DC-8 STUDY GUIDE

PNEUMATIC SYSTEM

PNEUMATICS
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TABLE OF CONTENTS
TABLE OF CONTENTS................................................................................................................................................... 1

TABLE OF FIGURES ...................................................................................................................................................... 2

PNEUMATIC SYSTEM .................................................................................................................................................... 3

INTRODUCTION............................................................................................................................................................... 3

PNEUMATIC SYSTEM DESCRIPTION (DC-8-70) ...................................................................................................... 5

PNEUMATIC SELECTOR SWITCH.................................................................................................................................. 5

PRESSURE REGULATING BLEED VALVE...................................................................................................................... 5

BLEED AIR SHUTOFF VALVE.......................................................................................................................................... 5

PNEUMATIC TEMPERATURE CONTROL SYSTEM ....................................................................................................... 5

FIRE LEVER OPERATION ............................................................................................................................................... 6

PNEUMATIC CROSSFEED .............................................................................................................................................. 6

PNEUMATIC SYSTEM INDICATORS AND WARNING LIGHTS ................................................................................ 6

MANIFOLD AIR TEMPERATURE INDICATOR................................................................................................................. 6

PNEUMATIC MANIFOLD AIR PRESSURE INDICATOR .................................................................................................. 6

MANIFOLD AIR PRESSURE LIGHT................................................................................................................................. 7

ENGINE HIGH STAGE OPEN LIGHTS (70 SERIES) ....................................................................................................... 7

MANIFOLD OVERTEMPERATURE WARNING LIGHT .................................................................................................... 7

MANIFOLD FAILURE LIGHT ............................................................................................................................................ 8

ENGINE OVERPRESSURE LIGHTS.............................................................................................................................. 10

PNEUMATIC SYSTEM DESCRIPTION (DC-8-62/63)…………………………………………………………………….12

PNEUMATIC SELECTOR SWITCHES ........................................................................................................................... 12

(HIGH-AUTO-OFF) ......................................................................................................................................................... 12

PRESSURE REGULATING AND BLEED AIR SHUTOFF VALVE................................................................................... 12

PRESSURE RELIEF VALVE........................................................................................................................................... 13

PNEUMATIC TEMPERATURE CONTROL ..................................................................................................................... 13

FIRE SHUTOFF VALVE .................................................................................................................................................. 13

FIRE LEVER OPERATION ............................................................................................................................................. 13

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TABLE OF FIGURES

Figure 1: CONTROLS and INDICATORS....................................................................................................................... 3

Figure 2: PNEUMATIC SELECTOR SWITCH ................................................................................................................ 5

Figure 3: PNEUMATIC CROSSFEED SWITCH ............................................................................................................. 6

Figure 4: MANIFOLD PRESSURE INDICATOR ............................................................................................................. 7

Figure 5: ENGINE HIGH STAGE OPEN LIGHTS ........................................................................................................... 7

Figure 6: MANIFOLD FAILURE LIGHT........................................................................................................................... 8

Figure 7: ENGINE OVERPRESSURE LIGHTS .............................................................................................................. 9

Figure 8: ENGINE PNEUMATIC SYSTEM (70 SERIES)................................................................................................ 9

Figure 9: PNEUMATIC SYSTEMS - FUNCTIONAL SCHEMATIC (70 SERIES).......................................................... 10

Figure 10: ENGINE PNEUMATIC MECHANICAL- 70 SERIES .................................................................................... 11

Figure 11: PNEUMATIC SELECTOR SWITCHES........................................................................................................ 12

Figure 12: PNEUMATIC SYSTEMS - MECHANICAL SCHEMATIC (62/63 SERIES) .................................................. 14

Figure 13: PNEUMATIC SYSTEM FUNCTIONAL (62/63 SERIES).............................................................................. 15

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PNEUMATIC SYSTEM

Figure 1: CONTROLS and INDICATORS

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INTRODUCTION
The pneumatic power system, a low pressure system, utilizes bleed air from the engines to provide power, or
hot bleed air, for operation of the:
• Air conditioning system
• Pressurization system
• Ice protection system
• Windshield rain removal system
• Engine starting system
• Engine thrust reverser system [JT3D]
Air is taken from each engine through either a low stage/pressure or high stage/pressure bleed port. A
pneumatic manifold starts at each outboard engine, continues up through the engine pylon to the wing leading
edge to the fuselage and then forward into the fuselage nose section, where the left and right sections are
connected by a pneumatic crossfeed valve.
When referring to high stage (high pressure) air, or low stage (low pressure) air, the following stages are
associated with the engines installed on DC-8's and reference N2 compressor:

