1T-38A-2-1.pdf

T.O. 1T-38A-2-1

TECHNICAL MANUAL

ORGANIZATIONAL MAINTENANCE

GENERAL AIRPLANE

USAF SERIES

T-38A AND AT-38B

AIRCRAFT

(ATOS-HILL)

Prepared By: TRI-COR Industries, Inc.

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT E: Distribution authorized to DoD components only, direct military support, 15 May 2013. Refer other requests for this document to AFLCMC/WLDEH, Hill AFB Utah 84056-5811.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq). Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE: Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published under authority of the Secretary of the Air Force

30 NOVEMBER 2005 CHANGE 11 - 15 MAY 2013

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . 30 November 2005 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . 15 August 2006 Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 31 May 2007 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . 15 December 2007 Change . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . 15 June 2008 Change . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . 15 September 2008

Change . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . 15 December 2008 Change . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . 15 March 2010 Change . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . 15 May 2011 Change . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . 15 September 2011 Change . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . 15 May 2012 Change . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . 15 May 2013

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 152, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - iii iv Blank v - viii ix x Blank 1-1 - 1-6 1-7 1-8 - 1-11 1-12 1-12.1 - 1-12.2 Added 1-13 1-14 - 1-43 1-44 1-45 - 1-46 1-47 1-48 - 1-57 1-58 1-59 1-60 1-61 - 1-62 1-63 - 1-66 1-67 1-68 1-69 - 1-70 1-71 1-72 1-73 1-74 2-1 - 2-6 2-7 2-8 3-1 - 3-2 3-3 3-4 - 3-8 4-1 - 4-3

4-4 Blank 4-5 4-6 Blank 4-7 4-8 Blank 4-9 4-10 Blank 4-11 4-12 Blank 4-13 - 4-15 4-16 Blank 5-1 - 5-4 6-1 - 6-3 6-4 Blank 7-1 - 7-6 8-1 - 8-5 8-6 Blank 9-1 9-2 9-3 9-4 Blank Index 1 - Index 7 Index 8 Blank

*Zero in this column indicates an original page

A Change 11 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS......................................iii 1.33 General Information and Precau-tions for Aircraft Jacking ....................1-58

1.34 Jacking at Main Gear Strut ......................1-65

INTRODUCTION........................................................v 1.35 Lowering at Main Gear Strut...................1-65

1.36 Jacking at Nose Gear Strut ......................1-65

1.37 Lowering at Nose Gear Strut ...................1-67

1 AIRCRAFT GENERAL INFORMATION .............1-1 1.38 Jacking at Wing Points/Fuselage Points....................................................1-67

1.39 Lower Aircraft from TripodSECTION I DESCRIPTION..................................1-1 Jacks .....................................................1-68

1.40 Leveling ....................................................1-681.1 Aircraft General Description......................1-1

1.41 Parking ......................................................1-681.2 Aircraft Dimensions ...................................1-1

1.42 Towing Safety Precautions.......................1-701.3 General Arrangement .................................1-4

1.43 Towing Preparation ..................................1-711.4 Principal Components.................................1-4

1.44 Towing Operation.....................................1-711.5 Instrument Panels and Consoles ................1-4

1.45 Completion of Towing .............................1-731.6 Honeycomb Components ...........................1-4

1.46 Installing Aircraft into Sound1.7 Stations and Frames ...................................1-4

Suppressor ............................................1-731.8 Walkways....................................................1-4

1.47 External Static Grounding of Air-1.9 Cockpit Access ...........................................1-4 craft ......................................................1-731.10 Access and Inspection Doors ...................1-34

1.48 Edge Sealing of Decals ............................1-731.11 Access Door Fasteners .............................1-34

1.12 Engine Fire Fighting Access....................1-35 2 GROUND HANDLING, SERVICING

1.13 Flight Status Pins......................................1-35 AND LUBRICATION .........................................2-1

1.14 Landing Gear Ground Safety

Pins.......................................................1-35

SECTION I GROUND HANDLING ....................2-1

SECTION II MAINTENANCE ...........................1-38

2.1 Mooring.......................................................2-1

1.15 Danger Areas ............................................1-38 2.2 Ground Crew Interphone Con-

1.16 Torque Limits ...........................................1-38 nection ....................................................2-1

1.17 Duct Connectors .......................................1-38 2.3 External Grounding T-38A Air-

1.18 Installation of Standard AN737 craft ........................................................2-1

Clamp ...................................................1-38 2.4 Ground Handling Equipment .....................2-1

1.19 Installation of Marman Clamp .................1-38 2.5 Miscellaneous Equipment and

1.20 Torque Wrenches......................................1-44 Forms Stowage ......................................2-1

1.21 Hydraulic System Line Assem-

blies ......................................................1-44 SECTION II SERVICING .....................................2-2

1.22 Flight Control Cables ...............................1-47

1.23 Safetying Procedures ................................1-47 2.6 Servicing Fuel System................................2-5

1.24 Installing Rod-End Key Washer 2.7 Servicing Fuel System Safety

Locking Device....................................1-47 Precautions .............................................2-5

1.25 Installing Rod-End Tab Lock 2.8 Pressure Fueling .........................................2-5

Locking Device....................................1-47 2.9 Manual Fueling...........................................2-5

1.26 Installing Koroseal Lacing .......................1-52 2.10 Defueling.....................................................2-5

1.27 Fastener Restriction ..................................1-52 2.11 Draining ......................................................2-5

1.28 Fraction Conversion .................................1-52 2.12 Fuel Strainers..............................................2-5

1.29 Disconnecting Aircraft Battery ................1-53 2.13 Servicing Engine Oil System.....................2-5

1.30 Connecting Aircraft Battery .....................1-53 2.14 Servicing Hydraulic System Res-

1.31 External Electrical Power Con- ervoirs.....................................................2-7 nection ..................................................1-56 2.15 Servicing Landing Gear Shock

