R-3896-11
TECHNICAL MANUAL OPERATING INSTRUCTIONS
F-1 ROCKET ENGINE
(ROCKETDYNE)
LATEST CHANGED PAGES SUPERSEDE IN| THE SAME PAGES OF PREVIOUS DATE Insert changed pages into basic
on Notct publication. Desiroy superseded pages,
PREPARED UNDER AUTHORITY OF THE NATICNAL AERONAUTICS AND SPACE ADMINISTRATION
" ] APRIL 1969
CHANGE NO. 14 9 OCTOBER 1972
R-3896-11
LIST OF EFFECTIVE PAGES
NOTE The portion of the tent affected by Ihe changer 4 indicated by o verticat haw in the outer morgins al the page
TOTAL NUMBER OF PAGES IN THIS PUBLICATION 15
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Upon receipt of the second ond subsequent changes fo this technical manual, personel respenuble for mountoiing this pyblicahon in current status will ascertain thal al previous changes have heen received and incorporated, Action should he taken promptly +f the publication is iacomplete.
listed must be in the manual to make this
This page reflects the current atatus of the complete manuri. All pageg publication current and complete.
Change No. 14 - 9 October 1972
R-33806-11
LIST OF EFFECTIVE PAGES
Page Change Page Change Page Changa No No Juve No No iisue No No istue
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Change No. 14 - 9 October 1972 B/C
R-3896-11 Contents
TABLE OF CONTENTS
PARAGRAPH TITLE PAGE ”ARAGRAP TUE PAGE INTRODUC LTON 1,1.10 Thrust Chamber Injector : > OP 1 . Contamination Inspection ........ 1-24 1 OUTLINE OF ENGINE Q!ERATING L TEESE A ATOR: eer fe 1,1.11 Thrust Chamber Injector 9 ENGINE OPFRATING INSTRUCTIONS Damage Inspection ,....eevesseese 1-24
6 : . 1.1.12 Thrust Chamber Drain Adapter (HOT) CONTRO: AND REVISION SYSTEM, vi P oeTh ae bt a Torque Verification cicccsseeeres 1-24
1 ECP Approval Baseli Sivieate pees: MEET
2 Index. of OICN Chahees eeecnnensces X 1,1, 124 Engine Joints Closure Removal
3 Engine Baseline MD Configuration . xi n, verification at MTF .....eseseeee 124A % ADBHRENIATIONS,....ccecsceceeeesees Xi 1,1.12B Engine Jointa Closure Removal
h DEFINITIONS isi swetvecnsseceranag. 2! Verification ot KSC .....sseeeeee 1-24C A s ‘Raa ee LL ee ER Mca | 1.1.13 Checkout Valve Ground Position
5 ADDI TIONAI, DATA AND TNFORMATI ON we OX Verification cociscccenavteecesee 1-24D 6 CONFIGURATION IDENTIFICATION ..... xiii Liu.’ Propellant Valves Closed
us F-1 Rockel Fngine .ccsccecsseecees XIV Verification ...... wa pesebecosen » 1-25 5 MUcSyACCR: cocsvel sce meneame dee OAV 1.1.15 LOX Dome and Gas Generator 1,0X
Injector Purge Operation VorificAtbion ceeussacecereresenes LHQ5
SECTION T 1.1.16 Hypergol Installed Switch OPERATING REQUIREMENTS Pickup Verification .....cecsee08 1-25 1.1.17 Igniter Links Installed : le-1 Scheduled Authorized Field Verification ..ccccseeecaueennees 1-25 Activities cocsccceevcuaageercsane 1-2 1.1.18 Turbopump Heater Power on 12 Nonseheduled Authorized Verification .eccasececnecenveaee 1-285 Field Activities woccccseeancesses l-? 1,1.18A Turbopump LOX Seal Purge Verification oven eet eee reenter 1-25 1.1 ANSPEGTIONS secceerensestceoeesces 1-10 1,1.19 LOX Dome and Gos Generator LOX 1.1.1 Qvernll kngine Visual Inspection Injector Purge off Verification for Uninstalled Engines During for Abort Prior to Gas Generator Receiving Inspeotion ......+..+.+. 1-10 Tgnition .ocvesescacennaecssseeas LH25 1.1.2 Overall Engine Visual Inapection 1.1.20 LOX Dome and Gas Generator LOX for Uninstalled Engines in Injector Purge off Verification Storage wocvsccsconccscseneceetree Lobo for Abort After Gas Generator 1,1,3 Overall Engine Visual Inspection Tgnition ..ccseccecscseeeeceesese 126 for Installed Engines in Storage . 1-13 1.1.21 Cocoon Purge on Verification .,., 1-26 1.1.4 Overall Engine Visual Inspection 1,1,22 Thermal Insulation Visual for Installed Engines Prior to Inspection .icccssceescceeeressae 1-26 Stage Shipment to MAF cr MIF ..... l-lh 1,1.23 Overall Engine Visual Inapection 1.L.4A Overall Engine Visual Inspection for Uninstalled Engines Prior to for Installed Engines During Shipment coivcsscccesveccssecsees 1-26 Receiving Inspection at MAF ,..... 1-16 1,1.25 Thrust Chamber Nuzzle Extension 1,1.4B Overall Ungine Visual Inspection Visual Inspection Subsequent to for Installed Engines Prior to Launch Abory co... cece ene ceeeenne = 1-28 Stage Shipment to KSC .....,e008.- L-18 1.1.27 Thrust Chamber Nozzle Extension t.1.5 Overall Engine Visual Inspection Fastener Torque Verification for Installed Engines During Subsequent to Statio Test Abort . 1-28 Receiving Inspection at MIF 1,1.28 Thrust Chamber Drain Plug Bod KSC ,.cccta ee rcceensccnevecene t-21 Torque Verification ...ceeseroene 1-28
1,1.6 Overall Engine Visual Inspection
Subsequent to Engine Static Test 1,2 ELECTRICAL TESTS ... ccs ccesesesee 1-28 and Test Abort ..scccuvecesseeveee 1-23 1.2.1 Flight Instrumercation System
1.1.7 Thrust Chamber Nozzle Extension Function Test for Uninstalled Visual Inspection During EngineS wore recesecvscssatesseeee§ 1-28 Receiving Inspection ,...s.e.000+4 1-25 1.2,2 Flight Instsumentation Syaten
1.1.8 Theust Chamber Nozzle Extension Function Test for Installed Visual Inspection Subsequent to Engines ,.c.aceessesoevereesrenss 1-32
‘Engine Static Test .....c.neeeeees 1-23 1.1.9 Thrust Chamber Tubes Visual Inspection sscscccencsenttcrenteer 1-24
Underlined numbers denote figures, Underlined titles denote primary paragraphs.
Change No. 8 - 3 September 1970 i
Contents
PARAGRAPH TITLE 1,2.4 Turbopiuup Heater Function Test.. 1.2.4 Hyperzol Installed Switch Function Testisssscessreavervens 1,25 Checkont Valve Timing Test...... 1,2.6 Engine Safety Circuita Function Teat at MTF. seca ssc reac ees eunnes 2, Engine Safety Cirendtsa Function Test At KSC... cet cece eee teens 1.2.8 Engine Sequence Verification TPB 0x9 5'sarda a ceceane wee a gna, aioe cd ce Weak 1.2.9 Teniter Test.ccssscuncescacnres : 1,2,10 Tuert Tgniter Test... ceceseeeres 1,2,0t Igniter Harnesa Continuity Test. 1.2,12 Vibration Safety Cutoff Veri~ fication Testicccccccusceevseves 1,2.13 Thrust OK Pressure Switch Function Test,,........ Saierd: Aon tebe 1,8.04% Tyniteyv Harneas Continuity and Insulation Reaistance Test,..... 1.2.15 Checkout Valve Nngine Return Switch Position Verification.... 1,3 LEAK AND FUNCTION THSTS......... e341 Turbopump Torque Test.crcrsceees 1.3.3 Thrust OK Pressure Switch Leak and Function Test......ccesauees 1.3.4 LOX Dome and Gas Generator LOX Injector Purge Leak and Function Teast for Uninstalied Engines.... 1.3.5 LOX Dome and Gas Generator LOX Injector Purge Leak and Function Seg for Inetalled Engines n ereeeovnne ee eee eee seo anreseneese 1.3.5 LOX Dome and Gas Generator LOX Injector Purge Leak and Function Test at MTF and KSC... . cree ees 1.5.6 LOX Pomp Seal Purge Leak ard Function Teast at MAP and K3C.... 1.3.7 LOX Pump Seal Purge Leak and Function Test at MIF... ce cca eee 1.3.8 Cocoon Purge System Leak and Funetion Test at MAF, ...... ‘ 1.3.9 cocoon Purge Syatem Leak and Function Test at KSC........05 1.3.10 Heat Exchanger Helium System Leak Test for Uninstalled Hine gw... cece cence seeeens askerase 1.3.11 Heat Exchanger Helium Systew Leak Test at KSC... cc reassess 1.3.12 Heat Exchanger Helium Syatem Leak Teat at MIP... caver een veee 1.3.13 Heat Exchanger Relium System Leak Test at MAF Subsequent vo StQtie “Tes tes. pein S08 ay enreata’e otal 1.3.14 Heat Exchanger LOX System Leak Test for Uninstalled FEngines.... 1.3.15 Heat Exchanger LOX System Leak Test at KSC...... peaiea Sete telien'd ealaeigiela 1.3.16 Heat Exchanger LOX bysten Leak
Test at MTF
ee ee 2 a
Underlined numbers denote figures. Underlined titles denote primary paragraphs.
ii
Change No. 13 ~ 4 April 1972
R-3896-11
TALE OF CONTENTS
(continued ) PAGE PALAGRAPH TITLE 1-32 1.3.17 Heat Exchanger LOX System Leak Teat at MAF Subsequent to 1-33 Static Tester rsscerececccceaveres 1-33 1.3.19 Hydraulic Control System Leak and Function Test for Uninstalled 1-34 Engine, and Installed Engine at MTF (Prior to Static Test) and 1-34 BG. KSC i gies sce ieee ib G0 0G Seen iS 1.3.19A Hydraulic Control Syatem Leak and 1-34 Function Test at MTF Subsequent 1-34 to Static Teste... cece cence wer eee 1-35 1.3.198 Hydraulic Control Syatem Leak and 1-35 Function Test at MAF Subscquent to Static Tests. cccaccsavacanaae, 1-36 1.3.20 Ignition Moniter Valve Diaphragm Leak Test.. ceccccarrvcsacenenes 1+37 1.3.21 Hypergol Manifold Leak and Function Tests... ccncee scene eens 1-37 1.3.22 Ilgnition Monitor Valve Interflow TOMY cp peste 8 eed eR Hae TG CaO 1-38 1.3.23 Ignition Monitor Valve Shuttle Prensure Tegtisccceeccccceereoene (38 1.3.24 Valve Timing Teat for Unin= 1-38 stalled Engines. .ceeecereancernne 1.3.25 Valve Timing Test for Installed 1-38 PrypeimO der ceccevnecansevrsaccaseca 1.3.20 Fuel Feed System Leak Test for Uninstalled Enginea.... cee races 1-39 1.3.28 Fuel Feed System Leak Test at MIF 1.3.29 Fuel Feed Syatem Leak Test at MA¥ Subsequent to Static Test and at 1-39 WSC iis visas aie latina e606 bv awe ae erase ce Oca 1.3.30 LOX Feed System Leak Teast for Uninstelled Engines. My 1.3.32 LOX Feed System Leak ‘Test ‘at “MIF, 140 1.3.33 LOX Feed System Leak Test at MAP Subsequent to Static Test and at 1-40 MSO es ested tots oer eat eter teh] 1.3.35 Exhaust System Leak Test at MAF., L3.39A Exhaust System Leak Test at KSC,, “41 1.3.38 Turbopunp Bearing Coolant Syxtem Leak and Function Testecs.eeeae ee leo 1.3.39 Throgt Chamber Pneumatic Leak 7 Test for Uningtalted Engines..... 1,3.40 Thrust Chamber Pneumatic Leak pehe Tesi for Installed Engines at a MAR rete ws eee Etech pea e in wets 1-424 1.3.40 Thrust Chamber Pneumatic Leak Test for Installed Engines at 1.-4°R RSG tess cece eas Soe eee eS 1,3.40B Thru: t Chamber Prefill Line Leak and Function Test at MIF.....000. 1-42C 1.3.41 Thrust Chamber Prefill Line Leak and Punctlion Teat.c..... sev eenes 1-43 1.3.4LA Ignition Monitor Valve Poppet Position Verification... ....ceeees l=hh 1.3.42 Thrust Chamber Liquid Lea Test.. 1.3.43 Thrust Chamber Post-Flush Leh Poeumitic Leak Test at KSC... cease
PAGE
bet
15
1—4é
1-;BA 1~48C L=48C 1-49
1-49
PARAGRAPH
1Le4 1.4.1
1.4.2 1.4.3 Lattat
1.4.5
1.5.14 1.5.10
1.5.14 Te5.14A
1.5.15
1.5.16
1.5.17
TITLE
STORAGE PREPARATION. .occecsaees Storage Preparation for Unin- Stalled Pnginesscccacesesecrnes Storage Preparation for Tnstalled Unginessccsescunecnes Storage Preparation for Thrust Chamber Novzle Extension... Storage Preparation for Ordnance... .esecsusarsvesuvncess Storage Preparation for Mis- cellancous Loase Equipment. . eer
SERVICING. .cosccevenvesevecenst LOX Dome and Gas Generator
LOX Injector Plush. ...eaeaeecee LOX Yome Flush. ces ssaaes dias Gererator LOX Injector
aabbeve
Flush, cocconscosccsneccueannec i Thrust Chamber Puel Jacket Flushiscssscscoveceveccoens eves
ingine Residual FI vid
Removal at MIP sie ot bes ase rare ee ea Engine Residual Fluia
Removal at KG sais 105 see ewceews Admitting Fuel to Engine.....e> Admitting Prefill to Mngine,... Admitting LOX to Engine at
MIP 6: osia a: 058 a-acece hese 6-o oie 64s we eere ee Admitting LOX to Engine at
SG ale skavaiaiate coat ayeraxe Riavarei Ora lece Oratelece LOX Feed System Boiloff at
PELE oi 5:06:35 0 a voreceiwsece: witeve-sbieetecevetaoas LOX Feed System Boiloff at
KSC wa. Fuel Feed System Drain ab MTF and KSC Subsequent to Stage Notation to Vertical Position...... Fuel Feed System Drain During Post~Static-Test Securing. cseee Fuel Feed System Drain With Stage Pre-Valves Closetlessacees Gag Generator Combustor THralticscos. csvsccveasnssecesees Thrust Chamber Fuel Jacket Drainsscasecvaconsnseesteaerens Thrust Chamber Fuel Inlet Manifold Draineasceccrvsacceane Thrust Chamber Fuel Inlet Manifold Drain, Post CDDT,..... Turbopump Preservationseressecs
ee oe
ee
Underlined numbers denote figures. Underlined titles denote primary paragraphs.
R-3896-11
TABLE O1
CONTENTS
(continued) PAGL PARAGRAPII 1-70A 1.5,22.1 1-70A
1.5,22,2 1-71 1-73 1.5.25 1-74
1.6 1-74 1.64.1
1.6.2 1-73
1.6.3 1-75 1.0.4 1-78
1.6.5 1-78)
1.6.6 1~78E ;
1.0.7 1-81
1.6.8 1-81 1-82 1.6.10 1-B4A
1.6.12 1-85
1.6.13 1-86
1.6.14 1-87 1.6.15
1.6.16 1-88
1.6.17
1.6.18 1-88 1.6.29 1-89 1.6,20 1-89 1.6.21 1-90 1.6.92 1.90 1.6.23 1-91 1.6.24 1-92 1.6.25 1-9 2A
Contents
TITLE
Turbopump Preservation
(Tngines Not Tncorporating MDUAS Chunge).sccersecscenesenes Turhopunp Preservation
(Mngines Incorporating
MDIAG Change). cncesvceeuseaanne Fuel Feed System Drain Sub. sequent to Static Test Ahorty...
JIANDLING. «2. Bngine Installation at MAP... Thrust Chumber Novzle Extension Installation, .eeuseaae a alidaig ieor as 9S Teniter Harness Tnstatlation,... Thernal Insulation Tnstalla- th ESSER Rie ne eee ee Ergine Dnvironmental Cover Trstal lation. seccessecsscuseceae flypergol Cartridge Weight
ee
CHEEK 3. iss 6aieie W:0b Fe eee ews bee eee Teniter Instatlatian for Stutic Test and Launch... Inert Teniter Tnatallation for Countdown Demonstration Test.... Hypergol Cartridge Tnatalla- tion, se ueesenueueen Kngine Environmental Cover Romovanls caaccancneccnetuvcccenne Expended Hypergol Cartridge Removal .cescccscccsesseceasvesce Expended Igniter Removal. c.seeee Inert Tgniter Removal... Thrust Chamber Nozzle Extension Homoval, cecccscneecsee Tgniter Harness Removal....eeeee Thrust Chamber Throat Security Closure Installation. ..ecees oon Thrust Chamhor Throat Security Closure Removals. sascsceercececes Thrust Chamber Throat Plrvy Tustallation.s .sacsecccucacoaveon Thrust Chamber Throat Plag Removals scecscseessecsecsasarare Turbine Exhaust Exit Pressure Test Fixture Installation. ....+. Turbine Exhaust Exit Pressure Test Fixture Removal, atreeneanate Cover and Closure Tnstallation for Uninstalled Mngines, enoedens Cover and Closure Installation for Installed Fegines...esseseus
seGetseseseas
Oreerarorn
Change No. 13 - 4 April 1972
fil
Contents
PARAGIAPIL
1.0.26
1.0,27
2.1.2.3
ts — ts wi
TITLE
Cover and Closure Removal for Ininstabled Eng@imes...cerceeaen Cover and Closure Remeval for Tngine Installation in Stage... Cover and Closure Iemoval for Tustalled Mugines.....- ee aie ee Horizontal Rngine Removal
OU MAR cc cece rece rsceetereeoene Vertical Mngine Hemovalsc.eeses Vertical Tngine Installation... Thermal Insulation Renoval..o.. Live Teniter Removals .cereenres Live Hypergol Cartridge Itemoval Engine Damage Limitss..e cere nee Thermal Insulation Damage Lamits. ccc sc cc ew enenan ence nesen
SECTION II GENERAL REQUIREMENTS
FLUID INPUT ‘OUTPUT REQUIREMENTS
Purge Requirements, ...eeeeeeeee &
Turbopump LOX Seal Purge
S¥slem Requirements esccereseeee &
Operational HigheLevel LOX
Dome and Gas Generator LOX Injector Purge Systen Requirements, ccc eeeccennaanesas Operational Low-Level LOX
Dome and Gas Generator LOX Injector Purge System
Requirement arcs rcecceseenrneeee &
Cocoon Purge System Requirements eaessccnceerenneene Cocoon Thermal Conditioning Reqd rements cscs cccececeennce aa G2030 LOX Dome and Gas Gener ator LOX Tnjeetor Purge
System Requirements... cece Thrust Chamber Fuel Jacket Purge Systom Requirements... .es . Ilvpergol Servicing Purge
System Requirements... ..e sees 2
Ilvpergol Malfunetion Purge System Requirements. ..cececeane ‘ Igniter Fuct Valve lockup Nequirements....ccc eee eneaeenns Yurbopump Preservation Servic ing Purge System Requirements, .
Heat Exchanger Requirementa.... 2
Neat Exchanger Helium Inlet System Requirements... .csseeves fleat Exchanger Heliun Outlet System Conditions. .ccccsenveens Heat Exchanger GOX Quiput Conditiony.........00- sea eeeeae Oxidiver Feed Requirements..... LOX Pump Inlet Conditions......
"Underlined numbers denote cigures. Underlined titles denote primary paragraphs.
iv Change No. 14 - 9 October 1972
R- 3896-11
1-127
TABLE OF CONTENTS
(rontinued ) PAGE PARAGHAPI 2-3 1-113 a 2.1.5 1-113 eee 2.1.6 1-113 dae? 1b 9.1.48 1-113 1-118 2.1.8.1 1-120 1=120 L-12) 205 1-124 =<
2.1.8.2
2.1.9
2.1.10
ETL, Acceptable Pump Lilet PrOQHUTOR canes cence neereneeeean Fuel Feed Requirements... ..eee Fuel Panp Inlet Conditiens..... Hydraulic Grounl Supply Noqudvemontycccecssaresercesens Prefill Supply Requirements.... Flushing Solvent Supply Requirements ccs eevcecreeaerens LOX Done and Gay Generator
LOX lnjeetor Flushing System Requirements. .......ee. Eater yea (Widiver Dome Flushing Kit
Inet all ation. ccrccecceser sans Thenust Chamber Fuel dacket FJushing Requirementy......eee Preservation Flaid) Supply Requirement ss ceccseccvrcarcrer a Corrosion-Preventive Roquivements.ccccecccssesecvers
ELECTRICAL INPUT REQUIREMENTS , . AC Power Requirements sc... eee DC Power Requirementacesceriees
ENGINE REQUININENTS ON STANDDY, STATUS ccc eee sarc a race nerereaeee Standby Status Definition,..... Preparation of Uninstalted Fngine for Standby Status...... Preparation of Installed Engines for Standby Status.....
ENVTRONMINTAL REQUIREMENTS... 4.
Engine Invironmental Conditions. .ccrcecce raven Sa aha to Nozzle Extengion Environ mental Conditions........00000- Pyrotechnic Tpgnites Nnviron- mental Conditions.....ceeceeeee Pyrotechnic Igniter Storage.... Pyrotechnic [gniter Service
LUPO ccc eee c enter er reer er eennes Pyrotechnic Tgniter Repack- ALAN. ccc eee rce reer ance eee me
Pyrotechnic Igniter Disposal... Hypergol Cartridge REnviron= mental Conditiong....sceraccaae Hypergol Cartridge Storage..... Hypergol Cartridge Service LifOscsrceceeenvves aire ice peiy aus coat Hypergol Cartridge Restoration. Hypergol Cartridge Repack- ABAUMNa cere caccantarececaersrees Hypergol Cartridge Disposal.... Miscellancous Loose Equipment Fnvironmental Conditions.......
2-10 2-10
2-10
2-1LO0A
2-108
2-108
2-1)
R-3896-11 Contenta
Table of Contents
{continued ) PARAGRAPH TITLE PAGR PARAGRAPH TITLE PAGE
2.3.6 Nesiccant Mnvirenmental Condi tionS....ccrccasceereveceee BH1Z
2.3.6.1 Desiccant Storage... .ccceeeeeees 213 2.3.6.2 Desiccant Installation.......555 Qt 2.4 MAINTENANCE HEQUIREMINTS....665. Q-14 2.4.1 Seal Usage... cccscscceneecene Pam1h 2.4.2 Fastener Weegee ce lec: 21% 2h. Fastener Crosa-Torque
Requiromenticcssceccrcueceans sve 2-14 2.4. 3A Damage Dispositiou....... tereves Owl 2.4 Component Removal, Inatalla-
tion, Repair, Modification,
and Inspeetior Conatrainta..... » 2=15 26 Component Replacement, Rein=
stallation, and Adjugtment
Requiromonta. soccer sees neve eoae BATS 2-7 Propellant Duct Fit-Check and ae Alinenment Requirenients......e.e- 2-1 2-8 Tube Alinement Requirements..... 217 Qe MA Component Replacement Hffects
on Ingine Performance at Sea
Level... eeraee etme recess ee raeeae 2=1k8 2-9 Deviations in Engine Perform-
ance Due to Component
Replacements. .cccceeeseecveceees Qa1BA 2.4.5 Lockwire RepIncement.......,+65. 2-20 2.4 6 Cover and Closure Requirement... 2-20 2.4.7 Engine Soft Goods Verification... 2-20 2.4.8 Engine Orifice Verification..... 2=26 2.4.9 Cleanliness Requirement for
External Connections....cceseees 2-21
2.4.10 Syatem Interconnection Constraints..... do eesaneaes avooe 2021 2.4.11 Turbopump Preservation Requirements. ccssecrereeee revere 2-2)
2.4.12 Hardware Attachment Conatraints. 2-21
2.5 OPERATIONAL TEST REQUIREMENTS... 2=22 2.5.1 Safety Requirements When Work~
ing With Thermal Insulation,.... 2-U2 ?,9,.2 Safety Shielding and Safe
Operating Test Pressures....56., 2-22 2-10 Safe Operating Preasure
Requirementa,scrssccarsccerarees 2Q02BZ 2.5.3 Safety Requirements When Work-
ing With Pneumatic and Hydraulic Systema ccccsscseceacseceeverecaer 2923
Underlined numbers denote figures. Underlined titles denote primary paragraphs.