STAGES: 70 60
HIGH 9th 16th
LOW 5th 12th
NOTE: When counting stages of compression on the -70, the N1 compressor is NOT included.
Thus, 9th stage air is from the 9th stage of the N2 compressor.
The common duct of each engine incorporates the following components which may be combined with other
components on some installations:
• A high stage/pressure bleed air valve (shutoff valve).
• A low stage/pressure bleed air valve (check valve).
• Bleed air pressure regulator valve.
• Bleed air shutoff valve.
• Pressure relief valve [JT3D only].
• Engine bleed air precooler.
• Pneumatic system fire (pylon) shutoff valve.
An outer wing pneumatic duct shutoff valve, located outboard of engines No. 1 and No. 4 when closed, isolates
the sections of the pneumatic manifold. The valves are open to allow the ducting outboard of engines No. 1 and
No. 4 to be pressurized only when the wing de-icing system is in use.
The system is operated by means of four, three-position switches located on the Flight Engineer's panel. The
switch positions are:
DC-8-73/71 - AUTO, HIGH, and OFF
DC-8-63/62 - HIGH, LOW, and OFF or AUTO, HIGH, and OFF
During normal operation, the pressure regulator and precooler control the air pressure and temperature
respectively of the air entering the pneumatic manifold.
Provisions are also made for connecting an external pneumatic source to the airplane when the airplane is on
the ground. A connector and check valve, located on the bottom centerline of the fuselage nose, aft of the
radome, are connected to the RH rain removal duct. When a ground pneumatic source is connected, the check
valve opens and air can flow into the pneumatic system. Some (ex-FLYING TIGER) 70 series aircraft have an
additional ground port provided (on the left forward fuselage below the cabin entrance door) for adding a second
external pneumatic power source during starting.

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PNEUMATIC SYSTEM DESCRIPTION (DC-8-70)

PNEUMATIC SELECTOR SWITCH

Four three-position (AUTO, HIGH, OFF) pneumatic selector switches are located on the Flight Engineer's air
conditioning panel to control engine pneumatic bleed. The OFF position electrically shuts off engine pneumatic
bleed. Both the AUTO and HIGH positions allow a 5th stage bleed air pressure sensing circuit to automatically
operate the 9th stage (high bleed) valve. In AUTO, when 5th stage pressure falls below the operating range of
the bleed air regulating valve (approximately 28 psi), the high stage bleed valve will automatically open to
provide additional pressure. In HIGH, the 9th stage bleed valve opens whenever 5th stage bleed air pressure
drops below the regulated 9th stage output (approximately 42 psi), to allow higher temperature air into the
aircraft pneumatic system. Circuit breaker protection is provided from DC Buses No. 1 and 4 for engines 1 & 4
and the Battery bus for Engines 2 & 3.

Figure 2: PNEUMATIC SELECTOR SWITCH

Low-pressure bleed air is ducted from the engine 5th stage bleed port, through a check valve and into the
ducting upstream of the pressure regulating bleed valve.
High stage bleed air is ducted from 9th stage bleed ports, through a high stage bleed air shutoff valve, where it
joins 5th stage ducting leading to the bleed air pressure regulating valve and bleed air precooler. From the
precooler, the air is ducted through an electrically controlled, pneumatically actuated bleed air shutoff valve; a
mechanically operated pneumatic system (pylon) fire shutoff valve, and then into the pneumatic manifold.

PRESSURE REGULATING BLEED VALVE

The pneumatically actuated and operated pressure regulating bleed valve attempts to maintain a constant 38
PSI into the pneumatic manifold for a wide range of thrust settings and bleed conditions.

BLEED AIR SHUTOFF VALVE

The pneumatically actuated, electrically controlled, Bleed Air shutoff valve serves two basic functions. First, it
may be electrically closed to isolate a bleed source from the rest of the pneumatic manifold, either by the control
switch on the Flight Engineer's air conditioning panel or by moving the FIRE HANDLE beyond the WHITE DOT
position. Secondly, an overpressure sensing system will automatically close this valve pneumatically if an
overpressure condition (caused by faulty bleed air pressure regulation) is sensed, an amber ENG OVER
PRESS light, located on the Flight Engineer's panel, illuminates.
When the bleed air shutoff valve is closed, the associated high pressure (9th stage) valve is also closed.