1.32 External Hydraulic Power Con- Struts ......................................................2-7 nection ..................................................1-58

Change 8 i

2.16 Servicing Oxygen System ..........................2-7 6 FUEL SYSTEMS......................................................6-1

2.17 Servicing Tires............................................2-7

2.18 Servicing Battery ........................................2-7 6.1 Fuel Supply System....................................6-1

2.19 Servicing Air Conditioning Unit................2-7 6.2 Fuel Vent System .......................................6-1

2.20 Servicing Gearboxes...................................2-7 6.3 Fuel Quantity Indicating System ...............6-1

2.21 Servicing Canopy Dampers........................2-7 6.4 Fuel Drains and Filters...............................6-1

2.22 Cockpit Drains............................................2-7 6.5 Single-Point Fueling System......................6-1

6.6 Fuel Cells....................................................6-3 SECTION III LUBRICATION..............................2-8 6.7 Fuel Low-Pressure Caution Sys-tems ........................................................6-3

2.23 Lubricants ...................................................2-8

7 INSTRUMENTS.......................................................7-1

3 AIRFRAME SYSTEMS...........................................3-1

7.1 Flight Instruments.......................................7-1

3.1 Fuselage ......................................................3-1 7.2 Altimeter .....................................................7-1

3.2 Wing............................................................3-1 7.3 Accelerometer .............................................7-1

3.3 Ejection Seats .............................................3-1 7.4 Airspeed/Mach Indicator ............................7-1

3.4 Canopies......................................................3-1 7.5 Angle-of-Attack Indicator ARU-

3.5 Canopy Jettison System .............................3-2 26/A........................................................7-1

3.6 Landing Gear ..............................................3-2 7.6 Angle-of-Attack Indexer ARU-

3.7 Nosewheel Steering System.......................3-2 27/A........................................................7-1

3.8 Wheel Brake System ..................................3-2 7.7 Vertical Velocity Indicator.........................7-2

3.9 Aileron System ...........................................3-2 7.8 Clock ...........................................................7-2

3.10 Rudder System............................................3-2 7.9 Magnetic (Standby) Compass ....................7-2

3.11 Horizontal Tail System...............................3-3 7.10 Attitude Director Indicator .........................7-2

3.12 Wing Flap System ......................................3-3 7.11 Standby Attitude Indicator .........................7-2

3.13 Flap-Horizontal Tail Interconnect 7.12 Horizontal Situation Indicator....................7-2

System....................................................3-3 7.13 Engine Instruments .....................................7-2

3.14 Stability Augmenter System.......................3-3 7.14 Oil Pressure Indicators ...............................7-2

3.15 Speed Brake System...................................3-3 7.15 Fuel Flow Indicators...................................7-2

7.16 Tachometers................................................7-2 4 PNEUDRAULIC SYSTEMS ...................................4-1 7.17 Exhaust Gas Temperature Indica-tors..........................................................7-2

4.1 Hydraulic Power Systems ..........................4-1 7.18 Nozzle Position Indicators .........................7-3

4.2 Hydraulic Reservoir Pressuriza- 7.19 Miscellaneous Instruments .........................7-3 tion System ............................................4-1 7.20 Cabin Pressure Indicator ............................7-3

4.3 Canopy Seal Pressurization Sys- 7.21 Hydraulic Pressure Indicators ....................7-3 tem..........................................................4-1 7.22 Fuel Quantity Indicators.............................7-3

4.4 Cabin Pressurization System......................4-1 7.23 Wing Flap Position Indicators ...................7-3

4.5 Cabin Air Conditioning System.................4-3 7.24 Liquid Oxygen Quantity Indica-

4.6 Anti-G Suit System ....................................4-3 tors..........................................................7-3

4.7 Liquid Oxygen System...............................4-3 7.25 Pitot-Static System .....................................7-3

4.8 Electrical And Electronic Equip-

ment Cooling System ............................4-3 8 ELECTRICAL POWER SYSTEMS........................8-1

5 POWER PLANT.......................................................5-1 8.1 AC Power ...................................................8-1

8.2 DC Power ...................................................8-1

5.1 Power Plant General Description...............5-1 8.3 External Power ...........................................8-1

5.2 Starting System...........................................5-1 8.4 Lighting Circuits.........................................8-1

5.3 Oil System ..................................................5-1 8.5 Engine Start and Ignition Control

5.4 Fuel System ................................................5-1 Circuit.....................................................8-1

5.5 Afterburner System.....................................5-1 8.6 Fuel System Circuits ..................................8-3

5.6 Variable Geometry System ........................5-1 8.7 Landing Gear Circuits ................................8-3

5.7 Variable Exhaust Nozzle Control 8.8 Landing Gear Control and Warn-

System....................................................5-3 ing Circuits.............................................8-3

5.8 Engine Anti-Icing System ..........................5-3 8.9 Landing Gear Downlock Indica-

5.9 Airframe-Mounted Accessory tor Circuit...............................................8-3

Power Assembly ....................................5-3 8.10 Landing Gear Safety Circuit ......................8-3

5.10 Engine Bay Cooling System ......................5-3

ii Change 8

8.11 Nosewheel Steering Circuit........................8-3 9 RADIO, COMMUNICATION AND

8.12 Flight Control Circuits ...............................8-3 NAVIGATION SYSTEMS .................................9-1

8.13 Trim Control Circuits .................................8-3

8.14 Wing Flap Control Circuit .........................8-3 9.1 UHF Command Radio System

8.15 Speed Brake Control Circuit ......................8-3 AN/ARC-164(V)....................................9-1

8.16 Heating and Cooling Circuits.....................8-4 9.1.1 Before Dual Radio TCTO 1T-

8.17 Pitot Heater Circuit.....................................8-4 38A-991 .................................................9-1