Change No. 14 - 9 October 1972 ivA/ivB
=
t
=
t
>
ic
THE
Safety Requirements When Work= ing With Electrical Systems..... Satety Hequirenents When Working With Solvents. ce... eee Snofety Hequivrementa Cor
Thrust Chambor Untry...... cae pe Safety Heqniremonta Pos Mandling Ignilers and Hyperzol Carteidges... Ground Support Pquipment and Special Tool Requiremonts....... Engine Service Life,. Component Service Life..., Component Cyele Life Limits..... Component Cyele Definition
and Limits...csee. Gimbal Cacle Limitations,....... Gimbal Bearing and Wrap-
Around Line Cyele Limitations... Ingine Chechout Conateaintsa..... Kngine Checkout: Requirements Aftor Stovapowscccceeces Kngine Checkout Requirements After Storage in Accortance With MFPSC-STI-FOO.. cee secre Engine Checkout Requirements After Standby Statugi..ccesseeae Engine Starting Attitude CONStrAINlS srs crccrcserccerreaes Slave Hardware Use During Static Testing of Engine at MNTF......., Gimbal Limit Conatraints....6.., Heat Exchanger Dry-oil Testing CONStPAINES cr career cer rcrenveaee Cocoun Purge Stub Line Static Testing Constraints. cs cscs seaes Firex Constraints... Thermal Tusulation Requirements. Thermal Insulation Installation Requirements Priar to Stage Shipm ntl to KSC.ccveecvcces veces Thermal Tnsulation (ngulator Access DoOrssisccr verre aacncaaes Contre] System Sewuencing and Klectrical Safety Circuit Requirements ..sccreuevccaneveeee Electrical Control System Sequencing and Safety Circuits..
Cavern caenne
Ce
peeetone
ed
Underlined numbers denote figures, Underlined titles denote primary paragraphs.
R-3896-11
TABLE OF CONTENTS (continued)
B=")
2-28A
2-2HA
2650 2-30
2-30 2-})
2-30 2=30
PARAGIAPH
271A
2.5.19 J-1?
2-18
eld pol)
2-0
2.6.4.2 2.04.3 2.0.4.4
2.7
Contents
TUL: PAGE Flight Instrumentation System Voltage Limits csc cceee reece rees STO Instrumentation Requirements..., 230A Static Test Instrumentation Category ROquirement sos cceeeeeee Ua 5O Static Teast Operating Redline Tnstramentalion Requirements.... 0 2-h5 Launch Toa trumentation Category Requirements. .cceccnes Uet& Launeh Operating Redline [nv trasentation Requirement4..,. 28352 Detormioing Acceptability of Wetted Surface Leakage cies. eceees 35 Fuel Overboard Drain System Tyolation Requirements. cer rece e ee 2835 Fue) Peed Sy4tem Drain Tequire- MONUD. core cee teen reer eee Sabeusiete 2-30 Uninstalted Digine, Vertical Toma tions csccuevcnceccnes peeeeee 250 [nstalled Engine, Vertical Position....... Parad ewes cae ieee “2SSOA, Invtalled Engine, Horizontal POMTCTON cece eee e er ee rere eases LOA ENGINE REQUIREMENTS AFTER A LIGHTNING STRIKB. ccc eee eee eee) OMRON Instrumentation Monitored and No Data Anomalies Noted During Lightning Strikes..... vessaasaas S@30A Instrumentation Not Monitored or Tust'umentation Monitored and Data Anomalies Noted During Lightning Strikes. sceceeeeeer ees Le FHA DOCUMENTATION REQUIREMENTS...... 2-361 Engine Log Rook Kntries,......-. 2=FH)} Unsatisfactory Condition Report Submittals sscccssecereees 253560 Chechoul Dalacsscccccecceceeeees 2-368 Static and Blight Teast Data..... 2-30C Ingine Redline Parametore....... S506 Test Lustramentation..sceereeee. 2300 Data Roduetionscesccsrccseeeesas 29300 Data Interval Definition........ 2-360 APPLICADLE SPECEFICATIONS....... 25% Change No. 14 - 9 October 1972 v
Contents
PARA GRAPTL TITLE:
SECTION TIT OPERATING PROCEDURES
INSPECTIONS . ccc ce ec cee nn eeanes Variable Ovifiee Inspection ,.. Oldeat Assembly/Tnstallation
Date Tnspection vececscecnrccce
PREVINTTON vi cee csv ecae de eeeeus
Alternate Protective Closure a for Enmine Lines ceseeeeeeccrar
MAIERTAIS woceceescvsneveces ene
UNTNSTALLED-ENGINGE TLST PROCEDURES cece eee e eee ee anwae Proparing Engine anil | nine Checkout Console For Test cence Ingine to Engine Checkant Console Teat Setup Cable DIAGRAM coor ccceecctoesrevcacee Mngine Connect Points for Tonting...... Re ee CT Bleetrical Tests for Unin- adalled Engines... sccr seve enaae Primary Flight Instrumentation Schematic... ccc cee ence eee eene Auxiliary Flight Instrumoenta~ tion Schematic (Engines Not Incorporating MDI Change)? Hleetrieal Control Schematic. Flight Instrumentation system Function Test.asss ese) 9 606: Oi wig wien ar Turbopump Heater Function Test. Uypergol Installed Switch Function Teatsscsrscceenree acini Checkout Valve Timing Test..... Leak and Funetion Test Proce dures for Uninatalled Nnginea.. Flnid Control Schematic........ Fluid Purge and Drain Schematic Seal Monitoring Port Plug Requirements. .cscccaseseeaseers Turlbopump Torque Teat.....seae- Thrust OK Pressure Switches Leak and Function Test.....200- LOX Pump Seal Purge Leak and Function Teat..... aceratacesdaetecdceai® Neat Exchanger Helium System Leak Testscrccrecscucnsvcseseer Heat Exchanger LOX System Leak
POG G.cic Soca twee aeiece. ee ee ae ee eT
R-3896-11
TAAL OF CONTENTS (continied) PAGE PARAGILAPH TITLI: 3.2.3.7 Ilvpergol Manifold Leak and Funetion Test cesccerecsvescee
3.2.3.8 Ilydraulic Control System Leak
3-1 and Funetion Toat wis eeeeesees
3-1 3.9.3.9 Tpnition Monitor Valve Shittle
Yresqure Teste sceececounanae
Ignition Monitor Valve Diaphragm
Leak Teatrccsesncccccunnetevvas
Underlined numbers denote figures. Underlined titles denote primary paragraphs,
vi Change No. 14 - 9 October J972
3-2 3.2.3.10 Tpnition Monitor Valve Tntor- flow Test scacccccsncevvenrecs 3.2.3.1] Valve Timing Teat.....ee. eee 4-2 3.2.3.12 Fuel Feed System Leak Test.... 3.2.3.13 LOX Feed System Lenk Test...., creer 3.2.3.th Evhaust System Leak Test...... 3.2.3.15 LOX Dome and Gas Generator 3-21 LOX Ingector Porge Leak and Funetion Test. c cca. cca eee e eae 3.2.3.16 Turbopump Bearing Coolant 4-21} System Leak and Funetion Test. 3.2.3.17 Thrust Chamber Pneumatic Leak 3-2F Teat..caee Se aca ele eared 3.8.4 Tsulation Test “‘Dpacaduran for Uninstalled Fngines.,......... 3-26 3.2.4.1 LOX Pump Seal Taolation Test., 3.2.4.2 Fuel Overboard Drain Line 3-4 Isolation Test........00. 3.2.4.3 Checkout Valve Iselation ak Bah Toatbrccrssveecsstversacvecneen 3.0,4.4 (as Generator Puel Feed Sys~ 3-7 tum Isolation Leak Test...... ‘ 5.2.4.5 Puel Valves Skirt and Nose Seal Isolation Leak Test...... 3-38 3.2.4.6 Gas Generator LOX Feed System 3-9 Isvlation Leak Test....ccseuee 3.2.4.7 Oxidizer Valves Skirt and Jot Nose Seal Isolation Teak Test. 3a 3.2.4.8 Oxidizer Dome Purge Check 7 Valve Isolation Leak Test.... ~h $a5 3.3 INSTALLED-ENG INE TEST PROCEDURES... . - Pi cued carbs enn lice Jar bsene 3-10 3.3.1 Nleetrical Teats for Installed 5-1 Ini EDCGeick eves pacwawesw sere ee $n12 3.3.1.1 Plight Instromentation Syatem Fonction Test. .cccsceaeesecuae Fa1's 3.3.1.2 Turbopump Heater Function Test 3-10 3.3.1.3 Rypergol Installed Switch Function Test..ccseeseercneres 3-10 3.3.1.4 Checkout Valve Timing Test.... 3.3.1.5 Safety Circuits Function Test. 3-16 3.3.1.6 Engine Sequence Verification YO: ne ee RC aPC eC er ee Ba 3-17 3.3.1.7 IRgniter Lest. .cccccceecereenes 3.3.1.8 Inert Igniter Test.csccarensen 3-18 3-19
PAG
5-208 3-22 ren)
3-27 BrURA 3-30 PHAN 3-37
3-56 3-38 Be58A
PARAGRAPH TITLE 3.3.1.9 Vibration Safety Cutoff Veri-
3.3.1.10
3.3.1.11
4.3.2.8
343.2,5A
3.3.2.8B
3.3.2,15
fication Teat cessccecencaunece Thrust OK Pressure Switch Function Test cacccsscesrevcees Tgniter Harness Continnity and Insulation Resistance Test wove Leak and Funetion Testa for Tnstalled Engines wsscee ene eune Turbopump Torque Test cesereres LOX Pump Seal Purge Leak and Function Test eeeerenreretenteoe Cocoon Purge Leak and Function Test Sco rome secs er seenneneetonre Heat Exchanger Helium System Tonk Test sccasccsnseracroenece Heat Exchanger LOX System Leak Toatsaccssecocsnccsasnscccensere Tgnition Monitor Valve Dia- phragm Leak Test..ssccscsavecns Hypergol Manifold Leak and Function Tentsrcorsvccerocsteses Hydraulic Control System Leak and Function Test at MTF (Prior to Static Test} and at KSC...6- Hydraulic Control System Leak and Function Test at MTF Sub- sequent to Static Test..ocsoees Hydraulic Control System Leak and Function Test at MAF cases Valve Timing Terbessccssesesers Fuel Feed System Leak Test,.... LOX Feed System Leak Teateceess ixhaust System Leak Testesscare Turhopump Bearing Coolant Sys- tem beak and Function Test...s. Thrust Chamber Pneumatic Leak TGS b cada certs teste eee e-waste ee’ Thrust Chamher Prefill Line Leak Tents recccsessceccassenece LOX Dome and Gas Generutor LOX Injector Purge Leak and Function Testrsccacccsssesseeee Thrust Chamber Liquid Leak Test Tgnition Monitor Valve Poppet Position Verification Test..... Isolation Tests for Installed ENZinedsssessecsvccnvsvssessece LOX Pump Seal Isolation Test... Fuel Overboard Drain Line Isolation Test. .acorveesescense Prefill Check Valve Isolation Teths sassevrcasvcacvccenssesoer Oxidizer Dome Purge Check Valve Tsolation Leak Tent. rcccscessre
Underlined numbers denote figures. Underlined titles denote primary paragraphs.
R-3896-11 Contents
TABLE OF CONTENTS
(continued)
PAGE PARAGRAPH TITLE PAGE a) STORAGE PREPARATION ...ccce rere 3-92 3~59 : 305 SERVICING ccccceereeereeectceces I-92 3-62 3.9.1 LOX Dome and Gas Generator LOX Injector Flush csccccsererecsees 92 3-62 3-9 Lubricating Uypergol Manifold OCG, Hives eerie trea ee cececceviene 1295 3-63 3.3.1.1) Ovxidivzer Dome Flushing Kit Tn- 3-63 atallation for LOX Dome and Gas Generator LOX Tnjector Flush ... 3-95 3-63 3-10 Oxidizer Dome Flushing Kit Manifold Bracket Installation .. 3-94 3-63 3.5.1.2 Onidizer Dome Flushing Kit Itemoval for LOX Dome and (ias 3-64 Generator LON Injector Flush ... 3-97 3.59.2 TOX Dome Flush pu eeeennerersoret 5297 3.65 3.5.0.1 Ovidiver Dome Flushing Kit [n- stallation for LOX Dome Flush ,. 3-99 3-H6A 3.5.2.2 Ovidizer Dome Flushing Kit Nemoval for LOX Dome Flush p60. 3-101 3-67 4.563 (fas Genevator LOX Injector Flush 3-101 3.5.3.1 Oxidizer Dome Flushing Kit Tne
stallation for Gas Cenerator 3469 LOX Injector Flush oom eet ao ranes 3-103 3.5.3.2 Oxidizer Dome Flushing Kit Removal for Gas Generator LOX
3-74 Injector Flush PREC o meee eenee 5-104 3.5.4 Thrust Chamber Fuel Jacket Flush %3-104A 5a7h 3.544 Thrust Chamber Post-Flush Pneu- 3=74D matic Leak Test at KSC ..cseee5e 3-106 3-75 3.5.5 Engine Residual Fluid Removal .. 3-104B 3-76A 3.5.6 Admitting Prefill to Engine .... 3-106B 3-79 3.5.7 Admitting Fuel to Engine .....5. 3-106C 3.5.8 Admitting LOX to Engine...escse. 3-108 3-81 3.5.9 Ignition Monitor Valve Sense Line Drain. ccsesescescaseveesese 3-108 3-89 3.5.10 Residual Fuel Drainsesecscsseaee 3-108 3-11 Fuel Drain Vent Adapter Instal- z Labionssaccccnsevcesccecssercess J-108 3nBS 3.51 Fuel Feed System Drainsssseseeee 3-109 3.5.12 Gus Generator Combustar Drain... 3-111 3.3.13 Thrust Chamber Fuel Jacket Drain 3-111 3-86 5.5.14 Thrust Chamber Fuel Inlet 3.86 Manifold Drainsaccsaccsccsenrans 3-112 ray 3.5.15 . Turbopump Preservation, ,vseceees 3-113 3.5.15.1 Turbopump Preservation lingine 3-88 Not Tncorporating MD1LA5 change): 5-113 3.5.15.2 Turbopump Preservation (Engines 3-8BA S-11A incor pera ae MDLAS Sia 3-114 - Jonnecting Scavenge Pu 3~88A bas Sere seamen SK aa, mo 7 3.5.16 Loosening and Securing Insu- 5-89 lator LAS5LO, cccreceuvesanccasons 3-115 3-91 3.6 HANDING. weacevucenccsecncsseees SHLLS 3.6.1 Engine Installation. ccascosseses 3-115 3-91 3-12 Gimbal Bearing Lock installation 3-116 5,0,2 Thrust Chamber Nozzle Extension
Installation, cicsccssccecstsenne 3~117
Change No. 13 - 4 April 1972 viA
Contents
PAAGRAPIE
3.0.8.1
3.0.7
3.0.4 3.6,9 3.6,10 3.0,10A 3-16-1 5.0,10A,1
3.6, 10A,2 3.6,10A,3 3,6, 10A.4 3.6, 10A.5 3.6, 3.6.10 3,.6.12.1 3.59.15 3.6.12.3 3.6.13 3.6.14 3.6.15 3.6.16 3.0.17 3.6.18 3.6.19 3.6.20 %,6.20A 3.6.21 3.6.21.1 3.6.21.2
TARLE OF CONTINTS (continued)
TITLE
Oxidizer Overboard Drain Line and Nitrogen Overboard Drain Vine Tnatallatiou.sccecoe ceene Fuel Overboard Drain Line Tustalladion sescscscerecucanes Igniter Harness Installation .. Ipeniter Harness Removal .....6. Fagine Environmental Cover Trnstal lation ccsccccnsccacceees [Ingine Environmental Cover Removal ..... 26 'eleru aia ire meth e a ewes Phernal Tnsntation Installation Ard Removal secccescvessseveces Tyniter Tnatallation ...cceeee, Live Igniter Removal .....0. Sala Expended Tyniter Removal oe... Hypergol Cartridge Servicing ., Hyperyot Cartridge Packing .. Uvypergol Cartridze Renoval
From Container ...ancecsneeaees Hypergol Cartridge Inspection , Hypergol Cartridge Restoration. Uvypergol Cartridge Weight Chock Iypergol Cartridge Repackaging, Iypergol Cartridge Installation Hypergol Cartridge Removal .,.. Live Hypergol Cartridge Removal When Danaye is Stspeeted ....., Live Hypergol Cartridge Removal When No Damage is Suapected.... Expended Hypergel] Cartridge Removal secures ecaceeceereace Fi Thrust Chamber Throat Security Closure Installation ....eeeees Thrust Chamber Throat Security Closure Removal ...eceseeeeerae Theust Chamber Throat Plug Tnstallation ...ce acces ate cnee Thrust Chamber Throat lug Removal .ecevecccanvecsevesecne Turbine Exhaust Exit Preasare Teast Fixture installation ..... Turbine Exhaust Exit Pressure Teast Tixture Removal .ececeases Interface Panel Access Door Removal .cscrccncearectanaceicn
Interface Panel Access Door Installation .ccsccassseneeeees Fuel Inlet Elbow Tnsulation Boot Installation ....cececcees Thrust Chamber Nozzle Extension Removal ...... stew cece Fuel Overboard Drain “hine Removal eee ere eer eee eee eee eee Oxidizer Overboard Drain Line and Nitrogen Overboard Drain Line Removal ..cceccce tev ec nes
Underlined numbers denote figures. Underlined titles denote paragraphs,
vi3
Change No, 13 -4 April 1972
R-3896-11
PAGE
!