PNEUMATIC TEMPERATURE CONTROL SYSTEM

The pneumatic temperature control system regulates manifold air temperature by controlling the flow of cooling
air through a bleed air precooler heat exchanger. This is an air-to-air type heat exchanger located in the
forward end of each pylon. Engine fan air is used as the cooling medium to maintain the manifold air
temperature within limits. After passing through the heat exchanger, the cooling air is discharged into the pylon
enclosures and then overboard through a fixed louver outlet on the forward left side of the pylon. The precooler
control valve is thermostatically controlled. There are no electrical inputs.

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FIRE LEVER OPERATION

If a fire shutoff lever is moved forward 23? (WHITE DOT) toward the SELECT AGENT position, a switch de-
energizes the bleed air shutoff valve solenoid, closing the bleed air shutoff valve and de-powering the
associated amber ENG OVERPRESSURE light. When the fire shutoff lever continues forward to the FUEL, AIR
& HYD OFF position, the cable operated pneumatic system fire (pylon) shutoff valve in the supply duct is
mechanically closed.

PNEUMATIC CROSSFEED

A low-pressure pneumatic manifold crossfeed shutoff switch, located on the Flight Engineer's pneumatic control
panel, electrically controls the pneumatically operated crossfeed valve in the fuselage nose section. When the
switch is in the guarded NORM (normal) position, the valve is automatically controlled by the nose wheel ground
shift mechanism. On the ground, the valve is normally open. After liftoff, the valve closes. The valve can be
overridden either open or closed anytime by placing the pneumatic crossfeed switch to the OPEN or CLOSED
position, respectively.

PNEUM A TIC CROSSFEED SWITCH

OPEN
OPEN Overrides all signals and commands valve t o t he OPEN posit ion.
CLOSED Overrides all signals and commands valve t o t he CLOSED posit ion.
CLOSED NORM A L ON GROUND - Valve open.
(Funct ion of Ground Cont rol Relay)
NORM
IN FLIGHT - Valve closed.
PNU X - FEED

Figure 3: PNEUMATIC CROSSFEED SWITCH

PNEUMATIC SYSTEM INDICATORS AND WARNING LIGHTS

MANIFOLD AIR TEMPERATURE INDICATOR

A dual scale manifold air temperature indicator is located on the Flight Engineer's pneumatic control panel. The
left scale indicates the temperature in the pneumatic duct inboard of engine No. 2. The right scale indicates the
temperature inboard of engine No. 3. The manifold air temperature indicator is calibrated in degrees centigrade
from 0 to 3 X 100. The scale has an under temperature range, marked by a yellow arc from 182?C to 214?C, a
normal operating range, marked by a green arc from 214?C to 242?C, and an over temperature range marked
by a yellow arc from 242?C to 258?C. The maximum allowable temperature is marked by a pink radial line at
258?C.

PNEUMATIC MANIFOLD AIR PRESSURE INDICATOR

A pneumatic manifold air pressure indicator, with two independent pointers on the dial, is located on the Flight
Engineer's pneumatic control panel. One pointer is placarded "L" for the left system, and "R" for the right
system. The indicator is calibrated in psig from 0 to 50. The indicator is a direct reading pressure indicator and
indicates the pressure on each side of the pneumatic crossfeed valve in the nose section. This pressure is less
than the regulated pressure at the pressure regulators, due to pressure drop in the duct system.

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Figure 4: MANIFOLD PRESSURE INDICATOR

MANIFOLD AIR PRESSURE LIGHT

An amber, press-to-test MAN AIR PRESS light will illuminate for:

Under pressure condition in the manifold, as sensed by under pressure switches in each half of the
manifold. Light will illuminate at 12.5 psi.
[60 ONLY] Overpressure condition (45 +2 psi) when one or more engine pressure-relief valves are
open.

ENGINE HIGH STAGE OPEN LIGHTS (70 SERIES)

Four green press-to-test HIGH STG OPEN indicating lights, one for each engine, will come on when the
corresponding high stage bleed valve is NOT fully closed. The light can be dimmed when the WARN LTS - PULL TO
DIM switch on the overhead switch panel is pulled.

Figure 5: ENGINE HIGH STAGE OPEN LIGHTS

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MANIFOLD OVERTEMPERATURE WARNING LIGHT

The DC-8-62/63/73 has four red press-to-test MAN AIR O'TEMP lights, one for each engine, located on the
Flight Engineer's pneumatic control panel. The light circuit is closed by temperature sensing elements located
just inboard of the inboard pylons within the supply bleed air ducts.