8.18 Cabin Conditioning Circuit ........................8-4 9.1.2 After TCTO 1T-38A-991 ...........................9-1

8.19 Engine Anti-Ice Circuit ..............................8-4 9.2 Intercom System AN/AIC-18.....................9-1

8.20 Equipment Compartment Cooling 9.3 Instrument Landing System (ILS)

Circuit.....................................................8-4 AN/ARN-147 .........................................9-1

8.21 Miscellaneous Circuits ...............................8-4 9.4 AN/ARN-118(V) TACAN Sys-

8.22 Electronic Test Receptacles .......................8-4 tem Functional Description ...................9-3

8.23 Electrical Power Test and Bus 9.5 AIM System................................................9-3

Monitor Receptacle................................8-4 9.6 Landing Gear Warning System..................9-3

8.24 Power Seat Circuit......................................8-4

INDEX .............................................................. Index 18.25 Canopy Seal Circuit ...................................8-4

8.26 Warning and Caution Circuits ...................8-4

8.27 Caution Light Circuit .................................8-5

8.28 Fire Detection Circuits ...............................8-5

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 T-38A Aircraft ................................................ 1-2 1-29 Leveling the Aircraft .................................... 1-69 1-2 Aircraft Dimensions........................................ 1-3 1-30 Towing the Aircraft ...................................... 1-72 1-3 General Arrangement...................................... 1-5 1-31 External Grounding Attach Points ............... 1-74 1-4 Principal Components..................................... 1-6 2-1 Ground Handling (Sheet 1 of 3) .................... 2-2 1-5 Interior Arrangement of Compartments ......... 1-7 2-2 Servicing Diagram .......................................... 2-6 1-6 Structural Components.................................. 1-18 3-1 Ejection Seat ................................................... 3-4 1-7 Stations and Frames...................................... 1-19 3-2 Canopy Jettison and Seat Ejection Sys- 1-8 Walkways ...................................................... 1-20 tem .............................................................. 3-5 1-9 Cockpit Access.............................................. 1-21 3-3 Crew Escape System Schematic .................... 3-6 1-10 Access and Inspection Doors (Sheet 1 3-4 Wheel Brake System Schematic .................... 3-7 of 13) ........................................................ 1-22 3-5 Speed Brake System Schematic ..................... 3-8 1-11 Engine Bay Fire Fighting Access ................ 1-35 4-1 Hydraulic Power Supply System Sche- 1-12 Flight Status Pins .......................................... 1-36 matic ........................................................... 4-2 1-13 Landing Gear Ground Safety Pins ............... 1-37 4-2 Hydraulic System Schematic (Sheet 1 1-14 Danger Areas ................................................ 1-39 of 3) ............................................................ 4-5 1-15 Torque Limits (Sheet 1 of 5) ....................... 1-40 4-3 Cabin Air Conditioning and Pressuriza- 1-16 Installing Duct Connectors ........................... 1-45 tion System Schematic............................. 4-11 1-17 Torque Wrench Usage .................................. 1-46 4-4 Canopy Seal Pressurization System ............. 4-13 1-18 Safetying Procedures (Sheet 1 of 3) ............ 1-48 4-5 Anti-G Suit System....................................... 4-14 1-19 Rod-End Safetying Procedures..................... 1-51 4-6 Oxygen System Schematic ........................... 4-15 1-20 Installing Koroseal Lacing............................ 1-52 5-1 J85-GE-5 Turbojet Engine.............................. 5-2 1-21 Fraction Conversion Chart............................ 1-53 5-2 Engine Start System........................................ 5-3 1-22 Disconnecting Aircraft Battery..................... 1-54 5-3 Engine Fuel Control System Schematic ....... 5-4 1-23 Connecting Aircraft Battery ......................... 1-55 6-1 Fuel System Schematic................................... 6-2 1-24 Connecting External Electrical Power ......... 1-56 7-1 T-38A Instruments (Sheet 1 of 2).................. 7-4 1-25 Connecting External Hydraulic Power......... 1-59 7-2 Pitot-Static System Schematic........................ 7-6 1-26 Access Door Requirements for Aircraft 8-1 Electrical Power Components ........................ 8-2

Ground Handling (Sheet 1 of 2) ............. 1-61 9-1 Radio, Communication and Navigation 1-27 Jacking the Aircraft (Sheet 1 of 2) .............. 1-63 System (AF65-10364 and .......................... 9-2 1-28 Jacking the Aircraft at Main and Nose

Gear Strut ................................................. 1-66

Change 8 iii/(iv blank)

INTRODUCTION

values in Chapter 1. Nonstandard torque limits are given in1. STUDY YOUR MANUAL − IT HAS THE INFO.

the written instructions or the applicable illustrations throughout the system manuals.Organizational maintenance instructions for T-38A aircraft come to you in a series of 11 manuals. But it is not To help you find what you need to know in a hurry, eachnecessary for you to use the whole set every time you need manual has a Table of Contents listing all chapters withinformation. Just remember that the first two books of the their section and main paragraph breakdowns. At a glance,series are of interest to all specialists and mechanics, while you can determine what is covered in each chapter. Alongthe other nine are concerned with specific systems or with the Table of Contents is a List of Illustrations whichseveral closely related systems. Refer to T.O. 1T-38A-2-1 includes not only all the illustrations in the manual, but alsofor aircraft general information not contained in this T.O.

the tables. The titles give you a good idea of the informa-tion provided in each figure. Therefore, you can often findEveryone should read T.O. 1T-38A-2-1, the General Air-what you want by skimming this list.plane manual, for an overall view of the aircraft, the systems and their interrelationships. This manual contains As a final aid in finding the specific procedure you need, anbrief discussions of ground handling and servicing tech-index is included in the back of each manual. In the indexniques and short descriptions of the aircraft systems.

all systems, components and functions covered in the manual are listed alphabetically and are cross-referenced.Another must on your reading list is T.O. 1T-38A-2-2, You can find the procedures for a system listed under theGround Handling, Servicing and Airframe Maintenance.