3-128 3-129 3-129 3-170 3-130 3+150
4-130 4~150
Fo 130A
=a
we wl tid WA
NISIND wing spsteer su
TITLE
Fngine Retioval escesscaseencen Horizontal Pugine Removal ..... Vertical Engine Removal ,.e.ee. Fuel Overboard Ovain System THatabion ccc r cerns cee c ance eane lreparing Drnin System Por
THol ation .icccuveserevarcevecs
Netermining Inspection Intervals
of Drain System Tsolation Bags. Securing Drain System From Tsolution ...enees sear Drain Syston solotion. Nag Thstaltation trepteat)
@wetener
Preparing and Securing Ovxidiszer
and Nitrogen Overboard Drain Lines for Rotating Stage to Horizontal Position .o.ecsences
Preparing Oxidizer and Nitrogen Overboard Drain Lines for Rotat-
ing Stage to Horizontal
ost tion secasesacasecesan-s Seeuvingy Oxidizer ant Nit open Overloard Drain Lines .. ceeees
MAINTATNING INGENT) LOG BOOK... PULPOSO oreeccerccaccenecerenes Sonree Documentation wo... eeees When to Update Log Book ......5 How to Update Log Book ..cseee, AlDreviltiond vaocaveeccarsceees Definition of Terms wisssssoees Identifying Vehicle, Orpaniza- tion, and Location co. cecaeenes Entering Dates ..cace cen eaeeeas Rounding-OFf Parameter Valucs,. Verifying Log Book Entries (og Book Audit) ..... Deleting Log Book Enirics Mide in Lrror ..caeaeeneeennees Indicating Obsolete bet Book Iintries ...cae, beeaes Tnserting Additional or New Log Book Forms .scuccsnescovaes Ratering Tnspection Saka OY SUaMpt vervcesseeeverarceees Transferring Log Book .aveveees Log Book Forms That Require Post-Delivery Maintenance ....- How to Determine Log Book Entry Requirements ci. senceeens Mininum Log Book Entry Requirements ceressecscereeenes Primary Instrumentation System Road Map sicsesassrecseusecrace Component Test Record we.aevees Post-Delivery lerformance Uncertainty CCOVd .asesesneces Engine Weight Record .....eeece Engine Test Recor cessveneeres Configuration Hecord ..... Delivered Serialized Component, Record ocnet erase eeeseeovavraeavas igid-Duct Spacer Dimensions Engines Not Incorporating MD137 Change) .ecccecescaceuees
aeeambnean
PAGE
43-1404 FaT ZO 5-151 5-132 3-132 3-1) 320 5-1392C 35-152
3-132)
3-1352D 3-232)
3-133 3-133
BeLB S-19% Br 1 3o1 54
3-754 3-194
3-154 5n155 3-136
3-73? 5-158 3-139 3-140 3-141 3=142
Beal NF
3m 1A
OTCNs
TABLE OF CONTENTS
TITLE
Rigid-Duct Spacer Dimensions (Engines Incorporating MD1L37 Change) Post-Delivery Serialized Com- Ponent Replacement Hecord .-.. Post-De.ivery Flight Instru~ tentution Pressure Tranaducer Replacement Record ..eees-eree Delivered Orifice Record ..... Post-Delivery Orifice Replace- ment Record ...cecee eas eresens Cperational Pata (Heat Exchanger Yerformance Summary) Post-Delivery Component Cycle Record wice Discrepancy Record .....4. Tnapectiun Record ...seeececoe Turbopump Preservation Reanrd, Age Control Log for Component Synthetic Rubber Itens....0655 Loose-Equipment Plight Installation Record Transfer Record ..esecccceenes
terete ameter wmetawantasee
ery
see eaveveas
APPENDIX
ee ee
Underjdined numbers denote figures, Wnderlined titles denote paragraphs,
PAGE
R-3896-11
continued)
Ba1U45
3-146
5-148 5-1AB
53-1484 3~148B 5-150 52152 5-153 5-154 3-155
3-156 3=158
A-1
PARAGRAPH
Contents
Change No, 13 - 4 April 1972
PAGE
yiC
R-3896-11
LIST OF ILLUSTRATIONS
lilustrationa FIGUI TITLE 1 ECP Approval Haseline.....cescenees 2 Index of OICN Changes... ,ccrereneen 3 Fngine Baseline MD Configuration... N ¥-1 Rocket ORE RS Semis et e ek se se 9 MD Syatem....sereeee be dia bea wh eras i-] Scheduled Authorized "Field AOtivitiess cc cere cece reese eeeee 1-2 Nonscheduled Authorized Field Activitiog...... Gienelese Wea santa Ce sace 1-3 Engine Damage Limits..............- 1-4 Thermal Insulation Damage Limits... 2-1 Cocoon Thermal Conditioning Requirements... ccc e eee eenet encase 2-2 LOX Pump Inlet Conditions..,......- 2-3 Acceptable Pump Inlet Pressures.... 2m— Fuel Pump Inlet Conditiona......... 2~5 Oxidizer Dome Plushing Kit UnStal lation... cccccuverecersavvreaer 2 Component Replacement, Reinstalla- tion, and Adjustment Requirements... 2-7 Propellant Duct Fit-Cheek and Alinoment Requircoments.....seeesaes 2+8 Tube Alinement Requirements.......- 2-9 Deviations in Engine Performance Due to Component Replacement....... 2-10 Safe Operating Pressure Require- [cts 6 a a 2-1) Component Cycle Definition and Limita........ : ala celeistWy ere eat eo aie-ete Z-i2 Gimbal Hearing and Wrap-Araund Line Cycle Limitations ...-. sss eeaee -13 Engine Checkout Requirementa After Storage in Accordance With MSPC-STD-300. . ccc erecta rece raanes 2-13A [ngine Checkout Requirements After Standby Statug....-. cca e sence ceeee 2-14 Thermal Insulation Inatallation Requirements Prior to Stage Shipment to KSC... cceecacccnecaneen 2-15 Thermal Inaulation Inanulator Acceas DOOTK sci cesccnareusocravtecreasnsar 2-16 Electrical Control Syatem Sequenc=- ing and Safety Circuita..cccccreces 2-16A Flight Inatrumentation System Voltage Limite... scceerrccereanecas 2-17) Static Teat Instrumentation Category Requirements... ..escerees 2-18 Static Teat Qperating Redline Tnatrumentation Requirements....... “19 Launch Instrumentation Category Requirementa,...ceeccereaaresescens 2-20 Launch Operating Redline Instrumentation Requirementa....... 3-Al ss Alternate Protective Closures for Engine Lined eseesre reset eeeuns 3-A2 Materials Specified in Thia Manual . 3-1 Engine to Engine Checkout Co isole Test Setup Cable Déaygram...csee cee viD Change No. 14 - 9 October 1972
viii x
xi xiv
PIGURE
3-2 3-3
3a)
TITLE
Engine Connect Points for Testing. Primary Plight Instromentation Schematicscaccrneseneceuererrceces Auxiliary Flight Instrnmentation Schematic (Engines Not Incorpo- rating MD9G Change)..... we Blectrical Control Schemat‘2...... Fluid Control Schematic...... ae aa Fiuid Purge and Drain Schematic... Seal Monitoring Port Requirements. Lubricating Hypergol Manifold Bore Oxidizer Dome Flushing Kit Manifold Hracket Installation.... Fuel Drain Vent aeapye® Installation. .....eeee bts Sd ile Connecting Scavenge Pump 42039 to Engine. cca sear acaae sae eens Loosening and Securing Insulator TAG5LOW cas Gimbal Bearing Locks “Installation, Nozzle Extension Installation..... Overboard Drain Line Installation. Igniter Harness Jnstailation...... Engine Environmental Cover TInatatlation.......... Hypergol Cartridge Packaging..... Hypergol] Cartridge Reatoration.... Fue] Inlet Elbow Insulation Boot Installation........-. Sealers a9 arate entre Drain System Isolation Bag Installation (Typical),.......2085 Minimom Log Hook Entry
eeeerace
pee eres er
eT
Requirements... ce eee eens seueee Vrimary Inatrumenta':on Syatem Road Maps. .ccaccscccnetennseersten
Component Test Record.,«ss.as. Post-Dolivery Performance Uncertainty Record....... Engine Weight Record,. Engine Test Record... Configuration Record..ss.ae Delivered Serialized Component Record. srccsrsascncves BREE Reals ative Rigid=Duct Spacer Dimensions (Ingines Not Incorporating
MD137 Change ).... Riyid-Duct Spacer Dimensions . (Engines Incorporating MDL37 Change ) PE a re oekgnthe cétatare arate Beart Post-Delivery Serialized Compo- nent Replacement Recordssssceereus Poat-Delivery Plight Instrumen= tation Pressure Transducer Replacement Record... Delivered Orifice Record..... Post-Delivery Orifice Replace~ ment Record,.....0. o Operational Pata (Heat Exchanger Performance Summary)..ccereereeees
eee e naan
tervrrerataee
oe
aenanene
eeu wrae
soereeeon we
PAGE
3-3 4~6 3-8 3~9 3-1} 3-12 3-14 3-95 3-94 3~108 BeLIGA 3-115 3~116 3-118 3-120 3-12) 3-123 3-12hA 35-1248 3-150 3-1 520 3-146
3-137 3-158
3-139 5-180 3-14) 3-142
3-143
3~1454
3145 3-146 3-148 3-148 S-1NBA
3~-148B
R-3896-11 Mliustrations
LIST OF ILLUSTRATIONS (continued )
FIGURE TITLE PAGE FIGURE: TITLE PAGE_
3-3i Post-Delivery Component
Cycle Record... cceseseecesececenee 350 3-32 Niscrepancy Record...,..ccceereeeee IMLGZ 3-33 Inapection Record. ...escveereeree Bel ZF 3-34 Turbopump Preservation Record..... 53-15% 3-35 Age Control Log for
Component Synthetic Rubber Itema,., 3-155 3-36 «Lovse-Fquipment Fiight
Installation Record........::- eeee 5156 3-37 Transfer Record,......eeae: Haletetes 3-158
Change No, 13 - 4 April 1972 vIE/ViF
R- 3896-11
Introduction
INTRODUCTION
SCOPE. This manual contains operating re- quirements and recommended procedures to support these requirements, for the F-1 Rocket Engine, Part Number 104001, Serial Numbers F.2029 through F~2098, designed and manufac- tured by Roc’etdyre, a division of North American Rockwell Corporation, 6633 Canoga Avenue, Canoga Park, California 91304.
1, OUTLINE OF ENGINE OPERATING IN- STRUCTIONS INFORMATION,
Operating and General Requirements,
Section 1, Operating Requirements, and section II, General Requirements, provide ali the spe- cific and general requirements for the activities to be performed, acceptability criteria for these activities, limits, special constraints, safety precautions, and sequences required to satis- factorily accomplish the activities. Sections I and II represent requirements that have been agreed to by NASA, the Stage Contractor, and the Engine Contractor. Changes to these sec- tions are Class I type changes and are subject to contractual approval. Exceptions to the re- quirements, limits and constraints specified in sections I and IT require the approval of NASA.
Operating Procedures.
Section III outlines the procedures recommended by the Engine Contractor to satisfy the require- ments of sections I and Il most effectively. Where applicable, maintenance and repair type manuals are referenced to avoid duplications of existing field procedures for maintenance and repair, routine handling, and engine buildup.
2. ENGINE OPERATING INSTRUCTIONS (EOI) CONTROL AND REVISION SYSTEM.
Section I and II Control and Revision.
Changes to sections I and II of this manual are Class I by definition and require an Engineering Change Proposal (ECP), approved by NASA change order, before such changes can be in- corporated into the manual. When the need for a change occurs, a Preliminary Operating In- struction Change Notice (POICN) is submitted with the engine hardware ECP or by separate ECP, as applicable, to NASA for coordination with the Stage Contractor and subsequent ap- proval. NASA approve} of the ECP and POICN authorizes release of an Operating Instruction
Change Notice (OICN) to all manual holders. Revisions or changes to sections I and II will be made periodically to incorporate outstanding OICNs into the manual. When a Class I change to section I or I] affects the information in sec- tion IJ, the section IL{f changes will also appear on the OICN, when practicable, to ensure con- currency between all sections of the manual.
Section III Control and Revision.
Changes to section III of this manual are Class Il by definition. Changes to section III that are not concurrently released with an OICN change to sections I or I], will be issued, as required, by revision, change, or if urgency demands, by a noncontractually approved OICN, to update the data or convey new methods that develop through field or factory experience. Revisions, changes, and OICNs applicable to section III will be sub- mitted to the Resident NASA Quality Control Office for acceptance in accordance with estab- lished contractual requirements.
Index of OICN Changes.
This manual incorporates engine operating requirements for the ECPs and corresponding engine MD number, listed in figure 1, that were contractually approved as of 1 April 1969. These ECPs form the approval baseline for sections I and IJ. The index of OICN changes, figure 2, reflects the ECP/OICN changes that were
issued after the initial release of this manual, The index of OICN changes includes the approved ECP number that authorizes the incorporation
of an OICN, the related engine MD number (if applicable), the OICN number and date, and the pages affected by the change. Upon receipt of an OICN, make an appropriate reference to the OICN in the margin next to the data changed. In figure 2, enter the ECP and engine MD number (if applicable), OICN number and date, and the affected pages. File all OICNs in the Appendix to this manual.
Engine Baseline Configuration. Figure 3 rep- resents the engine baseline wonfiguration for requirements and procedures included in this manual. The manual is coded for engines in- corporating or not incurporating, as applicable, MD configurations that are different from the baseline model.
Change No, 2 ~ 14 May 1969 vii
Introduction R-3896-11
Approved Engine Approved Approved Engine Approved
ECP No. MDNo. ECP No. ECP No. MD No. ECP No. MD No, Fi-38 37 F1-62 Fi-80 7 F1-100 7 Fi-38R1 a F1-64 7 F1-82 18 F1-101 8 Fi-39 11 F1-65 7 F1-85 7 F1-106 7 F1-40 F1-67 10 F1-86 7 F1-108 7 F1-42 7 F1-69 7 F1-90 7 Fi-124 7 F1-45 7 F1-71 9 Fi1-91 7 F1i-129 8 F1-56 7 F1-74 7 F1-95 7 F1-129R1
F1-57 7 F1-76 24 F1-97 7 F1-131 7 Fi-59 7 F1-76R1 F1-98 20 F1-132 7 F1-60 16 Fi-78 F1~-99 14 F1-135 7
Figure 1, ECP Approval Biseline (Sheet 1 of 3)
vill Change No. 2 - 14 May 1969
Approved ECP Ne.
F1~-143 F1-143R1 F1-146 F1-147 F1-149 F1-153 F1-154 F1-165 F1-165R1 F1-166 F1-168 F1-169 F1-172 Fi-174 F1-174R1 F1-176 F1-180 F1-182 F1-185 F1-185R1 F1-188 F1-188R1 F1-189 Ft-101 F1-192 Fj-192Ri F1-192R2 F1-193 F1-193R1 Fi1-194 F1-195 Ft-196 F1-197 F1-198 F1-198R1 F1-202 F1-206 F1-206R1 F1-206R2 F1-208 F1-208R1 F1-208R2 Fi-214 F'1-214R1 F1-216 F1-216R1 F1-217 F1-226 F1-228 F1-229 F1-229R1 Fi1-233 F1-235
ee
Approved ECP No,
F 1-236 F1-241 F1-242 FI-244 F1-251 F1-253 F1-254 F1-255 F1-2£9 F1-258R1 F1-258R2 F1-260 F1-260R1 F1-260R2 F1-261 F 1-262 F1-263 F1-267 F1-268 F1-268R1 F1-269 F1-270 F1-270R1 F1-270R2 F1-274 F1-276 F1-277 F1-278 F1-279 F1-279R1 F1+282 Fi-283 F'1-283R1 F1-283R2 Fi-285 F1-285R1 F1-287 F1-288 F1-289 F1-289R1 F1-289R2 F1-294 F1-294R1 F1-294R2 F1-303 F1-303R1 F1-304 F1-304R1 F1-305 F1-305R1 F1-306 F1-306R1 F1-306R2
Figure 1,
R-3896-11
Engine MD No.
Approved ECP No.
F1-307 F1-307R1 F1-308 F1-309
F1-310
F1-311 F1-311R1 F1-312 F1-312R1 F1-312R2 F1-312R3 F1-313 F1-313R1 F1-314 F4-315 F1-315R1 F1-315R2 F1-316 F1-317 F1-219 F1-320 F1-320R1 F1-321 F1-323
F1-323R1 F1-323R2 F1-323R3 Fi-324 F1-324R1 P1-326
I'i-328 F1-928R1 F1-331 F1-332 F1-333 F 1-335 F1-342 F1-343 F1-347 F1-352 F1-352R1 F1-353 F1-356 F1-357 F1-358 F1-360 F1-361 F1-362 F1-369
ECP Approval Baseline (Sheet 2 of 3)
Approved
ECP No,
F1-370 F1-370R1 F1-370R2 F1-370R3 F1-371 F1-372 F1-372R1 F1-372R2 F1-373 F1-378 F1-378R1 F1-378R2 F1-378R2 F1-279 F1-379R1 F1-379R2 F1-380 F1-381 F1-391 F1-391R1 F1-392 F1-392R1 F1-392R2 F1-405 F1-405R1 F1-405R2 F1-406 F1-407 F1-407R1 F1-406 F1-408R1 F1-409 F1-410 Fi-410R1 F1-415 F1-416 F1-416R1 F1-417 F1-418 F1-4i8R1 F1-419 F1-419R1 F1-420 F1-420R1 F1-421 F1-421R1 F1-422 F1-422R1 F1-423 F1-423R1 F1-424 F1-424R1 F1-426
Change No. 2 - 14 May 1969
Introduction
viliA/ViliB
R-3896-11 Introduction
Approved Engine Approved Engine Approved Engine Approved Engine
ECP No. MD No. ECP No. MD No. ECP No. MD No. ECP No. MD No. F1-426R1 F1-449 127 F1-500R1 F1-548 160 F1-427 111 F1-449R1 F1-502 148 F1-548R1
F1-427R1 a F1-452 126 F1-504 141 F1-552 170 F1-427R2 F1-452R) F1-504R1 F1-552R1
F1-428 BT F1-453 123 F1-505 161 F1-552R2
F1-428R1 F1-454 Ti8 F1-505Ri F1-568 N/A F1-430 112 F1-454Ri F1-506 159 F1+570 N/A F1-431 737 Fi-454R2 F1-507 F1-574 N/A F1-431R1 ~~ F1-456 124 F1--509 143 F1-578
F1-431R2 F1-456R1 ter Fi-510 152 K1-578R1
F1-432 125 F1-457 136 F1-510R1 F1-579 N/A F1-432R1 F1-459 130 F1-511 146 F1-580
F1-432R2 F1-464 N7A F1-511R1 F1-581 167, 168 F1-434 121 F1-467 F 1-512 177 F1-581R1
F1-434R1 F1-467R1 F1-512R1 Ts 9 F1-581l2
F1-4236 123 F1-468 128 F1-515 147 F1-581R3
F1-437 115 F1-470 140 F1-515R1 F1-581R4
F1-437R1 = F1-470R1 Ot F1-521 154 F1-586
F1-437R2 F1-470R2 F1-521R1 N7A F1-587
F1-437R3 F1-471 F1-521R2 F1-590
F1-438 131 F1-475 N/A F1-521R3 F1-590R1
F1-439 146 F1-475R1 F1-522 N/A F1-591 172 F1-439R1 aa F1-475R2 1-523 N/A F1-594
F1-441 140 F1-476 135 F1-524 153 F1-594R1
F1-441R1 F1-476R1 F1-525 157, 158 F1-596 174 F1-441R2 F1-478 137 F1-525R1 F1-597 Ti5 F1-443 129 F1-478R1 F1-526 156 F1-601
F1-444 139 F1-478R2 F1-526R1 F1-602 178 F1-444R1 F1-480 132 F1-530 162, 163
F1-444R2 F1-480R1 F1-530R1
F1-445 122 F1-482 142 F1-530R2
F1-445R1 aa F1-482R1 142 F1-530R2
F1-447 138 F1-495 14 F1-535 N/A
F1-447R1 3 F1-495R1 F1-543 165
F1-447R2 F1-498 145 F1-543R1
F1-448 149 F1-499 137 ¥1-545 154
F1-448R i F1-499R1 F1-546 N/A
F1-448R2 F1-500 150,151 F1-547 169
t TT Se SRE et ASSL
Figure 1. ECP Approval Baseline (Sheet 3 of 3)
1x
Introduction
ECP No. F1-900R1
F1-901R1
N/A
F1-902R1
N/A
F1-903 N/A
F1-905 N/A N/A
F1-906 N/A F1-907 N/A FL-908 #'1-909
F1-910
N/A N/A
Engine OICN No. MD No. and Date Affected Pages N/A 1, 24 June 1969 1-2 through 1-6, 1-43, 1-44, 1-56, 1-59, 1-67, and 2-29 N/A 2, 9 October 1969 1-8, 1-10, 1-11, 1-14, 1-16, 1-17, 1-18, 1-20, 1-21, 1-22, 1-40, 1-41, 1-45, 1-47, 1-72, 1-112, 1-115, 1-117, 2-10, and 2-35 N/A 3, 1 August 1969 3-124 N/A 4, 17 December 19€9| 1-4, 1-7, 1-8, 1-9, 1-12, 1-13, and as changed by 1-14, 1-16, 1-22, 1-27, 1-28, 1-29, Modification No. 301 | 1-33, 1-34, 1-37, 1-39, 1-55, 1-56, to Contract 1-57, 1-58, 1-59, 1-62, 1-63, 1-64, NAS8-18734 1-69, 1-78B, 1-78C, 1-79, 1-80, 1-81, 1-82, 1-83, 1-84, 1-85, 1-89, 1-99, 1-91, 1-92, 1-95, 1-96, 1-100, 1-105, 1-128, 2-1, 2-2, 2-3, 2-7, 2-14, 2-16, 2-21, 2-27, 2-29, 2-30, 2-934, 2-38, 2-40, 2-41, and 2-49 N/A 5, 24September 1969 | 3-14, 3-15, 3-44, 3-85, 3-95, 3-96, 3-99, 3-100, and 3-104 N/A 6, 11 December 1969 | 1-4 and 1-68 N/A 8, 3 Octcher 1969 3-23, 3-25, 3-26, 3-27, 3-28, 3-30, 3-31, 3-33, 3-36, 3-45, 3-46, 3-47, 3-48, 3-49, 3-50, 3-51, 3-52, 3-53, .| and 3-131 N/A 10, 11 December 1969} 1-44 and 1-45 N/A 11, 16October 1969 3-80 and 3-81 N/A 12, 22 October 1969 3-92, 3-94, 3-98, 3-99, 3-104, 3 106, 3- 110, 3-111, 3-112, and 3-115 N/A 13, 29 December 1969 1-2, 1-8, 1-35, 1-38, and 2-8 N/A 14, 12 November 1969 | 3~132 and 3-132A N/A 16, 25 March 1970 2-2, 2-49, and 2-53 N/A 17, 5December 1969 | 3-113, 3-114, and 3-124 N/A 19, 14 March 1970 1-2, 1-24, and 1-107 N/A 20, 25 March 1970 1-8, 1-18, 1-22, 1-33, 1-47, 1-48B, 1-50, 1-53, 1-67, 1-69, 1-79, 2-7, and 2-13 N/A 22, 9April 1970 1-12, 1-13, 1-14, 1-71, 1-72, 2-10, 2-14, 2-20, and 2-29 N/A 23, 9January 1970 3-114 N/A 24,4 February 1970 | 3-124A/3-124B, 3-125, and 3-126 Figure 2, Index of OICN Changes (Sheet 1 of 3)
R-3896- 11
x Change No. 11 - 6 May 1971
N/A
F1-915
F1-916 N/A
N/A F1-917
N/A F1i-918
N/A F1-919
F1-920
F1-921
N/A
Engine MP No.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A N/A N/A N/A N/A N/A
N/A
N/A
N/A
25,
26
-
27
28,
29
-
30,
31,
32,
33
-
34, 35, 36
37
38
39, 40
41,
42,
R-3896-11 OICN No.
and Date
22 May 1970
25 June 1070 29 June 1270
29 June 1970
13 February 1970 3 March 1970
30 September 1970
30 September 1970
29 April 1970
5 May 1970
30 September 1970 18 June 1970
30 September 1970 & July 1970
6 November 1970
3 February 1971
23 February 1971
2 Octo’x r 1970
Introduction
Affected Pages
1-101, 1-102, 1-104, 1-105, 2-12, and 2-13
1-93, 1-94, 2-3, and 2-8
1-42, 1-43, 1-44, 1-45, 1-55, 1-56, 1-58, 1-59, 1-60, 1-61, 1-62, 1-63, 1-64, 1-65, 1-67, and 2-29
1-34, 1-35, 1-38, 1-45, 1-47, 1-48A, 1-481, 1-53, and 1-67
3-135 and 3-149
3-66, 3-61, 3-132, 3-132A, and 3-132B
1-4, 1-6, 1-46, 1-47, 1-48, 1-77, 1-78B, 1-78E/1-78F, 1-100, 1-106, 1-197, 1-108, 2-1, 2-2, and 2-3 1-34, 1-35, 1-102, and 1-103
3-10, 3-13, 3-41, 3-62, 3-86, and 3-124
3-53, 3-54, 3-58, and 3-124 1-3, 1-60, 1-61, 1-66, and 1-87 3-1 and 3-148A
2-17
3-132D
1-26, 1-126, and 2-30
1-4, 1-5, 1-8, 1-82, 1-84, 1-84A/ 1-84B, 1-91, 1-92, 1-95, 1-96, 1-96A, 1-96B, 1-96C/1-36D, 1-97, 1-126, 2-45, 2-46, 2-52, 2-53, and 2-54
1-5, 1-6, 1-9, 1-11, 1-12, 1-13, 1-14, 1-16, 1-18, 1-21, 1-27, 1-48C/1-48D, 1-71, 1-72, 1-107, 1-108, 1-125, 2-18, 2-19, and 2-21
3-124D
Figure 2. Index of OICN Changeg (Sheet 2 of 3)
Change No. 11 - 6 May 1971 xA
Introduction
F1-932
N/A F1-934 F1-9385 F1-926 F1-937
N/A
xB
Figure 2.