Whenever the air temperature in a pneumatic supply bleed duct rises to within a range of 247?C to
262?C, the corresponding warning light will illuminate. The warning light will go out when the
temperature in the affected supply bleed air duct drops below 247?C.

NOTE: With the pneumatic shutoff switches in HIGH, the MAN AIR O'TEMP light may illuminate
in flight with takeoff power applied, if the bleed air pre-cooler heat exchanger capacity is
exceeded. All switches should be immediately placed in LOW or AUTO position.
If any manifold air overtemp warning light illuminates, the master warning light on the glareshield will also come
on. The light can be dimmed when the WARN LTS - PULL TO DIM switch on the overhead switch panel is
pulled.
The DC-8-71 has one red press-to-test MAN AIR O'TEMP warning light which is located on the Flight
Engineer's pneumatic control panel that illuminates whenever the air temperature in either half of the pneumatic
manifold rises above 234? to 258?C, as indicated by the manifold air temperature indicator. If the MAN AIR
O'TEMP warning light illuminates, the master warning light will also illuminate. The light can be dimmed when
the WARN LTS - PULL TO DIM switch on the overhead switch panel is pulled.

MANIFOLD FAILURE LIGHT

Two red low pressure pneumatic manifold failure warning lights, one for the left manifold and one for the right
manifold, are located on the Flight Engineer's pneumatic control panel. The lights, placarded L MAN FAIL
PRESS TO TEST and R MAN FAIL PRESS TO TEST, will illuminate whenever a leak occurs in the
corresponding manifold ducting inside the pressurized area, which is sufficient to locally heat a detector strip to
255?F ± ?2°F. Overheat detector strips are located along the outside surface of the manifold ducting. If a leak
occurs, the overheat detector strip senses the rise in air temperature, and actuates an electronic switch which
turns on the corresponding manifold failure indicating light. Since the heat from a ruptured duct may spread into
the adjacent area, a lockout relay prevents the remaining manifold failure indicating light from coming on, to
insure the crew can determine which pneumatic system has failed. Each manifold failure indicating light has a
press-to-test feature used to check the manifold failure circuits for proper operation. If a manifold failure
indicating light comes on, the master warning light on the glare shield will also come on. The light can be
dimmed when the WARN LTS - PULL TO DIM switch on the overhead switch panel is pulled.

M A NIFOLD FA ILURE INDICA TING LIGHTS

L MAN R MAN Illuminat es because of rupt ure in pneumat ic duct in pressurized area.
FA IL FA IL M ast er w arning light w ill also illuminat e.
When one light illuminat es a lockout relay is energized t o prevent t he
PRESS TO PRESS TO ot her light f rom illuminat ing.
TEST TEST Light s are pow ered f rom DC-1 & 4 syst em cont rol is A C-1 & 4 .

Figure 6: MANIFOLD FAILURE LIGHT

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ENGINE OVERPRESSURE LIGHTS

There are four amber press-to-test dimmable ENG OVERPRESS lights, one for each engine. These bleed air
valve disagreement lights will illuminate whenever the bleed air shutoff valve is closed, with the associated
switch in AUTO or HIGH and the fire handle AFT of the WHITE DOT. When the light is illuminated in normal
flight, an overpressure condition has occurred, and the associated pneumatic bleed air shutoff valve has been
automatically closed. The lights can be dimmed when the WARN LTS - PULL TO DIM switch on the overhead
switch panel is pulled.

ENG 1 ENG 2 ENGINE OVERPRESSURE LIGHT (A M BER)

OVER OVER
INDICA TES OVERPRESSURE CONDITION IN
PRESS PRESS PNEUM A TIC SYSTEM .
PNEUM A TIC BLEED A IR SHUTOFF V A LVE
ENG 3 ENG 4 CLOSED.
OVER OVER ONLY OPERA BLE W HEN A SSOCIA TED
PNEUM A TIC SWITCH IS IN A UTO OR HIGH.
PRESS PRESS

Figure 7: ENGINE OVERPRESSURE LIGHTS

Figure 8: ENGINE PNEUMATIC SYSTEM (70 SERIES)

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Figure 9: PNEUMATIC SYSTEMS FUNCTIONAL SCHEMATIC (70 SERIES)

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Figure 10: ENGINE PNEUMATIC MECHANICAL- 70 SERIES

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PNEUMATIC SYSTEMS DESCRIPTION (DC-8-62/63)