name of the system and also cross-referenced under suchAll maintenance personnel should study this manual and appropriate functions as removing, installing, testing,review it periodically for new or modified ground handling adjusting, rigging and so forth.equipment and instructions, additions to the complete tools list, and changes in servicing and lubricating procedures for This is your manual written for you with your needs inall systems. This detailed information may not be dupli-mind. The do-it-yourselfer and the brilliant innovator havecated in the individual system manuals, so it is important their place but it isn’t on the organizational maintenancethat you check this manual carefully for any instructions line. These books give you the approved short cuts andpertaining to your assigned system.

point out possible pitfalls. It’s a good idea to check the manual first for the correct procedure, then check out yourFor the electrical circuits for systems other than the radio, Talon. A conscientious effort is constantly expended incommunication and navigation systems, you should check improving and revising T-38 Maintenance Manuals. If youT.O. 1T-38A-2-7, Electrical Systems. You will find the find an error or deficiency which changes the meaning ofappropriate wiring diagrams in T.O. 1T-38A-2-11, Wiring the instructions or gives information preventing adequateDiagrams. Instruments of the various aircraft systems, performance of functions, refer to T.O. 00-5-1. This willexcept the fuel quantity indicators, can be found in T.O.

materially aid in correcting the deficiency, making the1T-38A-2-9, the Instruments manual.

manual more useful to you.

To aid in determining which book covers what system, the master book list in the front of each manual serves as a 3. KNOW YOUR AIRCRAFT − IT MAY NOT BE A ready reference. The list gives the manual titles, T.O. CARBON COPY.

numbers and chapter titles for the entire series.

Your T-38A is not a special order, custom-made

2. USE YOUR MANUAL − IT’S WRITTEN FOR one-of-a-kind T-bird, but on the other hand it is not a stamped out assembly line product either. While aircraft areYOU.

in production, systems, components or equipment may be improved or changed at the request of the Air Force or atThese manuals are your authoritative guide to good mainte-the suggestion of the contractor. In fact, this is suchnance. For your convenience, Chapter 1, GENERAL standard procedure that, at the beginning of the contract,INFORMATION, is identical in all manuals. Chapter 1 is aircraft are grouped into blocks to facilitate such changesintended to be a quick reference for pertinent data on the on the production line.T-38A and to provide necessary general information which does not easily fit into the specialized scope of the individ-ual manuals. For instance, you can find standard torque v

In order to help you identify your aircraft, instructions and USAF NAVY illustrations that do not apply to all aircraft are identified by SERIAL NO. BUREAU NO.

the following block numbers, as applicable: 68-8216 158201

67-14943 674943Block 25 − AF60-547 through AF60-553 Aircraft 67-14856 614856

Block 30 − AF60-554 through AF60-561 Aircraft 70-1575 701575

70-1579 701579Block 35 − AF60-562 through AF60-596 Aircraft 63-8135 638135

Block 40 − AF61-804 through AF61-947 Aircraft

Occasionally, a manufacturing change is effective at a pointBlock 45 − AF62-3609 through AF62-3752 Aircraft not included in the predetermined grouping; these aircraft are then identified by AF serial numbers. Where no codingBlock 50 − AF63-8111 through AF63-8247 Aircraft is given, you may assume that the information applies to all

Block 55 − AF64-13166 through AF64-13305 Aircraft aircraft. Procedures for aircraft that are no longer in the inventory have been deleted from this manual.

Block 60 − AF65-10316 through AF65-10475 Aircraft Paragraphs and illustrations also frequently include modifi-

Block 65 − AF66-4320 through AF66-4389 and cations which have been covered by Time Compliance AF66-8349 through AF66-8404 Aircraft Technical Orders (TCTO). These modifications may affect some or all blocks of aircraft and are usually incorporated Block 70 − AF67-14825 through AF67-14859 and in the aircraft over a protracted period of time. Therefore, AF67-14915 through AF67-14958 Aircraft in addition to knowing the block effectivity of your bird, you should check the records for its TCTO compliance.Block 75 − AF68-8095 through AF68-8217 Aircraft

Remember, you can avoid confusion and possible miscon-Block 80 − AF69-7073 through AF69-7088 Aircraft ceptions by knowing the block effectivity and TCTO com-pliance of your aircraft, then reading all titles carefully toBlock 85 − AF70-1549 and Later Aircraft be sure the information applies to your Talon.

The U.S. Navy aircraft covered by this manual are referred to in the manual by block numbers or by their correspond- 4. OZONE DEPLETING COMPOUNDS (ODC).

ing Air Force Serial Numbers. These USAF Serial Num-bers correspond to the following USN Bureau Numbers: This manual conforms to existing U.S. Government ODC

Class I requirements in effect when the manual was pre- USAF NAVY pared. Depending on location, requirements may be differ-

SERIAL NO. BUREAU NO. ent than U.S. Government requirements. In these cases, refer to the local Environmental Management Directorate68-8209 158198 for information.

