05167 1
13 52000859-1 Diverter Valve Assy. 2 Outlet, 05167 1
14 52100392-1 Tubing Assembly Formed, 05167 1
NS 40262-01 •Firex Nozzle, 30528 5
NS 40292-01 •Nozzle Flange, 30528 5
15 52100377-1 Tubing Assy., Formed, 05167 1
16 52100389-1 Tubing Assy., Formed, 05167 1

FIRE SUPPRESSION UNIT IPC

Figure 26.05-18 (2 of 2)

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SUPPRESSION SYSTEM (cont’d)

20. Wiring Diagrams

SMOKE DETECTION/FIRE SUPPRESSION WDG 26-23-00, PAGE 1, SHEET 1

(-62/-72 Effectivity)
Figure 26.05-19 (1 of 2)

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SUPPRESSION SYSTEM (cont’d)

SMOKE DETECTION/FIRE SUPPRESSION WDG 26-23-00, PAGE 1, SHEET 2

(-62/-72 Effectivity)
Figure 26.05-19 (2 of 2)

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26.05 LOWER CARGO COMPARTMENT SMOKE DETECTION & FIRE
SUPPRESSION SYSTEM (cont’d)

SMOKE DETECTION WDG 26-23-00, PAGE 4

(-71/-73 Effectivity)
Figure 26.05-20

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26- FIRE PROTECTION

26.06 – INSPECT/TEST ENGINE FIRE EXTINGUISHING SYSTEM

RECURRING NON-ROUTINE JOB CARD
TABLE OF CONTENTS

RECURRING NON-ROUTINE JOBCARDS

26.06-1 INSPECT/TEST ENGINE FIRE EXTINGUISHING SYSTEM ----------- 26.06.1

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CHAPTER 26- FIRE PROTECTION

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARD
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 1 of 9
Mechanic Inspector
I. Purpose: To inspect and test the engine fire extinguishing system.
The applicable portions of the instructions on this job card are to be
complied with anytime an engine fire extinguisher is replaced, after each
maintenance action for the Firex Discharge system, or when otherwise
directed by the VPQC/VPOM.
II. References:
• FAA Airworthiness Directive 2005-08-08.
• Boeing Service Bulletin DC8-26A046 R1
• Boeing Service Bulletin DC8-26-047 R1
• DACO DC-8 Maintenance Manual (MM)
• Boeing Standard Wiring Practices Manual (SWPM)
• Applicable Wiring Diagram Manual, Chapter 26 (WDM)
III. General:

CAUTION: ELECTRICALLY GROUND THE AIRCRAFT.

WARNING: BEFORE INSTALLING EACH ELECTRICAL
CONNECTOR PULL CIRCUIT BREAKERS AND CHECK
EXPLOSIVE CARTRIDGE RECEPTACLE AND AIRCRAFT
HARNESS ELECTRICAL CONNECTOR FOR FOREIGN
PARTICLES AND CONTAMINATION THAT MAY CAUSE
AN ELECTRICAL SHORT. FAILURE TO DO SO MAY
RESULT IN DAMAGE TO EQUIPMENT AND/OR
PERSONAL INJURY.
WARNING: CHECK AIRCRAFT HARNESS ELECTRICAL
CONNECTOR WITH MULTI-METER AND VERIFY NO
D.C. VOLTAGE IS PRESENT.

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARDS (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 2 of 9
Mechanic Inspector
IV. Tasks:

A. Open circuit breakers located on the Electrical Power Center

(EPC) panel shown in Table 1 as required.

TABLE 1
Circuit Breaker Name
B1-602 Engine 1 Fire Agent Discharge and Low Pressure
Warning
B1-603 Engine 2 Fire Agent Discharge and Low Pressure
Warning
B1-604 Engine 3 Fire Agent Discharge and Low Pressure
Warning
B1-605 Engine 4 Fire Agent Discharge and Low Pressure
Warning

B. Open left and right wing lower access panels No. 523 located
between the engine nacelles on lower side of each wing, as
required. (See MM, Chapter 26-20-01, “Fire Extinguisher
Agent Containers – Maintenance Practices”)

C. Inspect fire extinguisher container explosive cartridge

electrical connectors shown in Table 2 and ensure
identification number labels are installed and legible.
Install/replace labels per the SWPM, Chapter 20 and WDM,
Chapter 26, as required.
Note: Each container has two explosive cartridges installed.
Installed position is determined by examining the
routing of the attached deployment line to the
respective engine.