44
45, 46, 41, 48, 49, 50, 53,
54,
55
~
56
a
57
58,
59,
8l,
63 64 65 66, 67,
}
a
68,
R-3896-11
OICN No.
and Date
, 9 October 1970
2 November 1970 4 November 1970 16 August 1971 15 February 1971 24 May 1971
20 July 1971
25 October 1971 25 May 1971
10 June 1971
15 August 1972 13 July 1971
4 August 1971
15 August 1972
6 March 1972
29 November 1971 31 March 1972
5 April 1972
24 May 1972
17 October 1972
13 June 1972
Affected Pages
3-18, 3-19, 3-41, 3-42, 3-44, 3-58, 3-65, 3-67, 3-77, 3-79, 3-81, 3-82, 3-83, 3-85, 3-86, 3-87, 3-92, 3-93, 3-97, 3-98, 3-101, 3-104, 3- 128, and 3-129
3-20, 3-67, and 3-80 3-84
1-85 and 1-125
3-141
1-30
2-54 and 2-55/2-56 2-21
3-74C, 3-74D, 3-94, 3-95, 3-96, 3-102, and 3-103
3-14, 3-15, 3-38, 3-80, and 3- 80A/3- 80B
1-60A, 1-60B, and 2-28
4, 3-15, 3-38, 3-80, and 0A/3- 80B
9, 3-75, 3- 76A/3~ T6B, 3- 80,
~1
8
~21, 3-22, 3-21, 3-34, 3-38, 3-68, -6
a -80A/3- 80B
1-12, 1- 1-27, 1-71, 1-72, 1-72A/1-72B, 2-10, 2-13, and 2-29
1-4, 1-48C/1-48D, 1-69, 2-10, and 2-55/2-56
3-1 and 3-155
2-12, 2-13, 2-14, and 2-54
1-81 and 1-82
2-364
1-13, 1-14, 1-16, 1-21, 1-27, and 2-21
3-1, 3-2, 3-2B, 3-130A/3-130B, and 3-131
Index of O[CN Changes (Sheet 3 of 3)
Change No. 14 ~ 9 October 1972
13, 1-14, 1-16, 1-20, 1-21,
Tx? i1x18 14x16x18x20 22x
—_
R- 3896-11
Introduction
20x91 33x 35x37 30x42 43x46 47x 49
BL x 54 85x 57x 50x 61x63 73x75 19x87 90x92x94x 100 101x104 105 x 107 x ig
UO0x 13x 115x117 122 x 124x126 x 130x133 135x137 139 x 142 x 144 x 149 x 155 x 156
ee — — —-——
158
Figure 3. Engine Baseline MD Configuration
3. ABBREVIATIONS.
The following abbreviations may appear through-
out this manual:
ac alternating cuxrent
AWG American Wire Gage
Rtu British thermal unit
Cc Celsius (Centigrade)
ce cubic centimeter
ce/m cubic centimeters per minute efm cubic feet per minute
cis cubic feet per second
cg center of gravity
cpm cycles per minute
cps cycles pet second
cu in. eubse inch
cu ft cubic foot
db decibel
de direct current
DNA does not apply
ECP Engineering Change Proposal F Fahrenheit
it= Ib foot-pound ft/sec feet per second
Fy force, x-axis
Fy force, y-axis
Fy force, z-axis
By gravitational constant GN2g gaseous nitrogen GOX gaseous oxygen
gpm gallons per minute gps gallons per second He helium
HE heat exchanger
in, inch
in-lb inch-pound
ke kilocycle
KSC Kennedy Space Center lb/sec pounds per second LN liquid nitrogen
LOX liquid oxygen
MAF Michoud Assembly Facility max maximum
min minimum
milliliter
millisecond
Mississippi Test Facility Marshall Space Flight Center not applicable
net positive suction hcad moment, x-axlsS
moment, y-axis
moment, Z-axis
number
nominal
Operating Instruction Change Notice chamber pressure
denotes acidity and alkalinity part number
parts per million
pounds per Square inch, absolute pounds per square inch, gage radius or resistance reference
ramjet fuel
root mean square
revolutions per minute standard cubic feet per minute standard cubic inch per minute second
serial number
square inch
square foot
stage static instrumentation thermal insulation sct
Vehicle Assembly Building volts alternating current
volts direct current
4, DEFINITIONS.
Stage Contractor
Engine Contractor
The Boeing Company and its affiliates or subcontractors
Rocketdyne and its designated represen- tatives, such as field engineering personnel
Change No, 13 - 4 April 1972 xi
Introduction
Customer Uninstalled engines Installed engines No damage is allowable.
Engine service life Engine start Component cycle No leakage is allowable
Fuzz Jeakage Hydraulic surface wetting
Long-term storage
Engine standby status
4A. SYMBOLS.
R-3896-11
NASA and its desig- nated representatives
Engines not installed in the S-IC stage
Engines installed in the S-IC stage
Defined in paragraph 2.4,.3A
Defined in paragraph 2.5.9
Defined in paragraph 2.5.9
Defined in paragraph 2. 5. 10
Defined in paragraph 2.5, 11
Defined in paragraph 2.5.11
Defined in paragraph 2. 5,20
Defined in paragraph 2,5.11,.1
Defined in paragraph 2.2A.1
Symbols used in the text and on illustrations
are as follows:
A change bar and an ECP number are placed adjacent to the text or illustration in sections I and II to indicate the area of 711 change made after the basic effort. The { index of OICN changes (figure 2) lista the corresponding OICN numbers.
or illustration in section IM to indicate the
| A change bar is placed adjacent to the text
area of change made after the basic effort.
'e| Used on illustrations to indicate effectivity of specific configurations.
xii Change No. 14 - 9 Octeber 1972
5. ADDITIONAL DATA AND INFORMATION.
The following documents provide additional in- formation on the F-1 rocket engine (figure 4) and F-1 ground support equipment and tooling:
R-3896-1, F-1 Rocket Engine Data Manual,
This manual contains engineering data includ- ing engine description, operation, and engine system functions.
R-3996-3, F-~1 Rocket Engine Maintenance and Repair Manual (Volume 1). This manual con- tains general engine maintenance, handling, component removal and installation, and post-
maintenance checkout requirements.
R-3996-3, F-1 Rocket Engine Maintenance and Repair Manual (Volume 1) This manual con- tains component repair and testing procedures
for individual engine components.
R-3896-4, F-1 Rocket Engine Illustrated Parts Wreskiowa Mancal Chie manual Wate and lee: trates the parts required for maintenance- level support of the F-1 rocket engine, including closures for the assembled F-1 rocket engine
and its individual components and parts.
R-3896-5, F-1 Rocket Engine Ground Support Equipment Maintenance and Operation Manual Volume I). This manual contains descz iption, theory of operation, maintenance and checkout data, maintenance-level codes keyed to parts lists, and proof loading and pressure test re- quirements for delivered F-1 rocket engine ground support equipment.
R-3896-5, F-1 Rocket Engine Ground Support
Equipment Maintenance and Operation Manual. COURCEE This manual contains physical and functional description, intended usage, equip- ment dimensions, weight, operating limitations, power and fluid requirements, a breakdown parts list, periodic maintenance and testing re- quirements, and other procedures for determin- ing that the equipment and T tooling are in an operable condition.
R-3896-6, F-{ Rocket Engine Thermal Insula- tion and ite air Manual. This manual contains descript‘on, installation and removal proce- dures, and data for repair of thermal insulation for the F-1 rocket engine.
R-3896-11
R-3896-9, F-1 Rocket nage Transportation Manual. This manual contains procedures for preparing the F-1 rocket engine, nozzle exten- sion, thermal insulation, and .-iscellaneous engine loose equipment for shipment and for shipping by truck, air, or by water. Included are recommended truck, air, and water trans- port checklists that may be used to verify that procedures and in-transit inspections have been performed.
R-5857, Saturn F-1 Configuration Identifica- tion & Status Report. This report provides a
record of the configuration, allocation, iden- tification, and status of delivered F-1 rocket engine and related support equipment.
R-6749, F-1 Engine Interface Document. This document is a summary and categorization of F-1 engine interface information necessary to
identify established design compatibility be- tween the engine and its mating system.
R-8842, Maintenance and Support Plan For Saturn F-1, H-1, and J-2 Rocket Engines,
This plan defines the various support functions and conveys maintenance and support planning information for the Saturn engines and support equipment,
6. CONFIGURATION IDENTIFICATION,
EQUIPMENT CONFIGURATION. The MD identification symbol and the equipment model designation indicate the configuration of the equipment and distinguish it from models incor- porating different changes and from basic models. A basic, unchanged configuration of the equipment has no MD identification symbol. MD identification symbols are added as changes affecting configuration are incorporated into the equipment. The MD identification symbol is stamped on the MD plate, vhich is mounted near the engine nameplate.
Introduction
incorporated or not incorporated into the equip- ment. The symbol represents a consecutively numbered series of MD changes. Any MD chang. . or series of MD changes, not incorpo- rated is represented by an "XX." Multi-digit numbers are underlined. Two figures together represent the limits of a series of incorporated MD changes. Figure 5 illustrates how MD changes incorporated in the engine are repre- sented by the MD identification symbol.
MD i¢centification plates RD171-1052-0001 through -C906 have preprinted numbers from 1 through 100 on the -0001 plate, 101 through 200 on the -0002 plate, etc. Modifications that are incorporated into the equipment are represented by the letter P (production) or K (kit) stamped in the square directly to the right of the appli- cable number. Omission of a P or K, indicates that the MD change is not incorporated. A
P or K with a bar (-) marked through the letter (BR, K) indicates a MD change deleted in its entirety by the incorporation of a later MD change. Figure 5 illustrates how MD changes incorporated into the equipment are represented by the MD identification symbol.
MANUAL REFERENCE, A reference that ap- pears in the manual may refer to a series of MD changes or to an individual MD change; fur example, 'MD9" refers to MD1 through MD9, but "MD9 change" refers to the individual MD change 9, This latter type of reference, illus- trated in figure 5, identifies separate sets of information required by differences in configu- ration, When an MD reference appears in the manual, examine the MD identification symbol on the equipment to determine which set of information is applicable.
MD IDENTIFICATION SYMBOLS. On MD identi- fication plate RN171-1022-0001, the identification symbol is a composite number representing all
the changes affecting configuration (MD changes)
Change No, 13 - 4 April 1972 xiil
Introduction R-3896-11
104001-E-3c
Figure 4. F-1 Rocket Engine xtv
R- 3896-11 Introduction
MD CHANGES INCORPORATED 2 3 4 5 6 1 8 9 19 ll 2
Pen See een ee (ee ee ee eer a MD 9 Re ee ae OE
MD IDENTIFICATION SYMBOL
! ae. f | ome irae | | LY | MID4X78X1012 ee ees en] TN a
| | [4 [ | | | 4 | | ; | MDXE0X1I a aR AOA ice
| | | | | | | | | ] hi | a || | || | | | |
MANUAL REFERENCE
MD? ea ae Toe ST a Ce Ea
| | | | | | | | | | | | MD@ C'IANGE [ise EN)
| | | | | | | | | | | | MD U3 TL TT Te Tae eae I EE
| | | | | | {| | | | | | | MD12 CHANGE | 4
NOTE; A HORIZONTAL LINE WITHIN THE CHART INDICATES THE MD CHANGE REFERRED TO IN THE SYMBOL OR REFERENCE AT THE LEFT,
GEN-63B
Figure 5. MD System
xV/xvi
R-3896-11
Section I
SECTION I
OPERATING REQUIREMENTS
SCOPE. This section outlines the scheduled and nonscheduled authorized enzine activities and the requirements, limits, and cunstraints necessary to satisfactorily comply with these activities.
Scheduled Authorized Field Activities, figure 1-1, lists fvom left to right the major engine events with respect to enyine status (a single engine or an engine installed ina stage). All activities fur each event must be accomplished before starving the next event. Activities listed for each event may be performed in any order unless otherwise specified in the referenced activity paragraph contained in the requirements, limits, and constraints tabular presentation.
Nonscheduled Authorized Field Activities, fig- ure 1-2, lists the activities that must be per~ formed during nonscheduled eveats. The events listed across the toy of this figure are grouped to reflect the location and conditions that pre- vailed at the time the accomplishment of a non- scheduled activity became necessary. The listed order of these events is not sequence oriented; therefore, the activities may be per- formed in any order unless otherwise sperified
in the referenced activity paragraph contained in the requirements, limits, and constraints tabular presentation. ‘The static test and launch abort activities assume that abort was not due to engine associated problems.
Requicemenuts, limits, and constraints are pre- sented in tabular form immediately followiny figure 1-2. These activities must be accom- plished during that phase of scheduled or non- scheduled engine flow specified in figures 1-1 and 1-2. During compliance with these activi- ties, the following general requirements shall apply:
a, The safety precautions specified in sec- tion IT must be complied with.
b. When the activity requires the application of a specific purge, the purge pressures and flowrates specified in section II must be applied, unless otherwise specified.
ec. When a checkout activity requires pres- surizing or purging a system or component, the fluid requirements specified tn section If for engine checkoul must be complied with.
1-1
Section I R-3896-11
SINGLE STAGE STAGE ENGINE PRE-STATIC STATIC TEST
Activity
Activity Number Receiving Inspection Preparation Post-Static- Test Securing
a #8 A AK 48 & AO
Installation Storage** Receiving Inspection Static Test Shipment
Shipment
s je} s 0
INSPECTIONS Overall engine visual 1.1,1 1.1.2 L2.9]1.1.4 71.1.5 [1.1.3 1.1.6 |1.1.4
Thrust chamber nozzle extension !1,1.7 1.1.7 1.1.8 visual
Thrust chamber tubes visual 1.1.9
Thrust chamber injector .1,10/1. 1.16 contamination
Thrust chamber injector damage 1.1.11 Thrust chamber drain adapter 1.1.12
torque verification Engine joints closure removal He 1. 122
verification
ELECTRICAL TESTS
Flignt instrumentation system 1.2.1 1,2,2 1,2.2 function
Turbopump heater function 1.2.3 1 2.3
Hypergol installed switch functio 1,2,.4 1,2.4
Checkout valve timing function 1.2.5 1,2,5
Engine safety cireults function 1.2.6
Engine sequence verification 1.2.8
Igniter test 1.2.9
Inert igniter test
Igniter harness test 1.2.14 Vibration safety cutoff verifica- 1.2,12 tion
Thrust OK preasure switch
function
Checkout valve engine return 1,2,15
switch position verification * Activity requires removal and reinstallation of thermal insulation panels. Refer to section Il for panel location. ** For engines stored in accordance with MSFC-STD-500, refer to paragraph 2.5.11.1 fur checkout requirements after ret
a
1.2, Change No. 7 - 28 April 1970 Figure 1-1. Scheduled Authorized Field Activities (Sheet
R~3896-11
STAGE STAGE STAGE post- PRE-STATIC STATIC TEST STATIC TEST VEHICLE (KSC)
¥
= 2 8 : E gE e
5 B 248 = Pa] a °
r [xz {Bs S4/82/82 1 ae w § GO |B [Esl g
1 R Ss a
'g |8 [28] 8 | as ]5h) aa | § a6 oot] & [82 Seo lSe ules
sp [2 |8e/& | geal ag |e ce: peal & [e> [28 8b ae
& ld |€8 1/84 |&6|#éle2 | & ae ae8| 2 |2e3 (/SAfI8AalSa E nH | «| ao {x [uu [m[wn [io ae
1.1.3]1.1.411.1.5 (1.1.3 1.1.6 \1.1.4] 1.1.44 1.1,3}1.1.4B} 1.1.5 1.1.3 1.1.7 1.1.8 1.1.7 1.1.9 1,101.1. 1.10 1.1.11 1,1.12 1.1.1 1.2.2 1.2.2 1.2.2 1.2.3 1.2.3 1.2.4 1.2.4 1.2.5 1.2.5 1,2.6 1.2.8 1.2.9 1.2.14 1.2.14 1.2.12 1.2.16
! tion panels. Refer to section I for panel location. to paragraph 2.5,11.1 for checkout requirements after removal from storage.
Figure 1-1, Scheduled Authorized Ficld Activities (Sheet 1 of 5)
R-3896-11 SINGLE STAGE STAGE “\ ENGINE PRE-STATIC STATIC TEST \ Event Activity
I 8 tn Q Z 55 B so a A) ba ee + aon Q o 8 <q as!
Pre-Static Checkout Static Test Preparacvion
Storage** Installation in Stage
S Ys QA asd me ov o & ® rm
Checkout Storage** Shipment Receiving Inspection Shipment
ae a
lool
LEAK AND FUNCTION TESTS
18 | Turbopump torque function 1,3.1 1.3.1 1.3.1 19 | Thrust OK pressure switch leak 1.3,3 1.3.3 and function 20 | LOX dome aml gas generator 1.3.4 13.54 LOX injector purge leak and function 21 | LOA pump seal purge leak and 1.3.6 1.3.7 function
22 | Cocoon purge leak and tunction
23 | Heat exchanger helium system 1,3.10 1.3, 12 leak
24 ) Heat exchanger LOX system leak 1.3.14 1.3.16
45 | Hydraulic system Jeak anc 1.3.19 1,3,19 1.3.1% function
26 {| Ignition monitor valve diaphragm 1,3.20 leak
27 | Hypergol manifold leak and 1.3.21 function
28 | Ignitton monitor valve lnterflow 1.3.22 1,3.22 function
29 | Ignition monitor valye shuttle 1.3.23
pressure function 30 | Valve timing function 1.3.24 1.3.25 Fuel feed system leak 1,3.26 1.3.28
LOX feed system leak 1.3.30 1.3.32 Exhaust system leak 1.3.35
Turbopump bearing coolant 1.3.98 system leak and function
** For engines stored in accordance with MSFC-STD-500, refer to paragraph 2.5.11.1 for checkout requirements after remo TE nang ee OO ee ee ne i ee nn ne ane is
Figure 1-1, Scheduled Authorized Field Activities (Sheet 2 ¢
R-3896-11 Section I
STAGE STATIC TEST
STAGE ROS - STATIC TEST
VEHICLE (KSC)
5 e| 38 , 3 3 | 8 | S48 . Pe) a) 2 o gun fo * o o z |#8 ael(fzlss le |] #sleel; | 2 |] FS O |5H |B 5S! 2 j900 w > 0 22 H1aAd & BLAS w os & oa ge7ls & E oY Oe | SB le & rey ! a a oS @ 3 #onlesules z lea ge rae | BE 1a | seas /s |S leeal & fee (2882 8 sige a m5 AO ;aa laa | & eSlade | & & |aa4 ># (688 (SAeaA pu M 1.3.1 taal 1,31 el 1.3.3 1.3.3 1.3.3 L3.5A 1.3.5 1.3.54 An i 1.3.6 1,3.3 1.3.8 1.3.9 1.3,12 1,3.13 1.3.11 | | 1.3.16 1.3.17 1,3.15 900 1,3.19 1.3,1¢ 1,3,19B 1,3.19 I 1.3.20 1.3.20 1,3.21 1.3.21 1,3,22 1.3.22 1.3.22 1.3.23 1.3.23 1.3.25 1.3.25 1.3.25 | 1,3.28 1.3.29 1.3.29 900 1.3.42 1.3.33 1,3.93 ; 1.3.35 13,354 ou 1.3.38 1.3.38
praph 2.5.11,1 for checkout requiremants after removal from storage. yo ee ee en Even
1-1. Scheduled Authorized Field Activities (Sheet 2 of 5) Change No. 9 - 2 December 1970 1-3
900
Section I R-3866-11
bs 3 E x 2B ra 3 <¢
SINGLE STAGE STAGE ENGINE PRE-STATIC STATIC TEST
Activity
Pre-Static Checkout Static Test Preparation Posit-Static- Test Securing
Receiving Inspection
" 8
~ av 5 qs BZ w iS) 3s
LEAK AND FUNCTION TESTS (cont)
Thrust chamber pneumatic leak 1,3.99
Thrust chamber prefill line leak 1.3408 and function
Ignition monitor valve poppet A414 position verification
Thrust chamber liquid leak 1.3.42 ]1.3.42 (Deleted)
STORAGE PREPARATION Engine 1.4.1 1.4.2 1.4.2
Thrust chamber nozzle extension 1.4.3 1.4.3 1.4.3 Ordnance 1.4.4 Miscellaneous loose equipment 1.4.5 1.4.5 1.4.5 SERVICING
LOX dome and gas generator 1.5.1 LOX injector Mush
Thrust chamber fuel Jacket flush 1.5.3 11.5.3 Engine residual fluid removal 1.5.5 41.5.5 Admitting fuel to engine 1.5.9 Admitting prefill to enyine 1.5.10 Admitting LOX to engine 1.5.12 LOX feed system boiloff 1.5.14 Fuel feed system drain 1,5.15 1,5.16 Gas generator combustor drain ' 1.5.18
* Activity requires removal and reinstallation of thermal insulation panels. Refer to section I for panel location. ** For engines stored in accordance with MSFC-STD-500, refer to paragraph 2.5.11.1 for checkout requirements aftex
te ee Change No, 13 - 4 April 1972 Figure 1-1, Scheduled Authorized Field Activities (Sh
R-3866-11
AGE STATIC
STAGE STATIC TEST
STAGE POST-
STATIC TEST VEHICLE (KSC)
= bo) P= a ae 3 8 Li e 8 i i) a 8 a 3 t » 5 Be)as Fs gels # bp § S) & BES! @ ag g $18& |" a Bele le a lgevls ele lee calas |= | eel26/e | = |f8l $ lea ee 0 (fails : gf aE |8% BB|5 | & [Beal & [se leeelee hae & & aelee ealéele a |@28| 2 (2 AeiSdaidia rF[oaftui{ii|sik« fet mM {Nn lo }lp |o]R /|s |r luitv pw 1.3.40 1,3,43* ee: 1.3.41 241A 1.3.42 | 1.3.42 4.2 1.4.2 1.4.2 1.4.2 14.3 1.4.3 1.4.3 1.4.3 1.4.4 1.4.4 ALB 1.4.5 AS 1.4.5 1,5,1 1.5.3 [1.5.3 ! 1.5.571,5,45 1.5.9 1.5.10 1.6.12 1.5.14 1.5.15 1.5.16 1,5,15 1.6.18
mels. Refer to section I for panel location, ‘agraph 2.5.11.1 for checkout requirements after removal from storage.
rene emcee Gener Laer ec KONO Pescara! Renee RESEND! eeeer ty
21-1, Scheduled Authorized Field Activities (Sheet 3 of 5)
R-3896-11
SINGLE EN, JE
STAGE STATIC TEST
STAGE PRE-STATIC
Event | iT 8 bb 5 ¢ is Zz Activit g § fs 2 ao|e% . as Fs js | % |3 # |#3 ge|fa)s2| 2 2 se /3 | % |s8 a 135 He jee las | s oe = © 4 bp a8 FS mB tA it os , = 4 vu [3 3 cP) (ats) =a 8 | ow 5 om | o & BF) i." o ao laa) aw Bs rz \. © x 2 eae S gy 2 wo MM ow Z < mG es) A 35 a eS AO, AG | ae a
| A [spite lp 5
SERVICING § (cont) |
Thrust chamber fuel jacket drain
Thrust chamber fuel inlet manifold drain
Turbopump preservation 1.5.2 1.5,22 HANDLING
Engine installation 1.6.1
Thrust chamber nozzle extension Installation
Igniter harness installation Thermal Insulation installation
Engine environmental cover installation
Hypergol cartridge weight check 1.6.6 | Igniter installation 1.6,% Hypergot cartridge installation 1.0.10
Engine environmental cover removal
Expended hypergol cartridge 1,6.13 removal
Igniter removal 1.6,14
Thrust chamber nozzle extension 1.6.16 remova
Igniter harness removal
Thrust chamber throat 1,6, 18/1.6. 18 1.6.181.6.18 1.6.18 |1,6.18 1.6.18 1.6.18 closure installation
* Activity requires removal and reinstallation of thermal insulation panels. Refer to section I for panel )ocation. ™ For engines stored in accordance with MSFC-STD-500, refer to paragraph 2.5, ‘1.1 for checkout requirements after rem
Cerne eeeaee) eaves vecO tine EEO! GORORO! Ceertll LAR OE SA Dee: CO ee CO
Figure 1-1, Scheduled Authorized Field Activities (Sheet 4
R-3896-11 Section I
STAGE y 4 STAGE POST VEHICLE (KSC)
CIC STATIC TEST STATIC TEST
oa 8 be & 8 3 3 3 of g oe |ns/2é z\|3% : 2 = |-84)] § 2 BS Sy |/oe |] as 2S) eo it + oS 2) es a5 9 @ |$¢ Selec lse cElas o | 3H en [oe [Series m 2 Y =u rs) gE las fecal eg oe poe BO | wo FE lege S< jess lgssiea & w Bs oe | sao] aa Ps fA in a B&O A S SER REulso xe % 2 H.C | Se} ow bY), ow 2 sea o See coord ey 7) [eopre} BO }AA | OAs mG) Ae “A A > OAR JUABRIHA
a fo fs Storage >) | a c
1.5.20 1.5.21 1,5,21*/1.5,.21A* 1,5,22 1.5.22 1.5.2 1.6.2 1,6.3 1,6.3 1.6.6 1.6.7 1.6,10 | 1.6.13 1.6.14 | 1.6.16 | 1.6.17 | fi.G.18 6.18 [1.6.18 1.6.18 [L.6.18 1,6.18]1.6,1811.6. 18
Refer to section I for panel location. ph 2.5. 41.1 for checkout requirements after removal from storage.