68-8158 688158

68-8214 158200 vi

MASTER LIST OF ORGANIZATIONAL 3. Aileron Control System

MAINTENANCE MANUALS IN THE 1T-38A-2 4. Horizontal Tail Control System

SERIES 5. Rudder Control System

1T-38A-2-1 6. Speed Brake Control System

GENERAL AIRPLANE 7. Wing Flap Control System

1. Aircraft General Information 8. Stability Augmenter Control System

2. Ground Handling, Servicing and Lubrication 1T-38A-2-4

3. Airframe Systems PNEUDRAULIC SYSTEMS

4. Pneudraulic Systems 1. Aircraft General Information

5. Power Plant 2. Pneumatic Systems

6. Fuel Systems 3. Cabin Pressurization System

7. Instruments 4. Air Conditioning Systems

8. Electrical Power Systems 5. Anti-G Suit System

9. Radio, Communication and Navigation Systems 6. Canopy Seal System

1T-38A-2-2 7. Liquid Oxygen System

GROUND HANDLING, SERVICING AND 8. Hydraulic Power Systems

AIRFRAME MAINTENANCE 1T-38A-2-5

1. Aircraft General Information FUEL SYSTEMS

2. Ground Handling 1. Aircraft General Information

3. Servicing 2. Fuel System General Information

4. Lubrication 3. Fuel Supply System

5. Wing 4. Single-Point Fueling System

6. Speed Brake Support Panel 5. Fuel Vent System

7. Fuselage 6. Fuel Cells

8. Windshields 7. Fuel Quantity Indicating System

9. Canopies 1T-38A-2-6

10. Ejection Seats POWER PLANT

11. Weapon System Support Pod (WSSP) 1. Aircraft General Information

12. Electrical Bonding 2. Power Plant General

1T-38A-2-3 3. Power Plant Rigging and Adjusting

FLIGHT CONTROL SYSTEMS 4. Engine Main Fuel Control System

1. Aircraft General Information 5. Afterburner System

2. Primary and Secondary Flight Controls 6. Lubrication System vii

7. Variable Exhaust Nozzle Control System 6. Wheel Brake System

8. Variable Geometry System 1T-38A-2-9

9. Engine Starting and Ignition System INSTRUMENTS

10. Engine Anti-Ice System 1. Aircraft General Information

11. Engine Instruments and Related Systems 2. Instrument Systems General Information

12. Airframe-Mounted Accessory Power Assembly 3. Flight and Navigational Instrument Systems

13. Throttle System 4. Flight Director System

14. Troubleshooting Engine and Related Systems − 5. Engine Instrument Systems System Analysis

6. Miscellaneous Instrument Systems 1T-38A-2-7

7. Pitot-Static System

ELECTRICAL SYSTEMS

8. Velocity, Gravity and Altitude (VGH) Data Recording

1. Aircraft General Information System

2. Electrical Systems General Information 1T-38A-2-10

3. AC Power Supply System RADIO, COMMUNICATION AND NAVIGATION

SYSTEMS

4. DC Power Supply System

1. Aircraft General Information

5. Lighting Circuits

2. AN/AIC-18 Intercom System

6. Engine Start and Ignition Circuit

3. AN/ARC-164(V) UHF Command Radio System

7. Fuel System Circuits

4. AN/ARN-58 Instrument Landing System (Aircraft Not

8. Landing Gear Circuits Modified by TCTO 1T-38-654)

9. Flight Control Circuits 5. AN/ARN-147 Instrument Landing System (Aircraft Modified by TCTO 1T-38-654)

10. Heating and Cooling Circuits

6. Altitude Incoder Measurement (AIM) System

11. Miscellaneous Circuits

7. Cockpit Control Transfer System

12. Warning Circuits

8. AN/ARN-118(V) TACAN Navigational System

1T-38A-2-8 1T-38A-2-11

LANDING GEAR SYSTEMS

WIRING DIAGRAMS

1. Aircraft General Information

1. Aircraft General Information

2. Landing Gear General Information

2. Wiring Data

3. Landing Gear System

3. Circuit Diagrams

4. Landing Gear Alternate Release System

4. Component Diagrams

5. Nosewheel Steering System viii

Time Compliance Technical Orders (TCTO) provide5. GENERAL AIRPLANE MANUAL.

instructions for modifying aircraft in service. Technical manuals affected by the modification must include anyYour General Airplane manual is the introductory manual information necessary to the operation and maintenance ofin the series of eleven covering organizational maintenance the aircraft modified by the TCTO. Information whichof the T-38A. This manual gives you THE BIG PICTURE applies to the aircraft before modification is retained in the−the overall view of the aircraft, its systems, and their manual until all aircraft affected by the TCTO have beeninterrelationships.

modified.

The purpose of the manual is to provide brief information In order to determine whether TCTO modifications whichon all systems in one volume; therefore, you should read it have been completed on your aircraft are covered in thisfor familiarization or quick review.

manual, you should check the following list. With each change or revision of the manual the list is expanded as You will find that the manual contains a general descrip-necessary to include the latest Time Compliance Technicaltion of the aircraft, including access and inspection provi- Orders incorporated in the manual. Therefore, it’s a goodsions, general arrangement, and safety provisions. It also idea to check this list each time you receive changed pagescovers information concerning ground handling, servicing, or a revision.and lubrication, and a description of each major system of the aircraft. Except for the procedures you will find in Chapter 1, no specific maintenance instructions are 6. TIME COMPLIANCE TECHNICAL ORDERS.

included. For detailed information concerning any system, you should refer to the appropriate system manual. The following list contains only those TCTOs that apply to this technical manual. TCTOs not yet released are not The date on the title page of this manual is the copy freeze included and those known to have been completed have date − the last day on which the writer could insert or delete been deleted.

information. All technical data received before this date has been incorporated into the manual; data received after this date will appear in the next change or revision.

List of Time Compliance Technical Orders

TCTO TCTO TCTO

Number Title Date

1T-38A-991 Installation of Rear Cockpit UHF Radio P/N RT-1168, Into the T-38A Aircraft 20110430

Change 8 ix/(x blank)

CHAPTER 1

AIRCRAFT GENERAL INFORMATION

SECTION I DESCRIPTION

1.1 AIRCRAFT GENERAL DESCRIPTION. 1.2 AIRCRAFT DIMENSIONS.

The T-38A is a two-place, twin-engine, training-type air- Aircraft dimensions are covered in the following tabulation craft capable of operation at high altitudes. Powered by two and are illustrated in Figure 1-2.