PNEUMATIC SELECTOR SWITCHES

Four three-osition (HIGH-LOW-OFF) selector switches, one per engine, are located on the Flight Engineer's
pneumatic control panel. OFF shuts off all engine bleed air to the pneumatic system. HIGH supplies electrical
power directly to the solenoid of the high-ressure bleed shutoff valve, opening it to allow high pressure bleed air
to enter the airplane pneumatic system. LOW provides low stage bleed air to the pneumatic system in flight.
On the ground, however, ground shift and throttle position determine whether high or low stage bleed is
supplied. If the throttle is retarded, the high stage bleed valve opens to augment the air supply. When the
throttles are advanced approximately 1 9/16 inches from the idle stop, throttle switches close the high stage
valve and only low stage air supplies the manifold.

Figure 11: PNEUMATIC SELECTOR SWITCHES

(HIGH-AUTO-OFF)
On some aircraft the Pneumatic Selector switches are labeled OFF, AUTO, and HIGH. OFF shuts off all engine
bleed air to the pneumatic system. AUTO provides either low or high stage bleed air to the pneumatic system
automatically. A low stage bleed air pressure sensor automatically opens the high stage valve anytime the
pressure falls to a low value (approximately 20 psi) and closes it when low stage pressure raises high enough to
supply all system needs. HIGH overrides the pressure sensing system to supply electrical power directly to the
solenoid of the high stage bleed valve, opening it and allowing high stage bleed air into the pneumatic system.

PRESSURE REGULATING AND BLEED AIR SHUTOFF VALVE

A pressure regulating and bleed air shutoff valve on each engine is installed downstream of the low pressure
and high pressure taps of the engine, and serves three functions:
1. Regulates low or high stage high pressure engine bleed air (whichever is selected) to 38 psi;
2. Functions as an electrically controlled bleed air shutoff valve, and;
3. Prevents reverse flow of external bleed air into the engine.

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PRESSURE RELIEF VALVE

In the event of an overpressure condition due to a failed pressure regulator, a poppet-type pressure relief valve
will open at 45 psi and dump air overboard. Whenever ANY relief valve opens, a switch will be actuated that will
illuminate the amber MAN AIR PRESS light.
The pressure relief valve may open momentarily and the light illuminate under the following conditions:
1. If all of the systems which use bleed air are off on one or both sides and the corresponding low pressure
pneumatic shutoff switches are in HIGH. Under these conditions, the only bleed flow is the normal
pneumatic manifold leakage. The pressure regulators cannot control these low airflows.
2. Sudden, large changes in bleed air requirements resulting in pressure spikes.
Air is normally supplied from the 12th stage (LOW) unless the temperature is insufficient for ice protection
(minimum 190?C), or pressure is inadequate to prevent cabin turbo-compressor "stall". In that case, the system
may be switched to 16th stage (HIGH).

PNEUMATIC TEMPERATURE CONTROL

The pneumatic temperature control system regulates manifold air temperatures through a precooler control
valve, in conjunction with a thermistor that regulates the flow of engine fan cooling air through a bleed air pre-
cooler heat exchanger. After passing through the heat exchanger, the cooling air is discharged into the pylon
enclosures and overboard through a fixed louver outlet on the forward left side of the pylon.

FIRE SHUTOFF VALVE

A low-pressure pneumatic system fire shutoff (pylon) valve is located in the manifold supply duct in each pylon.
The fire shutoff valve is controlled by a cable connected to the respective engine fire shutoff lever. If a fire
shutoff lever is moved from the NORMAL position to approximately 23? (white dot) toward the SELECT AGENT
position, a switch is actuated to electrically close the pressure regulating valve and the bleed air shutoff valve on
the corresponding engine. When the fire shutoff lever reaches the FUEL, AIR & HYD OFF position, the fire
shutoff valve in the supply duct (pylon) is fully closed.

FIRE LEVER OPERATION

If a fire shutoff lever is moved forward 23? (WHITE DOT) toward the SELECT AGENT position, a switch closes
both the high stage bleed air shutoff valve and the low stage bleed air regulating and shutoff valve. When the
fire shutoff lever continues forward to the FUEL, AIR & HYD OFF position, the cable operated pneumatic
system fire (pylon) hutoff valve in the supply duct is mechanically closed.

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Figure 12: PNEUMATIC SYSTEMS - MECHANICAL SCHEMATIC (62/63 SERIES)

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Figure 13: PNEUMATIC SYSTEM FUNCTIONAL (62/63 SERIES)

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