Scheduled Authorized Field Activities (Sheet 4 of 5) Change No. 11 - 6 May 1971 1-5
R-3896-11
Section I
STAGE STATIC TEST
STAGE PRE-STATIC
SINGLE ENGINE
c
Pre-Stati Checkout
Test Securing
Post-Static-
Preparation
a a a £ 5 2 £ & rs <
Installation Receiving Inspection Static Test
Receiving Inspection Checkout
HANDLING (cont)
oh of 69 | Thrust chainber throat 1.6,19 1.6.19 1.6.18 Te closure removal 70 | Thrust chamber throat plug 1.6,20 installation 71 | Thrust chamber throat plug 1.6.21 removal
72 } Turbine exhaust exit pressure test fixture installation
73 | Turbine exhaust exit pressure test fixture removal
at aft 74 | Cover and closure installation .6.24 11.6.24/1,6.24 1,6.25)/f.6,251,6,25 |1.6. 25]1.6.25 «6.25 | | 75 | Cover and closure removal 1.6.26 1.6.26 . [k.6.27 1.6.28 1,6,281,6.28
**® For engines stored in accordance with MSFC-STD-500, refer to paragraph 2,5.11,1 for checkout requirements afte
Red ede (Ree Dee Lacan! ser OO (ON [OWN Enero [newer rec RASS (A
1-6 Change No. 11-- 6 May 1971 Figure 1-1. Scheduled Authorized Field Activities (
R-3896-11
STAGE STAGE STAGE POST- RE-STATIC STATIC TEST STATIC TEST VEHICLE (KSC) E ad =] else 4g 3 | 32 “ e {as ] ss «| 2 4 % |# | 82 a2|28|88 eSiH21% | € @ By 2 > oO ag S1aa BLAS w & g a | |g Pa eel ae gzgiscl@ | 8 2 l2§ 5 | |e e282 | 83 ee|88/5 | 2 cae: a a an] HO | ae | oe esgiae la a >a lOAa Ee are Lu |min |olp |e
a §.19 1.6.19
1,6.251,6,.25/1,6.25 /1.6. 25)1.6,25 1.6.25 1.6,25]1, 6.25 j1.6.25/1.6,.251.6.2511.6.25 1.6.28 1.6,281.6.28 1.6.28 1.6.28
paragraph 2.5.11.1 for checkout requirements after removal from storage,
igure 1-1, Scheduled Authorized Field Activities (Sheet 5 of 5)
R-3896-11
STAGE STATIC TEST (MTF)
Recycle Due to Abort
Reevcle Prior to Start Subsequent to Start
of Automatic Sequence
Kvent of Automatic Sequence 3 aa jes |s ' = ay 538 |S - os 2 an mi wl +. 2 ~ a Ke ww a ep 8 Activity S21 G3 £28 Pe |B2d! $s} E 3 aS jas pr ELAOG aeqal ad vA z Sw t v Del 3 oa] 30] wy £ a] 5 i 3 = 396 | Bo os 4 3 S 12RS oe BOMS! © BR 8 <1 Ho _ al 2» Sa} mit B hy ‘ny om 29 bp B ae) 38/38 aa 55 ea x E shale? aye B s ‘3 % 7 a | 3 » 2H a = a Salsa |48 | 68/22 1&2 |S (SSa) Be aaB| 2s ee a a INSPRCTIONS Checkout valve ground position 1.1.13 [1,1.13}f.1.13 ]1.1.13]2,1.138]1,1.13 j1,1, 1 verification Propellant valves closed verification 1.2.14 41.1.24)1.1,14 $1,1.1441,1.1¢)1.1.14 |1,1.14 LOX dome and gas penerator LOX 1.1.15/1,1.15 J, 1.15 injector purge operation verification Hypergol instailed switch pickup 1,1.16]/2.1.26]1.1.16]1,2.16 ]£.1,16]1,1.16]1.1.16 verification Igniter links installed verification LALLA. LT Lae Lt Turbopump heater power on verification 1.1,18)1.1,.18)1,1.18]1.1.18 }1.1.18 Turbopump LOX seal purge on verification 1.) LEAN UBAL LL L8A1.1.18ALL LLB ALLL LBA 1.1.18 LOX dome and gas generator LOX 1,1,19/1,1.19]1.1,20 J1.1.20
injector purge off verification Cocoon purge on verification
Thermal insulation visual
Overall engine visual 1.1.23 1.1.6 | 1.1.6 Thrust chamber nozzle extension visual 1.1.8 (1.1.8 Thrust chamber tubes visual 1.1.9 | 1.1.9 Thrust chamber injector contamination 1.1.10 | 1.1.10 Thrust chamber injector damage 12,11 } 1.1.21 Thrust chamber drain adapter torque 1,1, 12 verification
*Activity requires removal and reinstallation of thermal insulation panels. Refer to section Ii for panel location.
Figure 1-2. Nonscheduled Authorized Field Activities (Sheet
R-
3896-11
STAGE STATIC TEST (MTF)
Recycle Prior to Start of Automatic Sequence
3 o 3 2 3 Cal tne Eo)
ales \es |Bs Slaeata lad |Ae F | G
1,1,15 [1.12.13]1.1,13
be iL.1,14/1,1,14)1.1.14
16/1.1, 16)1.1,16)1,1, 16
1741,1.17)1,1,17)1.1,17 1.1,18 1.1,18A}1.1.18A}1,1,184
ls. Refer to section I for panel location.
Recycle Due to Abort Subsequent to Start of Automatic Sequence
as] ak les | 2 % oO a ' 24e/OBR |> e | é Ses/ ee | sof] BR] Ba eoblfo_| 823) 2 | BS pH Be) AO” 26am) ad | as mola Os | ocd ka BeOly sg MOMS! OS | ee 2s yo] 4) ao Pl P <> Oo ted bs c & 8] ao ae Seclenk) G@hel Bo | oe OOm| PSa aan ws | &a el Ene a 1.1,13]0.2,09(1. 2.13 [2.2.13 1.1.14]1.1.14]1. 4.24 J1,1.14
1,1.15]1,1,15 2.1.15 1,1,16/1.1.16]1. 1.16 1.1.17
1,2.18/1,1.28)1.1.18 }1.1.18 1.1.18A}1.1,18A1.1,18A [1.1.18A
1,1,19]1,1,19/2.2.20 j1.1.20
11.6 | 1.1.6 1.1.8 11,1,8 1.1.9 | 1.1.9 1,4.10 | 1.1.10 1,1,12] 1.1.11
1,1, 12
ae eee as
1-2. Nonscheduled Authorized Field Activities (Sheet 1 of 3)
1,1,16]1.2,16 J1.1, 16 }i.1.16
Section I
VEHICLE (KSC)
Recycle Prior to Start of Automatic
Recycle Due to Aburt Subsequent to Start of
Hypergol Burst to Vehicle Lift-Off
Sequence Automatic Sequence » VDBDBo ao 88a a a~ses | o@ 8 eo od #8 ol o5 > efPOR [aw og a aGflgs | k= & > SE LO” Sq a Cs] gy ~ li © San ov 3 3) ae a ib'S 3 Pes a PL SSH fF ha on H a @ | &: = Balsew| Sa & 8 ‘v 6B 23 5\ sah} ok B bh § & Q sod Bo ao o.4 < oY 2 /OR MF P25) aam N_ | 0 P Qa it ris |
LiL.13 (L.1.13 §2.2.13 $2.1.1342.1.13)1,1. 13
1.1.04 [1,1.14 [1.1.14 [1.2.14 ]2.1.14]1.1.14
1.1,15/1.1.15
21,16 (LL. 1641.1, 16
LU UTH. 1.17 1.1027 1.1.17 fl 117
1.1.18 /1.1.18 J1.1.18/1.1.18 L.L.LBAJLLLBAIL LIB Al1 118A], 118A) 1.1.184
1.1.19 ]1.1.19]1,1.20
1.1.21 /1.1,21 ]1.1.21/1.1,21 1.1.22
1.1.25 1.1,9 1,1,10
1,1,11
Change No. 6 - 10 February 1970
4
1.1.13
1.1.14
1,1,15
1.7
Section I R-3896-11
STAGE STATIC TEST (MTF)
Recycle Due to Abort Subsequent to start of Automatic Sequence
Reeycle Prior to Start Prevent of Automatic Sequence
= V3) Sp qd > Ein Bd e wa i a> A £25/83 \s5 @ Activit es | 2 o&Sloh | oe oRl g y Se |aa mee ee | eSel £ Wo 1-0) ~ £ mo Bey f av “oO Hon) es 3 a} aS jas pre) =O a) Fam) o va 2 om 4 ~pBolmas Bo 7 > = ao | Uw 3 3 3 ZS IBeOl|, EMO HSI % 2 Bo{| 2m |@> 2 Bas = Siw beta) GS BO) | = Oo a ri) oi wae Pa ey MS oO 5 wv a HED C : ee| G2 lage | 28/36 | £6 [BS [BRE ee a Be S| : ™ < DH | Sa | 8a A2lmadt | at | 24 |OCom| PSal Aam) a INSPECTIONS (cont Py. (cont) E F G H I J
| {6| Thrust chamber nozzle extension 4: 902 fastener torque verification Thrust chamber drain plug torque verification ELECTRICAL TESTS Flight instrumentation system funct.on 1.2.2 |1. se igniter harness test 1.2.14 1/1. a Checkout valve engine return switcl 1.2. 15]1.2.15/1.2. i5 4.
position veitication
Igniter test
Thrust OK pressure switch tunction test LEAK AND FUNCTION TESTS Turbopump torque function
Ignition moniter valve poppet posifien verification
Thrust chamber liquii leak SERVICING
LOX dome flush
Gas generator LOX injector flush
LOX feed system boiloff
1.2.9 |t.2.9 [1,
1.5.14]7.5.14 | 1. 1.5.2> | L.
23 | Fuel feed systcm drain
24] Gas generator combustor drain 1.5.28 | 1. 5 | Thrust chamber fuel jacket drain 1.
26 | Thrust chamber fvel jacket Mush 1,
902/27 | Engtne residual fluid removak 1.5.5 [1.5.5 |] 1, ' 28 | Turbopump preservation 1.5,2211.5.22 (1.5.92 1.5.22 | 1, sao 29} Admitting fuel to engine 1.5.9 |1 30] Admitting prefill to engine 1.5.16 | 1.
i 4
* Activity requizes removal and reinstallation of thermal insulation panels. Refer to section II for panel location,
aides eRe! (ara, oR RRO RN SAB eked [eerereeteveh Pertoeenna 1-8 Change No, 1) - 6 May 1971 Figure 1~2. Nonscheduled Authorized Field Activities (SI
R-3896-11
STAGE STATIC TEST (MTF) VEHICLE (KSC)
tien tt RA A
Recycle Due to Abort Subsequent to Start of Aucomatic Sequence
Recycle Prior to Recycle Due to Abort Start of Automatic Subsequent to Start of Sequence Automatic Sequence
Recycle Prior to Start of Automatic Sequence
1.5,5A41L.5.5A*/1.5.5A*
es) ued Bue! 2 |e ala Su =a) v S2Rles v Ae E> | & ae a> | 2 ow Oo m | o GE 6%, i oO Yrdg!/Oo = I = 99 OD > oo om S| uot |= onl ge | & oEYIOe law owl ps Bersi@e (est) £8 | on ZBewwe | est eo a9 £2 | 2.3 3h a ¢ S6alegna $23 ge PTE coe SeR| Me | as oe SP) ear | aa a Pee Sul 8 uv So IsBSl (eH 0Ss| se | os] Sul Fz z Pl seklm Sa Os s a Bjl}os 5 jes pt} @ wm BS) rom | Be | Se 2 33 B)SSn vy hn) oth 4 DOs aes! | 22 lez |2ee|geel G28] 2s | Zs 22 | a2 | $2) x2 |Se8l28e] be8 32 an Q 6 eens ae Bl Gh. re =) & a ough Bl) bbe Ay & 52/23 |£2 183 |68é|bed Gaz] 23 | 28/52 |22 | £2 | S2|sfe Sed Gade} ES D E F H K H fe) R s 1.1. 27 1.1.284 b 1.2.2 1.2.2 |1.2,2 1.2.14 1,2,14*/1.2.14* 1.2. 15]1,2. 15]1.2. 15 1,2.15]1,2. 15]1.2.15 [1.2.15 1.2.9 |1.2.9 1.2.9 /1.2.9 |1.2.9 1.2.13 re on es 1.3.1*/1.3.1*14.3.1° 1.3.41A4 1.3.42 | 1.5. 14]1.5.14 LS 14A)1,R14A11.5.14A 1.5.25 1.5.17* |1.5.177 1.5.18 1.5,18* |1.5.18* 1.5.20* 1,5,3*
1,5,22 1,5,.22* 11.5.22* 1.5.9 1.5.9*|1.5,97 1.5.10 1.5.10 |1.5.10
|} panels. Refer to section Ii for panel location.
a No a Oe pure 1-2. Nonscheduled Authorized Field Activities (Sheet 2 of 3)
Event
Activity
Activity Number
SERVICING (cont) Admitting LOX to engine
HANDLING
32 | Thrust chamber throat closure installation
33 | Thrust chamber throat closure removal
34] Cover and closure installation
35| Cover and closure removal
36 | Engine environmental cover installation 37) Engine environmental cover removal
38 | Thrust chamber nozzle extension removal 39] Engine removal
40] Engine installation
41] Thermal insulation removal
42| Thermal insulation installation
43] Igniter removal
44] Hypergol cartridge removal
45] (Deleted)
(Deleted)
Hypergol cartridge weight chevk Igniter installation
Hypergol cartridge installation
R- 3896-11
MAF STAGE STATIC TEST (MTF)
Recycle Due to Abort Subsequent to Start of Automatic Sequence
Recycle Prior to Start of Automatic Sequence
q ® {98 bY tes | 8 fel S2el85 | @e | as Bea) Pe | oor] # & a ¥ mo Fl a rei 4 3 | ag jae re seo 8] 5 eA] A. 4 ge jee | ey 3 2S BZ [sso], 2H Ome) cs fe/ se se as] Bles | # [28 el baa] gah) & PH | Sa |§H OF lat pat [At |Oon| PS Hae! = B | c | p> e | r [ c [a _ 1.5.12 |1.5, 1.6,18]1,6.18|1.6.18 1.6.19]1.6.1911.6. 19 1,6.24/1.6.2511.6.25 1.6.26] 1.6.28|1.6.28 1.6.16 1.6.30 1.6.31 1.6.1 {1.6.33 1.6.36 1.6,.14]1.6.14 1.6.1 1.6.39 1,6.39 {1.6.1 1.6.6 | 1.6.6 1.6.7 [1.6.7 | 1.6.4 1.6.10 11.6.1
*Activity requires removal and reinstallation of thermal! insulation panels. Refer to section If for panel location
gece ts
Figure 1-2, Nonscheduled Autiorized Field Activitles (Shee
R-3896-11
or ————
Recycle Due to Abort Subsequent to Start of Automatic Sequence
Recye Recycle Prior to Start ecycle Prior to of Automatic Sequence Bi anie
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£.6.1411.6.14 {1.6.14 [1.6.36 1,6.39 j1,6.13 [1.6.39
1,6.6 | 1.6.6 1.6.7 [1.6.7 [1.6.7 1.6.40 |1,.6.10
vis. Refer to section II for panei location
Pia (een: EAT e! Cee CN! LOREEN CRON 1 e l-2. Nongcheduled Authorized Field Activities (Sheet 3 of 3)
STAGE STATIC TEST (MTF) VEHICLE (KSC)
Start of Automatic
Section I
Recycle Due to Abort
o 8B Sa
e | a S2kgleES | $ 2) oe na o SR) ET cd $901 oo ee 09 BVO 8 jan > c °
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Change No. 11 - 6 May 1971
Subsequent to Start of __ Automatic Sequence
Hypergol Burst to Vehicle Lift-Off
>
1-9
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6967 1940190 & - ¢ “ON odURYD
Paragraph Activities Requirements Limits 1.1 INSPECTIONS tit OVERALL ENGINE a. Verify receipt of all equipment VISUAL INSPECTION listed on shipping documentation. FOR UNINSTALLCED ENGINES DURING b. Visually verify that ail exposed and Damage within limits RECEIVING INSPECTION accessible nortions of engine have of figure 1-3 SO not sustaaned damage due to ship- ment. c. Remove all engine protective Fluid is not
i.
i.
closures. Inspect oxidizer over- board drain line and nitrogen purge overboard drain line exits for fluid.
Visually verify that engine exterior is free of residual fluid.
Visually verify that hydraulic con- trol system exterior does not ex- hibit surface wetting.
Visually verify that all macnined areas of thrust chamber outrigger arms, turbopump mounts, and in- Side diameter of engine handler bearing are coated with corrosion preventative.
Visually verify that turbopemp and outrigger arm surfaces de sot con- tain scratches through paint.
. Visually verify that gas generator
fuel feed line gimbal joint yokes are not corroded and are coated with corrosion preventative.
Visually verzfy that gas generator fuel and oxidizer feed line bellows are not corroded,
Visually verify that auminum foil tape is installed over space between thrust chamber exhaust manifold and thrust chamber tubes and that white sealant RTV-102 (General Electric), or equivalent, is installed between thrust chamber tubes and external bands.
allowable.
Residual fluid is rot allowable.
Surface wetting is not allowable,
Machined areas without corrosion preventative are not allowable.
Metal visible in scratch 1s not allowable.
Corrosiva is not allowable,
and yokes without corresion
preventative are not allow- able.
Corrosion is not allowable.
Missing or damaged tape or voids in sealant are not allowable.
Snerial Constraints and Remarks
Retain protective covers for reinstallation. 901
If surface wetting is noted on component or flanged joints, refer to section II for criteria to use to establish joint acceptability.
Verification that white sea‘ int, or equivalent, 1s installed, applies only to engines in which white sealant was installed dur- ing engine manufacture.
99g
J uo
TT-968E -Y
Requirements
Limits
Special Constraints and Remarks
Visually verify that thrust cham-~ ber interior and exterior and thrust chamber exhaust manifoid exterior surfaces do not exhibit damage, such as dents, cracks, or bent or broken studs.
Visually verify that engine ex- terior does not contain dents, scratches, broken or missing lockwire, chafed bellows re- strainers, .r open taps.
Visually verify line markings for correct color ending and flow direction.
After completion of visual inspec-
tion, reinstall all engine protective closures except for fuel overboard drain line exit cover.
Install a clean polyethylene bag (ane gallon minimum volume) on fuel overboard drain line.
Visually ver fy that turbopump housing ca ities do not contain voids in cavity filler material.
Visually verify that humidity ind:cator in thrust chamber throat closure is blue,
Verify that engine orifice sizes as identified on engine are same as those specified in Engine Log
NOTE
The actual orifice diameter and the orifice diameter recorded in the Engine Log Book may differ by the allow- able mach.aing tclerance of
Paragraph 1.1.1 k, (cont) 1 mm, n. nA. o. g P. B wm s-J 3 q. -_ _ : Book. a = fa bet 2 box ‘pals Ae
the individual or:fice.
Damage within limits of figure 1-3
Damage within limits of figure 1-3
Missing or incorrectly coded line markings are not allowable.
Voids in cavity filler material are not allow- able.
Color other than blue is not allowable.
Orifice sizes other than
those specified in Engine Log Book are not allow-
able.
Polyethylene bag installed on fuel overboard drain line must allew free flow but pre- vent entry of contaminants. 901 Bag must be secured ina manner that allows rotation of engine from horizontal to vertical with bag filled with fluid. I i
CAUTION
Personnel must not enter a horizontal thrust cham- ber without using protective pads since damage to thrust chamber tubes will occur.
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TI-9686-u
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ZL6E 4940190 6 - #1 “ON aBuEY:
Paragraph
1 (cont)
1.1.2
Activities
OVERALL ENGINE VISUAL
INSPECTION FOR UNIN- STALLED ENGINES ES STORAGE
Requirements
Verify that engine sertalized components are same as those specified in Engine Log Book.
Remove turbopump shaft pre- load fixture,
Visually verify that LOX pump inlet and the 2 fuel pump inlet closure humidity indicators (30% spots) are blue.
Remove Engine Cover G4047, if installed.
. (Deleted)
(Deleted)
Visually verify that all machined areas of thrust chamber outrig- ger arms, turkopump mounts, and inside diameter of engine handler bearing are coated with corrosion preventative.
Visua.ly verify that gas genera- tor fuel feed line gimbal joint yokes 1re not correded and are coated with corrosion preven- tative.
(Deleted)
(Meleted)
Visually verify that humidity indica-
tor (30‘c spot) in thrust chamber throat closure is blue.
Limits
Special Constraints and Remarks
Serialized components
other than those speed in Engine Log Book are not allowable.
Color other tnan blue in 30% spots is not allowable.
Machined area without corrosion preventat.ve is not allowable.
Corrosion is not allow- able, and yoke without
corrosion preventative 18 not allowa':le.
Color other than blue is not allowable.
910
Stepsdande are performed every six months.
910 | a 930 a to I CAUTION 510 # 21 Personnel must not |
enter a horizontal thrust chamber with- out using protective pads since damage to thrust chamber tubes will occur.
] Bolas
TI-968€-u
2L6F 1990}90 6 - I ‘ON aBueyD
eI-1
Activities
Requirements
Limits
Special Constraints and Remarks
1.1.3
OVERALL ENGINE VISUAL INSPECTION FOR INSTALLED ENGINES IN STORAGE
i. (Deleted)
j. (Deleted)
k. (Deleted)
1. Determine if turbopump requires represervation; represerve turbo- pump, if necessary, and enter date in Enyine Log Book.
m. Visually verify that LOX pump in- let and the 2 fuel pump inlet closure humidity indicators (30% spots) are blue.
n. Reinszall engine cover if removed in step a.
a. (Deleted)
0, (Deleted)
c. Visually verify that ali machined areas of thrust chamber outrigger arms, turbopump muunts, and in- side diameter of engine handler bearing are coated with corrosion preventative.
d. Visuatly verify that gas generator fuel feed line gimbal joint yokes are not corroded and are coated with corrosion preventative.
e. (Deleted)
Color other than blue in 30% spots is rot allowable.
Machined areas without corrosion preventative are not allowable.
Corrosion is not allow- abie, and yokes without corrosion preventative are not allowable.
Refer to Engine Log Book for date of iast turbopump pres- ervation. Refer ta section I for turbopump represervation frequency.
steps c and d are performed every Six months.
910
950
11-968e-u
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Paragraph ——$S
11.3 {cont)
1.1.4
Activities
OVERALL ENGINE VISUAL INSPECTION FOR IN- STALLED ENGINES PRIOR TO STAGE SHIPMENT TO MAF OR MTF
{, Visually veri
Requirements
that humidity indicator (30"c spot) in thrust chamber throat security closure is blue.
g. (Deleted)
h. (Deleted)
i. (Deleted)
}. (Deleted)
k, Determine if turbopump requires represervation; represerve tur- bopump, if required, and enter date in Engine Jog Book.
l. (Deleted)
a. Verity that all equipment required for shipment is listed on shipping documentation and available for shipment.
b. Visually verify that all exposed and accessible portions of equip- ment are noc damaged.
c. Remove all engine protective closures. Inspect oxidizer over- board drain line and nitrogen purge
overooard drain line exits for fluid.