J85-GE-5 turbojet engines, the aircraft is designed for speeds in the supersonic range. The tricycle-type retractable WEIGHT landing gear and the steerable nosewheel are hydraulically Design Gross Weight 12,020-pounds operated. Hydraulic power is also used to actuate primary

WINGSflight controls (rudder, ailerons and horizontal tail) and Span 303.00-inchesspeed brakes. The wing flaps are electrically actuated. The pressurized cockpit has two canopy enclosures, each hinged Airfoil Section NACA 0004.8-64 at the aft end; both canopies are jettisonable either from Chord (root) 134.65-inches inside or outside the aircraft. Both crewmembers’ ejection

Chord (tip) 26.93-inchesseats are equipped with rocket-type catapults actuated by Incidence 00.00 degreespercussion-type initiators. The fuel supply is contained in two independent fuel systems. Each system consists of a Sweepback (25% chord) 24.00 degrees single multicell fuel tank, which normally supplies fuel Aspect Ratio (projected) 3.75 under boost pump pressure to a single engine. The two fuel

HORIZONTAL TAILsupply systems are interconnected by a crossfeed valve, which allows either system to supply fuel to both engines. Span 170.00-inches Hydraulic power is supplied by two independent systems, Chord (root) 80.00-inches each powered by a hydraulic pump. Each engine drives an

Chord (tip) 20.00-inchesairframe-mounted gearbox on which is mounted an AC Airfoil Section NACA 65A004generator and a hydraulic pump. The engines may be removed or replaced without disturbing the gearbox or Incidence (normal) 00.00 degrees accessories. The flight control hydraulic system pump is Cathedral 4.00 degrees driven by the right engine and supplies half the power for

VERTICAL STABILIZERthe primary flight controls. The utility hydraulic system Airfoil Section NACA 65A004.5pump is driven by the left engine and supplies the other half of the power for the primary flight controls and all the FUSELAGE power to operate speed brakes, landing gear, stability Height (gear extended) 154.64-inches augmenter and nosewheel steering. The wheel brakes are

Height (maximum) 100-inchesactuated by a completely independent hydraulic system.

Pressing the brake pedals in either cockpit generates Width (maximum) 71.034-inches hydraulic pressure for the brakes. Electrical power is pro- Length 556.32-inches vided by two engine-driven AC generators, each function-

AREASing independently to supply 115/200-volt, 320 to 480 HZ, Wings (total) 170.00 square feet3-phase alternating current. All aircraft are equipped with two transformer-rectifiers. Each transformer-rectifier sup- Flaps (total) 20.50 square feet plies a part of the 28-volt DC requirements. If one trans- Ailerons (total) 9.24 square feet former-rectifier malfunctions, the other unit continues to

Speed Brakes 6.42 square feetsupply the DC power for the entire aircraft. During normal Horizontal Tail 59.00 square feetoperation, each generator carries about half the total load, but if one generator fails, the load automatically changes Vertical Stabilizer 41.07 square feet over to the remaining generator. A 24-volt sealed lead acid Fin (vertical stabilizer 34.11 square feet battery is provided to supply limited emergency power if minus rudder) both transformer-rectifiers fail to supply voltage to the

Rudder (aft of hinge line) 6.37 square feetprimary DC bus. A liquid oxygen system supplies breath-ing oxygen for high altitude operation.

1-1

Figure 1-1. T-38A Aircraft

1-2

Figure 1-2. Aircraft Dimensions

1-3

1.3 GENERAL ARRANGEMENT. 1.8 WALKWAYS.

The T-38A aircraft (see Figure 1-3) is a two-place train- Figure 1-8 shows the areas on the aircraft where it is ing-type aircraft with the rear cockpit behind and higher permissible to walk; all others are to be considered NO than the front cockpit. The two turbojet engines are placed STEP areas. Walking or standing on the inlet ducts, wing side by side in the aft portion of the fuselage. Inlet ducts on leading or trailing edges, or control surfaces must be both sides of the center fuselage supply the engines with avoided at all times to prevent damage to the thin skin and air. All fuel is carried in cells installed in the fuselage honeycomb construction. The aircraft should not be pushed center section, including the dorsal area. The main landing or lifted by applying any force to the leading or trailing gear retracts into the wing and the nose gear into the edges of the wings or control surfaces.

fuselage nose section. The nose section also houses much of the electronic equipment, the battery and the oxygen 1.9 COCKPIT ACCESS.

converter.

CAUTION1.4 PRINCIPAL COMPONENTS.

The principal aircraft components which are readily remov-

• The rear cockpit canopy external controlable are illustrated in Figure 1-4. For further information on handle must be disengaged and in thethe removal procedures for airframe components, refer to stowed position before the internal controlapplicable maintenance manuals.

handle is operated. Failure to follow this procedure can result in damage to the con-1.5 INSTRUMENT PANELS AND CONSOLES.

trol mechanism and possible loss of canopy in flight.Figure 1-5 shows the general arrangement of both front and rear cockpit instrument panels, and consoles. Each cockpit • Use canopy control handles for actuation of contains a main instrument panel, a left and right vertical the locking mechanism only. Excessive lev-panel, a pedestal, and a left and right console. erage applied to handle may damage the idler crank splines and cause an out-of-rig

1.6 HONEYCOMB COMPONENTS. condition in the canopy latching mecha-nism. After initial movement of canopy Figure 1-6 shows the location of honeycomb constructed mechanism has been made, assist canopy components and the arrangement of the structural frames through opening and closing cycle with on the aircraft. Because of the thin skin type of construc- hand pressure applied at the forward frame.

tion, protective coverings should be applied to protect the Failure to follow this procedure can result in honeycomb components from damage when it is necessary loss of canopy in flight.

to work in areas of honeycomb constructed components.