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARDS (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 3 of 9
Mechanic Inspector
IV. Tasks: (cont’d)

D. Disconnect all fire extinguisher container explosive cartridge

electrical connectors shown below as required. (See MM,
Chapter 26-20-02, “Fire Extinguisher Agent Containers –
Maintenance Practices”)

WARNING: ONLY USE APPLICABLE AIRCRAFT

WIRING DIAGRAM. FAILURE TO DO SO MAY RESULT
IN DAMAGE TO EQUIPMENT AND/OR PERSONAL
INJURY.
INSERT AIRCRAFT WIRING DIAGRAM NUMBER USED
IN THE FOLLOWING SPACE:

Table 2
Fire Extinguisher Container Electrical Connector
Left Hand Outboard P1-1270 & P1-1271
Left Hand Inboard P1-1272 & P1-1273
Right Hand Inboard P1-1274 & P1-1275
Right Hand Outboard P1-1276 & P1-1277

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARDS (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 4 of 9
Mechanic Inspector
IV. Tasks: (cont’d)

E. Connect electrical connectors and test left outboard container

installation per following table as required:
Note: Fire extinguisher bottle low-pressure warning & firex
discharge press to test switches are located on the cockpit
overhead panel.
Left Outboard Firex Container / Cartridges
Step Procedure Observation
1 Connect electrical plug P1-1270 to Discharge line routes
Outboard cartridge. to Engine No. 1
2 Close ENGINE No. 1 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-602).
3 Simultaneously press FIREX BOTTLE Lamp illuminates*
LEFT WING OUTBD LOW PRESS
WARN & FIREX DISCHARGE LEFT
WING OUTBD ENGINE 1 – TEST.
4 Open ENGINE No. 1 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-602).
5 Connect electrical plug P1-1271 to Discharge line routes
INBOARD cartridge. to Engine No. 2
6 Close ENGINE No. 2 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-603).
7 Simultaneously press FIREX BOTTLE Lamp illuminates*
LEFT WING OUTBD LOW PRESS
WARN & FIREX DISCHARGE LEFT
WING OUTBD ENGINE 2 – TEST
* Prior to further flight, if lamp fails to illuminate, troubleshoot and repair system wiring per MM
Chapter 26, WDM Chapter 26 and SWPM Chapter 20.

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARDS (CONT’D
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 5 of 9
Mechanic Inspector
IV. Tasks: (cont’d)

8 Verify Lanyard is installed on Connector Lanyard only

P1-1271 to prevent cross connections IAW connects to
Boeing SB DC8-26-047. If not installed, Connector P1-1271
accomplish SB DC8-26-047 R1 or later.
9 Open ENGINE No. 2 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-603).
F. Connect electrical connectors and test left inboard container
installation per following table as required:
Left Inboard Firex Container / Cartridges
Step Procedure Observation
1 Connect electrical plug P1-1272 to Discharge line routes
INBOARD cartridge. to Engine No. 1
2 Close ENGINE No. 1 FIREX AGENT
DISCHARGE AND LOW PRESS WARN
circuit breaker (B1-602).
3 Simultaneously press FIREX BOTTLE Lamp illuminates*
LEFT WING INBD LOW PRESS WARN
& FIREX DISCHARGE LEFT WING
INBD ENGINE 1–TEST.
4 Open ENGINE No. 1 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-602).
5 Connect electrical plug P1-1273 to Discharge line routes
OUTBOARD cartridge. to Engine No.2
6 Close ENGINE No. 2 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-603).
7 Simultaneously press FIREX BOTTLE Lamp illuminates*
LEFT WING INBD LOW PRESS WARN
& FIREX DISCHARGE LEFT WING
INBD ENGINE 2-TEST.

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARDS (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 6 of 9
Mechanic Inspector
IV. Tasks: (cont’d)

9 Verify Lanyard is installed on Connector Lanyard only

P1-1273 to prevent cross connections IAW connects to
Boeing SB DC8-26-047. If not installed, Connector P1-1273
accomplish SB DC8-26-047 R1 or later.
10 Open ENGINE No. 2 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-603).
* Prior to further flight, if lamp fails to illuminate troubleshoot and repair system wiring per MM
Chapter 26, WDM Chapter 26 and SWPM Chapter 20.
G. Connect electrical connectors and test right inboard container
installation per following table as required:
Right Inboard Firex Container / Cartridges
Step Procedure Observation
1 Connect electrical plug P1-1274 to Discharge line routes
OUTBOARD cartridge. to Engine No. 3
2 Close ENGINE No. 3 FIREX AGENT
DISCHARGE AND LOW PRESS WARN
circuit breaker (B1-604).
3 Simultaneously press FIREX BOTTLE Lamp illuminates*
RIGHT WING INBD LOW PRESS
WARN & FIREX DISCHARGE LEFT
WING INBD ENGINE 3–TEST.
4 Open ENGINE No. 3 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-604).
5 Verify Lanyard is installed on Connector Lanyard only
P1-1274 to prevent cross connections IAW connects to
Boeing SB DC8-26-047. If not installed, Connector P1-1274
accomplish SB DC8-26-047 R1 or later.
6 Connect electrical plug P1-1275 to Discharge line routes
INBOARD cartridge. to Engine No.4
7 Close ENGINE No. 4 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-605).