Limits
Color other than blue is not allowable.
Damage within limits of figure 1-3
Fluid is not allowable.
ae ar oer area Special Constraints
und Remarks
CAUTION sod
Personnel must not
enter a horizontal
thrust chamber with-
out using protective
pads since damage to
thrust chamber tubes
will occur. |
Refer to Engine Log Book for date of last turbopump pres- ervation. Refer to section K 902 for turbopump represervation 921 frequency. 937
& ogo 10 % I
oom Some
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Paragraph Activities
rr
1.1.4 d. (cont)
i.
Requirements
Visually verify that all machined areas of thrust chamber outrigger arms, turbopump mounts, anc inside diameter of engine handler bearing are coated with corrosion preventative.
. Visually verify that turbopump
and outrigger arm surfaces do not contair scratches through paint.
Visally verify that gas generator fuel teed line gimbal joint yokes are not corroded and are coated with corrosion preventative.
Visually verify that gas generator fuel and oxidizer feed line bellows are not corroded,
Visually verify that aluminum foil tape is installed over space be- tween thrust chamber exhaust munifold and thrust chamber tubes and that white sealant RTV-102 (General Electric), or equivalent, is instilled between thrust cham- ber cubes and external bands.
Visually verify that thrust chamber and thnist chamber exhaust mani- fold exterior surfaces do not ex- hibit damage, such as dents, cracks, or beni or broken studs.
Visually verify that engine ex- terior does not contain dents, scratches, broken or missing iockwire, chafed bellows restrainers, or oven taps.
. Visually verify that engine exterior
is free of residual fluid,
Visually verify line markings for correct color coding and flow Girection,
Limits
Machined areas without corrosion preventative are not allowable.
Metal visible in scratch
is not allowabie.
Corrosion 1s not allow- able, and yokes without corrosion-preventative are not allowable.
Corrosion 1s noc allow- able.
Missing or damaged tape or voids in sealant are not allowable.
Damage within limits of figure 1-3
Damage within limits of figure 1-3
Residual fluid 1s not allowable.
Missing or incorrectly coded line murkings are not ullowable.
Spectal Constraints and Remarks
Verification that white seal- ant, or equivalent, is in- stalled, applies only to en- gines in which white sealont was instalied during engine manufacture,
TI-9686-uU
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ZLGT 1899790 6 - PT “ON d¥uryy
Paragraph
Lid fcont)
114A
Activities
OVERALL ENGINE VISUAL
EINSPECT'ON FOR INSTAL-
LED ENGINES DURING RECEIVING INSPECTION AT MAF,
Q
Requirements
Visually verify that hyaraulic control system exterior does not exhibit surface wetting.
Remove fuel overboard drain system isolation hoses and install polyethy- lene bags on drain system as out- lined in section 1. Visually inspect fuel overboard drain system isola- tion polyethylene bags for fluid prior to shipment. Empty bags and meas- ure quantity of fluid in accordance with section IL.
Visually verify that turbopump housing cavities do not contain voids in cavity filler material.
Atier completion of visual inspection, install 21! engine protective closures and instail gimbal boot.
Visually verify that nuridity indi- cator in thrust chamber tnocat closure is blue.
Determine if turbopump requires represervation; represerve turbo- pump, if required, und enter date in Engine Log Bock,
Verify receipt of all equipment listed on shipping documen‘ation.
Visually verity that all exposed and accessible portions of engine have not sustained damage due to shipment.
Limits
Surface wetting is not allowable.
Voids in cavity filler
material are not allow-
able,
Color other than blue is not allowable.
Damage within iimits of figure 1-3,
tr ppp
Special Constraints and Remarks
—_— TS Py ye oe VE m.
If surface wetting is noted on component or flanged joints, refer to section Ii for crite- ria to use to establish joint acceptability,
gal
AUTION a c te) ani
Perscnnel must not t enter a horizontal thrust chamber without using protective pads since
damage to thrust cham-
ber tubes will occur.
Refer to Engine Log Book for date of last turbopump pres- | ervation. Refer te section II 9902 for turbopump represervation 921 frequency. 937
I voHaag
TI-9686-H
Speaal Constraints
Paragraph Activities Requirements Limits and Remarks Lida e, Remove all engine protective Fluid is not allowable. Retain protective covers {cont) closures. Inspect oxidizer for reinstallation
overboard drain line and nitrogen purge overboard drain line exits for fluid.
cA. Visually inspect bags installed on fuel overboard drain system dis- connections for fluid: empty bags anu measure quantity of fluid in accordance with section Il.
dad. Visually verify that ali machined Machined areas without areas of thrust chamber outrigger corrosion preventative arms, turbopump mounts, and are not allowable,
instde diameter of engine handler bearing are coated with corrosion
preventative. e. Visually verify that .urbopump and Metal visible in scratch outrizger arm surfaces do not con- ls not allowable.
tain scratches through paint.
f. Visually verify that gas generator Corrosion is not allow- fuel feed line gimbal joint yokes able, and yokes without are not corroded and are coated corrosion preventative with corrosion preventative. are not allowable.
g. Visually verify that gas zenerator Corrosion is not allowable.
fuel and oxidizer {ced line bellows are not corroded.
h. Visually verify that aluminum foil Missing or damaged Verification that white tape ts installed over space be- tape or voids in sealant sealant. or equivalent, is tween thrust chamber exhaust man- are net allowable. installed, applies only to fold and thrust chamber tubes and engines in which white that white sealant RTV- 102 sealant was installed (Gencral Electric), or equivalent, during manufacture.
is installed between thrust chamber tubes and external bands.
i. Visually verify that thrust chamber Damage within limits and thrust chamber exhaust mani- cf figure 1-3 fold exterior surfaces do net exhibit damaze, suchas dents. cracks. or bent or broken studs.
G9BI 1990100 6 - G “ON asuEYD
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Paragraph
Activities
Special Constraints
Requirements and Remarks
Limits
1.1.4A (cont)
1.1.48
z Ni A a. INSPECTION FOR IN- STALLED ENGINES PRIOR TO STAGE SHIPMENT TO KSC
Visually verify that engine exterior does not contain dents, scratches, broken or missing lockwire. chafed bellows restrainers, or open taps.
Damage wrtnin linuts of figure 1-3
After completion of visual inspection, reinstall LOX and fuel high-pressure
covers, oxidizer overboard drain line cover, and nitrogen purge overboard
duct covers, thrust chamber stud
drain tine cover.
Visually verify that turbopump housing cavities do not contain voids in cavity filler material.
Visually verify that humidity indi- cator in thrust cuamber tnroat closure is blue.
Verify that engine orifice sizes as identified on engine are same as those specified in Engine Log Book. NOTE The actual orifice diameter aud the orifice diameter re-~ corded in the Engine Log Book may differ by the allowable
machining tolerance of the individual orifice.
Verily that components listed on Engine Log Book Post-Delivery Serialized Component Replacement Record are same as those installed on engine.
Veruly that all loose equipment required for shipment is listed on shipping doct mentation and avail- able for shipment.
Visually verify that all exposed and accessible portions of loose equipment are not damaged.
Voids in cavity filler material are not allow- able.
Color otuer tnan blue 1s not allowable.
CAUTION
Personnel must not enter a horizontal thrust chamber with- out using protective pads since damage to thrust chamber tubes
Orifice sizes other than will occur.
those specified in Engine
Log Book are notallowable.
Serialized components cther than those specified in Engine Log Book are not allowable.
Damage within limits of figure 1-3.
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TT-988€-H
696T 4999390 6 - ¢ “ON adUEYD
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Paragraph
Activities
Requirements
Limits
Special Constraints and Remarks
11.48 (cont}
Remove all engine protective closures. Inspect oxidizer overboard drain line and nitrogen purge overboard drain fine exits for fluid.
Visually verify/accomphsnh that thermal insulation bracketry shown in figure 2-14 is installed,
Visually verify/accomplish that loose equipment is installed with exception of the following items and attaching parts:
1} Thrust chamber nozzle extension
(2) Nitrogen purge overboard drain tube
(3) Fuel overboard drain line
‘4) Oxidizer overboard drain line
(5) Igniters (6) Hypergol cartridge
Visually verify that all machined areas of thrust chamber outrigger arms, turbcopump mounts. and in- side diameter of engine handler bearing are coated with corrosion preventative.
Visually verify that turbopump and outrigger arm surfaces do not con- tain scratches through paint.
Visually verify that gas generator fuel feed line gimbal joint yokes are not correded and are coated with corrosion preventative.
Visually verify that gas generator
fuel and oxidizer feed line beliows are not corroded.
Ftuid is not allowable.
Machined areas without corrasion preventative are not allowable.
Metal visible in scratch rs not allowable.
Corrosion is not 2liow- able, and yokes without corrosi’ n preventative are not allowabir,
Corresion 1s not allew- able.
IT-968£-u
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ZL61 2099790 6 - $1 “ON eduRYyD
Daragraph
i. 1L.4B cont)
4 ctivities
i.
Requireinents
Visually verify that aluminum foil tape is installed over space between thrust chamber exhaust manifold and thrust chamber tubes and that white sealant RTV-102 (General Flectric), or equivaient, *s in- stalled between thrust chamber tubes and external ‘ands.
Visually verify that thrust chamber and thrust chamber exhaust manifold exterior surfaces do not exhibit damage, such as dents, cracks, or bent or broken studs.
Visually verify that engine ex- terior does not contain dents, scratches, broken or missing icckwire, chafed bellows re- strainers. open taps.
Visually verify that engine ex- terior is free of residual fluid.
Visually verify tine markings for correct color coding and flow direction.
Visually verify that hydraulic
control system exterior does not exhibit surface wetting.
Remove fuel overboard drain system
isolation hoses and install polyethy-
lene bags on drain system as outlined
in section II. Visually inspect fuel overboard deain system isolation polyethylene bags for fluid prior to
shipment. Empty bags and measure
quantity of fluid in accordance with section JI.
Visually verify that turbopump housing cavities do not contain voids in cavity filler materiat.
After completion of visual inspec- tion, instali all engine protective closures and install gimbal boot.
Limits
Missing or damaged tape or voids in seaiant are not allowable.
Damage within limits of figure 1-3
Damage within limits of figure 1-3
Residual fluid is not allowable.
Missing or incorrectly coded line markings are not allov.able.
Surface wetting is not allowable
Voids in cavity filler material are not allow- able.
Special Constraints and Remarks
Verincation that white seal- ant, cree mlent, 18 in- stallea. applies only to en- gines in wai... white sealant was installed during engine man cu ture.
If suriace wetting 15 nated on components or flanged joints, refer to section I for criteria to use to es-
tablish jcint acceptability.
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Special Constraints
Paragraph Activities Requirements Limits and Remarks 1.1.4B s. Visually verity that humidity Color othe. than blue CAUTION (cont) indicator (30°O spot) in thrust is not a*lowable. Personnel anuctok chamber throat security : * closure is blue. enter a horizontal thrust chamber with- vut using protective pads since damage to thrust chamber tubes will occur.
t, Determine if turbopump requires Refer ‘o Engine Log Book represervation: represerve for date of last turbopump turbopump, if required, and preservation, Refer to enter date in Engine Log Book. section II for turbopump
represervation frequency, 1.1.5 ENGINE VISUAL a. Verify receipt of all equipment INSPECTION FOR INSTALLED listed on shipping documentation. TERGaT Ge b. Visually verify that all exposed and Damage within limits <o accessible portions of engine have of figure i-3 KSu not sustained damage due to shipment.
c. Remove all engine protective Fluid is not allowable. Retain protective covers closures. Inspect oxidizer over- for reinstallation. board drain line and nitrogen purge overboard drain line exits for fluid.
d. Visually inspect bags installed on fuel overboard drain system dis- connections for fluid; empty bags and measure quantity of fluid in accordance with section I.
e. Verify that engine soft good in- stalled life is within limits spect- fied in section II.
{. Visually verify that all machined Machined areas witl.:at areas of thrust chamber outrigger corrosion preventative arms, turbopump mounts, and is net allowab.e. inside diameter of engine handler bearing are coated with corrosion preventative.
g. Visually verify that turbopump and Metal visible in scratch outrigger arm surfaces ao not con- is not allowable.
tain scratches through paint.
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Activities
Requirements Limits and Remarks
11.5 (cant)
h,
i
Visually verify that gas cenerator fuel feed line gimbai joint yokes are not corroded and are coated with corrosion preventative.
Visually verify that gas generator fuel and oxidizer feed line bellows are not corroded.
Visually verify that aluminum foil tape is installed over spoce between thrust chamber exhaust manifold and thrust chamber tubes and that white sealant RTV-102 (General Electric), or equivalent, is installed between thrust chamber tubes and external bands.
Visually verify that thrust chamber and thrust chamber exhaust mani- fold exterior surfaces do not exhibit damage, such as dents. cracks, or bent or broken studs.
Visually verify that engine exterior does not contain dents. scratches. broken or missing lockwire, chafed bellows restrainers, or open taps.
After completion of visual inspection, reinstall LOX and fuel high-pressure
duct covers and thrust chamber jacket covers.
Visually verify that turbopump housizr, cavities do not contain voids in cavity filler materia!.
Verify that engine orifice sizes as identified on engine are same as those specified in Engine Log Book. NOTE The actual orifice diameter and the orifice diameter re- corded in the Engine Log Book may differ by the allowable machining tolerance of the individual or:fice, Verify that components listed on Engine Log Book Post-Delivery Serialized Component Replacement
Record are same as those installed on engine.
Corrosion is not allow- able, and yokes without corrosion preventative are not allowable.
Corrosion is not allow- able.
Missing or damaged tape or voids in seal- ant are not allowable.
Verification that white Sealant. or equ’valent. is installed, applies only to
engines in which white sealant was installed dur- ing engine manufacture.
Damage within limits of figure 1-3
Damage within limits of figure 1-3
mam S ure
Voids in cavity filler material are not allowable,
rifice sizes other than those specified in Engine Log Book are not allowable.
Serialized components other I than those specified in Engine 909 Log Book are not allowable.
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Activities
Requirements
Special Constraints
Limits and Remarks
a LE RT
1.1.6
OVERALL ENG™NE VISUAL
INSPECTION SUBSEQUENT
TO ENGINE STATIC TEST AND TEST ABORT
THRUST CHAMBER NOZZLE EXTENSION VISUAL IN- SPECTION DURING RECEIV- ING INSPECTION
THRUST CHAMBER NOZZLE EXTENSION VISUAL
INSPECTION SUBSEQUENT TO
ENGINE STATIC TEST
Visually verify that aluminum tape is installed over space between thrust chamber hot-gas manifold flame shield and thrust chamber tubes and that winte sealant RTV-102 (General Electric}. or equivalent, is installed between thrust chamber tubes and external bands.
Visually verify that thrust chamber and thrust chamber exhaust manifold exterior surfaces do not exhibit damage, such as dents, cracks. tensicn tie deformation, and bent or broken studs.
Visually verify that overall engine exterior does not con- tain dents. scratches. broken or missing lockwire. chated bellows restrarimers.
Inspect nozzle extension to verify that interior and extec- rior surface damage (e.u.. cracks, dents. missing nut plates. loose or damaged
blind nuts. thread damase,. or flange sealing surface damage) has not oceurred during shipping and handling.
Inspect nozzle extension for follow ing
(1) Distortion af outer shell
(2) Buckles or cracks in outer bands
(3) Carbon deposits around flange area (indication of seal leakae)
(4) Nutplates and blind nuts damaged, loose, or nussing
(5) Internal erosion (6) Shingle separation from Z-bars
(7) Shingle thermal buckling
Verification that white sealant. or equivalent. 1s instalicd. applics only to engines in which white 902 sealant was installed dur-
ing engine manufacture.
Missing or damaged tape or voids in sealant are not allowable.
Damage within limits of figure 1-3
Damage within limits of figure 1-3
Damage within limits of ficure 1-3
Perform after thrust chamber fuel yacket drain and fuel fecd system drain.
Damage within limits of figure 1-3
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ue 1.9
1.1.16
1.1.11
1,1,12
Activities
THRUST CHAMBER TUBES VISUAL INSPECTION
THRUST CHAMBER [IX-
JECTOR CONTAMINATION
INSPECTION
THRUST CHAMBER INJECTOR DAMAGE INSPECTION
THRUST CHAMBER DRAIN
ADAPTER TORQUE VERIFICATION
Requirements
Inspect thrust chamber internal surfaces for errosion, nicks, dents, and tube splits.
Visually inspect for the follow- ing:
(1) Injector orifices are re- stricted by foreign matter.
(2) Back of injector rings {as inspected through injector orifices) contain foreign matter,
Visually inspect thrust chamber mjector for the following:
(1) Baffle separation
(2) Baffle deformation
(3) Face and/or baffle e:osion
(4) Baffle orifice distortion and eracks
(5) Ring orifice distortion i6) Baffle-to-baiffle cracks (7) Ring-to-land separation Retorque and safetywire the 4 thrust chamber exit manifold
arain adapters, Record actual torque value.
Limits
See figure 1-3 for dam- age limits.
No contamination is al- lowable.
See figure 1-3 for dam- age l:mits.
Special Constraints and Remarks
Perform after thrust cham- ber fuel jacket drain and fuel feed system drain.
Accomplish subsequent to LOX dome flush, tnrust chamber fue! jacket flush, thrust chamber liquid leak test. and thrrst chamber pneumatic leak test, if performed.
Accomplish subsequent to thrust chamber fre! jacket flush, LOX dome flush, and thrust chamber hquid leak test, if performed.
Perform prior to thrust chamber lquid leak test, if performed,
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Paragraph Activities
Requirements
Special Constraints and Remarks
—— ese
1.1.12A ENGINE JOINTS
CLOSURES REMOVAL VERIFICATION AT
MTF
Visually verify removal of protective
closures from the following joints:
(1}
(2)
(3)
(4)
(5)
(6)
(7)
{8)
{9)
(10)
(11)
(12)
(13)
(14)
No. 1 fuel high-pressure duct to igniter fuel supply tube
Igniter fuel supply tube to igniter fuel valve
Hypergol manifold to hypergol manifold outlet hose
Hypergol manifold to hypergol bleed adapter
Thrust OK pressure switch to thrust chamber fue] manifold
Onidizer bypass hose ta GOX duct (heat exchanger end)
Helium supply duct (heat exchanger end) to hehum bypass hose
Helium bypass hose to helium return duct (heat exchanger end)
Engine control valve ground hydraulic supply hose to GSE hydraulic supply check valve
Engine control valve supply tube to engine hydraulic supply check valve
Engine control valve to propel- lant valves close tube
Propellant valves open tube to No. 1 oxidizer valve
Propellant valves open tube to No. 2 oxidizer valve
No. 2 oxidizer valve sequence valve to sequence valve line
Perforin after last mainte- nance on specified joints
and prior to admitting fluid to }ainc for engine static test.
Closure removal tetween stage and engine interface shail be performed and verified by stage contractor.
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11,124 {cont)
{16}
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26}
(27)
(28)
{29)
Sequence vaive line to No. 1 oxidizer valve sequence valve
No. 1 oxidizer valve to gas generator open tube
Gas generator ball valve (oxidizer side} to gas generator injector
Fuel impeller balance cavity return hose to turbopump {orifice end)
Oxidizer seal vent tube to oxidizer overboard drain line
Cover plate to fuel drain manifold
Fuel drain manifold to fuel overboard drain line
Fuel overboard drain line to fuel overboard drain line
Turbopump to turbine bearing lube drain hose
No. 2 bearing lube drain line to fuel drain manifold (cover on engines incorporating MD145 change)
No. 1 bearing lube arain line to fuel drain manzfold (rover on engines incorporating MD145 change)
Turbine bearing lube drain hose to fuel drain manifold
Gas generator oxidizer purge tube to purge check valve
Purge check valve to gas generator ball valve
Pump seal purge line to oxidizer pump seal purge tube
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Activities
Requirements
Limiis
Special Constraints and Remarks
A yrs hes sss
1.1, 123
ENGINE JOINTS CLOSURE REMOVAL VERIFICATION AT KSC
Visually verify removal of protective
closures from the following joints:
(1)
(2;
{3)
{5)
(6)
{7)
(8)
(9)
(10)
(11)
(12}
(13)
(143
No. | fuel high-pressure duct to igniter fuel supply tube
Irniter fuel supply tube to igniter fuel valve
Hypergol manifold to hypergol manifoid outlet hose
Hypergol manifold to hypergol bleed adapter
Thrust OK pressure switch to thrust chamber fuel manifold
Oxidizer bypass hose to GOX duct (heat exchanger end)
Helium supply duct (heat exchanger end) to helium bypass hose
Helium bypass hose to helium return duct (heat exchanger end)
Engine control valve ground hydraulic supply hose to GSE hydraulic supply check valve
Engine control valve supply tube to engine hydraulic supply check valve
Engine control valve to propel- lant valves close tube
Propellant valves open tube to No. 1 oxidizer valve
Propellant valves open tune to No. 2 oxichzer valve
No. 2 oxidizer valve sequence valve to sequence valve Line
Perfcrm after last mainte- nance on specified joints and prior to closing vut therma) insulation installa- tion over specified joints.
Closure removal between Stage und engine interface shall be performed and verified by stage contractor.
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Paragraph
1.1. 12B (cont)
1.1.13
Activities
CHECKOUT VALVE GROUND POSITION
VERIFICATION
(18)
(19) (20) (21} (22) (23)
(24)
{25)
(26) (27) (28)
(29)
Requirements
Sequence valve line to No. 1 oxidizer valve sequence valve
No. 1 oxidizer valve to gas generator open tube
Gas generator ball vaive (oxidizer side) to gas generator injector
Fuel impeller balance cavity return hose to tirbopump {orifice end)
Oxidizer seal vent tube to oxidizer overboard drain line
Cover plate to fuel drain manifold
Fuel drain manifold to fuel overboard drain line
Fuel overboard drain line to fuel overboard drain line
Turbopump to turbine bearing lube drain hose
No. 2 bearing lube drain line to fuel drain mamfold (cover on engines incorporating MD145 change)
No. 1 bearing lube drain line to fuel drain manifeld (cover on engines incorporating MD145 change)
Turbine bearing lube drain hose ta fuel drain manifold
Gas generator oxidizer purge tube to purge check valve
Purge check valve to gas generator bal. valve
Pump seal purge Line to oxidizer pump seal purge tube
Verify by instrumentation indication that checkout valve is in the ground position.
rrr ee
Special Constraipts and Remarks
Perform prior to fuel feed syStem drain, if performed.
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1.4.14
1.1.15
1.1.16
1.1.17
1.1.18
1.1.18A
1.1.19
Activities
PROPELLANT VALVES
CLOSED VERIFICATION
HYPERGOL INSTALLED
VERIFICATION
LOX DOME AND GAS GEN- ERATOR LOX INJECTOR PURGE OFF VERIFICATION FOR ABORT PRIOR TO GAS ENERATOR IGNITION
Requirements
Verify by instrumentation indication tnat the fullowing propellant valves arc closed:
(1) No. t fuel valve
(2) No. 2 fuel valve
(3) Gas generator ball valve
(4) No. 1 oxidizer valve
(5) No. 2 oxidizer valve
Verify by instrumentation indica-
tion that operational high-level purge was on.
Verify by instrumentation indica- tion that hypergol installed switch remains picked up,
Verify by instrumentation indica- tion that igniter links have not broken.
Verify that turbopump heater power
is turned on and thermostats are cycling as long as LOX remains in engine system.
Verify by instrumentetion indica- tion that purge is operating as long as propellants remain in engine system.