Access to either cockpit is provided by a removable ladder

1.7 STATIONS AND FRAMES. or by a set of three retractable steps. With the canopy open, the ladder may be hooked over either cockpit rail. If the Figure 1-7 shows the arrangement of structural stations ladder is not available, three steps built into the left side of which form a reference for determining the location of any the fuselage may be used. The steps retract into the point on the aircraft. All fuselage stations are numbered in fuselage when not in use and are held in place by detents.

inches, starting at a point ahead of the actual tip of the Both canopies may be unlocked or locked either from aircraft nose. This point is designated fuselage station 0.00 inside or outside the cockpit. From inside the cockpit, the and all fuselage stations are numbered in inches aft of this canopy is unlocked or locked, using the interior control point. Canted fuselage stations are designated in inches aft handle. From outside the cockpit, either canopy may be of station 0.00 as measured at the longitudinal centerline of unlocked or locked by opening an access door on the left the fuselage. Wing locations are determined by wing sta- side of the fuselage just below the cockpit rail between the tions measured in inches outboard of the fuselage center- canopies, unstowing the appropriate handle, and operating line, and by wing spar locations expressed in percent of the the handle to lock or unlock the canopy. The canopy is mean aerodynamic chord. Location points on the horizontal opened or closed by hand, with pressure applied at the tail and vertical stabilizer follow a system similar to that forward frame (see Figure 1-9).

used for the wing.

1-4

Figure 1-3. General Arrangement

1-5

Figure 1-4. Principal Components

1-6

Figure 1-5. Interior Arrangement of Compartments (Sheet 1 of 13)

Change 8 1-7

Figure 1-5. Interior Arrangement of Compartments (Sheet 2)

1-8

Figure 1-5. Interior Arrangement of Compartments (Sheet 3)

1-9

LEGEND

1. Landing Gear Position Indicator Lights 18. Fuel Flow Indicators

2. Engine Fire Warning Light 19. Hydraulic Pressure Indicators

3. AOA Indexer Dimmer 20. Vertical Velocity Indicator

4. Floodlight 21. Horizontal Situation Indicator

5. AOA Indicator 22. Marker Beacon Light

6. Airspeed/Mach Indicator 23. Navigation Mode Switch

7. Attitude Director Indicator 24. Steering Mode Switch

8. Altimeter 25. Standby Attitude Indicator

9. Master Caution Light 26. Clock

10. Canopy Warning Light 27. Accelerometer

11. Engine Tachometers 28. Downlock Override Button

29. Landing Gear Lever12. Exhaust Gas Temperature Indicators (warning flags front cockpit only) 30. Landing Gear Warning Silence Button

13. Cabin Altimeter (front cockpit only) 31. Magnetic Compass (front cockpit only)

14. Oil Pressure Indicators 32. Angle-of-Attack Indexer (front cockpit only)

15. Fuel Quantity Indicators 33. Oxygen Quantity Indicator

16. Nozzle Position Indicator 34. Flap Position Indicator

17. Card Clip

Figure 1-5. Interior Arrangement of Compartments (Sheet 4)

1-10

Figure 1-5. Interior Arrangement of Compartments (Sheet 5)

1-11

Figure 1-5. Interior Arrangement of Compartments (Sheet 6)

1-12 Change 8

Figure 1-5. Interior Arrangement of Compartments (Sheet 6.1)

Change 8 1-12.1

Figure 1-5. Interior Arrangement of Compartments (Sheet 7)

1-12.2 Change 8

Figure 1-5. Interior Arrangement of Compartments (Sheet 7.1)

Change 8 1-13

Figure 1-5. Interior Arrangement of Compartments (Sheet 8)

1-14

Figure 1-5. Interior Arrangement of Compartments (Sheet 9)

1-15

Figure 1-5. Interior Arrangement of Compartments (Sheet 10)

1-16

Figure 1-5. Interior Arrangement of Compartments (Sheet 11)

1-17

Figure 1-6. Structural Components

1-18

Figure 1-7. Stations and Frames

1-19

Figure 1-8. Walkways

1-20

Figure 1-9. Cockpit Access

1-21

Figure 1-10. Access and Inspection Doors (Sheet 1 of 13)

1-22

Figure 1-10. Access and Inspection Doors (Sheet 2)

1-23

Figure 1-10. Access and Inspection Doors (Sheet 3)

1-24

Figure 1-10. Access and Inspection Doors (Sheet 4)

1-25

Figure 1-10. Access and Inspection Doors (Sheet 5)

1-26

Figure 1-10. Access and Inspection Doors (Sheet 6)

1-27

Right-Hand Engine Bay Firewall Panels

Panel Numbers for Aircraft Item No. Access Areas Blocks 25 and Up

1 Panel, Outboard Firewall REB-1

2 Panel, Outboard Firewall REB-2

3 Panel, Outboard Firewall REB-3

4 Panel, Outboard Firewall REB-4

5 Panel, Outboard Firewall REB-5

6 Panel, Outboard Firewall REB-6

7 Intercostal, Outboard Firewall REB-7

8 Panel, Outboard Firewall REB-8

9 Firewall, Outboard Overboard Bleed Duct RH REB-9

10 Panel, Outboard Firewall REB-10

11 Web, Outboard Firewall REB-11

12 Panel, Inboard Firewall REB-12

13 Cover, Inboard Firewall REB-13

14 Panel, Inboard Firewall REB-14

15 Panel, Inboard Firewall REB-15

16 Firewall, Inboard REB-16

17 Intercostal, Inboard Firewall REB-17

18 Panel, Inboard Firewall REB-18

19 Firewall Assembly, Inboard REB-19

20 Panel, Inboard Firewall REB-20

21 Panel, Inboard Firewall REB-21

22 Pan Assembly, Inboard Firewall REB-22

23 Panel, Inboard Firewall REB-23

24 Panel, Inboard Firewall REB-24

25 Panel, Inboard Firewall REB-25

26 Panel, Inboard Firewall REB-26

27 Panel, Inboard Firewall REB-27

Figure 1-10. Access and Inspection Doors (Sheet 7)