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AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARDS (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 7 of 9
Mechanic Inspector
IV. Tasks: (cont’d)

8 Simultaneously press FIREX BOTTLE Lamp illuminates*

LEFT WING INBD LOW PRESS WARN
& FIREX DISCHARGE LEFT WING
INBD ENGINE 4-TEST.
9 Open ENGINE No. 4 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-605).
* Prior to further flight, if lamp fails to illuminate troubleshoot and repair system wiring per MM
Chapter 26, WDM Chapter 26 and SWPM Chapter 20.
H. Connect electrical connectors and test right outboard container
installation per following table as required:
Right Outboard Firex Container / Cartridges
Step Procedure Observation
1 Connect electrical plug P1-1276 to Discharge line routes
INBOARD cartridge. to Engine No. 3
2 Close ENGINE No. 3 FIREX AGENT
DISCHARGE AND LOW PRESS WARN
circuit breaker (B1-604).
3 Simultaneously press FIREX BOTTLE Lamp illuminates*
RIGHT WING OUTBD LOW PRESS
WARN & FIREX DISCHARGE LEFT
WING OUTBD ENGINE 3–TEST.
4 Open ENGINE No. 3 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-60
5 Verify Lanyard is installed on Connector Lanyard only
P1-1276 to prevent cross connections IAW connects to
Boeing SB DC8-26-047. If not installed, Connector P1-1276
accomplish SB DC8-26-047 R1 or later.
6 Connect electrical plug P1-1277 to Discharge line routes
OUTBOARD cartridge. to Engine No.4
7 Close ENGINE No. 4 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-605).

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DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARDS (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 8 of 9
Mechanic Inspector
IV. Tasks: (cont’d)

8 Simultaneously press FIREX BOTTLE Lamp illuminates*

RIGHT WING OUTBD LOW PRESS
WARN & FIREX DISCHARGE RIGHT
WING OUTBD ENGINE 4-TEST.
9 Open ENGINE No. 4 FIREX AGENT
DISCHARGE AND LOW PRESSURE
WARNING circuit breaker (B1-605).
* Prior to further flight, if lamp fails to illuminate troubleshoot and repair system wiring per MM
Chapter 26, WDM Chapter 26 and SWPM Chapter 20.
I. Safety explosive cartridge electrical connectors shown in Table 3
to cartridge to discharge valve bonnet with lockwire as required
(See MM, Chapter 26-20-02, “Fire extinguisher Agent
Containers – Maintenance Practices.”)
Note: No removal of electrical connectors should be required after
completion of the preceding inspection and test procedures.
Table 3
Fire Explosive Discharge
Connector
Extinguisher Cartridge Tube Engine
Plug
Container Position Routing
Outboard No. 1 Engine P1-1270
Left Outboard
Inboard No. 2 Engine P1-1271
Inboard No. 1 Engine P1-1272
Left Inboard
Outboard No. 2 Engine P1-1273
Outboard No. 3 Engine P1-1274
Right Inboard
Inboard No. 4 Engine P1-1275
Inboard No. 3 Engine P1-1276
Right Outboard
Outboard No. 4 Engine P1-1277
J. Close left and right wing lower access panels No. 523 located
between the engine nacelles on lower side of each wing as
required.

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DC-8 MAINTENANCE MANUAL
CHAPTER 26 – FIRE PROTECTION
RECURRING NON-ROUTINE JOB CARDS (cont’d)

ATI RECURRING NON-ROUTINE ATI-001

A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER

26.06-1
JOB TITLE
Inspect/Test Engine Fire Extinguishing System
Job Card Reviewed By Date
Page 9 of 9
Mechanic Inspector
IV. Tasks: (cont’d)

K. Close circuit breakers located on the EPC panel shown in Table

1 as required.

L. Include the following entry as part of the Corrective Action in

the aircraft logbook: “Recurring Non-Routine Job Card
26.06-1 complied with. Engine Fire Extinguishing System
Inspect/Test completed.” Attach completed and signed copy of
job card to the log page and forward to Q/C Records.

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