Turn operational high-level purge off as soon as it hus been verified that ignition did not occur.
Limits
Within limits specified in section 0
Within limits specified in section 0
Within pressure limits specified in section 0
Within limits specified in section
Special Constraints und Remarks
Perform prior to fuel feed system drain, if performed.
If purge was off or not within limits during engine shutdown, the LOX dome and gas generator LOX in- jector must be flushed,
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1.1. 20
1.1.21
1.1. 22
1.1.23
Activities
LOX DOME AND GAS GENERA- TOR LOX INJECTOR PURGE
OFF VERIFICATION FOR
>
TOR IGNITION
COCOON PURGE ON VERIFICATION
THERMAL INSULATION VISUAL INSPECTION
OVERALL ENGINE VISUAL INSPECTION FOR UXIN- STALLED ENGINES PRIOR TO SHIPMENT
BORT AFTER GAS GENERA-
co
c.
Requirements
Turn off operational inga-level purge, and turn on operational low-level purge. Maintain opera- tional low-level purge for one hour after engine shutdown.
Verify that cocoen purge is cycled, as required.
Visually inspect exterior surfaces for cracks, dents, broken fasten- ers, missing or loose fasteners, and erasion.
. Verify that all loose equipment required
for snipment is listed on shipping documentation and availavie for shipment,
Visually verify that all exposed and accessible portions of loose equipment are not damaged.
Visually verify tnat 211 machined areas of thrust cnamber outrigger arms, turbopump mounts, and inside diameter of engine handler bearing are coated with corrosion preventative.
Visually verify that turbopump and outrigger arm surfaces do not con- tain scratches through paint.
Visually verify that gas generator fuel feed line gimbal joint yokes are not corroded and are coated with corrosion preventative.
Visually verify that gas generator fuel and oxidizer feed line bellows are not corroded,
Limits
Within limits speci- fied in section I
To maintain engine temperature within limits specsfied in section I
Damage within limits of figure 1-4
Damage within limits of figure 1-3
Machined areas without corrosion preventative are not allowable.
Metal visible in scratch 1s not allowable.
Corrosion 15 not alluw- able, and yokes without corrosion preventative are not allowable.
Corrosion 1S net allow- able.
Special Constraints and Remarks
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Paragraph Activities
Requirements
Limits
Speeial Constraints and Remarks
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1.1. 23 ge {cont)
- ry
j.
1%
Visually verify tnat aluminum
foil tape is installed over space between thrust chamber exhaust manifold and thrust chamber tubes and that white sealant RTV-102 (Generali Electric), or equivalent, is installed between thrust cnamber tubes and external bands.
Visually verify that thrust cham- ber and thrust chuniber exhaust munifold exterior surfaces do
not exhibit damage, suca as dents, cracks, or bent or broken studs,
Visually verify that engine exte-
rior dves not contain dents, scracches, broken or missing lockwire, chafed bellows restrainers, or open taps.
Visually ve rify that turbopump housing cavities do not contain voids in cavity filler material.
Remove drainage line from fuel overboard drain line exit; then after completion of visual inspection, install al! engine protective covers and install gimbal boot.
Visually verify that humidity indi- cator in thrust chamber throat closure is blue,
. Determine if turbopump requires
represervation; represerve turbo- pump, if required, and enter date in Engine Log Book.
. Install turbopump shaft preioad
fixture.
Missing or damaged tape or voids 1n sealant are not alluwable.
Damage within limits of figure 1-3
Damage witoin limits of figure 1-3
Voids in cavity filler material are not allow- able.
Color other than blue 1s not allowable.
Verificution that woite s@alant, or equivalent,
is installed, applies only to engines in which white sealint was installed dur- ing engine manufacture.
CAUTION
Personnel must not enter a horizontal thrust chamber without using protective pads since damage to thrust cham- ber tubes will occur.
P«fer to Engine Log Book
fux date of last turbopump w preservation, Refer to 902 section H Zor turbopump 921 represervation frequency. 937
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Activities
Requirements
Limits
a
Special Constraints aad Remarks
OO OO Eee ESE
1.1.23 {cont)
1.1.24
1.1.25
1. 1.26
1.1.27
1.1.28
1.2
1.2.1
{Deleted}
THRUST CHAMBER NOZZLE EXTENSION VISUAL IN- SPECTION SUBSEQUENT TO
LAUNCH ABORT
(Deleted)
THRUST CHAMBER NOZZLE SION FASTENER
TORQUE VERIFICATION SUB- SEQUENT TO STATIC TEST
ABORT
THRUST CHAMBER DRAIN PLUG TORQUE VERIFICA-
TION
ELECTRICAL TESTS
FLIGHT INSTRUMENTATION a. SYSTEM FUNCTION TEST
FOR UNINSTALLED EN-
GINES
Visually verify that LOX rump inlet and the 2 fuel pump inlet closure humidity indicators (20% spots) are blue.
Visually inspect nozzle ex- tension interior for erosion, shingle separation frum Z-bars. and shingle thermal buckling.
Perform torque check ofnozzle extension flange fasteners. Re- cord results.
Retorque and safetywire the 4 thrust chamber exit manifold drain plugs. Record actual torque value.
Measure and record ambient (run) output voltage of each pressure transducer.
Color other than blue 1s not alluwable.
See figure 1-3 for dam- age hinits.
Torque-check every tenth fastener. If any fastener is not within limits, retorque all 240 fasteners.
The voltage linnts for ambient {run}. tions must be withi. +3. (2250 millivolts} of full seate of the value re- corded in the Engine Log Book, F-1 Final Acceptance Checkout Data, after correction for ambient pressure difference. {Refer tu section YI for individual pressure transducer data. )
Perform subsequent to fuel feed system drain and thrust chamber fuel jacket drain
Perform after thrust chamber J liquid-leak test and thrust 2 chamber fuel jacket flush. |
an
Perform prior to hydraulic pystem leak and function test, valve timing test, fuel feed system leak test, LOX feed system leak test, heat exchanger hehum system leak test, heat ex- changer LOX system leak test, exhaust system leak test, turbopump heater function test. safety cir- cuits function test, and se- quence verification test, if performed.
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Special Constraints
Paragraph Activities Requirements Limits und Remarks 1.2.1 b. Measure and record 20% und 80% The voltage linuts for 20% and Use section I table for (cont) output voltage of each pressure 60% conditions must be witnin initial pressure trans-
¢
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(a) Engines not incorporating MD96 change
T
& (¢) Engines not incorporating MD176 change
triansducer.
Measure and record resistance of the following temperature trans- ducers:
(t} LOX pump bearing No, 1: {a} Pins Ato B t&) Pins AtoC
(2) (Deleted)
(3) Turbine iniet(¢): (a) Pins Ato B (>) Pins Ato C
(4) Engine environmental: {a} Pins Ato B (b} Fins Ato C
(5) Fuel pump inlet No. fa) Pins AtoB (b) Pins Ato €
2).
(6) Heat excnanger LOX inlet: (a) Fins Ato B fb) Fins Ato €
(7) Heat exchanger GOX outlet (a), (a) Pins Ato B (b} Pins Ato C (8) Heat exchanger helium outlet“), fa} Pins Ato B (b) Pins Ato C
(b) Resistance value is 465-=34 ohms on engines incorporating MD159 change
+2% (2100 millivolts) of full scale of the adjusted value recorded in the Engine Log Book, F-! Final Accep‘ance Checkout Datu. {Refer to section IL. }
Resistance value in ohms: 465 +34 465 +34
1,370 +100 1,370 +100
1,370 +100 1,370 4100
465 +34 465 234
465 +34 465 +34
ducer dat: for those in- struments that have no
data availiable in Engine Log Book,
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1.2.1 (cont)
Activities
Requirements
d. Mearure and record output «f
each heat ex hangsos Qowmete: <{ransuuce:' primary coil with 5.0 t0 7.5 vac peak. 200 +20 cps input on s-condary coil.
Measure ond record output of primary soil of turbcpump speed transaucer with 5.0 to 7.5 vac peak, 200 +20 cos inpui on secondary coil.
Measure and record resistance ot the f[nllowing vaive potentioineters:
(1) No. i oxidizer valve (closed): (a) J102, pins Gto E fb) J102, sins E to F (c} 3102, pins G to F (d) J103, pin R to 7100 or J101, pin Cc (e} J193, pins RtoS
(2) Mo, L fuel valve (closed): (a) 102, pins P to B (>) J162, pins Broc {ec} 3102, pins Pte C {d} J103, pin F, to J100 or J101, pin Cc fe) J103 pins E to F
{3) No. 2 oxidizer vulve (closed): (aj) J102, pins TtoH {b) J102, pins H to J {c} J102, pins T to J (d) 3103, ,in T, to J100 or J101, pin Cc {e} J103, pins T to J
(4) No, 2 fuel valve (closed): {a) J102, pins S to D fo} J102, vins Dito R {c) J102, pins Sto R (d) J103, pin H, to 3100 o: J101, pin c (e) J103, pins Gto H
Limits 0,2 to 3.0 vuc peak and approximately same frequency and wave shape a5 input voltage
0,4 to 5.6 vac peak and approximately same frequency and wave shape as input voltage
Resistance value in ohms:
————$————
Special Constraints und Remarks
ments column are on inter- face panel,
482 +80 2,120 +159 2, 000 +120
5 maximum infinity
500 +80 2,095 +345 2, 000 +120
5 maximum infinity
482 =80 2,120 +150 2,000 +120
5 maximum infinity
500 +80 2,055 +345 2,090 +120
§ maxinium infinity
Connectors Histea in Requice-
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Special Constraints
Paragraph Activities Require ments Limits and Remarks wad {5) No. 1 oxidizer valve (open): {cont} (a) J102, pins GtoE 2, 135 ~285 (b) 3102, pins E to F 465 +195 (c) J102, pins G to F 2,000 +120 (d) 3103, pin S, to J100 or J101, pin c 5 maximum (e) 3103, pins Rta S infinity (6) No. 1 fuel valve (open): (a) J202, pins PtoB 2,095 +345 (0) 3102, pins Bto Cc 495 +165 (c} J102, pins PtoC 2,000 +220 {d} J103, pin F, to J100 oz J101 pin C > maximum {e) J103, pins E to F infinity (7) No. 2 oxidizer valve (open): {a) J102, pins T tod 2,135 +285 (o) J102, pins H to] 465 +195 {c} J202, pins T to J 2,000 +120 (ad) 3103, pin C, to J100 or Ji0L, pin 5 maximum (e) J103, pins T to J infinity (8) No. 2 fuel valve (open): (a) J102, pins Sto D 2, 095 +345 {ob} J102, pins DtoR 495 +165 (c} J102, pins Sto R 2,000 +120 (d) J103, pin G, to 3100 or J101 pin 3 maximum (e) J103, pins G to H infinity (9) Gas generator ball valve (epen): fa) J103, pin C, to J100 or J101 pin C 5 maximum fb) J103, pin. C to D infinity (10} Gas generator ball valve {closed}: {a} J103, pin D, to J100 or J101, pan C 7 maximum fb} 2103, pins C to D infinity
11-968E-U
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1.2.3
Activities
FLIGHT INSTRUMENTATION SYSTEM FUNCTION TEST FOR INSTALLED ENGINES
TURBOPUMP HEATER FUNCTION TEST
a.
c.
e.
Requirements
Measure and record ambient (run} cutput voltage of each pressure transducer,
Meacure and record 20% and 80°% output voltage of each pres- sure transducer,
Test each temperature trans- ducer in conjunction with stage signal conditioning equipment during ambient calibration, for co, tinu.ty and resistance
Test heat exchanger flowmeter secondary and primary coil for continuity in conjunction with stage signal conditioning equipment,
Test tursopump speed transducer secondary and/or primary coil for continuity in conjunction wits stage signal conditioning equip- ment,
Meusure and record LOK pump vearing No. 1 temperature at wiicn turbopump tiermostats cycle.
Limits
Voitage limits for ambient (run) conditions muct be Within +5° (2250 millivolts) of full Veale of tue value recorded in tae Engine Lov Soox, F-1 Final Acceptance Cueckout Data, after cor~ rection for anvient pressure difference,
Voltage limits for 20% and 80% conditions must be within +2% {+100 millivolts) of full scale of the adjusted value re- corded in the Engine Log Book, F-1 Final Acceptance Checkout Data.
Ambient resistance value of each instrumert must meet values listed in paragraph 1.2.1. Continuity must exist between all pins.
Continuity must exist tnrougu
secondary and/or primary coil.
Continuity must exist toroug.
secondary and/or primary coil,
Tuermostat pickup and dropout muct occur ,éetween 65° and 180° F.
Special Constraints and Remerks
Perform prior to hydraulic control system leak and function test, valve timing test. fuel feed system leak and function test, LOX feed system leak and function test, heat exchanger helium system leak test, heat ex- changer LOX system leak test, exhaust system leak test, turbopump heater func- tion test, safety circuit funetion test. and sequence verification test, if per- ormed. Instrument sensing diaphragms must be exposed to ambient pressure during test.
Use section II table for ini-~ tial pressure transducer data for those instruments th. have no data available in ‘ue Engine Log Book.
Perform prior to safety cir- cuits function test and se~- quence verification tests, if performed, and after fligat instrumentation systems test.
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Paragraph
1.2.3 {cont}
1.2.4
1.2.5
Activities
HYPERGOL INSTALLED SWITCH FUNCTION TEST
CHECKOUT VALVE
TIMING TEST
Requirements
b, Measure and record turbopump heuter current drain,
Mechanically simulate nypergol installed switch pickup and drop- out indication.
Measure and rocord time required to cycle checkout valve from ground po. ition to engine position and from engine position to ground position, (Repeat tet 3 times.)
Limits
7,5 +2.5 amperes per weater
Hype cgol-installed indication must occur wien oypercol installed is simulated mecaanically and must drop out wnen nypergol-installed simulation is removed,
Ground position switen drop- out to engine position pickup must ve vetween 0.5 and 3.5 seconds. Engine pocition switen dropout to ground position switch pickup mest be between 0.5 and 3.5 seconds.
and Remarks
Perform prior to safety circuits function test, ig- nition monitor valve inter~ flow test, and sequence verification test, if per- formed.
CAUTION
Use extreme care when installing hypergol sys-~ tem test tool, to pre- vent damage to hypergol cartridge follower.
@ Make sure that threads of test tool cap are clean and free of nicks, to prevent galling threads of cap and inlet port.
Use hypergol system test tool 9021279, or equivalent, from
Hypergo! System Tool KitG3135
to actuate and deactuate switch.
Hypergol system test tool must be tested for proper operation,
prior to installing in hypergol manifold.
Perform prior to safety cir- cuits function test, sequence
verification test, and hydraul-
i¢ control system leak and function test, if performed.
CAUTION
Ground hydraulic pres- Sure must not be applied te the engine during checkout valve cycling.
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1.2.6
1.2.7
1.2.8
1.2.9
Activities
ENGINE SAFET £ CIRCUITS FUNCTION TEST AT MTF
ENGINE SAFETY CIRCUITS FUNCTION TEST AT KSC
ENGINE SEQUENCE VERIFICATION TEST
IGNITER TEST
Requirements
Verify safety circuits acceptabil- ity by performing electramechan- ical simulation of a static test for each satety circuit.
Verify safety circuits acceptabil- ity by performing an electromechan- ical simulation of a launch for each safety circuit.
Perform electromechanival simula- tron of an engine sequence te verify proper operation of each individual and combined electrica: and mechan- ical sequence requirement of section II.
a. Visually inspect each igniter prior to testing for: {1) Closure damage (2) Thread damage
(3) Bent ox Youse receptacle
: pins
(4) Nicked er scratcned gasket or gasket seating surfaces
(5) Six-month time exceeded since igniter was removed from container,
Limits
Within limits specified in section I for static test safety circuits
Within limits spe sified in Section I for launch safety circuits
Within limits specified in section I for engine se- quence acceptability
No damage is allowable. No damage is allowab!z. No damage is allowable.
No damage is allowable.
Special Constraints and Remarks
Perform subsequent to hy- draulic control system leak test, hypergol installed switch test, turbopump neater test, thrust OK pres- sure switch leak and function test, flight instrumentation system test, and checkout valve timing test, if appli- cable. Perform prior to engine sequence test and valve timing test.
Perform subsequent to hy- draulic control system leak test, hypergol installed switch test, turbopump heater test, thrust OK pres- sure switch leak and function test, checkout valve timing test, and flight instrumenta- tion system test. Perform prior to engine sequence test and valve timing test.
Perform subsequent to safety circuits function test.
Perlorm prior to installation on engine.
Use Igniter Tes‘er G3153, or equivalent. The igniter tester
must be tested for proper oper-
ation prior to conducting this test,
During testing. the igniter must
be installed in 4 protective de- vice that wil) prevert injury to
personnel in event cf accidental
firing of an igniter.
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Activities
Requirements
Limits
Special Constraints und Remarks
a TP ce sheesh
1.2.9 (cont)
1.2.10
1.2.11
INERT IGNITER TEST
IGNITER HARNESS CONTINUITY TEST
(6) Service life expired
b. Utilizing a high-voltage igniter tester, verify meter indications for the following switch selector settings in the order listed:
(1) No fire test (2) Fire test (3) Insulation test 1, 2, and 3 (4) Link a. Visually inspect each inert igniter prior to testing for: {1} Closure damage (2) Thread damage
(3) Lent or loose receptacle pins
(4} Nicked or scratched gasket ur gusket seating surfaces
b. Utilizing a high-voltage igniter tester, verify meter indications for the following switch selector in the order listed:
(1) No fire test
(2) Fire test
(3} Insulation test 1, 2, anu 3 (4) Link
c. Test insulation resistance at the following pins using 500 vde for 5-60 seconds:
(1) Pin B to case (2) Pin A toD
a. (Deleted)
b. Verify igniter harness pin-to- pin continuity.
c, (Deleted)
Service life must meet re- quirements of section II.
Less than one milliampere 3.5 to 8.0 milliamperes 100 megohms minimum
Jn green area of meter
No damage is allowable. No damage is allowable. No damage is aliowable.
No damage is allowable.
Lese than one milliampere Less than one milliampere Creater than 160 megohms
In green urea ot meter
Greater than 200 megohms Greater than 200 megohms
Pin-to-pin continuity.
916
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Perform prior to igniter installation.
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1.2.12
VIBRATION SAFETY a. CUTOFF VERIFICATION TEST
Requirements
Install accelerometers in engine taps CZA1, CZA10, and CZA4.
Connect and secure accelerometer
cable,
Visually verify the following vibration safety cutoff unit dial settings:
(1) DELAY TIME (2) STORAGE TIME
Allow isoiation amplifier and vibration safety cutoff unit temperature to stabilize.
Disconnect accelerometer leads fron: aceelerometer and test each isolation amplifier output to its vibration safety cutoff unit input as follows:
{1) Increase input voltage to each isolation amplifier to calculated cutoff voltage,
25%,
(2} Test voting logic circuit by paralleling input voltages to isolation amplifiers at cal- culated cutoff voltage +5% (2, 000 +20 cps).
Limits
276 £5%
zero
Cutoff indication on vibration safety cutoff unit. No engine cutoff from voting logic.
Engine cutoff must occur.
Special Constraints and Remarks
CAUTION
Torque must not exceed 20 inch-pounds or the acceler- ometer may be twisted off. The accelerometer cable must be disconnected (if attached) prior to the instal- lation of the accelerometer, to prevent possible twisting. The accelerometer is 2 sensitive instrument that can be damaged by rough treatment, such as drop- ping, sharp blows, or overtorquing. Do not secure accelerometer cable to cryogenic lines or surfaces. Verify that cable is not twisted or damaged,
Utilize a signal generator set at 2,000 +20 cps and an ac volt- age source of less than 0. 25 volts rms.
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122512 :. Perform an audio tap test after Audible output must exist (cont) installatio: of accelerometer from eacn vibration safety
wads by tapping gently on thrust cutoff unit. chamber dome.
1.28 THRUST OK PRESSURE Cycle switcnes 3 times from zero Swite. pickun pressure 1,060 CAUTION SWITCH FUNCTION TEST to 1, 240 +30 psig wit gaseous +65 psit on second and subse- Prngcurwalton rates fusk nitrogen applied at calivration quent cycles; switen dropout be limited to 50 psig sec Port. pressure 50-100 psig below pees
from 0-895 psig and 5 psig/ sec from 895 to 1,270 psig. Depressurization rates must be {imited to 5 psig/ see from 1,270 to 895 psig-
pickup pressure on second and subsequent cycles.
age
1.2.14 IGNITER HARNESS a. Disconnect igniter harness plug Perform prior to igniter CONTINUITY AND INSUL- P47 from receptacle J47. installation, ATION RESISTANCE TEST
b. Measure igniter harness pin- Onc chm maximum between to~pin resistance a. fallows: pins
From To
P47-B P43-B P47-D P43-D P47-C P43-A P47-T P43-C P47-U P44-C P4T-A P44-A P47-J P44-D P47-F P44-B P47-K P45-B P47-H P45-D kaT-M P45-C P47-R P45-A P47-N P46-2 P47-G P4c-A P47-S P46-B P47-E P46-D
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Activities
Requirements
Limits
Spe cial Constraints and Remarks
1.2.14 {cont}
1.2.15
L322 1.3.3
CHECKOUT VALVE ENGINE RETURN SWITCH POSITION VERIFICATION
E, iD FUNCTION TESTS TURBOPUMP TORQUE Test (Deleted)
THRUST OK PRESSURE
SWITCH LEAK AND FUNCTION
TEST
Apply 500 vdec for 6-50 seconds between each pin and connector shell and every other pin in the pame connector except those pins that are interconnected to ‘the shielding and measure har- nesS insulation resistance.
Connect igniter harness plug P47 to receptacle J47. Torque and safetywire plug to receptacle.
Verify continuity of engine rewin switch motor circuit {J-18, pins t to p).
Rotate turbopump one full revo- lution (minimum) in clockwise and counterclockwise direc- tron. Measure and récord turbopump Shaft breakaway and running torque.
200 megohms minimum
20 foct-pounds maximum. No birding, scuffing, rubbing, runeven torque is allowable,
Leak-test all joints at 1,125-* 200 No exteraal leaka se is
psig gaseous nitrogen pressu.e.
allowable.
CAUTION
Insulation resistance test must not be per- formed if connectors are wt and voltage must not be applied
to interconnected pins at the same time since a short circuit can result in damage to equipment,
Perform requirement subse- quent to last checkout valve actuation prior to static test at MTF and launch at KSC
Connectors listed in Require- ments column are on interface panel. Measurement may be taken in facility circuitry.
Perform prior to fuel feed system leak test and LOX feed system leak test and after fuel feed system drain and LOX feed system bciloff when required by static test or launch abort.
One revolution of the turbo- pump shaft requires 5 revo- lucious of the torque pinion gear. Locking pin and torque pinion gear must be fully ex- tended after test,
Perform prior to safety cir- cuits function test, sequence verification test, and thrust chamber pneumatic leak test, if performed.
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13.3 {cont}
1.3.5
Activities
LOX DOME AND GAS GENERATOR LOX IN- JECTOR PURGE LEAK
AND FUNCTION TEST FOR UNINSTALLED ENGINES
LOX DOME AND GAS
INSTALLED ENGINES AT MAF
a.
Requirements
b, Cycle switches 3 times from
zero te 1,240 +30 psig with gaseous nitrogen pressure applied at calibration port.
Perform external leak test of joints and fittings at 100 +5 psig gaseous nitrogen.