1-28

Figure 1-10. Access and Inspection Doors (Sheet 8)

1-29

Left-Hand Engine Bay Firewall Panels

Panel Numbers for Aircraft Item No. Access Areas Blocks 25 and Up

1 Panel, Outboard Firewall LEB-1

2 Panel, Outboard Firewall LEB-2

3 Panel, Outboard Firewall LEB-3

4 Panel, Outboard Firewall LEB-4

5 Panel, Outboard Firewall LEB-5

6 Intercostal, Outboard Firewall LEB-6

7 Intercostal, Outboard Firewall LEB-7

8 Panel, Outboard Firewall LEB-8

9 Panel, Outboard Firewall LEB-9

10 Intercostal, Firewall LEB-10

11 Firewall, Outboard Overboard Bleed Duct LEB-11

12 Panel, Inboard Firewall LEB-12

13 Cover, Inboard Firewall LEB-13

14 Panel, Inboard Firewall LEB-14

15 Panel, Inboard Firewall LEB-15

16 Firewall, Inboard LEB-16

17 Intercostal, Inboard Firewall LEB-17

18 Panel, Inboard Firewall LEB-18

19 Firewall Assembly, Inboard LEB-19

20 Panel, Inboard Firewall LEB-20

21 Panel, Inboard Firewall LEB-21

22 Pan Assembly, Inboard Firewall LEB-22

23 Panel, Inboard Firewall LEB-23

24 Panel, Inboard Firewall LEB-24

25 Panel, Inboard Firewall LEB-25

26 Firewall, Inboard Assembly LEB-26

27 Panel, Inboard Firewall LEB-27

28 Panel, Outboard Firewall LEB-28

Figure 1-10. Access and Inspection Doors (Sheet 9)

1-30

Figure 1-10. Access and Inspection Doors (Sheet 10)

1-31

Right-Hand Boat Tail Firewall Panels

Panel Numbers for Aircraft Item No. Access Areas Blocks 25 and Up

1 Firewall Pressure-Relief Door BTR-1

2 Firewall, RH Inboard Side BTR-2

3 Firewall Intermediate RH Side BTR-3

4 Blanket, Firewall BTR-4

5 Firewall Panel BTR-5

6 Firewall, LH Inboard Side BTR-6

7 Firewall, Top Inboard BTR-7

8 Firewall Panel BTR-8

9 Firewall Panel BTR-9

10 Firewall Panel BTR-10

11 Firewall Panel BTR-11

12 Firewall, Outboard BTR-12

13 Firewall Panel BTR-13

14 Firewall Panel BTR-14

15 Firewall Panel BTR-15

16 Firewall Panel BTR-16

17 Firewall Panel BTR-17

18 Firewall Panel BTR-18

19 Firewall Panel BTR-19

Figure 1-10. Access and Inspection Doors (Sheet 11)

1-32

Figure 1-10. Access and Inspection Doors (Sheet 12)

1-33

Left-Hand Boat Tail Firewall Panels

Panel Numbers for Aircraft Item No. Access Areas Blocks 25 and Up

1 Firewall Assembly BTL-1

2 Firewall Pressure-Relief Door BTL-2

3 Firewall Intermediate LH Side BTL-3

4 Blanket, Firewall BTL-4

5 Firewall Panel BTL-5

6 Firewall Panel BTL-6

7 Firewall Panel BTL-7

8 Firewall Panel BTL-8

9 Firewall Panel BTL-9

10 Firewall, Outboard BTL-10

11 Firewall Panel BTL-11

12 Firewall Panel BTL-12

13 Firewall Panel BTL-13

14 Firewall Panel BTL-14

15 Firewall Panel BTL-15

16 Firewall Panel BTL-16

17 Firewall Panel BTL-17

Figure 1-10. Access and Inspection Doors (Sheet 13)

284.0) and attaching hardware (stud, recep-1.10 ACCESS AND INSPECTION DOORS.

tacle and retaining ring, etc.) shall be visu-ally inspected for worn, missing or brokenAccess and inspection doors are provided throughout the parts. Discrepancies shall be corrected prioraircraft to allow access to compartments for inspection and to flight.maintenance of aircraft components. Figure 1-10 shows the locations of these doors and inspection panels and lists • The torq-set recess fastener is used primarilythem by numbers. An identifying number is placarded on for access door installation on T-38A air-each door, and a corresponding number is placarded on the craft. Removal or installation of doors withadjacent structure to facilitate replacement when a number this type fastener will require the use of theof doors have been removed at one time. Some exterior torq-set adapter tools. Use of the correct sizedoors have interior doors beneath them. Most interior doors torq-set tool is required to prevent damageare chained to avoid their loss or misplacement; therefore, to the fastener. Quick-acting Zip-Loc,interior doors are not called out in the door diagram.

Calfax and Camloc fasteners are used in some areas for structural access panels and

NOTE doors which are frequently removed. The Calfax and Camloc fasteners have the

When fitting replacement access doors, consult torq-set recess type studs. The Zip-Loc fast- T.O. 1T-38A-3 for proper fitting procedure and ener has a hexagon opening to accept a gap tolerances. 7/32-inch hexagon bit for removal or instal-lation. On access doors utilizing Zip-Loc or

1.11 ACCESS DOOR FASTENERS. Calfax fasteners, normal pressure applied to fastener stud with installation tool should be adequate to start fastener stud threads into

CAUTION receptacle threads. If excessive force is used, damage to fastener will result (see Figure 1-15).• Whenever access doors/panels are opened for any reason, forward of air inlet ducts (FS

1-34

Figure 1-11. Engine Bay Fire Fighting Access of the pin and inserting the pin into the hole in the legbrace.1.12 ENGINE FIRE FIGHTING ACCESS.

This prevents movement of the handgrips. The flight status pins must always be installed when the aircraft is on theAn engine bay fire warning system is provided in both ground.