VerLfy purge flow,
Perform external leak test of joints and fittings at 120-220 psig gaseous nitrogen,
Verify purge flow at 120-220 psig.
Limits
Switch pickup pressure 1,060 +65 psig on second and subsequent cycles; switch dropout pressure 50-100 psig below pickup pressure on second and subsequent cycles,
No external leakage is allowable.
Autible flow from gas generator igniter port, thrust chamber injector, and overboard drain line; er by feeling individual purge system lines.
No external leakage is allowable,
Audible flow from gas generator igniter port, thrust chamber injector, and overboard drain line: or by feeling individual purge system lines.
Specia] Constraints und Remarks
Perform switch pickup and dropout pressure test sub- sequent to leak testing of joints.
CAUTION
Pressurization rates must be limited to 50 psig/sec from 0-895 psig and 5 psig/sec from 895 to 1,270 psig. Depressurization rate: must be limited to
5 psig/sec from 1,270 to 895 psig. A, Perform afte: thrust chamber pneumatic leak test and ex-
haust system leak test.
The turbine exhaust system J must be vented during perform- $2 ance of this activity.
Thrust chamber exit and throat closures and LOX overboard drain line closure must be removed during this test.
Leak-cest compound must not be used on overboard drain line exits or braided flex line bellows,
Perform after exhaust system leak test and sequence verifi- cation test.
Thrust chamber exit and throat closures; and LOX overboard drain line closure must be re- moved during this test.
Leak-test compound must not be used on overboard drain line exits or braided flex line bellows.
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1.3.54
1.3.6
Activities
LOX DOME AND GAs GENEXATOR LOX INJECTOR PURGE LEAK AND FUNCTION TEST
AT MTF AND KSC
LOX PUMP SEAL PURGE
LEAK AND FUNCTION
TEST AT MAF AND KSC
sie
ake
Requirements
Perform external leak test cf joints and fittings at 120- 220 psig museous nitrogen,
Verify purge flow at 120- 226 psig.
Verify and record operational low-level und high-level purge pressure settings:
{1) Low-level purge (2) High-level purve
(3) Maximum purge syatem lockup pressure
Perform external leak te .t of joints and fittings at 85 +10 psig gaseous nitrogen,
Limits
No external leakaye is wilowable.
Audible flow from aus generator igniter port,
thrust chamber injector, and overboard drain line; or by
fecling individual purge system lines,
4£20-220 psig 600-1, 000 psig 1, 200 psig
No external leakige is towable.
Specral Construnts wand Remarks
Perform after exhaust system leak test and sequence verifi- caution test.
Thrust chamber exit and throat closures and LOX overboard drain line closure must be re- moved during this test.
Leak-test compound must not be used on overboard drain line exits or braided flex line bellows.
Perforn: this test prior to driin system leak tert, and LOX feed systeim leak test if performed.
Leak-test compound muct not be used on overboird drain line exits or braided flex line bellows,
Oxidizer overboard drain line and nitrogen purge drain line closures must be removed during this test.
NOTE
Absence of fluid from oxidizer and nitrogen purge overboard drain lines must be ver:fied when covers are re- moved from lines and when turbopump LOX seal purge pressure 15 first apphed.
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Activities Requirements
Limits
Special Constraints and Remarks
yp
1.3.6 {cont}
1.3.8
b. Simultaneously measure and record (at 85 :10 psig) purve system flowrate from oxidizer overboard drain line and nitro- fen purce drain line.
LOX PUMP SEAL PURGE a. Perform external leak test of LEAK AND FUNCTION joints and fittings at 85 :10 TEST AT MTr Psig gaseous nitrogen.
b. Verify purge flow.
COCOON PURGE SYSTEM a. Perform external leak test of LEAK AND FUNCTION system Joints at 20:5 psig TEST AT MAF HAaSeOUS nitrogen pressure.
b. Verify purge flow at leak-test pressure.
5.00 seim maximum from each drain fine. Combined drain line flowrete must be in oxcess of 0 scim.
No externai leakage 1s allewable.
Purge flow from oxidizer overboard drain I:ne and/or nitrogen purge drain line, or by feeling purce supply line.
Fuzz leakave (as defined in section IE) is allowable,
Audible flow from purge mani- told, or by feeling purge supply line
Perform flow test from drain lines after external leak test.
Leak-test compound must not be used on overboard drain line exits or braided flex line bellows.
Oxidizer overboard drain line and nitrogen purge drain line closures must be removed during this test.
NOTE
Absence of fluid from oxidizer and nitrogen purge overboard drain lines must be verified
when covers are re- 901
moved from lines and when turbopump LOX seal purge pressure 15 first applied,
Leak-test compound must not be used on purge manifold orifices or braided flex line dcllows.
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Paragraph Activities Requirements Limits and Remarks 1.3.9 COCOON PURGE SYSTEM a. Perform external leak test Fuzz leakage (as defined in Perform prior to thermal in- LEAK AND FUNCTION of system joints at gaseous section IT} is allowable. sulation installation. TEST AT KSC nitrogen pressure within inter- ote. re face acceptability limits spect- Pressure-temperature accept- fied in section I. ability limits may be obtained
1.3.10 HEAT EXCHANGER HELIUM a. SYSTEM LEAK TEST FOR UNINSTALLED EXGINES
using umbilical measurements corrected for measurement tapoff location.
Leak-test compound must not be used on purge manifold ori- fices or braided flex line
bellows. Verify purge flow at leak-test Ardible flow from purge pressure, manifold Verify purge interface pressure- Within limits specified in temperature relationship is s ction H acceptable. Leak-test at 400 =10 psig gaseous helium or nitrogen and refrigerant, Type 12, the following system parts: (t} (Deleted) (2) Flanges, fittings, instrumen- No external leakage ts Leak-test compound must not tation lines, and bellows allowable except at joints be used on braided flex line listed in substep 3. bellows. (3) Joints having allowable Fuzz leakage (as defined in external leakage: section II) is allowable,
{a} Helium supply duct (heat exchanger end) to heat exchanger
(b}) Heat exchanger to helium return duct ‘heat ex- changer end)
(c) Helium bypass hose to helium return duct (heat exchanger end}
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Activities
Requirements
Limits
SSS A yey
1.3.10 (cont)
1311
=
HEAT EXCHANGER HELIUM SYSTEM LEAK TEST AT KSC
(d) Heat exchanger helen outlet instrumentation hose to helium return duct instrumentation tap HH3a (on engines not incorporating \IDS6 change) *t
(e) Heat exchanger helium . outlet instrumentation hose to transducer (on engines not incorporating MD9€ change}
(f) Heat exchanger helium outlet temperature trans- ducer to helium outlet duct tastrumentation tap HH3b (on engines not incorporating 4IDS6 change) a
b. Using a leak detector at thrust chamber exhaust manifold exit, determine helium coil leakace at leak-test pressure.
Leak-test at 20G +10 psig gaseous helium, nitrogen, or nitrogen and refrigerant, Type 12, the following system parts:
(1} (Deleted)
{2} Flanges, fittings, instrumen- tation lines, and bellows
(3) Joints having allowable external leakage:
{a} Helium supply duct (heat exchanger end) to heat exchanger
(b) Heat exchanrer to helium return duct (heat exchanger end}
(c) Helium uypass hose to helium return duct {heat exchanger end)
Special Constraints and Remarks
No leakaye is allowable.
No external leakage 1s allowable except at joints listed in substep 3.
Fuzz leakage (as defined in section II} 1s allowable.
Leak-test compound must not be used on braided flex line bellows.
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Reguire ments
Paragrash Activities 13.11 (d) icont} (e) (f) - {g) t.3.1z
Limits
UY Seg
Helum return duct (heat exchanger end) to helium wrap-around duct
Heat exchanger helium outlet instrumentation hose to helium return duct instrumentaticn tap KE3a (on engines not incorpo- rating MD96 change}
Heat exchanger helium outlet instrumenta rion hose to transducer (on engines not incorporating MD965 change)
Heat exchanger helium outlet temperature trans- ducer to helium outlet duct instrumentation tap HH3b (on engines not incerporating MD96 change) _
Leak-test at 200 +10 psig caseous helium or nitrogen the following system paris:
(1) Flanges, Hittings, instrumen- No external leakage is
(2)
tahion lines, and bellows
Joinis having allowable externa! leakage:
fa)
{b}
(d)
allowable exc :pt at jcints listed in supstep 2,
Fuzz leakage as defined in section Ii) is allowable, Helium supply duct
(heat exchanger end}
to heat exchanger
Heat’ exchanger ta helium return duct (heat exchanger end)
Helium bypass hose to helium return duct (heat exchanger end)
Helium return duct (heat exchanger end) to helium «rap-around duct
Special Constraints and Ren.arks
Leak-test compound must not be used on braided flex line bellows.
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Paragrapa Activities Requirements Limits and Remarks 1.3.12 (e) Heat exchanger helium (cont) outlet instrumentation
1.3.43 HEAT EXCHANGER HELIUM SYSTEM LEAK TEST AT MAF SUBSEQUENT TO
STATIC TEST
hose to helium return duct instrumentation tag HH3a (on engines not incorpo- rating MD96 change)
(f) Heat exchanger helium outlet instrumentation hose to transcucer (on engines not incorporating . MD9€ change} i
(g) Heat exchanger helium outlet temperature trans- ducer to helium: cutiet duct instrumentation tap . HH3b (on engines not incorporating \D96 change)
Leak-tesi at 200 +10 psig gaseous helium vr nitrogen and refrigerant, Type 1c, the following system parts:
(1) (Deleted)
(2) Flanges, fittings, instrumen- No external leakage is Leak-test compound must not tation lines, and bellows allowable excent at joints be uSed on braided flex line Usted ir ubstep 3. bellows. (3) Joins having allowable Fuzz leakace ‘as defined ia esterual leakage: section II} 1: .ttowuble.
(a} Helium supply duct (heat exchanger end, to heat exchanger
(b) Heat exchanger to helium retura duct (heat exchanger end)
(ce) Helium bypass hose to helium return duct (heat exchanger end)
{d) Helium return duct (heat exchanger end) tu helium wrep-arouad duct
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3.3.18 {cont}
b.
1.3.14 HEAT EXCHANGER LOX a. SYSTEM LEAK TEST FOR UNINSTALLED ENGINES
Special Constraints Requirements Limits and Remarks
(e) Heat exchanger helium outlet instrumentation hose to helium return duct instrumentation tap HH3a {on engines not incorpo- rating MD96 change)
if) Heai exchanger hehum outlet instrumentation hose to transducer (on 913 engines not incorporating MD96 change}
(g) Heat exchanger helium outlet temperature transr ducer to helium outlet duct instrumentation tap HH3b (on engines not incorporating MD96 change)
Using a leak detector at thrust No leakage is allowable. chamber exhaust manifold exit,
determine helium coil leakage at
leak-test pressure.
Leak-test at 1,400 -20 psig Perform prior te thrust 90 gaseous nitrogen and refrigerant, chamber pneumatic leak test. . Type 12, the following system
parts:
oe
(1) (Deleted)
(2) Flanges, fittings, bellows, No externa) leakage i> Leak-test compound must not and instrumentation lines alluwable except at joints be used on braided flex line listed in substep 3. bellows, (3) Joints having allowable Fuzz leaka :e (as defined in external leakage: section I} .s allowable. 915
(a) Heat exchanger to GOX duct (heat exchanger end)
(bo) Oxidizer bypass hose to GOX duct (heat exchanger end)
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Paragraph Activities Requirements Limits and Remarks 1.3.14 b. Perform reverse-flow leak 50 scim maximum Install Thrust Chamber Throat ‘conts test of heat exchanger check Plug G3136 to monitor heat valve at 106 =5 psig gaseous exchanger check valve reverse- nitrogen and refrigerant, flow leakage. Type 12. c. Using a leak detector at thrust No leakace 18 allowable. chamber exhaust manifold exit, determine LOX coil leakage at leak-test pressure. 1.3.15 HEAT EXCHANGER LOX Leak-test at 300 +10 psig gaseous Perform prior to thrust SYSTEM LEAK TEST nitrogen the following system parts: chamber pneumatic leak test, AT KSC if performed. (1 (Deieted) {2 Flanges. fittings. instrumen- No external leakage is Leak-test compound must not tion lines, and bellows allowable except at joints be used on braided flex line listed in substep 3. bellows, (3° Joints having allowable Fuzz leakage (as defined .n external leakage: section II is allowable, (as Heat exchanger to GOX duct fheat exchanger end) (bo, Oxidizer bypass hose to GOX duct (heat exchanger end’ 1.3.15 HEAT EXCHANGER LOX Leak-test at 1,000 =50 psig gaseous
SYSTEM LEAK Test “TMTF
nitregen as follows:
(l’ Flanges, fittings, instrumen- tation lines, and bei'ows
(2° Joints having allowable external leakage:
(a) Heat exchanger to GOX duct (heat exchanger end)
(bo) Oxidizer bypass hose to GOX duct (heat exchanger end}
No exter:.il leakage is allowable except at Joints listed in substep 2.
Fuzz ‘eakare (as defined in section II' 1s allowable.
Leak-test conipound must not be used on braided flex line bellows.
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Paragraph Activities 1.3.16 (cont) 1.3.17 HEAT EXCHANGER LOK Qe SYSTEM LEAK TEST AT MAF SUBSEQUENT TO STATIC TEST b. Cc. 1.3.18 (Deleted} 1.3.19 HYDRAULIC CONTROL a.
SYSTEM LEAK AND FUNCTION TEST FOR TNINSTALLED ENGINE, AND INSTALLED EN-_ CINE AT MTF (PRIOR TO STATIC TEST) AND AT KSC
Requirenients
(c) GOX duct fheat exchanger rd) to heat exchanger GOX wrap-around duct
Leak-test at 300 -10 psig gaseaus mtrogen and refrigerant, Type 12, the following system parts:
(1) (Deleted)
(2) Flanges, fittings, bellows, and instrumentation lines
(3) Joints having allowable external leakage:
{a} Heat exchanger to GOX duct (heat exchanger end)
(b) Oxidizer bypass hose to GOX duct {neat exchanger end)
“erform reverse-flow leak test of heat exchanger check valve at 300 +10 psy gaseous nitrogen and refrigerant, Type 12
Using a leak detector at thrust cnamber exhaust manifold exit, determine LOX coil leakage
at leak-test pressure.
Leak-cest closed side of hy- drauhe contro} system at 1,800 =50 psig hydraulic p7essuce and as outlined
in steps b through d.
Limits
No external leakage 1s allowable except at joints listed in substep 3.
Fuzz leakage {as defined in section IT) is allowable.
50 scim maximum
No leakayve is allowable
No externa: leakre ts allowabl: .
Spe ciel Constr ints and Remarks
Perform prior to thrust chamber pneumatic leak tesu.
Leak-test compound must not be used on braided flex line bellows,
Install Thrust Chamber Throat Plug G3136 to moni- tor heat exchanger check valve reverse-flow leakage.
Perform «his test prior to ignition monitor valve inter- flow test, ignition monitor valve shuttle pressure test, exhaust system leak test, thrust chamber pneumatic leak test, thrust chamber liquid leax test, LOX feed system leak test, engine valve timing test, and fuel feed system leak test, if performed, and after (light instrumentation system test and ignition monitor valve diaphragm test, if performed.
915
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1.3.19 (cont)
Activities Requirements
b. Mcnitor fuel overboard drain line, at thrust chamber exit, for «fuel leakage. Any leakage may reauire isolation fram overboard drain line and recording of leakage rate of the following components:
(1) Redundant shutdown vaive
(2, Ignition monicor valve
(3) Engine control valve
(4° Al other corsponents com- mon to this drain system
Limits
Special Constraints and Remarks
2 cc m fuel leakage maxi- mum from drain port
5 cc’m fuel leakage maxi- mum from drain port
5 ce’m fuel leakage maxi- mura from override drain port
No leaka ze is allowable.
If surface wetting is noted on components or flanged joints, refer to section f for eriteria to use to establish joint acceptability.
Checkout valve must be in ground return position.
The engine propellant feed sys- tems must be at ambient pressure during this test.
The redundant shutdown valve must not be energized more than 15 minutes, since the tempera- ture buildup will cause the valve to actuate slower.
Deenergizing the redundant shut- dow:1 valve will cause approxiraately 25 ce of hydraulic fluid to be ex- pelled from the DRAIN port. Per- sonnel must be clear of DRAIN port, and hydraulic Fluid must not drain onto the engine,
Apply pressure to hydraulic con- trol system at suitable increments beginning with lowest pressure capability, increasing to maximum test pressure required, and moni- tor for leakage while pressvre is increased,
Past recorded component leakage shall be used as a guide for determi- ning component isolation require-
915
ment. When leakage is accounted for, no further isolation is required.
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Requirements
imits
Special Constraints and Remarks
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Paragraph Activities 1.3.19 c. (cont) d. €, f,
Monitor checkout valve bail seal
leakage at engine hydraulic return
line quick-disconnect,
Monitor engine control valve engine supply check valve reverse leakage at engine nydraulic supply line quick- disconnect.
Leak-test gimbal hydraulic return line quick-disconnect (center engine only) at 1,550 +50 psig hydraulic pressure with cap removed.
Leak-test open side of hydraulic control system at 1,800 +50 psig hydraulic pressure and as outlined in step g.
2 cc ‘nm: maxizaum
2 ce/m matimum
5 drops per minute
No external leakage is allowable,
Actuate engine valves at hy- draulic supply pressure be- tween 900 and 1. 600 psir and hydraulic return system pres- sure below 100 psig.
CAUTION
Supply pressure to 1g- nition monitor valve CONTROL port musx not exceed 100 psig since damage to ignition mouni- tor valve and hyperzol manifold can result.
e Do not allow hydraulic return system leak-test pressure to exceed 525 psig.
if surface wetting is noted on components or flanged joints, refer to section II for criteria to use to establish joint acceptability.
Hydraulic leakage may be noted from the fuel overboard drain system during actuation of .he redundant shi: wn valve.
This leakage is acceptable,
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Paragraph
1.3.19 (eont)
L3.19A
Activities
HYDRAULIC CONTROL
SYSTEM LEAK AND FUNCTION TEST AT MTF SUBSEQUENT TO STATIC TEST
32
a.
Requirements
Monitor fuel overboard drain line, at thrust chaniber exit, for fuel leakage. Any leakage may require isolation fram overboard drain line and re- cordi:.g of leakage rate of the following components:
(1) Redundant shutdown valve
(2) Ignition monitor valve
(3) Engine control valve
(4) All other components com- m+ 1 to this drain system
Leak-test closed side of hydzaulic control system at 1,800 =50 psig hydraulic pressure,
Limits
2 cc ’m fuel leakage maximum from drair port
5 ce m fucl leakage maximum from drain port
See .a fuel leakage maximum from override drain port
No leakage 1s allowable.
No external leakage ts allowable.
Special Constraints and Remarks
Past recorded component leakage shall be used as a guide for devermining com- ponent isolation requirement. When leakage is accounted for, no further isolation 1s required.
’
Perform this test subsequent
to fuel feed system drain and
prior to stage rotation tu hor- ‘zontal.
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If surface wetting 1s noted on
components or flanged joints,
refer to section I for criteria
to use to establish joint ac-
ceptability.
Ch 901 eckout valve must be in
ground return position.
Apply pressure to hydraulic control system at suitable increments beginning with lowest pressure capability, increasing to maximum
test pressure required. and monitor for leakage while pressure is increasca.
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Limits
Special Constraints and Remarks
Paragraph Requirements 1.3.194 b. Moniter fuel overbvara drain {cont)
l:ne, at thrust chamber exit, for fuel leakage. Any leakage may require isolation from overboard drain line ond re- cording of leakage rate of the following components:
{1) Redundant shutdown valve
(2} Ignition monitor valve
‘3) Engine control valve
(4) All other components com- mon to this drain system
Monitor checkout vaive ball seal leakage at engine hydraulic return line quick-disconnect.
Monitor engine conten! valve engine supply check valve reverse leakage at engine hydraulic supply line quick-disconnect.
2 cc/m fuel leakage maxi- mum from drain port
5 cc‘’m fuel leakage max.- mum ‘rom drain port
5 cc/m fuel leakage maxi- mum from override drain port
t
No leakage is allowable.
2 cc ’m maximum
2cc m maximum
Fast recorded cemponent leak- age shall be uSed as a guide for determining component isola- tion requirement. When leakage is accounted for, no iurther isolation is required.
915
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Paragraph ———
HYDRAULIC CONTROL
1.3. 19B
Activities
SYSTEM LEAK AND FUNCTION TEST AT
MAF SUBSEQUENT TO
STATIC TEST
Requirements
a. Leak-test closed side of hydrave control system at 1,800 +50 psig hydrauhe pressure.
A
Limits
No cxternal ieakoage 1s Allowable.
Special Constraints and Remarks
Perform this test prior to lgaition monitor valve inter- flow test, ignition monrtor valve shuttl* pressure test. exhaust system leak last, thrus: chamber pneumatic leak test, LOX fved system leak test. engine valve timing test. ana fuel feed system leak test, if per- formed, and after flight instrumentation system test and ignition moniter valve diaphragm test, if performed.
Y surface wetting 3s noted on components on flanged joints. refer to section II for criteria to use to os-
tablish joint acceptability.
Checkout valve must be in ground return position.
The engine prcpellant feed systems must be at ambienc pressure during this test.
The redundant shutaown valve must not be energized more than 15 minutes. since the temperature buildup will cause the valve to actuate slower.
Apply pressure to hydraulic control system at suitable increments beginning with lowest pressure capability. increasing to maximum test pressure required. and monitor for leakaxe while pressure is increased.
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Paragraph
1.2.198 (cont)
Activities
rr per
b.
Requirements
Leak-test gimbal hydraulic return line quick-discunnect {center engine only) at 1,550 250 psig hydraulic pressure with cap removed.
Leak-test open side of hydraulic control system at 1,800 +50 psig hydrauhe pressure,
Limits
5 drops per minute
No external leakage is allowable.
Special Constraints and Remarks
Actuate engine valves at hydraulic supply pressure between $00 and 1,600 psig and hydraulic return sys- tem pressure below 100 psig.
CAUTION
Supply pressure to ignition monitor valve CONTROL port must not exceed 100 psig since damage to igni- tion monitor valve and hypergol manifold can result.
e Do not atlow hydraulic return system: leak-test pressure to exceed 525 psig.
if surface wetting is noted on components or flanged joints. refer to section 0 for criteria to use to establish joint ac- ceptability.
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Paragraph
1.3.20
Activities
IGNITION ... SNITOR VALVE a. DIAPHRAGM LEAK FEST
HYPERGOL MANIFOLD a. LEAK AND FUNCTION TEST
Requirements
Meusure and record leakice from ignition monitor valve ATMOS REF port with 1,400 =20 psig gaseous nitrogen applied to CONTROL port.
Leak-test ignition monitor valve cup external joints at 1, 400 +20 psig guseous nitroven.
Verify hypergol installed switch actuation and hypergol cartridge follower freedum of movement when hypergol cartridge follower is manually depressed sith CON-
TROL port pressure at zero psig.
Measure and record leakige at the following ports at 200 +10 psig gaseou. nitrogen:
(1) Purge quick-disconnect (2) Ezniter fuel valve vent port
(3) Ignition mesitor valve ATMOS REF port
Lenk-test hyperol manifold exiernal joints and ports at 200 +10 psie paseous nitrogen pressure,
Limit:
No leakage is allowable.
No external leakave is allowable,
3 scum maximum Q.25 seing mexzmiun
0.25 scitn maximum